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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

A Novel Manufacturing Process of Lightweight Automotive Seats (Integration of Additive Manufacturing and Reinforced Polymer Composite)

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components. However, fabricating these metal polymer composite structures through traditional manufacturing processes limits their mechanical properties due to limited design freedom, lack of control over fiber orientation in composite parts, and poor interfacial bonding between the constituent materials. It is essential to develop a novel manufacturing process to enable high throughput production of lightweight automotive seats using metal and polymer composites. As such it is important to design the automotive seat suitable for manufacturing via this process and perform mechanical characterization on various subcomponents of the seat to ensure that the design and performance requirements provided by the auto manufacturer are met. The aim of this project is to develop a novel manufacturing technique to produce lightweight automotive seat by combining AM with conventional manufacturing processes. The car seat back panel will be designed via topology optimization and numerical simulations to minimize the overall weight while ensuring it meets all the performance requirements. The optimization of the seat back structure will be based on computational stress analysis to maximize the stiffness and minimize the weight. Materials currently used by Ford Motor Company will be adopted for a few subcomponents while the in-house composite materials will be used for the rest of the seat back. The composite and metallic materials will be tested to determine their mechanical properties as these are necessary for simulations. A novel manufacturing process will be developed to integrate AM metal inserts with discontinuous reinforced composite through large scale additive manufacturing and compression overmolding processes. The developed manufacturing technique will be used to fabricated various subcomponents suitable for the seat back design and mechanically tested to determine their properties. The manufacturing of the lightweight seat back design through this process involves integrated AM metal inserts with the composite structure for recliner connection. The manufacturing of the entire seat back which is lightweight through the novel manufacturing process will be discussed. The performance of the designed seat back will be investigated through numerical simulations and shown to meet all the requirements provided by the auto manufacturer. The final goal of developing a novel manufacturing process for lightweight automotive seats is met through design optimization of seat back, manufacturing of subcomponents, mechanical characterization, and validation through numerical simulations. The routes to achieve the final goal of the project and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. The project resulted in the development of a novel manufacturing process to integrate metal inserts with tailored polymer composite preforms through overmolding. Leveraging this proven manufacturing process, a lightweight seat back was designed through topology optimization and numerical simulations. The designed seat back uses AM metal inserts and compression overmolding of tailored polymer composite preforms obtained via large scale additive manufacturing. The metal polymer composite structures fabricated through this process exhibited enhancement in stiffness and improved ductility upon testing. Overall, the project provided an alternative design and manufacturing technique for automotive seat back that enables weight saving while meeting the safety and performance requirements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

King City Asbestos Corporation (KCAC) Mine Carbon Mineralization Field Test (Final Combined Report)

