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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Advanced Compressors for CO2-Based Power Cycles and Energy

Pumped thermal energy storage (PTES) is a cost-effective method for grid-scale, long-duration electrical energy storage (LDES). PTES uses a heat pump cycle to transfer thermal energy from a low temperature reservoir (LTR) to a high temperature reservoir (HTR), later using a heat engine cycle to reverse the process. A key component of the PTES system, the heat pump compressor, represents a significant driver to the cost, performance and operating characteristics of the PTES system. For grid-scale charging (>100 MW), traditional compressor scaling charts indicate that the operating conditions needed would be best served by a multistage axial compressor. While frame gas turbine compressors at these power ratings exist and operate at higher pressure ratios than needed for the CO2 PTES system, the inlet pressure and fluid density of this application exceed experience values. A conceptual design of a large-scale CO2 axial compressor was completed, including mean-line estimates of the compressor performance at full power conditions. The results of the conceptual design were used to refine the PTES cycle design, and updated operating conditions provided for further aero design optimization. A roughly one third scale of the first three stages of the 100 MW compressor was designed, built, and tested at relevant PTES charging conditions. Results of this test program are compared against high-resolution computational fluid dynamics models.

Compressor Heat↗
DOE OSTI2024

NBI optimization on SMART and implications for scenario development

Abstract The SMall Aspect Ratio Tokamak (SMART) under commissioning at the University of Seville, Spain, aims to explore confinement properties and possible advantages in confinement for compact/spherical tokamaks operating at negative vs. positive triangularity. This work explores the benefits of auxiliary heating through Neutral Beam Injection (NBI) for SMART scenarios beyond the initial Ohmic phase of operations, in support of the device’s mission. Expected values of electron and ion temperature achievable with NBI heating are first predicted for the current flat-top phase, including modeling to optimize the NBI injection geometry to maximize NBI absorption and minimize losses for a given equilibrium. Simulations are then extended for a selected case to cover the current ramp-up phase. Differences with results obtained for the flat-top phase indicate the importance of determining the plasma evolution over time, as well as self-consistently determining the edge plasma parameters for reliable time-dependent simulations. Initial simulation results indicate the advantage of auxiliary NBI heating to achieve nearly double values of pressure and stored energy compared to Ohmic discharges, thus significantly increasing the device’s performance. The scenarios developed in this work will also contribute to diagnostic development and optimization for SMART, as well as providing test cases for initial predictions of macro- and micro-instabilities.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Development of a high-temperature Inconel 625 heat exchanger by model design and binder jetting additive manufacturing

A nickel-based Inconel 625 superalloy heat exchanger for high-temperature applications was developed via binder jetting additive manufacturing. The material properties were characterized first on printed and sintered parts. Two sintering temperatures were used to investigate the effects of the temperature on densification and microstructure. For channel geometry design, the heat transfer capabilities of the heat exchanger were optimized for the cross-section geometry of fluid flow channels in a counterflow configuration, and a stress analysis was conducted to investigate the effects of channel geometry. After headers were incorporated into the heat exchanger as a one-piece component, a prototype was printed. A complete depowdering was achieved via compressed air blowing, and sintering was performed with the developed profile. Ultimately, a one-piece heat exchanger with a nearly full density was obtained. Heat transfer tests were performed on this unit, and the results were compared with those from the simulations. In this study, systematic processes were developed for an additively manufactured Inconel-based heat exchanger for high-pressure, high-temperature heat transfer applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Deep reinforcement learning to discover multi-fuel injection strategies for compression ignition engines

Over the past several decades, regulation of compression ignition engine emissions has become increasingly stringent as concern about the environmental and health implications of these emissions has grown. These changing constraints have led to a series of new, alternative fuel injection strategies that aim to maintain power output while reducing in-cylinder generated emissions by operating in the low-temperature combustion (LTC) regime. These advanced injection strategies are created and retuned for individual combinations of engine geometry, fuel, and emissions constraints. Deep reinforcement learning has been shown to be an effective alternative to traditional optimization approaches for highly combinatorial control problems, such as discovering the optimal injection schedules for compression ignition engines. In this study, we deploy a previously presented deep reinforcement learning framework to iteratively optimize a series of engine geometries over a range of increasingly strict NO x emissions regulations. We then examine the resulting injection schedules. We discuss the potential for using this deep reinforcement learning framework for fuel selection screening and for discovering unique injection strategies for different engine geometries and future emissions standards.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Aerosol‐Jet‐Printable Covalent Organic Framework Colloidal Inks and Temperature‐Sensitive Nanocomposite Films

