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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

In situ measurement of phase transformations and residual stress evolution during welding using spatially distributed fiber-optic strain sensors

Welding of high-strength steels can result in large tensile strains as the base metal and filler material cool from their molten state. To combat these large tensile strains, low-transformation-temperature (LTT) metal fillers have been proposed. These fillers undergo a martensitic phase transformation at a lower temperature which can ultimately reduce the tensile strain or can even introduce compressive strain adjacent to the weld metal. However, the process for optimizing the composition of the LTT material, as well as various weld parameters for each unique weld geometry, can be quite expensive, especially if the acceptance criterion requires using neutrons, x-ray beams, or destructive techniques to characterize residual stresses. This work describes a simple, low-cost method for quantifying residual stresses and phase transformations in situ during welding. Spatially distributed fiber-optic sensors were bonded to a cast iron plate, along with tack-welded thermocouples, to measure temperature and strain during multiple passes with LTT filler metals. Results show that the fiber-optic sensors can successfully resolve compressive strain adjacent to the weld region caused by the martensitic phase transformations in the LTT filler material.

47 OTHER INSTRUMENTATION↗
DOE OSTI2018

Prototyping and Manufacturing of Magnetic Gearbox Components using Innovations in Castings

This project combines additive manufacturing with the broadly deployed practice of metal casting. Combining these methods will unlock new design possibilities while reducing the economic burden of early stage prototyping while leveraging well established high throughput sand casting. Two main approaches are evaluated: direct printing of single use sand molds and printing of reusable impression patterns used to create sand molds. Reusable impression molds typically can be used to produce hundreds to several thousands of casting thereby amplifying the function of the 3D printed replica mold. Emrgy’s newly developed and tested proprietary magnetic gearbox system for low head hydroelectricity generation was the subject part of this study. Leveraging ORNL’s additive manufacturing capability and expertise, a pattern impression was produced and used to create multiple sand molds of the gearbox during phase 1. Even before considering the cost savings possible once rigging and pattern mounting is optimized through repetition and improved design, final part costs using this combined method resulted in an 80% cost reduction over EMRGY’s previous method of subtractive manufacturing for gearbox production.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Additive Manufacturing Case Study

Geothermal technologies include an extremely wide range of products required for well construction, completion, production, intervention and surface energy conversion activities. Many of these products are geometrically complex, require multi-step and highly specialized fabrication processes, and are expensive due to the low production numbers typically associated with the geothermal market. These challenges along with the high temperature demands of the geothermal environment have also hindered the adoption of many tools routinely used in the oil & gas industry.Recent advancements in Additive Manufacturing (AM) materials of construction, build volumes and part quality have transitioned the technology from primarily cosmetic prototyping applications to the point where AM can be used to make production parts, even for the most demanding applications. These improved AM capabilities along with the inherent ability of AM to produce complex parts and, in some cases, geometries that cannot be manufactured using conventional casting, machining and joining fabrication approaches motivate an exploration of its potential to positively impact geothermal well construction and operations technologies.Sandia National Labs collaborated with Oak Ridge National Laboratory on a case study examining additive manufacturing opportunities for Geothermal applications. The study focused on designing components with improved performance characteristics that cannot be fabricated conventionally. A rotor for a downhole motor was chosen based on the potential for improving its rotational dynamics. Topology optimization was used as a design method to reduce the rotational inertia of the part while preserving sufficient rotational stiffness to transmit the torque required for the drilling application. The optimization resulted in a nearly 50% reduction in polar moment of inertia while maintaining other desired performance characteristics. The design developed using the topology optimization approach was fabricated using additive manufacturing and cannot be fabricated conventionally. This paper will discuss the design approach, performance improvements and manufacturing methods used to produce the part.

Polsky, Yarom↗
DOE OSTI2020

Structure and Stability of the Ionic Liquid Clusters [EMIM]n[BF4]n+1- (n = 1 – 9): Implications for Electrochemical Separations

Precise functionalization of electrodes with size-selected ionic liquid (IL) clusters may improve the application of ILs in electrochemical separations. Herein, we report our combined experimental and theoretical investigation of the IL clusters [EMIM]????[BF4]????+1- (n = 1 – 9) and demonstrate their selectivity and efficiency towards targeted adsorption of molecules from solution. The structures and energies of the IL clusters, predicted with global optimization, agree with and help interpret the ion abundances and stabilities measured by high mass resolution electrospray ionization mass spectrometry and collision induced dissociation experiments. The [EMIM][BF4]2- cluster, which was identified as the most stable IL cluster, was selectively soft landed onto a working electrode. Electrochemical impedance spectroscopy revealed a lower charge transfer resistance on the soft-landed electrode containing [EMIM] [BF_4 ]_2^- compared to an electrode prepared by drop casting of IL solution, which contains the full range of IL clusters. Our findings indicate that specific IL clusters may be used to increase the efficiency of electrochemical separations by lowering the overpotentials involved.

