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At least 217 records · Page 12

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DOE OSTI2020

Electrochemical Deposition of Aluminum-Based Coatings From Aqueous Systems

The electroplating of aluminum has represented a challenge for the coatings industry for decades. The reactivity of aluminum metal leads to a very negative reduction potential. This leads to abundant gas evolution instead of aluminum reduction in water. Current aluminum deposition technology overcomes this limitation by excluding oxygen and water from the process with rigorously dry solvent and airtight plating tanks. These adaptations yield metallic aluminum depositions with significant impurities affecting its properties. In addition, this approach requires a great capital investment and cost of process maintenance. An alternative approach to Al electrodeposition has been developed based on the the use of organic ligands to stabilize the Al3+ ion in water-based solutions. By using a ligation approach, we can create aluminum species that remain stable in water while lowering the reduction potential of the aluminum complex by 0.5V. This improvement in reduction potential gives the possibility for the deposition of aluminum without significant competition from hydrogen evolution. With this platform we can deposit highly adherent aluminum-based layers on metal surfaces. The aluminum/aluminum oxide layers appear as thin, coherent and highly adherent coatings. This aluminum/alumina layer can then be chemically treated to achieve desirable surface properties which were previously inaccessible. For example, the coating can be made hydrophobic, highly adherent to different polymer coatings or even dyed using common anodizing dyes.

36 MATERIALS SCIENCE↗

DOE OSTI2020

ELECTROCHEMICAL DEPOSITION OF ALUMINUM-BASED COATINGS FROM AQUEOUS SYSTEMS

36 MATERIALS SCIENCE↗

DOE OSTI2020

Validated model of a thermoelectric heat pump clothes dryer using secondary pumped loops

The energy associated with clothes drying makes up 4% of the total residential electrical energy consumption in the US. The cost is high since most clothes dryers use electric resistance heating which is inexpensive but also energy inefficient. State-of-the-art vapor-compression heat pump clothes dryers offer significant energy savings but have limited market penetration in the US. Here, a new configuration of clothes dryer was studied that utilizes a solid-state thermoelectric heat pump with pumped secondary water loops and conventional fin-and-tube water-to-air heat exchangers. Experimental results are presented for the thermoelectric dryer prototype with a combined energy factor of 6.89 lb BDW /kWh (specific moisture extraction rate of 1.71 kg w /kWh) and a dry time of 84 min for a standard load size of 8.45 lb (3.83 kg) with 57.5% starting moisture content. This is a 85% energy efficiency improvement over baseline electric resistance dryers. The efficiency and drying time results achieved are similar to vapor compression heat pump dryers. Compared to previous air-based thermoelectric clothes dryers, the energy efficiency has been increased by 6%, but drying time has been reduced by as much as 47% using secondary pumped loops and separate heat exchangers, which represents a significant advancement in the technology. In addition to the experimental prototype, a model was also developed to study the performance. The model was validated against experimental prototype data and used to identify the range of performance (dry time and efficiency) that could be expected of the design.

42 ENGINEERING↗

DOE OSTI2025

A Comparison of Battery Charge Controller Technologies for Wave Energy Converters

Wave energy is a uniquely challenging field for electrical system designers. High peak and low average power potential with a constantly varying energy input is difficult to harness and control through conventional means. To power the blue economy, low-powered wave energy converters (WECs) need batteries for energy storage. Safely and effectively charging batteries from waves requires a charge controller to properly monitor and control voltage and current going to the battery. Currently, off-the-shelf charge controllers exist for other renewable generation such as wind, hydro, and solar. Two topologies were validated: a buck converter and a pulse width modulation (PWM) charge controller. Using an in-lab dry testbed, wave energy power inputs were simulated to properly validate the effectiveness of existing charge controller technologies, identifying the shortcomings and improvements needed to effectively harness wave energy.

