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At least 181 records · Page 10

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Gecko Mobility Aids for a Common Habitat Architecture

Spacecraft large enough for crew to move around inside them have traditionally used handrails and foot restraints to enable crew mobility. The mass of this hardware can become significant in large spacecraft such as the Common Habitat. Additionally, handrails and foot restraints in a multi-gravity habitat are trip hazards when the habitat is in a gravity environment. Further, ISS crew have noted risks of breaking ankles and wrists when using handrails for translation and have noted places where not enough handrails are present. Robotic gecko-derived grippers developed by JPL to retrieve satellites can be adapted to crew-worn pads that can adhere to surfaces to enable crew translation in microgravity. This technology will help to eliminate the need for handrails and foot restraints for mobility in crewed microgravity spacecraft cabins. It has the potential to achieve significant mass reductions in future space habitats, with application to suborbital flight, LEO, cislunar space, interplanetary space, the Moon, and Mars. Additionally, it can prevent crew injury and discomfort. Project goals and objectives are to prepare gecko uniform prototypes for use in multi-gravity testing and conduct initial investigations into human factors of postures and motions needed for intravehicular activity (IVA) translation and restraint in multiple gravity environments, without the use of handrails or foot restraints. Gecko grippers have been tested for use as robotic end effectors terrestrially, on microgravity aircraft, and aboard the ISS. Using the grippers as a body-mounted system to achieve IVA crew mobility is a new application that has not been pursued outside of this effort. This work will continue paper studies performed by NASA student interns by developing physical prototypes of spacecraft crew uniforms with gecko-derived body-mounted grippers. Clothing prototypes may include long sleeves, short sleeves, long pants, shorts, gloves, and/or booties equipped with gecko gripper pads. Forward work is to test these uniforms in a 1g environment to verify that the design does not introduce obstructions, trip hazards, or other consequences when used in terrestrial gravity. Based on the 1g test results, the uniform prototypes will be refined, and a test plan developed for testing at 0g, (1/6)g, and (3/8)g.

Restraints and Mobility Aids↗

DOE OSTI2020

Optical fiber connector ferrule assembly having dual reflective surfaces for beam expansion and expanded beam connector incorporating same

An expanded beam ferrule includes a first ferrule halve having first reflective surfaces and a second ferrule halve having second reflective surfaces, which together retain optical fibers. The pair of reflective surfaces output collimated light parallel to the mid-plane of the ferrule. An external sleeve aligns the external surface of two similar ferrules, with corresponding second reflective surfaces of the ferrules facing each other. Output light from an optical fiber held in one ferrule is bent twice by the pair of reflective surfaces, with beam divergence after the first bent, and collimation after the second bent. The collimated light is transmitted to the facing second reflective surface in a facing second ferrule aligned by the sleeve, which is subject to optical reshaping in reverse to that undertaken in the first ferrule, so as to converge and focus light to input to the optical fiber held in the other ferrule.

42 ENGINEERING↗

DOE OSTI2021

Cylinder cooling in opposed-piston engines

A cylinder assembly with a cylinder liner and a sleeve is provided that includes features that reduce coolant flow stagnation. The sleeve encloses a center section of the cylinder liner to form cooling channels that removes excess heat from the combustion area of the cylinder. The cylinder liner includes features for cooling between bridges in the cylinder's exhaust port.

Sahasrabudhe, Abhishek↗

DOE OSTI2021

Tribological behavior of ceramic-alloy bearing contacts in molten salt lubrication for concentrating solar power

Molten salts are considered as candidate heat transfer fluids and thermal energy storage media for next generation concentrating solar power (CSP). A molten salt circulates inside the piping and heat exchanger and also functions as a lubricant for the sleeve bearings of the CSP pump. Furthermore, wear- and corrosion-resistant high-temperature bearing materials are critical for the pump efficiency and durability. This study evaluated the tribological performance of candidate bearing materials in lubrication of a molten chloride salt mixture (20% NaCl + 40% MgCl 2 + 40% KCl) at 750 °C in an inert argon gas (a simulative CSP pump environment). Six ceramic-alloy pairs were tested, zirconia and silicon nitride against Haynes 244, Hastelloy C276, and Tribaloy T900 alloy, and ranked by the friction coefficient and wear loss. Characterization of worn surfaces suggested the wear mechanism as a combination of abrasion, adhesion, and tribocorrosion. Results from this study provide fundamental insight for the development and selection of bearing materials for molten salt powered CSP pumps.