Zhang, Jun↗
DOE OSTI2020

Performance of a Printed Bimetallic (Stainless Steel and Bronze) Engine Head Operating under Stoichiometric and Lean Spark Ignited (SI) Combustion of Natural Gas

Additive manufacturing was used to fabricate a head for an automotive-scale single-cylinder engine operating on natural gas. The head was consisted of a bimetallic composition of stainless steel and bronze. The engine performance using the bimetallic head was compared against the stock cast iron head. The heads were tested at two speeds (1200 and 1800 rpm), two brake mean effective pressures (6 and 10 bar), and two equivalence ratios (0.7 and 1.0). The bimetallic head showed good durability over the test and produced equivalent efficiencies, exhaust temperatures, and heat rejection to the coolant to the stock head. Higher combustion temperatures and advanced combustion phasing resulted from use with the bimetallic head. The implication is that with optimization of the valve timing, an efficiency benefit may be realized with the bimetallic head.

42 ENGINEERING↗
NASA NTRS1972

Optimization in the design of a 12 gigahertz low cost ground receiving system for broadcast satellites. Volume 1: System design, performance, and cost analysis

The technical and economical feasibility of using the 12 GHz band for broadcasting from satellites were examined. Among the assigned frequency bands for broadcast satellites, the 12 GHz band system offers the most channels. It also has the least interference on and from the terrestrial communication links. The system design and analysis are carried out on the basis of a decision analysis model. Technical difficulties in achieving low-cost 12 GHz ground receivers are solved by making use of a die cast aluminum packaging, a hybrid integrated circuit mixer, a cavity stabilized Gunn oscillator and other state-of-the-art microwave technologies for the receiver front-end. A working model was designed and tested, which used frequency modulation. A final design for the 2.6 GHz system ground receiver is also presented. The cost of the ground-terminal was analyzed and minimized for a given figure-of-merit (a ratio of receiving antenna gain to receiver system noise temperature). The results were used to analyze the performance and cost of the whole satellite system.

Ohkubo, K.↗
NASA NTRS1997

Fundamentals of Mold Free Casting: Experimental and Computational Studies

Researchers are developing the technology of 'Ballistic Particle Manufacturing' (BPM) in which individual drops are precisely layered onto a substrate, and the drops are deposited so as to prevent splatting. These individual drops will ultimately be combined to form a net-shape, three-dimensional object. Our understanding of controlled drop deposition as applied to BPM is far from complete. Process parameters include the size and temperature of the liquid metal drop, its impact velocity and trajectory, and the condition and temperature of the substrate. Quantitative knowledge of the fluid mechanics and heat transfer of drop deposition and solidification are necessary to fully optimize the manufacturing process and to control the material microstructure of the final part. The object of this study is to examine the dynamics of liquid metal drops as they impinge upon a solid surface and solidify under conditions consistent with BPM (i.e. conditions which produce non-splatting drops). A program of both numerical simulations and experiments will be conducted. Questions this study will address include the following: How do the deformation and solidification of the drop depend on the properties of the fluid drop and the solid substrate? How does the presence of previously deposited drops affect the impingement and solidification process? How does the impingement of the new drop affect already deposited material? How does the cooling rate and solidification of the drops influence the material microstructure?

Tryggvason, Gretar↗
DOE OSTI2022

Reduction of detection limit and quantification uncertainty due to interferent by neural classification with abstention

Many measurements in the physical sciences can be cast as counting experiments, where the number of occurrences of a physical phenomenon informs the prevalence of the phenomenon's source. Often, detection of the physical phenomenon (termed signal) is difficult to distinguish from naturally occurring phenomena (termed background). In this case, the discrimination of signal events from background can be performed using classifiers, and they may range from simple, threshold-based classifiers to sophisticated neural networks. These classifiers are often trained and validated to obtain optimal accuracy, however we show that the optimal accuracy classifier does not generally coincide with a classifier that provides the lowest detection limit, nor the lowest quantification uncertainty. Here, we present a derivation of the detection limit and quantification uncertainty in the classifier-based counting experiment case. We also present a novel abstention mechanism to minimize the detection limit or quantification uncertainty a posteriori. We illustrate the method on two data sets from the physical sciences, discriminating Ar-37 and Ar-39 radioactive decay from non-radioactive events in a gas proportional counter, and discriminating neutrons from gammas in an inorganic scintillator and report results therefrom.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2018