battery storage↗

DOE OSTI2024

High‐Loading Lithium‐Sulfur Batteries with Solvent‐Free Dry‐Electrode Processing

Abstract Lithium‐sulfur (Li‐S) batteries, with their high energy density, nontoxicity, and the natural abundance of sulfur, hold immense potential as the next‐generation energy storage technology. To maximize the actual energy density of the Li‐S batteries for practical applications, it is crucial to escalate the areal capacity of the sulfur cathode by fabricating an electrode with high sulfur loading. Herein, ultra‐high sulfur loading (up to 12 mg cm −2 ) cathodes are fabricated through an industrially viable and sustainable solvent‐free dry‐processing method that utilizes a polytetrafluoroethylene binder fibrillation. Due to its low porosity cathode architecture formed by the binder fibrillation process, the dry‐processed electrodes exhibit a relatively lower initial capacity compared to the slurry‐processed electrode. However, its mechanical stability is well maintained throughout the cycling without the formation of electrode cracking, demonstrating significantly superior cycling stability. Additionally, through the optimization of the dry‐processing, a single‐layer pouch cell with a loading of 9 mg cm −2 and a novel multi‐layer pouch cell that uses an aluminum mesh as its current collector with a total loading of 14 mg cm −2 are introduced. To address the reduced initial capacity of dry‐processed electrodes, strategies such as incorporating electrocatalysts or employing prelithiated active materials are suggested.

Chemistry↗

DOE OSTI2024

A Comparison of Battery Charge Controller Technologies for Wave Energy Converters: Preprint

battery storage↗

NASA NTRS2014

Space Launch System Upper Stage Technology Assessment

The Space Launch System (SLS) is envisioned as a heavy-lift vehicle that will provide the foundation for future beyond low-Earth orbit (LEO) exploration missions. Previous studies have been performed to determine the optimal configuration for the SLS and the applicability of commercial off-the-shelf in-space stages for Earth departure. Currently NASA is analyzing the concept of a Dual Use Upper Stage (DUUS) that will provide LEO insertion and Earth departure burns. This paper will explore candidate in-space stages based on the DUUS design for a wide range of beyond LEO missions. Mission payloads will range from small robotic systems up to human systems with deep space habitats and landers. Mission destinations will include cislunar space, Mars, Jupiter, and Saturn. Given these wide-ranging mission objectives, a vehicle-sizing tool has been developed to determine the size of an Earth departure stage based on the mission objectives. The tool calculates masses for all the major subsystems of the vehicle including propellant loads, avionics, power, engines, main propulsion system components, tanks, pressurization system and gases, primary structural elements, and secondary structural elements. The tool uses an iterative sizing algorithm to determine the resulting mass of the stage. Any input into one of the subsystem sizing routines or the mission parameters can be treated as a parametric sweep or as a distribution for use in Monte Carlo analysis. Taking these factors together allows for multi-variable, coupled analysis runs. To increase confidence in the tool, the results have been verified against two point-of-departure designs of the DUUS. The tool has also been verified against Apollo moon mission elements and other manned space systems. This paper will focus on trading key propulsion technologies including chemical, Nuclear Thermal Propulsion (NTP), and Solar Electric Propulsion (SEP). All of the key performance inputs and relationships will be presented and discussed in light of the various missions. For each mission there are several trajectory options and each will be discussed in terms of delta-v required and transit duration. Each propulsion system will be modeled, sized, and judged based on their applicability to the whole range of beyond LEO missions. Criteria for scoring will include the resulting dry mass of the stage, resulting propellant required, time to destination, and an assessment of key enabling technologies. In addition to the larger metrics, this paper will present the results of several coupled sensitivity studies. The ultimate goals of these tools and studies are to provide NASA with the most mass-, technology-, and cost-effective in-space stage for its future exploration missions.