The overall objective of the KCAC carbon mineralization project is to determine the most successful approaches to CO 2 mineralization of asbestos-bearing serpentinite rocks and mine waste at the closed KCAC asbestos mine. The objectives of Budget Period 1 (BP1) are to characterize the site including, mineralogical and geochemical variability in site materials, baseline conditions including CO 2 flux and local climate, and to establish the designs for the second, experimental phase of the project. As described in Section 3 of this report, all tasks outlined in the Statement of Project Objective (SOPO) have been completed or are on schedule to be completed by the end of BP1. As described in Section 4, all success criteria and milestones have been met or will be met by the end of BP1. We conclude that the findings of BP1 strongly support moving to the second phase of the project to investigate methods to increase the rate of CO 2 mineralization. CO 2 flux monitoring during BP1 established an estimated baseline uptake of CO 2 over the 142,193 m 2 KCAC mine site of 147 and 179 metric tons CO 2 /yr using dynamic closed chamber and eddy covariance monitoring methods, respectively. Mineralogical analysis shows that the loose surficial waste material contains pyroaurite and minor hydromagnesite, indicating past carbon mineralization. Sediment samples at depths below 60 cm contained ~3 wt% brucite and localized high brucite contents of ~24 wt% were measured at depth, indicating significant unreacted material at relatively shallow depths. Together, these results demonstrate that despite prolonged exposure to the atmosphere, reactive material is still present and accessible and is naturally taking up atmospheric CO 2 . However, these natural rates are still well below rates that can be achieved by applying practices that can accelerate the CO 2 mineralization reaction. Designs for the Field-Testing Phase (BP2) of the project have been established, incorporating the findings of BP1. Based on results to date we have selected two methods to accelerate the rate of CO 2 mineralization, which we refer to as the Tilling Method and the Greenhouse Method. We hypothesize that these methods can increase the CO 2 mineralization rate by up to 5 times greater than the natural background rate measured in BP1. An Initial Lifecyle Assessment (LCA) and techno-economic analysis (TEA) were conducted for these two methods. The LCA concluded that the baseline version of the Greenhouse and Tilling methods at commercial scale are expected to achieve a CDR efficiency of 97% and 71%, respectively (cumulative, over 30 years of operation). Incorporating the net CO 2 removal rates calculated in the LCA, the TEA found the levelized, 30-year costs of the baseline Greenhouse and Tilling methods to be $\$$95/t-CO 2 and $\$$119/t-CO 2 , respectively, and that costs could be brought to well below $\$$100/t-CO 2 for either method by scaling up the volume of rock utilized. An initial EH&S Risk Assessment, evaluating the potential EH&S risks of the proposed carbon mineralization methods at commercial scale, was completed by LLNL EH&S professionals for these two methods.

58 GEOSCIENCES↗
DOE OSTI2025

April 2025 Semiannual Composite Salt Waste Processing Facility (SWPF) Decontaminated Salt Solution (DSS) Toxicity Characteristic Leaching Procedure (TCLP) Results

The aqueous waste from the Salt Waste Processing Facility is sampled semiannually for transfers to the Saltstone Production Facility. Salt solution is treated at the Saltstone Production Facility and disposed of in the Saltstone Disposal Facility. Per request of customer, X-TTR-Z-00027, Revision 0, one Saltstone Disposal Facility waste form was prepared at Savannah River National Laboratory using the Salt Waste Processing Facility Decontaminated Salt Solution and Z-area premix material for the April 2025 semiannual Toxicity Characteristic Leaching Procedure sample. The sample contained 60:40 (by weight) of slag and fly ash (referred to as the “Cement-Free grout sample”). Results from the technical report support Task 2: ‘Grout Leaching Analyses’ of the Task Technical Request prepared by Savannah River Mission Completion. At 43 days cured, the Saltstone sample was collected and shipped to a certified laboratory for analysis using the Toxicity Characteristic Leaching Procedure. The April 2025 semiannual Cement-Free grout sample met the South Carolina Code of Regulations for Hazardous Waste Management Regulations 61-79.261.24 and 61-79.268.48 requirements for a non-hazardous waste form with respect to the Resource Conservation and Recovery Act metals and Underlying Hazardous Constituents, and met the Saltstone Production Facility Waste Acceptance Criteria that was in effect at the time of the sample collection at the Salt Waste Processing Facility.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Commercial Building HVAC Technology Challenge - Carrier (Final Report)

The purpose of this Cooperative Research and Development Agreement (CRADA) was to test two rooftop commercial heating, ventilation, and air conditioning (HVAC) systems supplied by Carrier Corporation to determine if they met the laboratory test requirements of the United States Department of Energy (DOE) Commercial Building HVAC Technology Challenge (hereafter noted as “the Challenge”). Results of the laboratory testing completed at Oak Ridge National Laboratory (ORNL) demonstrated that the systems met all requirements of the Challenge. Carrier Corporation has successfully completed this aspect of the Challenge. This CRADA report will briefly describe the Challenge, the test plan created to measure the success of systems provided by Challenge participants, and the results of laboratory testing of the Carrier commercial rooftop systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

October 2025 Semiannual Composite Salt Waste Processing Facility Decontaminated Salt Solution Toxicity Characteristic Leaching Procedure Results

