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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Economic and Environmental Assessment of Biological Conversions of Agile BioFoundry (ABF) Bio-Derived Chemicals

Bio-derived chemicals are an essential part of the growing bioeconomy. They possess the potential to boost a new domestic bioproduct industry, improve the sustainability of integrated biomanufacturing, and reduce U.S. dependence on fossil energy. The Agile BioFoundry (ABF) consortium, a Department of Energy (DOE)-sponsored collaboration, is investigating biobased pathways to produce advantaged products including advanced biofuels, fuel intermediates, and bioproducts. ABF is integrating advanced computational tools for biological engineering, process design and data analysis, and economic/sustainability modeling tools into a comprehensive and dynamic platform for biomanufacturing of microbes and using them to produce key metabolic intermediates or beachhead molecules which may be derivatized into several distinct bioproducts of industrial interest. In this presentation, we first discuss a methodology to select a single exemplar product molecule to represent each beachhead pathway based on similarities with other end-molecule options (yields/titers/rates, fermentation operation mode, oxygen requirements, general separations challenges, etc.), in order to maintain a reasonable number of cases for rigorous process simulation. We then use techno-economic analysis (TEA) and life-cycle analysis (LCA) to highlight sensitivities and trends around economic performance and environmental footprint, reflecting examples for two selected ABF technology pathways to bio-derived chemicals: 1) adipic acid production via muconic acid fermentation from mixed sugars with Pseudomonas putida and 2) cineole via geranyl diphosphate with Rhodosporidium toruloides. We present multi-variable scan plots highlighting key drivers on costs and greenhouse gas emissions in order to identify the parameter space in which each pathway could ultimately achieve economic and environmental sustainability meeting or exceeding commodity product benchmarks, thus prioritizing future R&D focus areas.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Advanced Manufacturing of Alpha Double Prime Iron Nitride (ADPIN): An Innovative Rare Earth Element (REE) Free Ultra-High Performance Permanent Magnet for Clean Energy Applications

Iron nitride magnets offer the potential for large magnetic remanence magnets absent any rare earth materials [1]. This project was submitted in response to the funding opportunity announcement (FOA) from the Advanced Manufacturing Office (AMO) of the Office of Energy Efficiency & Renewable Energy (EERE) of the Department of Energy (DOE): DE-FOA-0001465: Advanced Manufacturing Projects for Emerging Research Exploration; Topic Area 1: Advanced Materials; Subtopic 1.1: Innovative Advanced Materials Manufacturing for Clean Energy to explore nitriding iron powder using a fluidized bed technique which if successful would accomplish nitriding the iron powder with reduce industrial energy intensity. Of particular concern when using metal powders at high temperatures in a fluidized bed reactor is the defluidization temperature of the bed, also known as the ‘bed collapse’ temperature. Above the defluidization temperature the metal powders can no longer fluidize and instead become an undesirable packed powder bed. Using the published results from the Institute of Process Engineering at the Chinese Academy of Sciences in Beijing, China, FeNix Magnetics was able to develop a spreadsheet calculation that allowed predictive guidelines for the defluidization temperature of iron powder based on the type of carrier gas, flow rate of the carrier gas, and the iron powder diameter. FeNix Magnetics was not able to conclude whether the temperatures to avoid bed defluidization that were achievable in a fluidized bed reactor actually resulted in nitriding the iron powder to the required level. In order to measure the amount of nitrogen in the iron powder, FeNix Magnetics contracted with the DOE sponsored Advanced Photon Source (APS) at Argonne National Laboratory to conduct X-Ray diffraction measurements. Unfortunately, due to COVID-19 restrictions, the DOE sponsored APS was closed and unable to provide X-Ray Diffraction measurements during this program.

36 MATERIALS SCIENCE↗
DOE OSTI2024

FENIX: An Open-Source Multiphysics Integrated Framework Enabling Collaborative Development of Plasma Facing Component Modeling Capabilities

Advanced modeling and simulation tools have a crucial role to play in accelerating fusion energy deployment as a sustainable power source. Multiphysics, high-fidelity computational tools can help understand, model, and quantify the complex interactions between materials performance, plasma and neutron exposure, and engineering processes. As a result, they accelerate the design, safety analysis, and performance evaluation of fusion systems. This webinar introduces the Fusion ENergy Integrated multiphys-X (FENIX) framework, an open-source multiphysics tool for plasma facing component modeling. FENIX leverages the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework, which has been developed by the United States Department of Energy Nuclear Energy Advanced Modeling and Simulation (NEAMS) program. FENIX couples various MOOSE capabilities such as heat transfer, thermomechanics, thermal hydraulics, electromagnetics, and plasma kinetics with the MOOSE-based applications Cardinal (neutronics) and TMAP8 (tritium transport). During the webinar, we will present FENIX and discuss how its modularity, openness, software quality assurance processes, and licensing approach supports effective collaborations, including public-private partnerships.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