Holladay, Jon↗

NASA NTRS1993

Vehicle Systems Panel deliberations

The Vehicle Systems Panel addressed materials and structures technology issues related to launch and space vehicle systems not directly associated with the propulsion or entry systems. The Vehicle Systems Panel was comprised of two subpanels - Expendable Launch Vehicles & Cryotanks (ELVC) and Reusable Vehicles (RV). Tom Bales, LaRC, and Tom Modlin, JSC, chaired the expendable and reusable vehicles subpanels, respectively, and co-chaired the Vehicle Systems Panel. The following four papers are discussed in this section: (1) Net Section components for Weldalite Cryogenic Tanks, by Don Bolstad; (2) Build-up Structures for Cryogenic Tanks and Dry Bay Structural Applications, by Barry Lisagor; (3) Composite Materials Program, by Robert Van Siclen; (4) Shuttle Technology (and M&S Lessons Learned), by Stan Greenberg.

Bales, Tom↗

DOE OSTI2021

Preshaping clear glass at low temperatures

Advances in available glass chemistries and glass processing methods have accompanied and enabled some of the biggest technology revolutions, from the development and mass production of light bulbs to low-loss fiber optics and durable smartphone touchscreens. An emerging generation of low-temperature processing technologies aims to continue this important trend and make a broader array of glass components mass producible. In the issue, Mader et al. (1) describe one such innovation in glass processing—the use of low-temperature injection molding to preshape silica particle–filled composites that can later be transformed into transparent fused silica glass objects. Traditionally, transparent glass objects are manufactured in high volume from molten or softened glass, which is floated, drawn, blown, cast, or blow-molded to a desired shape (see the figure, top). The glass composition and processing technique dictate the working temperature, which is usually quite high (near 1000°C) and often restricts the choice of compatible equipment or limits the choice of glass composition. Because geometry-specific capital investment is required for production, drastic or frequent component design changes or small batches may be cost prohibitive. Alternatively, transparent glass components can also be shaped at ambient temperature from solid glass by a series of subtractive processes, including cutting or multiple stages of grinding, followed by slower processing steps, such as polishing or etching. This approach is somewhat less amenable to mass production, and certain geometries containing tool-inaccessible regions cannot be fabricated in this way. Several emerging glass-shaping technologies aim to reduce the required manufacturing temperatures and still provide access to a broader range of glass compositions and component geometries (see the figure). These approaches use a three-step process. First, a desired shape is preformed at low temperature from a glass-forming, organic-inorganic composite. Next, the preform is dried, and organic materials used to bind particles are removed. Finally, the preform is heated (sintered) well below the glass-melting temperature to densify to transparent glass. Although the second and third steps do occur at increased temperatures, only standard, geometry-agnostic driers and furnaces are required. This strategy builds on the well-studied sol-gel approach to forming monolithic glass, where silica network–forming chemical solutions are poured into molds, slowly dried, and condensed into dense glass without melting (2). In a departure from the sol-gel process, these new technologies use solvents, cross-linkers, and polymers to formulate organic-inorganic composites tuned for compatibility with a particular shaping process, with formats ranging from photocurable liquids to shear-thickening pastes to solids. The composite inorganic loadings are also typically higher than those in the pure sol-gel approach, which drastically reduces shrinkage in comparison.

36 MATERIALS SCIENCE↗

NASA NTRS1970

Progress in research on chlorate candle technology

Research and development program improves sodium chlorate candle formulation, production method, and igniter design. Cobalt is used as the fuel, dry processing methods are used to lower the water content, and a device based on pyrotechnic heater concepts is used as the igniter.

Littman, J.↗

DOE OSTI2021

Roadmap for the Completion of the Design and Implementation of a Remote Canister Monitoring System

The Office of Environmental Management within the Department of Energy is currently investigating technical issues associated with extended dry storage (50+ years) of aluminum spent nuclear fuel. As part of these efforts, a remote canister-monitoring system (RCMS) has been proposed to collect the real-time data of the environmental conditions in the canisters used for the dry storage of aluminum spent nuclear fuel in the CPP-603 facility at Idaho National Laboratory (INL). The proposed RCMS would provide the opportunity to evaluate the appropriate technologies for monitoring, to collect canister environment conditions as soon as possible, to verify and validate current laboratory-based study results and analytic modeling approaches, and to potentially identify additional dry storage options for aluminum spent nuclear fuel at the INL Site. The document provides a brief update on the progress that has been made toward deploying the RCMS and will present at a high level, the general system design philosophy behind the project and the key future tasks necessary for the completion of the RCMS system design, fabrication of the RCMS prototype, testing, and eventual deployment of the RCMS, and a tentative timeline for these tasks.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2003

