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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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Methods of making and inspecting a web of vitreous lithium sulfide separator sheet and lithium electrode assemblies
A lithium ion-conductive solid electrolyte including a freestanding inorganic vitreous sheet of sulfide-based lithium ion conducting glass is capable of high performance in a lithium metal battery by providing a high degree of lithium ion conductivity while being highly resistant to the initiation and/or propagation of lithium dendrites. Such an electrolyte is also itself manufacturable, and readily adaptable for battery cell and cell component manufacture, in a cost-effective, scalable manner. An automated machine based system, apparatus and methods assessing and inspecting the quality of such vitreous solid electrolyte sheets, electrode sub-assemblies and lithium electrode assemblies can be based on spectrophotometry and can be performed inline with fabricating the sheet or web (e.g., inline with drawing of the vitreous Li ion conducting glass) and/or with the manufacturing of associated electrode sub-assemblies and lithium electrode assemblies and battery cells.
Perspectives on three-dimensional printing of self-assembling materials and structures
Spiders, silks, and webs are marvels of nature that have inspired high-performance material design, resilient structural design, and innovative manufacturing in the materials science and engineering fields. In this article, we review the roles and mechanisms of self-assembly and spinning processes for making hierarchical structures of synthetic and natural fibers with multifunctionality. We discuss the ability of spider webs to maintain their functionality under construction while withstanding predator, human, and environmental threats, which comes from their self-assembled structures from nanoscales to macroscales. We conclude by exploring the future of novel mobile, autonomous, time- and cost-effective spider-inspired three-dimensional printing technology for making resilient biomaterials, structures, and synthetic silk materials.
Reverse engineering environmental metatranscriptomes clarifies best practices for eukaryotic assembly
Abstract Background Diverse communities of microbial eukaryotes in the global ocean provide a variety of essential ecosystem services, from primary production and carbon flow through trophic transfer to cooperation via symbioses. Increasingly, these communities are being understood through the lens of omics tools, which enable high-throughput processing of diverse communities. Metatranscriptomics offers an understanding of near real-time gene expression in microbial eukaryotic communities, providing a window into community metabolic activity. Results Here we present a workflow for eukaryotic metatranscriptome assembly, and validate the ability of the pipeline to recapitulate real and manufactured eukaryotic community-level expression data. We also include an open-source tool for simulating environmental metatranscriptomes for testing and validation purposes. We reanalyze previously published metatranscriptomic datasets using our metatranscriptome analysis approach. Conclusion We determined that a multi-assembler approach improves eukaryotic metatranscriptome assembly based on recapitulated taxonomic and functional annotations from an in-silico mock community. The systematic validation of metatranscriptome assembly and annotation methods provided here is a necessary step to assess the fidelity of our community composition measurements and functional content assignments from eukaryotic metatranscriptomes.
Laboratory Upgrade Point Absorber (LUPA) CAD Files
The Laboratory Upgrade Point Absorber (LUPA) is an open-source wave energy converter designed and tested by Oregon State University. The computer-aided design (CAD) files are provided here in two forms: the original SOLIDWORKS (2021) model as "LUPA SOLIDWORKS.zip" and as a STEP file "LUPA-A1000.step". The bill of materials is provided as an Excel file with assemblies (LUPA-Axxx), part numbers (LUPA-Axxx-Pyyy), part descriptions, manufacturers, and manufacturer part numbers. This comprehensive CAD model represents LUPA as it was deployed in Fall 2022 testing at the O.H. Hinsdale Wave Research Laboratory. The mass properties including mass, center of gravity, and moments of inertia have been overridden for some parts and assemblies to match the physical device properties as determined from experiments. This appears as "overridden by user" when viewing mass properties in SOLIDWORKS. The LUPA-A1000.SLDASM file from the LUPA SOLIDWORKS.zip folder is the topmost assembly, open this file to see the entire model as one assembly. See "PMEC Page", "OpenEI Wiki Page", and the "Signature Project Page" resources below for more information on LUPA.