A Surety Engineering Framework and Process to Address Ethical Legal and Social Issues for Artificial Intelligence

The ethical, legal, and social issues (ELSI) surrounding Artificial Intelligence (AI) can have as great of an impact on the technologies’ success as technical issues such as safety, reliability, and security. Addressing these risks can counter potential program failures, legal and ethical battles, constraints to scientific research, and product vulnerabilities. This paper presents a surety engineering framework and process that can be applied to AI to identify and address technical, ethical, legal and societal risks. Extending sound engineering practices to incorporate a method to “engineer” ELSI can offer the scientific rigor required to significantly reduce the risk of AI vulnerabilities. Modeling the specification, design, evaluation and quality/risk indicators for AI provides a foundation for a risk-informed decision process that can benefit researchers and stakeholders alike as they use it to critically examine both substantial and intangible risks.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2015

KIVA Software

KIVA is a family of Fortran-based Computational Fluid Dynamics (CFD) software that predicts complex multi-species multi-phase turbulent fuel and air flows. KIVA models all engine combustion processes with models for spray, soot formation, spark ignition, and reactive chemistry (including pollutantformation processes). Employing KIVA software helps to optimize internal combustion engine processes, including diesel engines, for higher efficiency and lower emissions. KIVA engine modeling routines such as spray and core CFD Arbitrary Lagrangian-Eulerian (ALE) algorithms are now ubiquitous in the industry of engine code simulators. In addition, many engineers and researchers have made modifications to or enhanced our routines to address specific problems in engine designs.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2017

Pulsed Plasma Processing of Diesel Engine Exhaust Final Report CRADA No. TC-0336-92-1-C

The goal was to develop an exhaust-gas treatment process for the reduction of NO x and hydrocarbon from diesel engines. The project began believing that direct chemical reduction on NO x was possible through the use of non-thermal plasmas. The original CRADA began in 1993 and was scheduled to finish in 1996. It had as its goals three metrics: 1) remove two grams/brake-horse-power-hour of NOx, 2) have no more than five percent energy penalty, and 3) cost no more than ten percent of the engine cost. These goals were all aimed at heavy-duty diesel trucks. This CRADA had its Defense Program funding eliminated by DOE prior to completion in 1995. Prior to loss of funding from DOE, LLNL discovered that due to the large oxygen content in diesel exhaust, direct chemical reduction was not possible. In understanding why, a breakthrough was achieved that combined the use of a non-thermal plasma and a catalyst. This process was named Plasma Assisted Catalytic Reduction (P ACR). Because of this breakthrough, the CRADA became a funds-in only CRADA, once DOE DP funding ended. As a result, the funding decreased from about 1M dollars per year to about $400k per year. Subsequently, progress slowed as well. The CRADA was amended several times to reflect the funds-in nature. At each amendment, the deliverables were modified; the goals remained the same but the focus changed from heavy-duty to lightduty to SUVs. The diesel-engine NO x problem is similar to the furnace and boiler NO x emission problem with the added constraint that ammonia-like additives are impractical for a mobile source. Lean-burning gasoline engines are an additional area of application because the standard three-way catalyst is rendered ineffective by the presence of oxygen. In the P ACR process an electrical discharge is used to create a non-thermal plasma that contains oxidative radicals O and OH. These oxidative radicals convert NO to NO 2 . Selective catalytic reduction using a readily available catalyst then converts the NO 2 to harmless gases, N 2 and 0 2 .

42 ENGINEERING↗
DOE OSTI2018

Comminution process to produce engineered wood particles of uniform size and shape from cross-grain oriented wood chips

Comminution process of wood chips to produce wood particles, by feeding wood chips in a direction of travel substantially normal to grain through a counter rotating pair of intermeshing arrays of cutting discs arrayed axially perpendicular to the direction of wood chip travel, wherein the cutting discs have a uniform thickness (Td), to produce wood particles characterized by a length dimension (L) substantially equal to the Td and aligned substantially parallel to grain, a width dimension (W) normal to L and aligned cross grain, and a height dimension (H) aligned normal to W and L, wherein the W.times.H dimensions define a pair of substantially parallel end surfaces with crosscut fibers.