Anionic multiblock copolymer membrane based on vinyl addition polymerization of norbornenes: Applications in anion-exchange membrane fuel cells

Stable, non-hydrolysable, hydroxide-conducting polymers are of interest for electrochemical devices such as fuel cells, electrolyzers and flow-batteries. In this study, a series of tetrablock copolymers containing an all-hydrocarbon backbone were synthesized. The synthesis is based on vinyl addition polymerization of norbornene using (η 3 -allyl)Pd( i Pr 3 P)Cl as the catalyst and lithium tetrakis(pentafluorophenyl)-borate·(2.5Et 2 O) (Li[FABA]) as the activator. The tetrablock polymers were cast into membranes with an ion-exchange capacity (IEC) between 1.55 and 2.60 milliequivalents per gram (meq/g). The number of bound and unbound water molecules per ion pair was measured and correlated with conductivity. The membrane with the highest IEC (2.60 meq/g) had 10.6 unbound (i.e. free) and 17.9 bound water molecules per ion pair within the polymer. The presence of excess unbound water has led to flooding of the ion conductive channels and low hydroxide ion conductivity. The optimal anion conductivity was found with about 6.7 unbound and 11.9 bound water molecules per ion pair. Excellent hydroxide conductivity (> 120 mS/cm at 80 °C) was obtained at an ion-exchange capacity of 1.88 meq/g. The results show that hydroxide mobility is aided by phase segregation within the copolymer. The ion conducting polymer was stable in 1M NaOH solution at 80 °C, showing essentially no loss in ion conductivity in 1200 h. Thermogravimetric analysis showed that the membrane backbone was stable up to 400 °C, consistent with previous polynorbornene-based materials. The peak power density of a H 2 /O 2 , hydroxide conducting fuel cell containing one of these membranes was 542.57 mW/cm 2 at 0.43 V and current density of 1.26 A/cm2 at 60 °C.

08 HYDROGEN↗
DOE OSTI2018

Numerical Simulation of the Effects of Horizontal and Vertical EMBr on Jet Flow and Mold Level Fluctuation in Continuous Casting

In this article, a new type of electromagnetic braking (EMBr), named vertical EMBr (V-EMBr) was introduced in the continuous casting process. In order to investigate its capability and applicability, the impacts of horizontal and vertical EMBrs on the flow pattern in a continuous casting mold were simulated by means of an implemented Reynolds-averaged Navier–Stokes (RANS) SST k–ω turbulence model. The characteristics of electromagnetic field and flow field inside a 1450 mm × 230 mm mold with Ruler-EMBr and V-EMBr have been compared. The numerical simulation results indicate that the static magnetic field generated by Ruler-EMBr can cover the main part of the discharging jet flow, which has a better control of the flow pattern in lower part of the mold. The static magnetic field generated by V-EMBr can cover both the vicinity of the mold narrow faces and the impingement region of the jet flow, which can effectively control the liquid steel flow in the upper recirculation zone. The parametric study also shows that the large vortices beneath the jet flow can be almost completely eliminated at an optimized magnetic flux density with Ruler-EMBr. In addition, the surface velocity and steel/slag interface fluctuation can be suppressed with the application of V-EMBr to acceptable values even with a wide variation of SEN port angles. It is estimated that to reach the same level of braking effect on the upper recirculation flow, a magnetic flux density of 0.1 T is sufficient for V-EMBr, while 0.2 T is needed for Ruler-EMBr. Based on the results, a second-generation V-EMBr has been developed, which combines both of the merits of Ruler-EMBr and V-EMBr.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Theory-guided design of duplex-phase multi-principal-element alloys

Density-functional theory (DFT) is used to identify phase-equilibria in multi-principal-element and high-entropy alloys (MPEAs/HEAs), including duplex-phase and eutectic microstructures. Here, a combination of composition-dependent formation energy and electronic-structure-based ordering parameters were used to identify a transition from FCC to BCC favoring mixtures, and these predictions experimentally validated in the Al-Co-Cr-Cu-Fe-Ni system. A sharp crossover in lattice structure and dual-phase stability as a function of composition were predicted via DFT and validated experimentally. The impact of solidification kinetics and thermodynamic stability was explored experimentally using a range of techniques, from slow (castings) to rapid (laser remelting), which showed a decoupling of phase fraction from thermal history, i.e., phase fraction was found to be solidification rate-independent, enabling tuning of a multi-modal cell and grain size ranging from nanoscale through macroscale. Strength and ductility tradeoffs for select processing parameters were investigated via uniaxial tension and small-punch testing on specimens manufactured via powder-based additive manufacturing (directed-energy deposition). This work establishes a pathway for design and optimization of next-generation multiphase superalloys via tailoring of structural and chemical ordering in concentrated solid solutions.