14 SOLAR ENERGY↗

DOE OSTI2021

High Temperature Alloys Session 1

Section III Division 5 overview Code materials VHTR materials 617 and 800H Qualification of additional materials Corrosion effects Operating plant experience Additive/advanced manufacturing Control rod sleeves Pressure Vessel Steels Allowed materials Elevated temperature limits and properties Supply chain Welding Radiation damage

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Thermal analyses of high-power advanced thermoacoustic radioisotope power system for future space exploration missions

This paper presents the results of 3-D thermal analyses of the heat source assembly of a 440 We advanced radioisotope power system (RPS) for future space exploration missions. This high thermal efficiency RPS employs a heat source assembly of eight Step 2 General Purpose Heat Source (GPHS) modules and four Thermoacoustic Power Converter (TAPC) units. Each unit is thermally coupled to two GPHS modules. Here, the analyses investigated the temperatures of the Iridium (Ir) alloy cladding of the 238 PuO 2 fuel pellets and the surface of the Fine Weave Pierced Fabric (FWPF) aeroshell in the GPHS modules to ensure reliable operation and safety in case of an unlikely reentry. Conductive coupling of the GPHS modules to the heater heads of the TAPC units produces relatively uniform axial and azimuthal distributions of heat flux and temperature. However, for this case the temperature of the Ir alloy cladding is lower than the desired values of 1173 K to maintain sufficient ductility. Adding a 5 mm wide He filled gap and decreasing the thickness of the graphite sleeve to 10 mm increased Ir cladding temperature to 1197–1174 K, which are in the desired range. The maximum surface temperatures of the FWPF graphite aeroshell of 1022–1131 K is well below the NASA specified limit of 1373 K. In addition, the total mass of the heat source assembly decreased by 19.6 kg, ~43% saving compared to original design.

42 ENGINEERING↗

DOE OSTI2020

A high-pressure flow through test vessel for neutron imaging and neutron diffraction-based strain measurement of geological materials

Neutron scattering and neutron imaging have emerged as powerful methods for experimentally investigating material deformation and fluid flow in the interior of otherwise inaccessible or opaque structures. This paper describes the design and provides example uses of a pressure cell developed for investigating such behaviors within geological materials. The cell can accommodate cylindrical samples with diameters up to 38.1 mm and lengths up to 154 mm. Additionally, ports in the cell and a pressure isolating sleeve around the sample allow the independent application of confining pressure up to 69 MPa and axial pressure up to 34.5 MPa. Furthermore, two material versions of the cell have been manufactured and used to date. An aluminum version is typically used for temperatures below 40 °C, because of its relative transparency to neutrons, while a titanium version, which is comparatively more neutron attenuating, is used for experiments requiring triaxial pressurization under conditions up to 350 °C. The pressure cells were commissioned at the VULCAN engineering diffractometer at the Oak Ridge National Laboratory (ORNL), Spallation Neutron Source, and have since been used at the ORNL high flux isotope reactor CG1-D imaging beamline, National Institute of Standard and Technology (NIST) BT-2, and NIST NG6 imaging beamlines.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Design and Analysis of an Integrated Additively Manufactured Test Article for Plasma-Facing Components

Current plasma-facing components (PFCs) used in helium-cooled divertor modules are complex structures with tungsten tile, steel sleeve components, and cartridges, all assembled in a helium-cooled multiple jet (HEMJ) structure. The goal of this project is to simplify the complex PFC design using additive manufacturing techniques to create a single integrated tungsten test article. Apart from the flexibility this opens up in exploring a wide array of geometries for the article, having a single integrated article significantly reduces the number of joints and parts in the article, thus reducing chances of leaks. A process called electron beam melting has shown to produce very high-density samples and unique geometries, enabling HEMJ or similar designs. To validate and optimize this novel design, the model underwent a series of computational fluid dynamics and finite element analysis simulations to replicate steady-state heat flux in the divertors. The simulations presented in this study consider a steady-state base heat flux of 5 MW/m 2 , with water serving as the coolant. Future research will explore the use of helium as a coolant, simulate edge-localized-mode conditions, and include experimental validation. Since 3D-printed tungsten is anisotropic, the build direction versus build plane of the article are taken into consideration for the test article strength. Because of the high operating temperatures and low ductility of tungsten, thermal creep and brittle fracture are important failure mechanisms to consider. In conclusion, the cap is evaluated with various flow velocities and nozzle diameters, and an optimal design choice is made for which this cap will survive the divertor conditions with a conservative safety margin.