09 BIOMASS FUELS↗
DOE OSTI2016

Interfacial engineering of solution-processed Ni nanochain-SiO{sub x} (x < 2) cermets towards thermodynamically stable, anti-oxidation solar selective absorbers

Cermet solar thermal selective absorber coatings are an important component of high-efficiency concentrated solar power (CSP) receivers. The oxidation of the metal nanoparticles in cermet solar absorbers is a great challenge for vacuum-free operation. Recently, we have demonstrated that oxidation is kinetically retarded in solution processed, high-optical-performance Ni nanochain-SiO{sub x} cermet system compared to conventional Ni-Al{sub 2}O{sub 3} system when annealed in air at 450–600 °C for several hours. However, for long-term, high-temperature applications in CSP systems, thermodynamically stable antioxidation behavior is highly desirable, which requires new mechanisms beyond kinetically reducing the oxidation rate. Towards this goal, in this paper, we demonstrate that pre-operation annealing of Ni nanochain-SiO{sub x} cermets at 900 °C in N{sub 2} forms the thermodynamically stable orthorhombic phase of NiSi at the Ni/SiO{sub x} interfaces, leading to self-terminated oxidation at 550 °C in air due to this interfacial engineering. In contrast, pre-operation annealing at a lower temperature of 750 °C in N{sub 2} (as conducted in our previous work) cannot achieve interfacial NiSi formation directly, and further annealing in air at 450–600 °C for >4 h only leads to the formation of the less stable (metastable) hexagonal phase of NiSi. Therefore, the high-temperature pre-operation annealing is critical to form the desirable orthorhombic phase of NiSi at Ni/SiO{sub x} interfaces towards thermodynamically stable antioxidation behavior. Remarkably, with this improved interfacial engineering, the oxidation of 80-nm-diameter Ni nanochain-SiO{sub x} saturates after annealing at 550 °C in air for 12 h. Additional annealing at 550 °C in air for as long as 20 h (i.e., 32 h air annealing at >550 °C in total) has almost no further impact on the structural or optical properties of the coatings, the latter being very sensitive to any interfacial changes due to the localized surface plasmon resonances of the metal nanostructures. This phenomenon holds true for Ni nanoparticle diameter down to 40 nm in Ni-SiO{sub x} system, where the optical response remains stable for 53 h at 550 °C in air. The oxidation vs. time curve also shows saturation behavior deviating from the kinetic Deal-Grove oxidation model. These results strongly suggest a promising approach to thermodynamically stable, anti-oxidation Ni/SiO{sub x} cermet absorbers via interfacial engineering.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2019

Development of a Hybrid Lagrangian–Eulerian Model to Describe Spark-Ignition Processes at Engine-Like Turbulent Flow Conditions

With the engine technology moving toward more challenging (highly dilute and boosted) operation, spark-ignition processes play a key role in determining flame propagation and completeness of the combustion process. On the computational side, there is plenty of spark-ignition models available in literature and validated under conventional, stoichiometric spark ignition (SI) operation. Nevertheless, these models need to be expanded and developed on more physical grounds since at challenging operation they are not truly predictive. This paper reports on the development of a dedicated model for the spark-ignition event at nonquiescent, engine-like conditions, performed in the commercial CFD code converge. The developed methodology leverages previous findings that have expanded the use and improved the accuracy of Eulerian-type energy deposition models. In this work, the Eulerian energy deposition is coupled at every computational time-step with a Lagrangian-type evolution of the spark channel. Typical features such as spark channel elongation, stretch, and attachment to the electrodes are properly described to deliver realistic energy deposition along the channel during the entire ignition process. The numerical results are validated against schlieren images from an optical constant volume chamber and show the improvement in the simulation of the spark channel during the entire ignition event, with respect to the most commonly used energy deposition approach. Further developmental pathways are discussed to provide more physics-based features from the developed ignition model in the future.