Clean Energy Manufacturing: Renewable Energy Technology Benchmarks
The manufacturing of clean energy technologies has become a global enterprise. An analysis of four clean energy technology manufacturing processes—wind turbine components, crystalline silicon solar photovoltaic modules, light-duty vehicle lithium-ion battery cells, and light-emitting diodes—was conducted to provide a reference point for comparison over time as this sector evolves. The manufacturing supply chain analysis included processing of raw materials, making required subcomponents, and assembling final products, using benchmarks that crossed 12 economies: Brazil, Canada, China, Germany, India, Japan, Malaysia, Mexico, South Korea, Republic of China (Taiwan), the United Kingdom, and the United States. Larger economies, with extensive manufacturing supply chains and high prevailing wages, tend to retain more value added from clean energy manufacturing than small economies. Manufacturing of clean energy technologies drives extensive trade among economies to support the widely distributed supply chain links. Production of wind turbine components and photovoltaic modules is more centralized than production of light-emitting diodes and lithium-ion battery cells. Across the four clean energy technologies evaluated, there was generally an excess of manufacturing capacity relative to global supply.
Solar Photovoltaic and Storage Supply Chains and Technology and Market Opportunities
This talk will highlight the most recent efforts from the National Renewable Energy Laboratory (NREL) to track solar photovoltaic (PV) and storage supply and demand in the United States and globally, as well as bottom-up calculations of manufacturing costs for facilities across the globe. We will begin with an overview of the global solar PV supply chain and 2022 benchmark input data used for NREL's bottom-up crystalline silicon (c-Si) and thin film PV module manufacturing cost models. For the polysilicon, wafer, cell conversion, and module assembly steps of the c-Si supply chain, and for thin film modules, we will review the industry-collected input data and methods used for calculating the costs of goods sold (COGS); research and development (R&D) expenses; and sales, general, and business administration (S, G, and A) expenses. This 2022 benchmark analysis is compiled for state-of-the-art c-Si and thin film PV module manufacturing in several countries and regions; and will also include a quantified summary of the impacts of the manufacturing incentives and tax credits that are available for solar manufacturing and installations within the United States. Next generation technologies that lower PV manufacturing and installation costs, reduce operations and maintenance (O&M) expenses, and improve system energy yield will also be highlighted. We will conclude with projections of solar market penetration to 2050 from NREL's Solar Futures Study and Annual Technology Baseline (ATB) model, which includes solar coupled with lower-cost storage scenarios as well as the range of future cost scenarios for other power generation sources. We look forward to sharing NREL's extensive work in these areas and discussing ideas for future directions.
Monolayer Plasmonic Nanoframes as Large‐Area, Broadband Metasurface Absorbers
Abstract Broadband absorbers are useful ultraviolet protection, energy harvesting, sensing, and thermal imaging. The thinner these structures are, the more device‐relevant they become. However, it is difficult to synthesize ultrathin absorbers in a scalable and straightforward manner. A general and straightforward synthetic strategy for preparing ultrathin, broadband metasurface absorbers that do not rely on cumbersome lithographic steps is reported. These materials are prepared through the surface‐assembly of plasmonic octahedral nanoframes (NFs) into large‐area ordered monolayers via drop‐casting with subsequent air‐drying at room temperature. This strategy is used to produce three types of ultrathin broadband absorbers with thicknesses of ≈200 nm and different lattice symmetries (loose hexagonal, twisted hexagonal, dense hexagonal), all of which exhibit efficient light absorption (≈90%) across wavelengths ranging from 400–800 nm. Their broadband absorption is attributed to the hollow morphologies of the NFs, the incorporation of a high‐loss material (i.e., Pt), and the strong field enhancement resulting from surface assembly. The broadband absorption is found to be polarization‐independent and maintained for a wide range of incidence angles (±45°). The ability to design and fabricate broadband metasurface absorbers using this high‐throughput surface‐based assembly strategy is a significant step toward the large‐scale, rapid manufacturing of nanophotonic structures and devices.
