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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Scalable Dry Printing Manufacturing to Enable Long-Life and High Energy Lithium-Ion Batteries

Slurry casting method dominates the electrode manufacture of lithium-ion batteries. The entire procedure is similar to the newspaper printing that includes premixing of cast materials into solvents homogeneously, and continuously transferring and drying the slurry mixture onto the current collector. As a market approaching US $80 billion by 2024, the optimization of manufacture process is crucial and attractive. However, the organic solvent remains irreplaceable in the wet method for making slurries, even though it is capital-intensive and toxic. In this paper, an advanced powder printing technique is demonstrated that is completely solvent-free and dry. Through removing the solvent and related procedures, this method is anticipated to statistically save 20% of the cost at a remarkably shortened production cycle (from hours to minutes). The dry printed electrodes outperform commercial slurry cast ones in 650 cycles (80% capacity retention in 500 cycles), and thick electrodes are successfully fabricated to increase the energy density. Furthermore, microscopy techniques are utilized to characterize the difference of electrode microstructure between dry and wet methods, and distinguish dry printing's advantages on controlling the microstructure. Finally, this study proves a practical fabrication method for lithium-ion electrodes with lowered cost and favorable performance, and allows more advanced electrode designs potentially.

25 ENERGY STORAGE↗
DOE OSTI2019

Carrier Dynamics and Morphology Regulated by 1,8-Diiodooctane in Chlorinated Nonfullerene Polymer Solar Cells

Very small amounts of 1,8-diiodooctane (DIO) are very effective at optimizing the performance of polymer solar cells (PSCs). To date, the underlying influences are not yet fully understood, especially in nonfullerene PSCs. Herein, the influence of DIO on carrier dynamics and morphology in the PBDBT2Cl:IT4F system was investigated in detail. We combined the characterization of the transient dynamics with the morphology characterization of PSC devices to explore the origin of enhanced performance. Compared to the cast device, the champion device with 0.5% DIO revealed the maximum of current density (J sc ) and fill factor (FF). The optimum DIO content helps to enhance carrier transport and optimize morphology, while excess DIO produces adverse effects due to the induced intense aggregation and dilated size in blend films. The results provide some hints of improved device performance upon using DIO as an additive in nonfullerene PSCs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2016

Microstructure evolution and mechanical properties of nano-SiCp/AZ91 composite processed by extrusion and equal channel angular pressing (ECAP)

Nano-SiCp/AZ91 magnesium matrix composite was fabricated by stir casting. The as-cast ingots were extruded at 350 °C, then processed by equal channel angular pressing (ECAP) at various temperatures (250 °C, 300 °C and 350 °C). Grains are significantly refined after the extrusion and the ECAP. A basal fibre texture was detected by neutron diffraction after the extrusion, which inclines about 45° to the extrusion direction (ED) after the ECAP. Nano-scaled SiC particles agglomerate in the as-cast composite. After the extrusion, the agglomeration tends to form continuous or discontinuous strips along the extrusion direction. By application of the ECAP, the agglomerated SiC particles are partly dispersed and the strips formed during the extrusion tend to be thinner and broken with the increasing pass number. The yield tensile strength (YTS) and the ultimate tensile strength (UTS) of the composite are dramatically increased after the extrusion. ECAP for one pass at various temperatures further increases the strength, however, the YTS decreases with the increasing ECAP temperature and the pass number. The Orowan equations predict the maximum YTS of the composite may be up to 400 MPa providing SiC particles are homogenously distributed in the matrix. - Highlights: •Nano-scaled SiC particles were successfully added into AZ91 by stirring casting. •Agglomeration of nano-particles were improved by extrusion and ECAP. •Yield strength of the composite is 328 MPa after one pass of ECAP. •Further ECAP process with optimized parameters may fully disperse nano-particles. •Yield strength is predicted to up to 400 MPa when particles are fully dispersed.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Automatic Rural Road Centerline Detection and Extraction from Aerial Images for a Forest Fire Decision Support System

To effectively manage the terrestrial firefighting fleet in a forest fire scenario, namely, to optimize its displacement in the field, it is crucial to have a well-structured and accurate mapping of rural roads. The landscape’s complexity, mainly due to severe shadows cast by the wild vegetation and trees, makes it challenging to extract rural roads based on processing aerial or satellite images, leading to heterogeneous results. This article proposes a method to improve the automatic detection of rural roads and the extraction of their centerlines from aerial images. This method has two main stages: (i) the use of a deep learning model (DeepLabV3+) for predicting rural road segments; (ii) an optimization strategy to improve the connections between predicted rural road segments, followed by a morphological approach to extract the rural road centerlines using thinning algorithms, such as those proposed by Zhang–Suen and Guo–Hall. After completing these two stages, the proposed method automatically detected and extracted rural road centerlines from complex rural environments. This is useful for developing real-time mapping applications.

