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Results for “photochemical machining”

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

Manufacturing Process Design of a Micro-Scale Liquid-Liquid Extractor and Multi-phase Separator

Advances in process innovation within the chemical process industry are impeded by the cost of producing new innovative components. In this paper, various manufacturing process routes were evaluated for scaling up a micro-scale liquid-liquid extractor and multi-phase separator capable of separating immiscible phases that are used for the extraction of a chemical product into a lower boiling point solvent to make downstream distillation easier. A manufacturing process design methodology was used to evaluate both photochemical machining and binder jetting as a means for producing the micropost arrays within the separator. Cost curves show that for a 0.3 mm deep micropost array, photochemical machining was found to be much cheaper than binder jetting. However, because binder jetting processes enable microposts with over 13 times higher depth-to-width aspect ratios, binder jetting was found to decrease the overall costs of the extractor/separator by more than half for a 500 barrel per day plant, with breakeven as low as 15 barrels per day. These economics were confirmed by building extractor/separator plates and characterizing them dimensionally and functionally. The binder jet plates were found to perform better than photochemical plates leading to the complete separation of the organic phase from water. The utilization of slower sintering cycles combined with surface grinding provided acceptable dimensional tolerances for the binder jet plates. Using pressurized air during depowdering improved the economics for the binder jetting process.

42 ENGINEERING↗
DOE OSTI2022

Validation of Manufacturing Process Designs for Stamped Microchannel Recuperators

Microchannel recuperators can achieve high-efficiency power cycles and chemical reactions by recovering waste heat from hot turbine exhaust and chemical reaction streams. However, the industrial application of microchannel recuperators are restricted by the high cost of patterning and bonding. The objective of this study was thus to investigate new methods for producing microchannel recuperators for emerging markets. Based on greenfield cost estimates, process designs based on stamping, laser welding and vacuum brazing of 316L stainless steel laminae were found to be more economical than conventional photochemical machining and diffusion bonding. Subsequently, validation experiments were conducted to produce stamped microchannel components using cost model parameters. At a mass flow rate of 0.99 g/s, the test article made with laser welding was found to provide higher effectiveness than the test article produced using vacuum brazing. Preliminary investigations showed that residual stresses during laser welding of the laminae led to significant warpage, collapsing channels and making lamina-to-lamina fit up challenging. In contrast, the test article produced by vacuum brazing of stamped laminae showed no clogging and 4.6% and 10.5% channel height standard deviation for the cold and hot channels, respectively. Channel variation in the vacuum brazing sample was determined to be caused by misregistration of laminae during brazing. In future work, efforts are needed to choose cheaper, more ductile brazing foils as well as design a brazing fixture to improve lamina-to-lamina registration.

42 ENGINEERING↗
NASA NTRS1978

Advanced fabrication techniques for cooled engine structures

An improved design for regeneratively cooled engine structures was identified. This design uses photochemically machined (PCM) coolant passages. It permits the braze joint to be placed in a relatively cool area, remote from the critical hot face sheet. The geometry of the passages at the face sheet also minimizes stress concentration and, therefore, enhances the low cycle fatigue performance. The two most promising alloys identified for this application are Inconel 617 and Nickel 201. Inconel 617 was selected because it has excellent creep rupture properties, while Nickel 201 was selected because of its predicted good performance under low cycle fatigue loading. The fabrication of the PCM coolant passages in both Inconel 617 and Nickel 201 was successfully developed. During fabrication of Inconel 617, undesirable characteristics were observed in the braze joints. A development program to resolve this condition was undertaken and led to definition of an isothermal solidification process for joining Inconel 617 panels. This process produced joints which approach parent metal strength and homogeneity.

Buchmann, O. A.↗
NASA NTRS2008

Fabricating High-Resolution X-Ray Collimators

A process and method for fabricating multi-grid, high-resolution rotating modulation collimators for arcsecond and sub-arcsecond x-ray and gamma-ray imaging involves photochemical machining and precision stack lamination. The special fixturing and etching techniques that have been developed are used for the fabrication of multiple high-resolution grids on a single array substrate. This technology has application in solar and astrophysics and in a number of medical imaging applications including mammography, computed tomography (CT), single photon emission computed tomography (SPECT), and gamma cameras used in nuclear medicine. This collimator improvement can also be used in non-destructive testing, hydrodynamic weapons testing, and microbeam radiation therapy.