Divertor↗

DOE OSTI2023

Design and Comparison of Surface Inset Permanent Magnet Machine and Surface Permanent Magnet Machine without Heavy Rare Earth Magnets for Traction Applications

This paper presents two machine designs: a surface inset permanent magnet (SIPM) machine and a surface permanent magnet (SPM) machine, both without heavy rare-earth magnets, that achieve 50 kW/L active power density and a constant-power speed ratio of 3 for EV traction applications. Compared to surface PM machines, SIPM machines do not require a special containment sleeve to hold the magnets in place at high speeds, provided that the rotor laminations are carefully designed together with the magnet mounting configuration to ensure the rotor’s structural integrity. Comparisons between the SPM and SIPM machines sharing the same stator, same current level, and same power speed envelope are presented. Both deliver very similar performance characteristics, but the SIPM machine’s simpler magnet containment configuration may give it an advantage in terms of reduced material and manufacturing costs.

42 ENGINEERING↗

DOE OSTI2020

Design of a 100 kW Surface Permanent Magnet Machine with Wide Constant Power Speed Ratio for Traction Applications

Surface permanent magnet (SPM) machines are considered to be strong candidates for traction applications due to their high power density and high efficiency. By adopting fractional-slot concentrated windings, SPM machines can achieve a wide constant power speed range. A carbon fiber sleeve is applied to ensure the retainment of the magnets at high speed operating conditions. The purpose of this paper is to present the design of a high speed SPM machine for traction applications with 25 kW/Liter active power density and a wide constant-power speed range that is consistent with guidelines and targets presented in the Electrical and Electronics Technical Team Roadmap published by the US Department of Energy. The predicted electromagnetic performance and structural characteristics are presented based on both analytical and FEA results.

42 ENGINEERING↗

DOE OSTI2020

Intubation Containment System for Improved Protection From Aerosolized Particles During Airway Management

Worldwide efforts to protect front line providers performing endotracheal intubation during the COVID-19 pandemic have led to innovative devices. Authors evaluated the aerosol containment effectiveness of a novel intubation aerosol containment system (IACS) compared with a recently promoted intubation box and no protective barrier. In a simulation center at the authors’ university, the IACS was compared to no protective barrier and an intubation box. Aerosolization was simulated using a commercial fog machine and leakage of aerosolize mist was visually assessed. The IACS appeared to contain the aerosolized mist, while the intubation box allowed for mist to contact the laryngoscopist and contaminate the clinical space through arm port holes and the open caudal end. Both devices protected the laryngoscopist better than no protective barrier. The IACS with integrated sleeves and plastic drape appears to offer superior protection for the laryngoscopist and assistant providers from aerosolized particles.

aerosols↗

DOE OSTI2023

Physics-Informed Deep Learning-Based Proof-of-Concept Study of a Novel Elastohydrodynamic Seal for Supercritical CO 2 Turbomachinery

Supercritical carbon dioxide (sCO 2 ) power cycles show promising potential of higher plant efficiencies and power densities for a wide range of power generation applications such as fossil fuel power plants, nuclear power production, solar power, and geothermal power generation. sCO 2 leakage through the turbomachinery has been one of the main concerns in such applications. To offer a potential solution, we propose an elastohydrodynamic (EHD) seal that can work at elevated pressures and temperatures with low leakage and minimal wear. The EHD seal has a very simple, sleeve-like structure, wrapping on the rotor with minimal initial clearance at micron levels. Here, in this work, a proof-of-concept study for the proposed EHD seal was presented by using the simplified Reynolds equation and Lame’s formula for the fluid flow in the clearance and for seal deformation, respectively. The set of nonlinear equations was solved by using both the conventional Prediction–Correction (PC) method and modern Physics-Informed Neural Network (PINN). It was shown that the physics-informed deep learning method provided good computational efficiency in resolving the steep pressure gradient in the clearance with good accuracy. The results showed that the leakage rates increased quadratically with working pressures and reached a steady-state at high-pressure values of 15~20 MPa, where Q = 300 g/s at 20 MPa for an initial seal clearance of 255 μm. This indicates that the EHD seal could be tailored to become a potential solution to minimize the sCO 2 discharge in power plants.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2022

A DNA molecular printer capable of programmable positioning and patterning in two dimensions