Lourenço, Miguel (ORCID:0000000157673394)↗
DOE OSTI2020

Highly permeable polyethersulfone substrates with bicontinuous structure for composite membranes in CO 2 /N 2 separation

Substrate morphology has a significant effect on the CO 2 transport performance of a thin-film composite (TFC) membrane. In this study, a new mixed solvent comprising 2-pyrrolidone (2-PD) and 2-methoxyethanol (2-ME) was used to prepare polyethersulfone (PES) substrates with bicontinuous structure by water vapor-induced phase separation, followed by immersion in water as nonsolvent. Here, compared with the commonly used solvent, N-methyl-2-pyrrolidone (NMP), the 2-PD/2-ME mixed solvent is more hydrophilic and can decrease the thermodynamic stability of the casting solution significantly. As a result, the phase separation was induced via the spinodal decomposition mechanism. The open morphology bestowed the optimized substrate with a very high CO 2 permeance of 133,226 ± 3,870 GPU (1 GPU = 10 –6 cm 3 (STP) s –1 cm –2 cmHg –1 = 3.3464 × 10 -9 kg-mol s –1 m –2 Pa –1 ), which was 5 times more permeable than the baseline substrate synthesized with NMP. By using this new substrate, the prepared TFC membrane containing amines showed an increased CO 2 permeance of 908 ± 8 GPU at 57°C, which was 48 GPU higher than that with the baseline substrate. Meanwhile, the CO 2 /N 2 selectivity was retained at 162 ± 4 at 57°C. In addition, the good scalability of the new PES substrate was demonstrated by roll-to-roll fabrication of a 50' long scale-up PES substrate with a width of 21".

2-Pyrrolidone↗
DOE OSTI2024

Cast Film Production with Polyethylene Recycled from a Post-Industrial Printed Multilayer Film by Solvent-Targeted Recovery and Precipitation

The solvent-targeted recovery and precipitation (STRAP) process separates and recovers the constituent resins in multilayer plastic packaging films by selective polymer dissolution. In this work, three different experimental methods were considered to recover a polyethylene (PE) resin from a printed multilayer film by STRAP. The methods consisted of (1) a filter bag system, (2) a Soxhlet extraction, and (3) a jacketed dissolution vessel. Cast films were produced with the PE recovered from each method and were analyzed for color, mechanical properties, and number of impurities. High-quality recycled PE cast films can be produced by increasing the solvent to plastic ratio, including a filter pore size of 100 μm, and optimizing temperature control in STRAP. Furthermore, this study demonstrates that STRAP polymers can be recycled back into plastic films, enabling the potential circularity of these packaging materials.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Decreasing the Impact–Abrasive Wear of Steel

A new method of assessing the impact–abrasive resistance of steel permits simulation of the impact–abrasive wear with variation in the magnitude and inclination of the impact force, type of abrasive, and its grain size and rate of consumption. The influence of five carbide-forming elements on the properties of the cast and quenched steel is studied: specifically, attention focuses on the abrasion resistance, impact–abrasive resistance, and hardness of the steel. Optimal steel compositions with abrasion resistance and impact–abrasive resistance greater than that of 35GL steel are identified.