Abstract With molecularly well‐defined and tailorable 2D structures, covalent organic frameworks (COFs) have emerged as leading material candidates for chemical sensing, storage, separation, and catalysis. In these contexts, the ability to directly and deterministically print COFs into arbitrary geometries will enable rapid optimization and deployment. However, previous attempts to print COFs have been restricted by low spatial resolution and/or post‐deposition polymerization that limits the range of compatible COFs. Here, these limitations are overcome with a pre‐synthesized, solution‐processable colloidal ink that enables aerosol jet printing of COFs with micron‐scale resolution. The ink formulation utilizes the low‐volatility solvent benzonitrile, which is critical to obtaining homogeneous printed COF film morphologies. This ink formulation is also compatible with other colloidal nanomaterials, thus facilitating the integration of COFs into printable nanocomposite films. As a proof‐of‐concept, boronate‐ester COFs are integrated with carbon nanotubes (CNTs) to form printable COF‐CNT nanocomposite films, in which the CNTs enhance charge transport and temperature sensing performance, ultimately resulting in high‐sensitivity temperature sensors that show electrical conductivity variation by 4 orders of magnitude between room temperature and 300 °C. Overall, this work establishes a flexible platform for COF additive manufacturing that will accelerate the incorporation of COFs into technologically significant applications.

2D materials↗
DOE OSTI2021

Computational design of microarchitected porous electrodes for redox flow batteries

Porous electrodes are used as the core reactive component across electrochemical technologies. In flowing systems, controlling the fluid distribution, species transport, and reactive environment is critical to attaining high performance. However, conventional electrode materials like felts and papers provide few opportunities for precise engineering of the electrode and its microstructure. To address these limitations, architected electrodes composed of unit cells with spatially varying geometry determined via computational optimization are proposed. Resolved simulation is employed to develop a homogenized description of the constituent unit cells. These effective properties serve as inputs to a continuum model for the electrode when used in the negative half-cell of a vanadium redox flow battery. Porosity distributions minimizing power loss are then determined via computational design optimization to generate architected porosity electrodes. The architected electrodes are compared to bulk, uniform porosity electrodes and found to lead to increased power efficiency across operating flow rates and currents. The design methodology is further used to generate a scaled-up electrode with comparable power efficiency to the bench-scale systems. Finally, the variable porosity architecture and computational design methodology presented here thus offers a novel pathway for automatically generating spatially engineered electrode structures with improved power performance.

25 ENERGY STORAGE↗
DOE OSTI2025

Improving Longitudinal Impedance of Inductive Inserts

In this article, we discuss methods for improving the longitudinal impedance of inductive inserts used for space charge compensation in the proton storage ring (PSR) at Los Alamos Neutron Science Center (LANSCE) Facility. The PSR relies on inductive inserts to counteract the capacitive impedance produced by the space charge of the proton beam, which can otherwise lead to beam debunching. Existing inductive inserts, which utilize Toshiba M4C21A ferrite, have been effective but require heating to reduce resistive components that can cause instabilities at higher frequencies. This article explores the potential of alternative ferrite materials, specifically National Magnetics C2050, to enhance the performance of these inserts by reducing the need for heating and minimizing resistive impedance. Through both analytical modeling and CST Particle Studio simulations, it is demonstrated that optimized ferrite materials and geometries can significantly improve space charge compensation while mitigating instability risks, ultimately enhancing the performance of the PSR.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Preliminary Assessment of Additively Manufactured Cooling Channel Performance for Helium-Cooled Blanket Concepts

Sufficient cooling of the blanket first wall remains a critical challenge for the design and deployment of fusion power plants. Helium has been targeted as a potential blanket coolant due to its inertness and low neutron interactivity, among other advantages. However, the low thermal mass of helium creates a need for heat transfer enhancements in coolant channels to provide adequate cooling to the blanket’s first wall. Toward this end, a series of ribbed flow channels of various rib cross sections and configurations has been produced via additive manufacturing (AM) to study the efficacy of AM for first wall heat transfer enhancement and the optimization of heat transfer geometries. Helium cooling performance is studied in AM test articles at 4 MPa operating pressure, Reynolds numbers up to 197 000, and outer surface heat fluxes up to 42 kW/m 2 in the recently commissioned helium flow loop experiment (HFLE). Preliminary results of this study are presented herein. Heat transfer performance of nominally smooth (i.e., featureless) AM channels is quantified via measured Nusselt numbers and friction factors and compared to off-the-shelf smooth pipe experiments. Results are compared to existing correlations and used to discuss the effects of the AM processes on thermal-hydraulic performance. It is seen that the inherent roughness of the AM channels leads to an increase in both heat transfer coefficient and pressure drop when compared to the conventional pipe. In conclusion, recommendations are made for future studies based on these findings and additional considerations for the deployment of AM blanket cooling components.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Nb 3 Sn coating of SRF cavity by cosputtering from a composite target