Appleby, Michael↗
NASA NTRS2011

Micro-Slit Collimators for X-Ray/Gamma-Ray Imaging

A hybrid photochemical-machining process is coupled with precision stack lamination to allow for the fabrication of multiple ultra-high-resolution grids on a single array substrate. In addition, special fixturing and etching techniques have been developed that allow higher-resolution multi-grid collimators to be fabricated. Building on past work of developing a manufacturing technique for fabricating multi-grid, high-resolution coating modulation collimators for arcsecond and subarcsecond x-ray and gamma-ray imaging, the current work reduces the grid pitch by almost a factor of two, down to 22 microns. Additionally, a process was developed for reducing thin, high-Z (tungsten or molybdenum) from the thinnest commercially available foil (25 microns thick) down to approximately equal to 10 microns thick using precisely controlled chemical etching

Appleby, Michael↗
DOE OSTI2023

Climate-driven deterioration of future ozone pollution in Asia predicted by machine learning with multi-source data

Ozone (O 3 ) is a secondary pollutant in the atmosphere formed by photochemical reactions that endangers human health and ecosystems. O 3 has aggravated in Asia in recent decades and will vary in the future. In this study, to quantify the impacts of future climate change on O 3 pollution, near-surface O 3 concentrations over Asia in 2020–2100 are projected using a machine learning (ML) method along with multi-source data. The ML model is trained with combined O 3 data from a global atmospheric chemical transport model and real-time observations. The ML model is then used to estimate future O 3 with meteorological fields from multi-model simulations under various climate scenarios. The near-surface O 3 concentrations are projected to increase by 5 %–20 % over South China, Southeast Asia, and South India and less than 10 % over North China and the Gangetic Plains under the high-forcing scenarios in the last decade of 21st century, compared to the first decade of 2020–2100. The O 3 increases are primarily owing to the favorable meteorological conditions for O 3 photochemical formation in most Asian regions. We also find that the summertime O 3 pollution over eastern China will expand from North China to South China and extend into the cold season in a warmer future. Our results demonstrate the important role of a climate change penalty on Asian O 3 in the future, which provides implications for environmental and climate strategies of adaptation and mitigation.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Exploiting correlations in multi-coincidence Coulomb explosion patterns for differentiating molecular structures using machine learning

Coulomb explosion imaging (CEI) is a powerful technique for capturing the real-time motion of individual atoms during ultrafast photochemical reactions. CEI generates high-dimensional data with naturally embedded correlations that allow mapping the coordinated motion of nuclei in molecules. This enables reliable separation of competing reaction pathways and makes this approach uniquely suited for characterizing weak reaction channels. However, rich information contained in experimental CEI patterns remains largely underexploited due to challenges in visualizing correlations between multiple observables in multi-dimensional parameter space. Here we present a new approach to CEI of intermediate-sized polyatomic molecules, detecting up to eight ionic fragments in coincidence and leveraging machine-learning-based analysis to identify patterns and correlations in the resulting high-dimensional momentum-space data, enabling robust molecular structure identification and differentiation. Our approach provides high-dimensional background-free data encoding exceptionally rich structural information and establishes an automated, scalable framework for extracting insightful information from the data. As a demonstration, we apply this method to image and distinguish dichloroethylene isomers, showcasing its potential for broader applications in molecular imaging. Our results pave the way for channel-specific analysis of ultrafast structural dynamics in chemically relevant systems, particularly for disentangling mixed reaction pathways and detecting contributions from weak channels and minority species.

Chemical Physics (physics.chem-ph)↗
NASA NTRS1967

Dual photochemical replenisher system reduces chemical losses

Dual replenisher system reduces chemical losses and maintains optimum solution concentration during long nonprocessing cycles of photo processing machines. Using a single 3-position switch and solenoid control valves, the system provides instantaneous flow control to each processing tank.

Kolber, J. M.↗
DOE OSTI2024

Quantitative gas-phase transmission electron microscopy: Where are we now and what comes next?