42 ENGINEERING↗
DOE OSTI2022

Control of High-Temperature Static and Transient Thermomechanical Behavior of SiMo Ductile Iron by Al Alloying

Abstract Silicon and molybdenum ( SiMo ) ductile iron is commonly used for exhaust manifolds because these components experience thermal cycling in oxidizing environment, which requires resistance to fatigue during transient thermomechanical loads. Previous studies have demonstrated that alloying elements, such as Al , to SiMo ductile iron reduces the amount of surface degradation during static high-temperature exposure. However, deterioration of sphericity of the graphite nodules and a decrease in ductility could affect the tendency of cracking during thermal cycling. In this article, the effect of Al alloying on static and transient thermomechanical behavior of SiMo ductile iron was investigated to optimize the amount of Al alloying. A thermodynamic approach was used to confirm the effect of the Al alloying on the phase transformations in two SiMo cast irons, alloyed by 1.8% Al and 3% Al . These two alloys were cast in a laboratory along with the baseline SiMo ductile iron. Several experimental methods were used to evaluate the dimensional stability, physical properties, static oxidation, and failure resistance during constrained thermal cycling testing to compare their high-temperature capability. Experimental results verified that Al alloying increases the temperature range and decreases volume change during eutectoid transformation, which together with enhancement of oxidation protection improved the dimensional stability. Thermocycling tests showed that the number of cycles to failure depends on the amount of Al alloying and the applied high-temperature exposure during each cycle. SEM/EDX, high-resolution TEM and µCT analysis were used to verify the mechanism resulting from the Al alloying protection. It was shown that an optimal level of Al alloying for balancing oxidation and thermal cracking resistance depends on thermomechanical conditions of application.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Development in corrosion resistance by microstructural refinement in Zr-16 SS 304 alloy using suction casting technique

Highlights: • Grain refinement was made in Zr–16 wt.% SS alloy while prepared by suction casting process. • Distribution of Laves phase, e.g., Zr{sub 2}(Fe, Cr) was raised in suction cast (SC) Zr–16 wt.% SS. • Corrosion resistance was improved in SC alloy compared to that of arc-melt-cast alloy. • Grain refinement in SC alloy assisted for an increase in its corrosion resistance. - Abstract: Zirconium (Zr)-stainless steel (SS) hybrid alloys are being considered as baseline alloys for developing metallic-waste-form (MWF) with the motivation of disposing of Zr and SS base nuclear metallic wastes. Zr–16 wt.% SS, a MWF alloy optimized from previous studies, exhibit significant grain refinement and changes in phase assemblages (soft phase: Zr{sub 2}(Fe, Cr)/α-Zr vs. hard phase: Zr{sub 3}(Fe, Ni)) when prepared by suction casting (SC) technique in comparison to arc-cast-melt (AMC) route. Variation in Cr-distribution among different phases are found to be low in suction cast alloy, which along with grain refinement restricted Cr-depletion at the Zr{sub 2}(Fe, Cr)/Zr interfaces, prone to localized attack. Hence, SC alloy, compared to AMC alloy, showed lower current density, higher potential at the breakdown of passivity and higher corrosion potential during polarization experiments (carried out under possible geological repository environments, viz., pH 8, 5 and 1) indicating its superior corrosion resistance.

36 MATERIALS SCIENCE↗
NASA NTRS2005

Distributed Adaptive Control: Beyond Single-Instant, Discrete Variables

In extensive form noncooperative game theory, at each instant t, each agent i sets its state x, independently of the other agents, by sampling an associated distribution, q(sub i)(x(sub i)). The coupling between the agents arises in the joint evolution of those distributions. Distributed control problems can be cast the same way. In those problems the system designer sets aspects of the joint evolution of the distributions to try to optimize the goal for the overall system. Now information theory tells us what the separate q(sub i) of the agents are most likely to be if the system were to have a particular expected value of the objective function G(x(sub 1),x(sub 2), ...). So one can view the job of the system designer as speeding an iterative process. Each step of that process starts with a specified value of E(G), and the convergence of the q(sub i) to the most likely set of distributions consistent with that value. After this the target value for E(sub q)(G) is lowered, and then the process repeats. Previous work has elaborated many schemes for implementing this process when the underlying variables x(sub i) all have a finite number of possible values and G does not extend to multiple instants in time. That work also is based on a fixed mapping from agents to control devices, so that the the statistical independence of the agents' moves means independence of the device states. This paper also extends that work to relax all of these restrictions. This extends the applicability of that work to include continuous spaces and Reinforcement Learning. This paper also elaborates how some of that earlier work can be viewed as a first-principles justification of evolution-based search algorithms.