Next generation ion engines: mission performances

Significant technology advances over the NSTAR DS1 ion engine were sought, especially an increase in specific impulse, total impulse, power and efficiency, and a decrease in propulsion dry mass. Two ion engine designs, one based on a derivative of the NSTAR 30-cm and the other one based on a 40-cm ion engine design, were identified as potential next generation technologies. This paper summarizes the characteristics of the three technologies in question, and their mission performances for Solar System Exploration and Primitive Bodies Exploration missions.

electric propulsion mission analysis↗

NASA NTRS1991

Technology and staging effects on two-stage-to-orbit systems

Horizontal takeoff and landing two-stage systems with an airbreathing first stage and rocket second stage are evaluated for staging Mach numbers that range from 5 to 14. All systems are evaluated with advanced technologies being developed in the NASP Program and sized to the same mission requirements. With these advanced technologies, the two-stage systems are heavier than the single stage. The weights of the two-stage systems are closely related to staging. Using a rocket on the first stage to accelerate from the turboramjet limit of Mach 6 to Mach 10 signiificantly decreases dry weight as compared to the Mach 6-staged system. The optimum dry weight staging Mach number for the scramjet two-stage system is Mach 12. At a 40 percent weight growth (current technology level), the scramjet two-stage systems are half the weight and less sensitive to weight changes than the single stage, but still require substantial technology development in the areas of inlets, nozzles, ramjet propulsion, active cooling, and high-temperature structures.

Wilhite, Alan W.↗

DOE OSTI2021

Environmental Influence on Fracture and Delamination of Electrically Conductive Adhesives

This paper presents our continued work on developing a degradation model for electrically conductive adhesive (ECA) interconnects in photovoltaic modules. Here, we characterize the fracture mechanics properties of an epoxy based ECA, for both critical and subcritical loading conditions. Emphasis is put on the influence of different environmental conditions such as temperature and humidity. We found that high levels of humidity not only weaken the adhesive joint but also promote subcritical debonding at significantly lower driving forces than in dry environments.

41 EE - Solar Energy Technologies Office (EE-4S)↗

NASA NTRS1992

Testing a Mars science outpost in the Antarctic dry valleys

Field research conducted in the Antarctic has been providing insights about the nature of Mars in the science disciplines of exobiology and geology. Located in the McMurdo Dry Valleys of southern Victoria Land (160 deg and 164 deg E longitude and 76 deg 30 min and 78 deg 30 min S latitude), research outposts are inhabited by teams of 4-6 scientists. It is proposed that the design of these outposts be expanded to enable meaningful tests of many of the systems that will be needed for the successful conduct of exploration activities on Mars. Although there are some important differences between the environment in the Antarctic dry valleys and on Mars, the many similarities and particularly the field science activities, make the dry valleys a useful terrestrial analog to conditions on Mars. Three areas have been identified for testing at a small science outpost in the dry valleys: (1) studying human factors and physiology in an isolated environment; (2) testing emerging technologies (e.g. innovative power management systems, advanced life support facilities including partial bioregenerative life support systems for water recycling and food growth, telerobotics, etc.); and (3) conducting basic scientific research that will enhance understanding of Mars while contributing to the planning for human exploration. It is suggested that an important early result of a Mars habitat program will be the experience gained by interfacing humans and their supporting technology in a remote and stressful environment.