Nanoscale manipulation and patterning usually require costly and sensitive top-down techniques such as those used in scanning probe microscopies or in semiconductor lithography. DNA nanotechnology enables exploration of bottom-up fabrication and has previously been used to design self-assembling components capable of linear and rotary motion. In this work, we combine three independently controllable DNA origami linear actuators to create a nanoscale robotic printer. The two-axis positioning mechanism comprises a moveable gantry, running on parallel rails, threading a mobile sleeve. We show that the device is capable of reversibly positioning a write head over a canvas through the addition of signaling oligonucleotides. We demonstrate “write” functionality by using the head to catalyze a local DNA strand–exchange reaction, selectively modifying pixels on a canvas. Furthermore, this work demonstrates the power of DNA nanotechnology for creating nanoscale robotic components and could find application in surface manufacturing, biophysical studies, and templated chemistry.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2021

Characterization of an electrically conductive proppant for fracture diagnostics

Fracture diagnosis with electromagnetic (EM) and electrical tools requires proppants with high electrical conductivity and mechanical strength. Lab measurements of the electrical and hydraulic conductivity of proppants are critical for selecting the best candidates. Such measurements greatly benefit simulations, field tests, and the ultimate application of such proppants in the field. To that end, a new lab protocol is developed for measuring the electrical and hydraulic conductivity of proppants. The lab setup, which mainly includes a resistivity core holder and a Hassler sleeve core holder, allows for simulation of realistic pressure and temperature conditions when making measurements. Petroleum coke (PC) is proposed as a candidate proppant because of its widespread availability and low cost. Lab measurements show that the effective electrical conductivity of pure PC in a model fracture is approximately 5000 S/m, under a closure stress greater than [Formula: see text] (4000 psi). When PC is mixed with sand, the effective electrical conductivity of the mixture decreases with an increasing weight percentage of sand. Although sand degrades the contact between PC particles, the electrical conductivity stays reasonably high (approximately 1700 S/m) when 50% sand is added. Hydraulic conductivity measurements show that when a fracture is propped with pure PC, the measured fracture conductivity is greater than [Formula: see text] ([Formula: see text]) (dimensionless fracture conductivity greater than 100 for a shale with [Formula: see text] or 100 nD permeability) under a confining pressure of [Formula: see text] (6000 psi). This means that a fracture propped with PC is infinitely conductive in a typical shale formation. When sand is added, the fracture’s hydraulic conductivity becomes even higher, which clearly shows PC’s ability of sustaining high stresses. The proposed protocol provides a robust and effective method that can be generalized for lab testing for other candidate proppants. The data presented clearly show that PC has the potential for field-scale applications in EM hydraulic fracture diagnostics.

Geochemistry & Geophysics↗

DOE OSTI2023

Utah FORGE 1-2551: Multi-Stage Fracturing System and Well Tractor to Enable Zonal Isolation During Stimulation and EGS Operations in Horizontal Wellbores - Workshop Presentation and Report

Included here are a presentation recording, slides, and report on the Multi-Stage Fracturing System and Well Tractor to Enable Zonal Isolation During Stimulation and EGS Operations in Horizontal Wellbores project by Colorado School of Mines, presented by Dr. William W. Fleckenstein. One goal of the project is to develop and demonstrate the use of low-cost, rapid multistage fracture stimulation technology with cemented casing frac sleeves that eliminates packers used in both conventional stimulation and injection flow control. The second goal is to develop and demonstrate the devices to effectively detect and control the flow of heat-carrier fluid solely from a long-reach injector through the network of induced and existing fractures and produced from an open-hole long-reach well to improve heat recovery. This presentation was featured in the Utah FORGE R&D Annual Workshop on September 7, 2023. The workshop provided a valuable opportunity to explore the progress made in each of the 17 Research and Development projects funded under Solicitation 2020-1 which aim to enhance our understanding of the crucial factors influencing the development of Enhanced Geothermal Systems (EGS) reservoirs and resources.

15 GEOTHERMAL ENERGY↗

DOE OSTI2021

A trait-based framework for linking microbial communities with carbon transformations under precipitation change