Wolpert, David H.↗
DOE OSTI2022

Non-trivial symmetries in quantum landscapes and their resilience to quantum noise

Very little is known about the cost landscape for parametrized Quantum Circuits (PQCs). Nevertheless, PQCs are employed in Quantum Neural Networks and Variational Quantum Algorithms, which may allow for near-term quantum advantage. Such applications require good optimizers to train PQCs. Recent works have focused on quantum-aware optimizers specifically tailored for PQCs. However, ignorance of the cost landscape could hinder progress towards such optimizers. In this work, we analytically prove two results for PQCs: (1) We find an exponentially large symmetry in PQCs, yielding an exponentially large degeneracy of the minima in the cost landscape. Alternatively, this can be cast as an exponential reduction in the volume of relevant hyperparameter space. (2) We study the resilience of the symmetries under noise, and show that while it is conserved under unital noise, non-unital channels can break these symmetries and lift the degeneracy of minima, leading to multiple new local minima. Based on these results, we introduce an optimization method called Symmetry-based Minima Hopping (SYMH), which exploits the underlying symmetries in PQCs. Our numerical simulations show that SYMH improves the overall optimizer performance in the presence of non-unital noise at a level comparable to current hardware. Overall, this work derives large-scale circuit symmetries from local gate transformations, and uses them to construct a noise-aware optimization method.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS2010

Adjoint-Based Design of Rotors Using the Navier-Stokes Equations in a Noninertial Reference Frame

Optimization of rotorcraft flowfields using an adjoint method generally requires a time-dependent implementation of the equations. The current study examines an intermediate approach in which a subset of rotor flowfields are cast as steady problems in a noninertial reference frame. This technique permits the use of an existing steady-state adjoint formulation with minor modifications to perform sensitivity analyses. The formulation is valid for isolated rigid rotors in hover or where the freestream velocity is aligned with the axis of rotation. Discrete consistency of the implementation is demonstrated by using comparisons with a complex-variable technique, and a number of single- and multipoint optimizations for the rotorcraft figure of merit function are shown for varying blade collective angles. Design trends are shown to remain consistent as the grid is refined.

Nielsen, Eric J.↗
NASA NTRS2009

Adjoint-Based Design of Rotors using the Navier-Stokes Equations in a Noninertial Reference Frame

Optimization of rotorcraft flowfields using an adjoint method generally requires a time-dependent implementation of the equations. The current study examines an intermediate approach in which a subset of rotor flowfields are cast as steady problems in a noninertial reference frame. This technique permits the use of an existing steady-state adjoint formulation with minor modifications to perform sensitivity analyses. The formulation is valid for isolated rigid rotors in hover or where the freestream velocity is aligned with the axis of rotation. Discrete consistency of the implementation is demonstrated using comparisons with a complex-variable technique, and a number of single- and multi-point optimizations for the rotorcraft figure of merit function are shown for varying blade collective angles. Design trends are shown to remain consistent as the grid is refined.

Nielsen, Eric J.↗
DOE OSTI2018

Additive Manufacturing: A New Paradigm for the Next Generation of High-Power-Density Direct-Drive Electric Generators

In recent years, there has been a growing demand for high-power-density direct-drive generators in the wind industry owing to their high reliability, torque per unit volume, and conversion efficiencies. However, direct-drive wind turbine generators are very large, low-speed electric machines, which pose remarkable design and manufacturing issues that challenge their upscaling potential and cost of implementation. With air-gap tolerance as the main design driver, the need for high stiffness shifts the focus toward support-structure design that forms a significant portion of the generator's total mass. Existing manufacturing processes allow the use of segmented-steel-weldment disk or spoke-arm assemblies that yield stiffer structures per unit mass but tend to be heavier and more expensive to build. As a result, there is a need for a transformative approach to realize lightweight designs that can also facilitate series production at competitive costs. Inspired by recent developments in metal additive manufacturing (AM), we explore a new freedom in the structural design space with a high potential for weight savings in direct-drive generators. This includes the feasibility of using nonconventional complex geometries, such as lattice-based structures as structurally efficient options. Powder-binder jetting of a sand-cast mold was identified as the most feasible AM technology to produce large-scale generator rotor structures with complex geometry. A parametric optimization study was performed and optimized results within deformation and mass constraints were found for each design. The response to the maximum Maxwell stress due to unbalanced magnetic pull was also explored for each design. Further, a topology optimization was applied for each parameter-optimized design to validate results and provide insights into further mass reduction. These novel designs catered for AM are compared in both deflection and mass to conventional rotor designs using NREL's systems engineering design tool, GeneratorSE. The optimized lattice design with a U-beam truss resulted in a 24% reduction in structural mass of the rotor and 60% reduction in radial deflection. It is demonstrated that additive manufacturing shifts the focus from manufacturability constraints toward lower mass.