The aqueous waste from the Salt Waste Processing Facility is sampled semiannually for transfers to the Saltstone Disposal Facility. Salt solution is treated at the Saltstone Production Facility and disposed of in the Saltstone Disposal Facility. Per request of customer, X-TTR-Z-00027, Revision 0, one Saltstone Processing Facility Decontaminated Salt Solution and Z area premix material for the October 2025 semiannual Toxicity Characteristic Leaching Procedure sample. The sample contained 60:40 (by weight) of slag and fly ash (referred to as the “Cement-Free grout sample”). Results from the technical report support Task 2: ‘Grout Leaching Analyses’ of the Task Technical Request prepared by Savannah River Mission Completion. At 51 days cured, the Saltstone sample was collected and shipped to a certified laboratory for analysis using the Toxicity Characteristic Leaching Procedure. The October 2025 Semiannual Cement-Free grout sample met 61 79.268.48 requirements for a non-hazardous waste form with respect to the Resource Conservation and Recovery Act metals and Underlying Hazardous Constituents and met the Saltstone Production Facility Waste Acceptance Criteria that was in effect at the time of the sample collection at the Salt Waste Processing Facility.

Hsieh, Madison [Savannah River National Laboratory↗
DOE OSTI2023

Magnesium production by molten salt electrolysis with liquid tin cathode and multiple effect distillation

Low-cost clean primary production of magnesium metal is important for its use in many applications, from light-weight structural components to energy technologies. This work describes new experiments and cost and emissions analysis for a magnesium metal production process. The process combines molten salt electrolysis of MgO using MgF₂-CaF₂ electrolyte and a reactive liquid tin cathode, with gravity-driven multiple effect thermal system (G-METS) distillation to separate out the magnesium product, and re-use of the tin. Electrolysis experiments with carbon anodes showed current yield above 90%, while a yttria-stabilized zirconia solid oxide membrane (SOM) anode experiment showed 84% current yield. G-METS distillation is an important component of the envisioned process. It can potentially lower costs and energy use considerably compared with conventional magnesium distillation. Techno-economic analysis including detailed mass and energy balances shows that this electrolyte composition could lower costs by utilizing CaO, which is the primary impurity in MgO, as the Hall-Héroult process uses the sodium impurity in alumina. Analysis options include: raw material types (magnesite rock vs. brine or seawater), drying and calcining using electricity vs. natural gas, and carbon vs. SOM anode type. Using SOM inert anodes results in a cost premium around 10%–15%, mostly due to higher electrical energy usage resulting from membrane resistance, and reduces GHG emissions by approximately 1 kg CO₂/kg Mg product. Capital and operating cost estimates, and cradle to gate greenhouse gas (GHG) emissions analysis under several raw material and process technology scenarios, show comparable costs and emissions to those of aluminum production.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Field-Scale Testing of a High-Efficiency Membrane Reactor (MR)—Adsorptive Reactor (AR) Process for H2 Generation and Pre-Combustion CO2 Capture

The study objective was to field-validate the technical feasibility of a membrane- and adsorption-enhanced water gas shift reaction process employing a carbon molecular sieve membrane (CMSM)-based membrane reactor (MR) followed by an adsorptive reactor (AR) for pre-combustion CO2 capture. The project was carried out in two different phases. In Phase I, the field-scale experimental MR-AR system was designed and constructed, the membranes, and adsorbents were prepared, and the unit was tested with simulated syngas to validate functionality. In Phase II, the unit was installed at the test site, field-tested using real syngas, and a technoeconomic analysis (TEA) of the technology was completed. All project milestones were met. Specifically, (i) high-performance CMSMs were prepared meeting the target H2 permeance (>1 m3/(m2.hbar) and H2/CO selectivity of >80 at temperatures of up to 300 °C and pressures of up to 25 bar with a <10% performance decline over the testing period; (ii) pelletized adsorbents were prepared for use in relevant conditions (250 °C < T < 450 °C, pressures up to 25 bar) with a working capacity of >2.5 wt.% and an attrition rate of <0.2; (iii) TEA showed that the MR-AR technology met the CO2 capture goals of 95% CO2 purity at a cost of electricity (COE) 30% less than baseline approaches.