Droughts are common throughout the world. As the climate changes, droughts may become more frequent and intense. Still, scientists are uncertain about how drought will affect the natural world, particularly the bacteria, fungi, and other microbes that live in soils. These tiny life forms are crucial because they control the Earth’s flows of carbon and essential nutrients. Researchers at the University of California, Irvine, and Lawrence Berkeley National Laboratory teamed up to study how the microbiome, or collection of bacteria and fungi in the soil, deals with drought. Since 2007, the researchers have used shelters with retractable roofs to prevent nearly half of normal rainfall from reaching grass and shrub ecosystems, and their soil microbiomes, in Southern California. The study team discovered that microbes have some clever tricks up their sleeve for surviving drought. When growing on dead grass as a food source, microbes ramp up production of specialized chemicals called osmolytes that keep their cells from drying out. But microbes growing on dead shrubs face another problem. Unlike grass, shrub leaves are a lousy food source. To digest and consume shrub leaves, microbes have to exude more enzymes, which act like biochemical chef knives that chop complex leaf molecules into bite-sized pieces. Carbon is the coin of the microbial realm, earned via enzyme action or slurping up dead plant juices. Microbes growing under normal conditions on tasty dead grass have it easy: they can spend most of their carbon currency on growth. With drought, life gets harder as microbes need to pay up for osmolytes and ramp down their growth. It gets worse with shrub leaves because microbes have to multi-task among growth, enzyme secretion, and osmolyte production. When drought hits, microbes on shrub leaves forgo the osmolytes, probably because losing the carbon revenue from enzyme investment would be a deal-breaker for survival. The next question tackled by the researchers asked how the genes controlling microbial lifestyles sort out across the tree of life. Most microbiologists thought these lifestyles would correspond to rather large branches on the tree. But the study team found that in fact, very closely related microbes differ in important and interesting ways. For example, bacteria that have nearly identical housekeeping genes respond distinctively to warming, rainfall, and plant chemistry. As a result, soil microbiomes are much richer in diversity than originally thought. And studying microbial diversity in much greater detail could open up many more possibilities for how microbial life deals with changing environmental conditions. Trying to understand microbial life without the fine details of genetic diversity is like trying to stream Netflix on a dial-up connection. By looking across the landscape, the researchers revealed that microbial diversity is absolutely critical for maintaining the planet’s flows of carbon and nutrients. The study team designed a new technology—microbial cages—for transplanting intact microbiomes. With the cages, the researchers could move microbiomes to novel environments and compare their ability to cycle carbon and nutrients. In some cases, performance tailed off when microbiomes found themselves in a new environment, but in other cases, performance rivaled or even exceeded that of the resident microbiome. And even the low performers eventually caught up to the native microbiomes if given sufficient time. These findings mean that microbiomes—at least in Southern California—may be resilient to climate shifts due to a high diversity of microbial lifestyles. Coping with heat and drought may literally be in their DNA. The last piece of the research puzzle, and a “Holy Grail” for microbial ecologists, is to forecast the behavior of diverse microbiomes. To meet this challenge, the study team developed new theory and computer models. For the first time, these models account for hundreds of different microbes and how their intricate lifestyles cope with drought. The models are starting to connect the tiniest microbes with the global cycles that sustain Earth’s farms, fields, and forests. With that connection, it will be easier for society to plan for a world with more droughts and other climate disruptions.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

High Toughness Cermets for Molten Salt Pumps

Concentrated Solar Power plants using nitrate salts used cantilevered pump designs to avoid use of bearings in the 565°C salt; however, this necessitated the use of a sump that added additional cost, complexity, and thermal losses. Sump systems had their own complications, including risk of flooding the sump due to control issues either with level indicators or failures in the control valve responsible for filling the sump. Long-shafted pumps were developed and tested, and they outline the need to develop journal sleeves and bearings for new salt systems. Based on reports, pumps will need to be a vertical single- or multi-stage type, mounted to the roof of the molten salt tanks. Design and service for molten salt pumps above 550°C is relatively limited, and at temperatures up to 750°C there is no available design or service experience. Long-shaft pumps that extend to the bottom of the thermal energy storage tank will require bearing materials that are suitable to the given salt chemistry. Lubricity of proposed salts is unclear and need to be determined, especially for cold-tank pumps that require multi-stages for lifting the salt to the top of the tower. Materials, design, and maintenance are all major unknowns.

14 SOLAR ENERGY↗

DOE OSTI2022

Seven Percent Critical Experiment Core Analysis Approach on Fuel Rods – Core Configurations T155-NoMo, and T155-397Mo.

A series of experiments will be performed to test the integral effects of molybdenum on the reactivity of a critical system. These experiments will use the 7uPCX assembly with the 1.55 cm triangular pitch grid plates. Molybdenum sleeves, consisting of 19.6 inch long 0.5-inch nominal outside diameter molybdenum tubes with 0.031-inch nominal wall thickness and centering hardware, will be placed on some of the fuel rods in the array. The purpose of this analysis is to examine two configurations of the 7uPCX using the 1.55 cm triangular pitch grid plates in fully-reflected approach-to-critical experiments with the number of fuel rods in the array as the approach parameter. This document presents the results of the analysis that was done to allow completion of the 7uPCX Configuration Checklist from Appendix A of SPRF-AP-005 [SNL 2020] for the cores noted above. The checklists for these cores are shown in Appendix A.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