36 MATERIALS SCIENCE↗
DOE OSTI2024

An optimization-based approach to tailor the mechanical response of soft metamaterials undergoing rate-dependent instabilities

An optimization-based design framework is proposed to tune the response of soft metamaterials involving both geometric instabilities and nonlinear viscoelastic material behavior. Designing the response of soft metamaterials to harness instabilities and undergo large, tailored configuration changes will enable advancements in soft robotics, shock and vibration mitigation, and flexible electronics. In line with the metamaterial concept, the response of these materials is governed to a large extent by the geometric and topological makeup of their small-scale features. However, the link between structure and response is less intuitive for soft metamaterials due to their reliance upon highly nonlinear responses triggered by geometric instabilities. This is further complicated by the effects of viscoelastic relaxation, which recent studies have shown to alter the emergence of instabilities in non-intuitive ways. Here, these effects are accounted for in our framework to achieve various design objectives, including tailored force–displacement response and maximized energy absorption from both geometric and material effects. To fully automate this process, it is essential to have a completely robust equation solver for forward problems involving instabilities and viscoelastic relaxation. We achieve this by casting the search for stable mechanical equilibrium — i.e. the forward problem — as a minimization problem and utilize a trust region algorithm to robustly handle instabilities and follow energetically-favorable equilibrium paths through critical points.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Magnetic Gears: The Key to Robust, Cost-Effective Hydropower Drivetrains

Based on previous demonstrated success at fabricating 5 and 10 kW scale magnetic gearbox (MGB) prototypes, Emrgy and its partners (the project team) proposed to design and construct a 100 kW scale MGB with a 30:1 gear ratio for the low-head hydro applications. The Statement of Project Objectives included tasks covering: 1) Market Applicability; 2) Technical Metrics; 3) Design (initial); 4) Electromagnetic (EM) Load and Structural Analysis; 5) Modal Analysis; 6) Sealing Design and 7) Final Design during Budget Period 1. Budget Period 2 included tasks covering: 1) Materials Procurement and Test Plan Development; 2) Assembly; and 3) Testing. The Market Applicability study (Task 1) led to a clear conclusion and recommendation toward “Low Head” technologies for maximum market share of both New Stream Reach development as well as powering Non-Powered Dams. The findings of this study also identified the opportunity for a larger scale magnetic gearbox-based drive train as a function of increased torque, as opposed to increased speed. The Technical Metrics Study (Task 2) concluded a horizontal orientation was preferred, examined potential loss mechanisms, concluded that a Halbach Array magnetic design was preferred, established a 30:1 gear ratio as optimal, and established a power rating of 100 kW as optimal. The subsequent initial and final detailed design process included electro-magnetic (EM) load and structural analysis (Task 4), a Modal analysis (for vibration) (Task 5), and a sealing design (Task 6) to assure water impermeability. The final design package (Task 7) included 729 individual parts, 117 unique part numbers, and 15 assemblies. In order to facilitate procurement, the full bill of materials was broken down into several sub-components: 1) custom magnetic parts; 2) custom machined parts; 3) custom casted parts; and 4) commercial off the shelf (COTS) parts. The casted parts were fabricated by Oak Ridge National Laboratory (ORNL) via a Cooperative Research and Development Agreement (CRADA) with Emrgy and funded by the Advanced Manufacturing Office (AMO). The procurement effort (Task 8) ultimately covered three time periods based on challenges encountered in meeting the budgeted cost for the prototype. Following the first effort in the early stages of Budget Period 2 in 2017, a no-cost time extension was granted to seek alternative fabrication and procurement options. The project was re-booted in 2020 based on the new ORNL CRADA that would focus on five (5) of the more difficult and expensive parts using their advanced manufacturing expertise. Procurement efforts for the other custom machined parts resulted in quotations that still exceeded the budget by more than $\$$100k. This was, in part, also due to the concurrent COVID-19 pandemic that caused both supply chain disruptions and labor shortages. As the project continued, pricing and availability degraded further. In Q2 FY’22, it was decided to not proceed with the fabrication of the prototype (Task 9) based on budgetary limitations. Outcomes included a full and detailed design of a 100 kW magnetic gearbox and associated indented bill of materials (BOM) and CAD drawings, a full assembly instruction manual with an associated BOM for materials necessary to support assembly, the fabrication of the double Halbach magnetic array for the rotor/stator system, fabrication of five (5) sand-casted/machined parts (via CRADA with ORNL) and an initial draft of a comprehensive testing plan. The most significant non-outcome was the actual fabrication and testing of the prototype gearbox based on budget limitations. Lessons learned included the need for an Application / Design / Cost trade analysis to better elucidate the cost potential of the MGB in the projected volumes anticipated for future demand. This would better establish the efficacy of the original cost target ($\$$0.80/Watt) and/or the need for reconsideration of designs and applications. Likewise, additional consideration of the prototype nature of the gearbox – single use, short lifetime, etc. - either as a separate exercise or in place of the design process completed, to reduce the cost of the demonstration prototype device. Additionally, project continuity was cited as a significant risk based on the loss of the primary design engineering firm after Budget Period 1. A design analysis exercise was conducted at the conclusion of the project to identify potential areas for cost reduction. One concept considered was the removal of the inner ring of magnets (with associated changes in the outer ring magnets) to enable a horizontal collapse of the design. It was estimated this could reduce cost by 10-25% without impacting performance.