42 ENGINEERING↗
DOE OSTI2021

Nonlinear Reconnection in Magnetized Turbulence

Recent analytical works on strong magnetized plasma turbulence have hypothesized the existence of a range of scales where the tearing instability may govern the energy cascade. In this paper, we estimate the conditions under which such tearing may give rise to full nonlinear magnetic reconnection in the turbulent eddies. When those conditions are met, a new turbulence regime is accessed where reconnection-driven energy dissipation becomes common, rather than the rare feature that it must be when they are not. We conclude that while such conditions are very stringent for fluid-scale eddies, they are easily met for kinetic-scale eddies; in particular, we suggest that our arguments may help explain recent Magnetospheric Multiscale (MMS) observations of (so-called) electron-only reconnection and of energy dissipation via electron Landau damping in the Earthʼs magnetosheath.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1972

Observations of proton spectra (1.0 less than or equal to proton energy less than or equal to 300 keV) and pitch angle distributions at the plasmapause

Detailed proton spectral and pitch angle distribution observations were obtained from two proton detectors and a fluxgate magnetometer flown on Small Scientific Satellite A (Explorer 45). The data of interest are from orbit 99 in-bound occurring on 17 December 1971, some 8 hours prior to the sudden commencement of a magnetic storm. The data are consistent with the initiation of ion cyclotron instability when certain requirements are met. These criteria are met initially at the altitude at which the sudden intensity decrease occurs. However, after the initiation of the instability, the linear theory is unable to explain the further evolution of intensities, pitch angle distributions, and energy spectra of the ring current particles.

Williams, D. J.↗
NASA NTRS1973

Eutectic superalloys strengthened by sigma, Ni3CB lamellae and gamma prime, Ni3Al precipitates

By means of a screening and solidification optimization study of certain alloys located on the gamma-sigma liquidus surface within the Ni-Cb-Cr-Al system, alloys with high temperature properties superior to those of all known superalloys were defined. One alloy, Ni - 19.7w/o Cb - 6.0w/o Cr - 2.5w/o Al, directionally solidified at 3 cm/hr met or exceeded each program goal. A second alloy, Ni-21.75 w/o Cb-2.55 w/o Al, although deficient in its inherent oxidation resistance, met the other program goals and combined a remarkable insensitivity of composite microstructure to solidification parameters with excellent low temperature toughness. This investigation demonstrated that useful properties for gas turbine airfoil application have been achieved by reinforcing a strong and tough gamma solid solution matrix containing precipitated gamma prime by a lamellar intermetallic compound Ni3 Cb having greater strength at elevated temperature.

Lemkey, F. D.↗
NASA NTRS1975

F-8 digital fly-by-wire flight test results viewed from an active controls perspective

The results of the NASA F-8 digital fly-by-wire flight test program are presented, along with the implications for active controls applications. The closed loop performance of the digital control system agreed well with the sampled-data system design predictions. The digital fly-by-wire mechanization also met pilot flying qualities requirements. The advantages of mechanizing the control laws in software became apparent during the flight program and were realized without sacrificing overall system reliability. This required strict software management. The F-8 flight test results are shown to be encouraging in light of the requirements that must be met by control systems for flight-critical active controls applications.

Zalai, K. J.↗
NASA NTRS1975

Scanning system tradeoffs for remote optical sensing from geosynchronous orbit

The scanning and telescope field of view requirements for making Earth Resources (ER) and Meteorological (MET) phenomena observations from a Synchronous Earth Observation Satellite (SEOS) have been defined. The equations relating spacecraft scan capability to user scan field of view requirements are given and evaluated using four different telescope fields of view. The tradeoffs between telescope field-of-view and user scan fields of view requirements are shown, and it was determined that a 0.6 degree by 1.2 degree telescope FOV is optimum for the SEOS telescope. It was shown that an internal scan as well as external scan is required to satisfy both ER and MET users.