42 ENGINEERING↗
DOE OSTI2018

DEVELOPMENT OF A HYBRID LAGRANGIAN-EULERIAN MODEL TO DESCRIBE SPARK-IGNITION PROCESSES AT ENGINE-LIKE TURBULENT FLOW CONDITIONS

With the engine technology moving towards more challenging (highly dilute and boosted) operation, spark-ignition processes play a key role in determining flame propagation and completeness of the combustion process. On the computational side, there is plenty of spark-ignition models available in literature and validated under conventional, stoichiometric SI operation. Nevertheless, these models need to be expanded and developed on more physical grounds since at challenging operation they are not truly predictive. This paper reports on the development of a dedicated model for the spark-ignition event at non-quiescent, engine-like conditions, performed in the commercial CFD code CONVERGE. The developed methodology leverages previous findings that have expanded the use and improved the accuracy of Eulerian-type energy deposition models. In this work, the Eulerian energy deposition is coupled at every computational time-step with a Lagrangian-type evolution of the spark channel. Typical features such as spark channel elongation, stretch, attachment to the electrodes are properly described to deliver realistic energy deposition along the channel during the entire ignition process. The numerical results are validated against schlieren images from an optical constant volume chamber and show the improvement in the simulation of the spark channel during the entire ignition event, with respect to the most commonly used energy deposition approach. Further development pathways are discussed to provide more physics-based features from the developed ignition model in the future.

Scarcelli, Riccardo↗
DOE OSTI2018

Multi-purposed Ar gas cluster ion beam processing for graphene engineering

Graphene, with unique mechanical and electrical properties, offers diverse application opportunities from beyond Moore’s nano-electronics to water filtration. However, accomplishing these relies on cleaning and processing large areas of supported and suspended graphene sheets. Here in this paper, we demonstrate the use of an Ar cluster ion beam as a versatile tool for graphene cleaning, defect engineering, and nanopore fabrication. In-situ and ex-situ characterization techniques were utilized in combination with first principles molecular dynamics, to highlight the differences in processing of the supported and suspended graphene samples. In this work, we monitor interaction of the Ar cluster ion beam with graphene as a function of ion dose with in-situ secondary ion mass spectrometry (SIMS), as well as ex-situ Raman spectroscopy measurements. Scanning transmission electron microscopy (STEM) results confirm that the Ar cluster ion beam can form nanopores in the suspended graphene; while the basal plane of graphene remains intact maintaining the lattice structure. Finally, Scanning Electron Microscopy (SEM) image analysis of the irradiated samples allows quantitative tracking of pore areas and their distribution as a function of ion dose. This study highlights the flexibility of the Ar cluster ion beam in 2D material processing, and offers insights into Ar beam interaction with graphene.

36 MATERIALS SCIENCE↗
DOE OSTI2015

LES FOR SIMULATING THE GAS EXCHANGE PROCESS IN A SPARK IGNITION ENGINE

The gas exchange process is known to be a significant source of cyclic variability in Internal Combustion Engines (ICE). Traditionally, Large Eddy Simulations (LES) are expected to capture these cycle-to-cycle variations. This paper reports a numerical effort to establish best practices for capturing cyclic variability with LES tools in a Transparent Combustion Chamber (TCC) spark ignition engine. The main intention is to examine the sensitivity of cycle averaged mean and Root Mean Square (RMS) flow fields and Proper Orthogonal Decomposition (POD) modes to different computational hardware, adaptive mesh refinement (AMR) and LES sub-grid scale (SGS) models, since these aspects have received little attention in the past couple of decades. This study also examines the effect of near-wall resolution on the predicted wall shear stresses. LES is pursued with commercially available CONVERGE code. Two different SGS models are tested, a one-equation eddy viscosity model and dynamic structure model. The results seem to indicate that both mean and RMS fields without any SGS model are not much different than those with LES models, either one-equation eddy viscosity or dynamic structure model. Computational hardware results in subtle quantitative differences, especially in RMS distributions. The influence of AMR on both mean and RMS fields is negligible. The predicted shear stresses near the liner walls is also found to be relatively insensitive to near-wall resolution except in the valve curtain region.

Ameen, Muhsin M↗
DOE OSTI2023

Additive manufacturing of a metastable high entropy alloy: Metastability engineered microstructural control via process variable driven elemental segregation