Automation and Quality Control for CMS Outer Tracker Module Assembly at Fermilab’s SiDet
Automation and quality control techniques for 2S and PS sensor modules for the CMS Outer Tracker for the HL-LHC era have been developed at the Silicon Detector facility at Fermilab. Examples include a laser scanning procedure to check manufacturing specifications for the 2S sensor modules, and an automated gluing process to accurately assemble PS sensor modules. Processes were verified and documented for the production stage of the Outer Tracker.
THERMAL STRUCTURAL AND SHOCK EVENT EVALUATIONS OF THE FUELING PELLET INJECTION SYSTEM FOR ITER
The US is among seven partner nations in a collaborative effort to design, build, and demonstrate fusion’s ability to be a large-scale carbon free energy source. Each country has its own Domestic Agencies (DA) that contribute directly to the ITER project. US ITER, which is a DOE Office of Science project managed by Oak Ridge National Laboratory, is developing world class engineering solutions to the design, construction, and assembly of the burning plasma experiment that can demonstrate the scientific and technological feasibility of fusion. US ITER’s scope includes completing the preliminary and final design, qualifying materials and processes for manufacture and testing, executing manufacturing, and delivering the Fueling Pellet Injection System (FPIS) to the ITER site for assembly. The US-ITER FPIS system is designed to inject cryogenically frozen pellets of deuterium-tritium (D-T) into the plasma. The FPIS has two main functions: 1. Provide a steady supply of deuterium and tritium fuel, 2. Mitigating the impact of edge localized modes on the plasma facing components. The FPIS will have the capability to reside in three port cells within a tritium second barrier containment cask. Each pellet cask contains three flight tubes linking with penetrations on the torus cryopump housing and vacuum vessel (VV): two for the magnetic high field side (HFS) pellet injection and one for the magnetic low field side (LFS) pellet injection. This paper presents results of the thermal-structural analyses of the FPIS flight tube structural components when subjected to various loads such as electromagnetic (EM) loads, nuclear heating, seismic, and operational, and dynamic shock events. The resulting temperatures and stresses under combined conditions have been found to satisfy the design criteria to ensure safe and reliable operation of the FPIS flight tubes within the vacuum vessel.
Thin film block copolymer self-assembly for nanophotonics
The nanophotonic engineering of light–matter interactions has profoundly changed research behind the design and fabrication of optical materials and devices. Metasurfaces—arrays of subwavelength nanostructures that interact resonantly with electromagnetic radiation—have emerged as an integral nanophotonic platform for a new generation of ultrathin lenses, displays, polarizers and other devices. Their success hinges on advances in lithography and nanofabrication in recent decades. While existing nanolithography techniques are suitable for basic research and prototyping, issues of cost, throughput, scalability, and substrate compatibility may preclude their use for many metasurface applications. Patterning via spontaneous self-assembly of block copolymer thin films offers an enticing alternative for nanophotonic manufacturing that is rapid, inexpensive, and applicable to large areas and diverse substrates. This review discusses the advantages and disadvantages of block copolymer-based nanopatterning and highlights recent progress in their use for broadband antireflection, surface enhanced Raman spectroscopy, and other nanophotonic applications. Here recent advances in diversification of self-assembled block copolymer nanopatterns and improved processes for enhanced scalability of self-assembled nanopatterning using block copolymers are also discussed, with a spotlight on directions for future research that would enable a wider array of nanophotonic applications.
BIL High Speed Fuel Cell Stack Manufacturing
General Motors LLC (GM) was awarded a project to develop and implement technologies for manufacturing 20,000 units of Fuel Cell Stacks per year on two shifts per day basis. GM leveraged prior in-house expertise in designing the Fuel Cells, deploying the manufacturing process steps in the laboratory environment as well as the deployment in the industrial environment on a smaller scale. The project focus was to design, build, and deploy a manufacturing line consisting of an anode and cathode electrode processing, unitized electrode assembly, fuel cell stacking, compression, testing, and final assembly of the fuel cell stack. The project was terminated in the first budget period.