Andersen, D. T.↗

NASA NTRS2008

Terrain-Adaptive Navigation Architecture

A navigation system designed for a Mars rover has been designed to deal with rough terrain and/or potential slip when evaluating and executing paths. The system also can be used for any off-road, autonomous vehicles. The system enables vehicles to autonomously navigate different terrain challenges including dry river channel systems, putative shorelines, and gullies emanating from canyon walls. Several of the technologies within this innovation increase the navigation system s capabilities compared to earlier rover navigation algorithms.

Helmick, Daniel M.↗

DOE OSTI2024

Fabrication and Testing of DOE Standard Canister Closure Leak Test Assembly

DOE manages over 300 types of spent nuclear fuel (SNF), many of which are located at the Idaho National Laboratory (INL) site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in onsite storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale road-ready dry storage program at the INL site. In support of establishing a large-scale road-ready dry storage program at the INL site, the Road-Ready Demonstration will first package Fort St. Vrain SNF currently in dry storage at INL into several DOE Standard Canisters (DOESCs). These DOESCs will in turn be loaded into another containment similar to commercial multi-purpose canisters. This multi-purpose canister will then be compatible with a transportation or storage system, such as a storage cask for interim storage or transportation package for offsite transport. These DOESCs will remain sealed over the course of their storage, transportation, and applicable disposal functions. The closure process for the DOESC will include fuel and basket loading, welding, inspection, leak testing, and, if needed, repair. As a follow-up to previous discussions on the design of the DOE Closure Leak Test Assembly (LTA), this report describes recent fabrication and testing efforts performed at INL. DOESCs are sealed by two sequential gas tungsten arc welds, both of which are performed by remotely operated and semiautomatic welding systems. The first weld is a circumferential pipe weld that completes the assembly of the canister body and lid assembly. The second and final closure weld attaches the vent plug to the vent socket via a butt joint. After the second weld is performed, the welds are helium leak tested using an evacuated envelope technique. The LTA was designed for both remote and manual operation. This report describes the fabrication and performance testing associated with the evacuated envelope technique. INL staff designed, fabricated, and tested the LTA at INL facilities. This testing included establishing technique and system sensitivities in accordance with ASME and American National Standards Institute N14.5 requirements. Forthcoming work will cover such areas as design optimization, process and personnel qualification, and implementation in Road-Ready Demonstration operations.

42 ENGINEERING↗

DOE OSTI2024

Drop Analysis of a Department of Energy Standard Canister Containing Fort Saint Vrain SNF– 24138

DOE manages over 300 types of SNF, many of which are located at the INL site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage (RRDS) is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in on-site storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale RRDS program at the INL site. One critical aspect of RRDS is the ability to certify the DOE Standard Canister and its associated transportation package in accordance with 10 CFR 71 for offsite transportation. Depending on the SNF type and transportation strategy, DOE Standard Canisters may be required to maintain structural integrity under hypothetical accident scenarios (e.g., drop events). The DOE Standard Canisters have been tested and analyzed under various SNF loading configurations and accident drop events in support of the Idaho Spent Fuel Facility and other DOE programs; however, no analysis has yet been completed in support of the recently initiated Road-Ready Demonstration. This paper presents preliminary results from a finite element analysis of the Ø45.7 cm × 4.6 m (Ø18 in. × 15 ft) DOE Standard Canister under the 9 m drop at 80 degrees off-vertical drop scenario considered in previous INL tests and analyses. It considers the Fort St. Vrain spent nuclear fuel loading configuration proposed for the Road-Ready Demonstration, uses updated material properties, and applies the strain-based acceptance criteria established in ASME Boiler and Pressure Vessel Code’s Section III, Division 3 rules for storage and transportation spent nuclear fuel containments. This updated analysis is compared to previous DOE Standard Canister drop analyses. Preliminary results from the updated analysis show that certain regions of the containment exceed the allowable limits during the accidental drop event. However, these regions are limited to components performing a non-structural function. While further work on this analysis will be pursued, this analysis serves as the foundation for formal calculations used to support applicable certification efforts of the RRDS system at INL.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