Abstract Based on historical developments and the current state of the art in gas-phase transmission electron microscopy (GP-TEM), we provide a perspective covering exciting new technologies and methodologies of relevance for chemical and surface sciences. Considering thermal and photochemical reaction environments, we emphasize the benefit of implementing gas cells, quantitative TEM approaches using sensitive detection for structured electron illumination (in space and time) and data denoising, optical excitation, and data mining using autonomous machine learning techniques. These emerging advances open new ways to accelerate discoveries in chemical and surface sciences. Graphical abstract

36 MATERIALS SCIENCE↗
DOE OSTI2023

LCA-based environmental sustainability assessment of hybrid additive manufacturing of a turbine blade

In this paper, a cradle-to-gate life cycle assessment (LCA) method is used to compare the overall energy consumption and environmental impact of hybrid additive manufacturing (HAM) and the traditional CNC milling process with a case study of turbine blade manufacturing. Six environmental impacts are assessed in this study: acidification potential (AP), eutrophication potential (EP), global warming potential (GWP), photochemical ozone creation potential (POCP), ozone depletion potential (ODP), and abiotic depletion potential (ADP). The results suggest that HAM can not only reduce energy consumption and material waste but also reduce the environmental impact by 53% from a life cycle perspective. Specifically, the results of GWP, AP, EP, ODP, POCP and ADP of the HAM are only 32.2%, 34.6 %, 44.7%, 27.2%, 25.6%, and 24.7 % of that in traditional CNC machining.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Physiochemical Machine Learning Models Predict Operational Lifetimes of CH3NH3PbI3 Perovskite Solar Cells

Halide perovskites are promising photovoltaic (PV) materials with the potential to lower the cost of electricity and greatly expand the penetration of PV if they can demonstrate long-term stability under illumination in the presence of moisture and oxygen. The solar cell service lifetime as quantified by the T80 (the time required for the power conversion efficiency to drop to 80% of its starting value) is a useful metric to assess stability. The T80 for utility, commercial, or residential PV systems needs to be several decades in order to yield low-cost electricity, and thus it is not practical to directly measure the T80. It would be useful if T80 could be predicted from the initial dynamics of a solar cell’s performance, but until now no models have been developed to forecast T80. In this work, we report the development of machine learning models to predict T80 of ITO/NiOx/CH3NH3PbI3/C60/BCP/Ag solar cells operating at maximum power point under 1-sun equivalent photon flux in air at varying temperatures and relative humidities. Efficiency losses are driven by short-circuit current and fill factor, indicating that chemical decomposition of the perovskite is a major contributor to degradation. Spatial patterns evident from in situ dark field optical microscopy suggest that the electric field gradient at device edges plays a significant role in perovskite decomposition, along with photochemical reactions with O2 and H2O. Models are trained using a menu of features from three distinct categories: (i) features based on measurements of the initial rates of change of device parameters, (ii) features based on the ambient conditions during operation (temperature, & partial pressure of H2O), and (iii) features based on underlying physics and chemistry. We show that a theory-based physiochemical feature derived from a model of the chemical reaction kinetics of the rate of degradation of the CH3NH3PbI3 is particularly valuable for prediction. This physiochemical feature was selected as the first or second most dominant feature in the best performing models. With a dataset consisting of 45 accelerated degradation experiments with T80 that range over a factor of 30, the model predicts T80 with an accuracy of about 40% (|predicted T80 - observed T80| / observed T80) on samples not used in training. This hybrid ML approach should be effective when applied to other compositions, device architectures, and advanced packaging schemes.

14 SOLAR ENERGY↗
DOE OSTI2022

Physiochemical Machine Learning Models Predict Operational Lifetimes of CH3NH3PbI3 Perovskite Solar Cells

Halide perovskites are promising photovoltaic (PV) materials with the potential to lower the cost of electricity and greatly expand the penetration of PV if they can demonstrate long-term stability under illumination in the presence of moisture and oxygen. The solar cell service lifetime as quantified by the T80 (the time required for the power conversion efficiency to drop to 80% of its starting value) is a useful metric to assess stability. The T80 for utility, commercial, or residential PV systems needs to be several decades in order to yield low-cost electricity, and thus it is not practical to directly measure the T80. It would be useful if T80 could be predicted from the initial dynamics of a solar cell’s performance, but until now no models have been developed to forecast T80. In this work, we report the development of machine learning models to predict T80 of ITO/NiOx/CH3NH3PbI3/C60/BCP/Ag solar cells operating at maximum power point under 1-sun equivalent photon flux in air at varying temperatures and relative humidities. Efficiency losses are driven by short-circuit current and fill factor, indicating that chemical decomposition of the perovskite is a major contributor to degradation. Spatial patterns evident from in situ dark field optical microscopy suggest that the electric field gradient at device edges plays a significant role in perovskite decomposition, along with photochemical reactions with O2 and H2O. Models are trained using a menu of features from three distinct categories: (i) features based on measurements of the initial rates of change of device parameters, (ii) features based on the ambient conditions during operation (temperature, & partial pressure of H2O), and (iii) features based on underlying physics and chemistry. We show that a theory-based physiochemical feature derived from a model of the chemical reaction kinetics of the rate of degradation of the CH3NH3PbI3 is particularly valuable for prediction. This physiochemical feature was selected as the first or second most dominant feature in the best performing models. With a dataset consisting of 45 accelerated degradation experiments with T80 that range over a factor of 30, the model predicts T80 with an accuracy of about 40% (|predicted T80 - observed T80| / observed T80) on samples not used in training. This hybrid ML approach should be effective when applied to other compositions, device architectures, and advanced packaging schemes.