17 WIND ENERGY↗
DOE OSTI2022

Manufacturing Science

The Manufacturing Science area of leadership spans the application of fundamental science research and development activities to understand the critical steps in manufacturing processes for the purposes of control and optimization. Although manufacturing is an applied area of research, fundamental science underpins our knowledge of both traditional and transformational manufacturing processes. For example, casting, welding, and many modern additive manufacturing processes that see wide use are broadly classified as solidification processes, with material transitioning from liquid to solid phases upon cooling from higher temperature. However, our understanding of the detailed physics involved in such processes is incomplete, and solidification remains a grand challenge for materials science. To enable adoption of transformative fabrication processes or to accelerate development of traditional ones, it is necessary to develop a detailed mechanistic understanding spanning multiple scales, starting with atomic building blocks (defects, interfaces, composition) and extending all the way up to macroscale performance in moderate and/or extreme environments.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Additive Manufacturing: A New Paradigm for the Next Generation of High-Power-Density Direct-Drive Electric Generators: Preprint

In recent years, there has been a growing demand for high-power-density direct-drive generators in the wind industry owing to their high reliability, torque per-unit volume, and conversion efficiencies. However, direct-drive wind turbine generators are very large, low-speed electric machines, which pose remarkable design and manufacturing issues that challenge their upscaling potential and cost of implementation. With air-gap tolerance as the main design driver, the need for high stiffness shifts the focus toward support-structure design that forms a significant portion of the generator's total mass. Existing manufacturing processes allow the use of segmented-steel-weldment disk or spoke-arm assemblies that yield stiffer structures per unit mass but tend to be heavier and more expensive to build. As a result, there is a need for a transformative approach to realize lightweight designs that can also facilitate series production at competitive costs. Inspired by recent developments in metal additive manufacturing (AM), we explore a new freedom in the structural design space with a high potential for weight savings in direct-drive generators. This includes the feasibility of using nonconventional complex geometries, such as lattice-based structures as structurally efficient options. Powder-binder jetting of a sand-cast mold was identified as the most feasible AM technology to produce large-scale generator rotor structures with complex geometry. A parametric optimization study was performed and optimized results within deformation and mass constraints were found for each design. The response to the maximum Maxwell stress due to unbalanced magnetic pull was also explored for each design. Further, a topology optimization was applied for each parameter-optimized design to validate results and provide insights into further mass reduction. These novel designs catered for AM are compared in both deflection and mass to conventional rotor designs using NREL's systems engineering design tool, GeneratorSE. The optimized lattice design with a Ubeam truss resulted in a 24% reduction in structural mass of the rotor and 60% reduction in radial deflection. It is demonstrated that additive manufacturing shifts the focus from manufacturability constraints toward lower mass.

17 WIND ENERGY↗
DOE OSTI2017

Fabrication of compact and stable perovskite films with optimized precursor composition in the fast-growing procedure

The fast-growing procedure (FGP) provides a simple, high-yield and lead (Pb)-release free method to prepare perovskite films. In the FGP, the ultra-dilute perovskite precursor solution is drop-cast onto a hot (~240 degrees C) substrate, where a perovskite film grows immediately accompanied by the rapid evaporation of the host solvent. In this process, all the raw materials in the precursor solution are deposited into the final perovskite film. The potential pollution caused by Pb can be significantly reduced. Properties of the FGP-processed perovskite films can be modulated by the precursor composition. While CH3NH3Cl (MACl) affects the crystallization process and leads to full surface coverage, CH(NH2)2I (FAI) enhances the thermal stability of the film. Based on the optimized precursor composition of PbI2(1-x)FAI xMACl, x=0.75, FGP-processed planar heterojunction perovskite solar cells exhibit power conversion efficiencies (PCEs) exceeding 15% with suppressed hysteresis and excellent reproducibility.

14 SOLAR ENERGY↗