Here, we deposited an Nb 3 Sn film on the inner surface of a 2.6 GHz Nb superconducting radio frequency cavity by cosputtering using a composite of Nb and Sn tube targets in a DC cylindrical magnetron sputtering system, followed by the thermal annealing of the coated cavity. An aluminum mockup cavity, replicating a 2.6 GHz Nb SRF cavity geometry, was utilized to optimize deposition parameters, resulting in cosputtered Nb–Sn films with an Sn content of 32–42 at. % on the beam tubes and equator positions. Several annealing conditions were investigated to improve the surface homogeneity of the Nb 3 Sn film. The best cosputtered Nb–Sn film was achieved after annealing at 600 °C for 6 h, followed by annealing at 950 °C for 1 h. The best process was applied to a Nb cavity, which was RF tested in a cryogenic dewar. RF testing of the Nb 3 Sn-coated cavity demonstrated a superconducting transition temperature of 17.78 K. The Nb 3 Sn cavity underwent light Sn recoating, followed by additional RF testing, resulting in the enhancement of the RF performance, primarily due to the improved surface homogeneity of the Nb 3 Sn coating.

Nb3Sn film↗
DOE OSTI2021

A simple levelset contact algorithm for large overlap removal and robust preloads

A simple approach to simulate contact between deformable objects is presented which relies on levelset descriptions of the Lagrangian geometry and an optimization-based solver. Modeling contact between objects remains a significant challenge for computational mechanics simulations. Common approaches are either plagued by lack of robustness or are exceedingly complex and require a significant number of heuristics. In contrast, the levelset contact approach presented herein is essentially heuristic free. Furthermore, the presented algorithm enables resolving and enforcing contact between objects with a significant amount of initial overlap. Examples demonstrating the feasibility of this approach are shown, including the standard Hertz contact problem, the robust removal of overlap between two overlapping blocks, and overlap-removal and pre-load for a bolted configuration.

42 ENGINEERING↗
DOE OSTI2022

Electrical-Discharge-Machining Contamination Removal from Metal Additively Manufactured Components

The use of an electrochemical dissolution process is shown to remove the recast layer contamination from the surfaces of electrical-discharge-machining cut components, as well as the interior exposed surfaces of the structure. The solution chemistry, cell potential, and exposure time are all relevant interdependent variables. Optimization of the electrode geometry should be made for each type of component. For the case of Cu-Zn recast contamination of 300-series alloy components, surface composition analysis indicates that complete electrochemical dissolution is achieved using a dilute solution of nitric acid (HNO 3 ). For example, electrochemical dissolution of the Cu-Zn recast is accomplished at 1.2 V cell potential using a 20% nitric solution and an exposure time of 4 h. The use of a nitric acid bath was specifically chosen since it’s chemically compatible and will not degrade the host alloy or the component. In sum, an electrochemically driven dissolution process can be tailored to remove of the recast contamination without affecting the integrity of the host component structure and its dimensional tolerances.

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

Detailed Structural and Chemical Analysis of Amorphous Compounds in Superconducting Qubit Systems

With massive improvements in device coherence times and gate fidelity over the past two decades, superconducting quantum devices have emerged as a leading technology platform for next generation quantum computing. While many of these improvements have been driven through optimized device designs and geometries, the presence of defects, impurities, interfaces, and surfaces in the constituent materials continue to limit performance and present a critical barrier in achieving scalable quantum systems with long coherence times. As part of the Superconducting Quantum Materials and Systems (SQMS) center, we have applied state-of-the-art materials characterization techniques, such as scanning/transmission electron microscopy, secondary ion mass spectrometry, and atom probe tomography, to identify structural defects and chemical inhomogeneities in superconducting qubits. In this review, we discuss the findings of these efforts as they relate to the inherent surfaces, interfaces, impurities, and defects in superconducting qubits. Through this comprehensive investigation, we provide insight into possible sources of dissipation in these systems. Further, we supplement these findings with potential strategies for mitigating these undesired features in an effort to systematically and intelligently improve the coherence times of superconducting qubits.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Fermilab Automation of Coil Winding System

The automated coil winder project creates a repeatable, scalable method for producing superconducting magnet coils with increased accuracy and efficiency. The design uses an ortho cyclic winding method to achieve high fill factors by combining computer numerical control (CNC), microcontroller-based controls, and sophisticated optimization techniques. The method optimizes coil turns, core geometry, and current consumption by utilizing analytical models based on magnetic moment, Ohm’s law, and power constraints. For particle accelerator applications, prototype testing using a 3D-printed coil winder has shown enhanced winding repeatability, thermal management, and manufacturability.