14 SOLAR ENERGY↗
DOE OSTI2026

High-Efficiency Solar-To-Fuel Photoelectrochemistry in Disordered Photonic Glass Electrodes (Final Technical Report)

This project investigated how photonic glass (PG) photoelectrodes—disordered arrangements of dielectric scatterers—can serve as scalable, tunable platforms for light trapping in photoelectrochemical (PEC) solar-to-fuel systems. By leveraging disorder-driven optical phenomena such as multiple scattering resonances and light localization, PG structures offer an alternative to conventional photonic crystals and inverse opals that require high structural precision. The scientific goals were to twofold: (1) develop approaches to predictive models for high performance PG electrodes based on light absorption simulations, and (2) fabricate, characterize, and optimize PG-based photoelectrodes for solar-to-hydrogen and solar-to-fuel photoelectrochemical applications. To overcome the complexity of ensemble optical simulations for disordered materials, the researchers developed a machine-learning-accelerated emulation of all configurations in the design space. With this approach, PG photoelectrodes based on a TiO2 semiconductor were designed to enhance PEC currents of up to one hundred times higher than the equivalent ultra-thin film photoanodes and several times higher than the equivalent photonic crystal. The research also explored integrated systems for electrochemical hydrogen production based on replacing water oxidation with the specific glycerol oxidation electrocatalysis. Overall, the project outlined an approach to a simple-to-fabricate photoelectrode system to drive photoelectrochemical reactions relevant to solar photochemical energy conversion.

14 SOLAR ENERGY↗
DOE OSTI2022

Filming movies of attosecond charge migration in single molecules with high harmonic spectroscopy

Electron migration in molecules is the progenitor of chemical reactions and biological functions after light-matter interaction. Following this ultrafast dynamics, however, has been an enduring endeavor. Here we demonstrate that, by using machine learning algorithm to analyze high-order harmonics generated by two-color laser pulses, we are able to retrieve the complex amplitudes and phases of harmonics of single fixed-in-space molecules. These complex dipoles enable us to construct movies of laser-driven electron migration after tunnel ionization of N 2 and CO 2 molecules at time steps of 50 attoseconds. Moreover, the angular dependence of the migration dynamics is fully resolved. By examining the movies, we observe that electron holes do not just migrate along the laser polarization direction, but may swirl around the atom centers. Our result establishes a general scheme for studying ultrafast electron dynamics in molecules, paving a way for further advance in tracing and controlling photochemical reactions by femtosecond lasers.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2026

Understanding and Controlling Photoexcited Molecules in Complex Environments (Final Technical Report)

Predicting the outcome of a photochemical reaction is complicated by factors outside the scope of tradition theoretical chemistry. On such small scales, fluctuations of the environment render outcomes stochastic, nonadiabatic dynamics blur the separation between nuclear and electronic motion, and ultrafast relaxation renders typical assumptions of equilibrium inappropriate. This project aimed to elucidate and control nonadiabatic molecular dynamics in condensed phases. We developed accurate, efficient simulation tools to study irreversible molecular processes computational across a range of scales. We applied these methodological advances to study electron transfer under exotic conditions where spin and topology opened new pathways for reactivity. We also brought these ideas to bare on light harvesting systems, where energy and charge transport are coupled, and where long lifetimes can be deleterious to function. These advances helped to establish general principles for chemical efficiency and guide the design of nanoscale energy materials, molecular machines, and related technologies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRSDate not supplied