Compositional paradigm shift in high entropy alloys (HEAs) provided new opportunities for microstructural engineering, whereas process control during laser powder bed fusion (LPBF) additive manufacturing (AM) enable fine microstructure tailoring. Metastability engineering in transformation induced plasticity (TRIP) HEAs by addition of minor alloying elements is an attractive strategy for fine microstructural tuning. This study explored in detail the microstructural evolution during LPBF AM of a metastable Fe 40 Mn 20 Co 20 Cr 15 Si 5 (at.%) dual phase HEA (CS-HEA). LPBF processing window for CS-HEA was established based on quantitative analysis and experiments. Based on melt pool overlap lack of fusion pores were observed at lower energy densities (J) of $\textit{J}$ ≤ 31.25 J/mm 3 and key-hole formation by melt pool destabilization in case of $\textit{J}$ ≥ 75 J/mm 3 . The microstructure of CS-HEA consists of metastable FCC-γ and HCP-ε phases; LPBF process parameters governed the final phase fraction in the alloy which has been correlated to metastability alteration of the high temperature γ phase. Final microstructural engineering was devised by LPBF process control which enabled cooling rate manipulation to guide Mn and Si segregation at the cell boundaries, thereby controlling the matrix metastability and final phase fraction. Additionally, high resolution transmission electron microscopy (TEM) revealed disparity in stacking fault morphology in CS-HEA with LPBF process variable alterations associated with local variations in chemical composition and stacking fault energy. Further, the phase evolution with process parameters also affected the nanomechanical behavior of the alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Efficient turbine engine using integrated ammonia fuel processing

A gas turbine engine includes a core engine that includes a core flow path where air is compressed in a compressor section, communicated to a combustor section, mixed with an ammonia based fuel and ignited to generate a high energy combusted gas flow that is expanded through a turbine section. The turbine section is mechanically coupled to drive the compressor section. An ammonia flow path communicates an ammonia flow to the combustor section. A cracking device is disposed in the ammonia flow path. The cracking device is configured to decompose the ammonia flow into a fuel flow containing hydrogen (H2). At least one heat exchanger is upstream of the cracking device that provides thermal communication between the ammonia flow and a working fluid flow such that the ammonia fluid flow accepts thermal energy from the working fluid flow.

Smith, Lance L.↗
DOE OSTI2017

Through-thickness microstructural evolution during grain boundary engineering type thermomechanical processing and its implication on sensitization behavior in austenitic stainless steel

Highlights: • GBE-treated 304L steel exhibits thickness-dependent microstructural evolution. • Degree of sensitization increases from surface to interior in GBE specimen. • Low fractal dimension and large TRD size lead to lesser sensitization at surface. • As-received specimen shows high albeit thickness-independent sensitization behavior. • Higher residual strain leads to higher sensitization at surface of deformed sample. - Abstract: Through-thickness microstructural variations and their synergistic influence on degree of sensitization in grain boundary engineering (GBE) treated 304L stainless steel was compared with solution-annealed and marginally cold-worked (~ 3% thickness reduction) specimens. The solution-annealed specimen has shown higher degree of sensitization due to the presence of lower fraction of Σ3 (as well as other low Σ CSL) boundaries and dominant random high-angle boundaries (RHAGBs) connectivity. However, it has shown thickness-independent sensitization behavior as grain boundary character distribution, residual strain and grain boundary network topology towards thickness direction are similar. Owing to higher residual strain, as revealed by local misorientation analysis, the cold-worked specimen showed maximum degree of sensitization (higher than solution-annealed condition) at surface. The GBE specimen has shown much lower degree of sensitization at surface due to higher-fraction of Σ3 boundaries and discontinuous RHAGBs connectivity. However, increasing fraction of RHAGBs and their connectivity, as confirmed by twinning-related domain and fractal analysis, cause more sensitization at interior of this specimen. In spite of this, the degree of sensitization at the interior of GBE specimen is lower than the solution-annealed or cold-worked specimen. Even though the residual strain in GBE specimen is higher than the solution-annealed condition, the lower degree of sensitization indicates that the grain boundary character distribution and grain boundary network topology have higher implication than residual strain in controlling sensitization.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Toward Low-Cost, High-Energy Density, and High-Power Density Lithium-Ion Batteries

Reducing cost and increasing energy density are two barriers for widespread application of lithium-ion batteries in electric vehicles. Although the cost of electric vehicle batteries has been reduced by ~70% from 2008 to 2015, the current battery pack cost (268/kWh in 2015) is still >2 times what the USABC targets (125/kWh). Even though many advancements in cell chemistry have been realized since the lithium-ion battery was first commercialized in 1991, few major breakthroughs have occurred in the past decade. Therefore, future cost reduction will rely on cell manufacturing and broader market acceptance. Here, this article discusses three major aspects for cost reduction: (1) quality control to minimize scrap rate in cell manufacturing; (2) novel electrode processing and engineering to reduce processing cost and increase energy density and throughputs; and (3) material development and optimization for lithium-ion batteries with high-energy density. Insights on increasing energy and power densities of lithium-ion batteries are also addressed.

25 ENERGY STORAGE↗