Dzida, Rafal [Northern Illinois U.]↗
DOE OSTI2022

Rare Higgs Processes at CMS and Precision Timing Detector Studies for HL-LHC CMS Upgrade

This thesis describes the search for two rare Higgs processes. The first analysis describes the CMS Run 2 search for $H$ $\rightarrow$ $\mu$$\mu$ decays, with 137.3 fb$^{-1}$ of data at $\sqrt{s}$ = 13 TeV. The analysis targeted four different Higgs production modes: the gluon fusion (ggH), the vector boson fusion (VBF), the Higgs-strahlung process (VH), and the production in association with a pair of top quarks (ttH). Each category used a dedicated machine learning based classifier to separate the signal from the background processes. A combined fit from all these categories saw a slight excess in the data corresponding to 3.0 standard deviations at $M$$_{H}$ = 125.38 GeV, and gave the first evidence for the Higgs boson decay to second-generation fermions. The best-fit signal strength and the corresponding 68% CL interval was found to be +0.17?????? = 1.19 $_{-0.39}^{+0.41}$ (stat)$_{-0.16}^{+0.17}$(syst) at $M$$_{H}$ = 125.38 GeV. The second analysis describes the CMS Run 2 search for 𝐻𝐻 → 𝑏𝑏𝑏𝑏 with highly boosted Higgs bosons. This analysis used a dedicated jet identification algorithm based on graph neural networks (ParticleNet) to identify boosted H→ bb jets. This search targeted the gluon fusion and the vector boson fusion HH production modes, and put constraints on the allowed values of the various Higgs couplings as: 𝜅𝜆 ∈ [−9.9, 16.9] when 𝜅𝑉 = 1, 𝜅2𝑉 = 1; 𝜅𝑉 ∈ [−1.17, −0.79] ∪ [0.81, 1.18] when 𝜅𝜆 = 1, 𝜅2𝑉 = 1; 𝜅2𝑉 ∈ [0.62, 1.41] when 𝜅𝜆 = 1, 𝜅𝑉 = 1. A scenario with 𝜅2𝑉 = 0 was excluded with a significance of 6.3 standard deviations for the first time, when other H couplings are fixed to their SM values. The combined observed (expected) 95% upper limit on the HH production cross section was found to be 9.9 (5.1) × SM. Finally, this thesis also discusses the planned MIP Timing Detector (MTD) upgrade for CMS at the HL-LHC. The MTD will be a time-of-flight (TOF) detector, designed to provide a precision timing information for charged particles using SiPMs + LYSO scintillating crystals, with a time resolution of ∼30 ps. This thesis describes several R&D tests that have been performed for characterizing the sensor properties (time resolution, light yield, etc.) and optimizing the sensor design geometry. This thesis also contains a description of mock test setups for cooling the sensors, since it is known to be an effective way of mitigating the increased dark current rates in the sensors due to radiation damage.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

First principles reaction discovery: from the Schrodinger equation to experimental prediction for methane pyrolysis

Our recent success in exploiting graphical processing units (GPUs) to accelerate quantum chemistry computations led to the development of the ab initio nanoreactor, a computational framework for automatic reaction discovery and kinetic model construction. In this work, we apply the ab initio nanoreactor to methane pyrolysis, from automatic reaction discovery to path refinement and kinetic modeling. Elementary reactions occurring during methane pyrolysis are revealed using GPU-accelerated ab initio molecular dynamics simulations. Subsequently, these reaction paths are refined at a higher level of theory with optimized reactant, product, and transition state geometries. Reaction rate coefficients are calculated by transition state theory based on the optimized reaction paths. The discovered reactions lead to a kinetic model with 53 species and 134 reactions, which is validated against experimental data and simulations using literature kinetic models. We highlight the advantage of leveraging local brute force and Monte Carlo sensitivity analysis approaches for efficient identification of important reactions. Both sensitivity approaches can further improve the accuracy of the methane pyrolysis kinetic model. The results in this work demonstrate the power of the ab initio nanoreactor framework for computationally affordable systematic reaction discovery and accurate kinetic modeling.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Proposed design and optimization of a higher harmonic cavity for ALS-U

Higher harmonic cavities (HHCs), also known as Landau cavities, have been proposed to increase the beam lifetime and Landau damping by lengthening the bunch and increasing the synchrotron tune spread. Here, we present an optimized 1.5 GHz normal conducting HHC design for the Advanced Light Source Upgrade project at Lawrence Berkeley National Lab with a superconducting-like geometry for lower R/Q. The optimization goal is to reach the required shunt impedance while maintaining a relatively high Q value of the cavities. A multi-objective genetic algorithm (MOGA)-based optimization process is applied to optimize the radio frequency (RF) design. This study serves as an example of how a genetic algorithm can be used to optimize RF cavities. Detailed exploration and characterization of the MOGA-based RF cavity optimization have been demonstrated from the aspects of minimizing the coupled bunch instabilities and analyzing the higher-order modes and the corresponding impedance of the HHC.

Feng, H. (ORCID:0000000319392692)↗