Linking OH Variability to Observable Variables, Meteorology and Transport

The hydroxyl radical (OH) plays a vital role in tropospheric chemistry, as it provides the dominant sink for a multitude of pollutants and climate-relevant gases such as methane. Observational constraints on the global distribution and temporal variability of OH are limited, and models simulate a wide range of OH distributions. While OH itself has a short atmospheric lifetime, OH is photochemically coupled to longer-lived species that undergo atmospheric transport. Here, we investigate how much of the OH variability within and between models can be explained by differences in observable species to develop diagnostics for OH differences. We find that NO 2 and water vapor together explain much of the spatial and temporal variability in simulated OH, and we use satellite observations to identify biases in these variables. The OH response to ENSO also differs between models, and we investigate potential causes of these differences such as differences in convection or lightning NOx. We also explore the potential of idealized tracers to represent the OH distribution. Within a single model, meteorological variables such as humidity and idealized tracers of transport can explain a significant portion of the OH spatial variability. We use a Gradient Boosted Regression Trees, a type of machine learning, to account for non-linear relationships between OH and the input variables.

Meteorology↗
NASA NTRS2001

Titan Airship Surveyor

Saturn's moon Titan is considered to be one of the prime candidates for studying prebiotic materials - the substances that precede the formation of life but have disappeared from the Earth as a result of the evolution of life. A unique combination of a dense, predominantly nitrogen, atmosphere (more than four times that of the Earth), low gravity (six times less than on the Earth) and small temperature variations makes Titan the almost ideal planet for studies with lighter-than-air aerial platforms (aerobots). Moreover, since methane clouds and photochemical haze obscure the surface, low-altitude aerial platforms are the only practical means that can provide global mapping of the Titan surface at visible and infrared wavelengths. One major challenge in Titan exploration is the extremely cold atmosphere (approx. 90 K). However, current material technology the capability to operate aerobots at these very low temperatures. A second challenge is the remoteness from the Sun (10 AU) that makes the nuclear (radioisotopic) energy the only practical source of power. A third challenge is remoteness from the Earth (approx. 10 AU, two-way light-time approx. 160 min) which imposes restrictions on data rates and makes impractical any meaningful real-time control. A small-size airship (approx. 25 cu m) can carry a payload approximately 100 kg. A Stirling engine coupled to a radioisotope heat source would be the prime choice for producing both mechanical and electrical power for sensing, control, and communications. The cold atmospheric temperature makes Stirling machines especially effective. With the radioisotope power source the airship may fly with speed approximately 5 m/s for a year or more providing an excellent platform for in situ atmosphere measurements and a high-resolution remote sensing with unlimited access on a global scale. In a station-keeping mode the airship can be used for in situ studies on the surface by winching down an instrument package. Floating above the surface allows relatively simple means for flight control. Mission requirements and possible methods of navigation, control, data acquisition, and communications are discussed. The presentation describes also the state-of-the art and current progress in aerial deployed aerobots.

Kerzhanovich, V.↗
NASA NTRSDate not supplied

Impact of COVID-19 Restrictions on Atmospheric Concentrations of O3 and NO2 Across the Globe

We use a machine learning algorithm combining information from the NASA GEOS composition forecast (GEOS-CF) model and surface observations of nitrogen dioxide (NO2) and ozone (O3) at more than 5,000 observation sites to assess the impact of COVID-19 restrictions on surface air quality in 46 countries. Our methodology removes the compounding impacts of meteorology, seasonality and atmospheric chemistry on air pollution, thus allowing for a quantitative estimate of the change in surface air quality following COVID-19 containment measures. Compared to GEOS-CF model predictions that do not include emission reductions related to COVID-19 restrictions, surface observations show a drop in surface NO2 of up to 60% after the implementation of lockdowns. Average NO2 concentrations between February 2020 to June 2020 were 18% lower than business as usual. The earliest and strongest declines are observed over China, followed by Europe and the US. While NO2 concentrations over China recovered within 2 months, the recovery has been slower over Europe and the US. The impact of COVID-19 restrictions on O3 is complicated by non-linear atmospheric chemistry. Locally, O3 can show a short-term increase of up to 50% as a result of the decrease in NO2, which leads to a reduction in night time titration. However, this effect is offset by a decrease in photochemical production during the day. Our results indicate that these two competing processes resulted in a net zero change in average surface ozone during the first 5 months of the pandemic. The results also indicate that the reduced photochemical production becomes increasingly important over time. Our analysis is based on surface observations and model simulations available in near real-time, and we will present an up-to-date view of the short and medium-term impacts of COVID-19 restrictions on air quality around the world.

COVID-19↗