Deuterium Concentration Effects on Cell Cycle Progression
Deuterium (D), which is found in natural water at ~ 150 ppm, seems to play an important role in biology. For example, D concentrations above 150 ppm are known to produce toxic effects in many organisms. There is also evidence to suggest D levels significantly less than 150 ppm can cause delays in progression through the normal mitotic cell cycle. Some have even theorized that the D:H ratio in cells may impact an organism’s radiation resistance. Therefore, evaluating the role of D and the D:H ratio in eukaryotic and prokaryotic cells should lead to a better understanding of cell cycle progression and radiation resistance in these organisms. Research in this field has likely been stalled by the limited availability of D 2 O with varying D concentrations needed to accurately study the deuterium effects. However, SRNL can currently manufacture D 2 O in varying concentrations, and we have assembled a unique team of radiation biologists, microbiologists, radiochemists, and health physics to form an interdisciplinary research group to study the cell cycle as a function of D concentration in order to address several fundamental science questions. Proposed work in FY20 was a collaborative effort with Augusta University to utilized BSL-2 mammalian cell lines. Lab work was halted due to the COVID-19 pandemic. An intensive literature review was performed and identified pertinent knowledge gaps that could be filled in future research efforts.
Use of Commercial Off-The-Shelf Parts with 3-D Printed Connectors for Powered Air Purifying Respirators
This report presents preliminary results from the performance evaluation of a powered air purifying respirator (PAPR) assembled from commercial off-the-shelf (COTS) parts. Cost is a major limiting factor to PAPR adoption in healthcare. Moreover, the lack of standardization for filters and batteries poses a challenge for clinics and hospitals. Rapid prototyping of connectors, both mechanical and electrical, offers a possible solution in addressing both issues. We used 3-D printed connectors to assemble COTS components into a prototype PAPR. Large-scale manufacturing of 3-D printed connectors may be accomplished by converting the computer-aided design (CAD) drawings to pressure-injection molds.
Functionally Designed Ultra-Lightweight Carbon Fiber Reinforced Thermoplastic Composites Door Assembly (Final Scientific/Technical Report)
This is the final technical report for a project that developed an ultra-lightweight carbon fiber reinforced thermoplastics composite door assembly for a mid-size SUV. The project was able achieve a weight reduction of at least 42.5% while maintaining or exceeding the fit, function, safety, stiffness, and crash performance requirements of the current baseline door. Additionally, the target cost was set at less than $5 per pound of weight saved. To accomplish these goals, the project team employed a systems approach that involves redesigning the door assembly, exploring novel materials, optimizing the design, and utilizing advanced manufacturing technologies.
Apparatus and method for manufacturing an air maintenance tire
Apparatus and method for manufacturing an air maintenance tire includes an air pumping tube assembly station constructing an air pumping tube sub-assembly, a tire preparation station for forming passageways in the tire to accept an outlet device of the air pumping tube sub-assembly, an air pumping tube sub-assembly installation station and a pressure regulator installation station. The air pumping tube sub-assembly inserts into an elongate tire groove opening, facilitated by groove-spreading apparatus.
Device and method to manipulate ions in multi level system
An apparatus includes multiple levels of ion transport channels, with successive levels coupled by elevator channels. Efficient three dimensional packing provides long path lengths in practical volumes for ion mobility separation with high resolving power. Disclosed elevator configurations provide efficient routing of ion transport channels across levels with low ion loss, enabling ion mobility separation over 100 levels or more. Elevator configurations include (i) opposed traveling waves meeting at an elevator entrance, (ii) external elevator with a wrap-around electrode bank, (iii) external elevator with electrode banks on parallel extension plates, or (iv) elevator operating in surfing mode, in various combinations. Manufacture is aided by printed wiring boards, with interchangeable boards. Assembly with motherboard, spacer block(s), and alignment pins provides efficient distribution of electrode excitations and accurate reproducible positioning.
MEA Manufacturing R&D
Presentation summarizing MEA manufacturing R&D project presented during DOE Hydrogen Program 2023 Annual Merit Review and Peer Evaluation Meeting.