Young, P. J.↗
NASA NTRS1975

The Large Area Crop Inventory Experiment /LACIE/ - An assessment after one year of operation

A Large Area Crop Inventory Experiment (LACIE) has been undertaken jointly by the U.S. Department of Agriculture (USDA), the National Oceanic and Atmospheric Administration (NOAA) of the Department of Commerce and the National Aeronautics and Space Administration (NASA) to prove out an economically important application of remote sensing from space. The first phase of the Experiment, which focused upon determinations of wheat area in the U.S. Great Plains and upon the development and testing of yield models, is now nearing completion. The system implemented to handle and analyze the Landsat and meteorological data has generally worked well and met operational goals. A very preliminary assessment of results to date indicates that the accuracy goals of the experiment can be met.

Macdonald, R. B.↗
NASA NTRS1977

Baseband recording and playback

Analog recordings of spacecraft telemetry signals are made by Deep Space Network Deep Space Stations to provide backup for both spacecraft and ground station anomalies. The requirements that must be met to insure successful baseband recording and playback are given. Recording and playback procedures are developed to insure that these requirements are met and performance results from tests conducted at the Compatibility Test Area (JPL) are tabulated.

Kent, S. S.↗
NASA NTRS1978

Predetection telemetry analog recording and playback for Pioneer Venus 1978

Prediction telemetry recording and playback capability was implemented in the DSN to meet PV-78 mission requirements. Test data, along with theoretical considerations, gives assurance that the data degradation commitment of 1.5 db will be met, and it is anticipated that in actual performance the design goal of 1.0 db will be met. The major technical problems requiring solution were elimination of image in the OLR and the reduction of analog recorder instabilities. These were solved through the use of single-sideband mixing techniques and the use of newer generation analog recorders.

Kent, S. S.↗
NASA NTRS1979

Roadside tree/pole crash barrier field test

A series of tests was carried out to evaluate the performance of a crash barrier designed to protect the occupants of an automobile from serious injury. The JPL barrier design is a configuration of empty aluminum beverage cans contained in a tear-resistant bag which, in turn, is encased in a collapsible container made of plywood and steel. Tests were conducted with a driven vehicle impacting the barrier. The basic requirements of NCHRP Report 153 were followed except that speeds of 30 mph rather than 60 mph were used. Accelerometer readings on the driver's helmet showed that the driver was never subjected to dangerous decelerations, and never experienced more than temporary discomfort. Also, all of the requirements of the cited report were met. An extrapolation of data indicated that the JPL barrier installed in front of a tree or telephone pole along a roadside would also have met the requirements at a speed of 40 mph.

Wilson, A. H.↗
NASA NTRS1980

Ball bearing versus magnetic bearing reaction and momentum wheels as momentum actuators

Different bearing technologies of momentum actuators for the attitude control of satellites are compared and a guideline for the selection of the suitable momentum actuators or momentum actuator configurations to meet given mission goals with high reliability and low cost is developed. The comparison between ball bearing and magnetic bearing momentum actuators shows that given mission requirements can be economically met by employing the ball bearing technology without decreasing reliability and lifetime. However, for some special mission requirements, such as 'zero friction at zero speed,' fine pointing (met by vernier gimballing), and/or active damping, magnetic bearings may be advantageous. This makes it evident that magnetic bearing technology will not replace ball bearing technology for momentum actuators, but will supplement it for some special mission requirements.

Auer, W.↗
NASA NTRS1978

Design and analytical study of a rotor airfoil

An airfoil section for use on helicopter rotor blades was defined and analyzed by means of potential flow/boundary layer interaction and viscous transonic flow methods to meet as closely as possible a set of advanced airfoil design objectives. The design efforts showed that the first priority objectives, including selected low speed pitching moment, maximum lift and drag divergence requirements can be met, though marginally. The maximum lift requirement at M = 0.5 and most of the profile drag objectives cannot be met without some compromise of at least one of the higher order priorities.

Dadone, L. U.↗