13 HYDRO ENERGY↗
NASA NTRS1986

Elevated temperature strengthening of a melt spun austenitic steel by TiB2

Mechanical properties of an iron-based alloy containing (by wt pct) 33Ni, 2Al, 6Ti, and 2B (resulting in an alloy containing 10 vol pct TiB2) were evaluated by hardness and tensile testing. The alloy was cast as a ribbon using a dual 'free-jet' variation of Jech et al. (1984) method of chill-block melt-spinning against a copper wheel; to simulate thermal cycles the alloy ribbon would experience during compaction into shapes, various segments of the ribbon were annealed under a vacuum at temperatures ranging from 500 to 1150 C. The results show that maximum strengths at 650 and 760 C were developed in ribbons annealed at 1100 C; in these ribbons an optimal combination of grain coarsening with minimum TiB2 particle growth was observed. However, the elevated-temperature strength of the TiB2-strengthened alloy under optimal annealing conditions was poorer than that of conventional iron-based superalloys strengthened by gamma-prime precipitates.

Michal, G. M.↗
DOE OSTI2022

Custom-designed heat treatment simultaneously resolves multiple challenges facing 3D-printed single-crystal superalloys

Single-crystal Ni-based superalloys are currently the material of choice for turbine blade applications, especially with the emerging additive manufacturing (AM) that facilitates the manufacture/repair of these single crystals. This promising AM route, however, comes with a dilemma: in the fusion and heat affected zones after e-beam or laser induced melting, one needs a solutionizing annealing to relieve the residual stresses and homogenize the chemical/microstructure. The super-solvus solutionizing temperature is usually adopted from the protocol for the cast superalloys, which almost always causes recrystallization and stray grain growth, resulting in a polycrystalline microstructure and degrading the high-temperature mechanical performance. Here, in this paper, we demonstrate a custom-designed post-printing heat treatment to replace the conventional super-solvus one. The recovery and relatively low temperature diminish the driving force for recrystallization and the movement of stray grain boundaries, without suffocating the chemical/microstructural homogenization thanks to the narrow dendrite width and short element segregation distance. The optimal duration of the heat treatment is proposed to achieve atomic-diffusion mediated chemical homogenization while limiting γ'-particle coarsening in the interdendritic regions. Our strategy makes it practically feasible to resolve several bottleneck problems with one processing/treatment, removing a seemingly formidable obstacle to effective additive manufacturing of superalloy single crystal products.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Improved Organic Electrochemical Transistors via Directed Crystallizable Small Molecule Templating

Organic electrochemical transistors (OECTs) are of great interest as biosensors and for flexible electronics applications. Historically, processing techniques have been widely used to improve the performance of polymers in organic electronics but have been underutilized in the field of OECTs. Here, in this work, we study the effects of a crystallizable small molecule template for improving the performance of poly(3-hexylthiophene-2,5-diyl) (P3HT)-based OECTs. We utilize 1,3,5-trichlorobenzene (TCB) as a crystallizable additive to induce directional crystallization during blade coating. This procedure results in an aligned, highly ordered, and moderately porous layer of the semiconducting polymer. We find that compared to neat P3HT solutions, films cast with TCB additive show a greater than 8× improvement in the steady state figure of merit for OECTs. Additionally, the optimum TCB loading produces anisotropic OECTs where the polymer chain aligned parallel to the current outperforms the perpendicular alignment by more than a factor of 10. We investigated the mechanism of this improvement and found that polymer alignment, polymer ordering, and film porosity all play a role in improving the device performance. Overall, these results demonstrate the importance of processing on the optimization of polymers for OECTs and suggest a route to greatly improve the performance of commercially available hydrophobic polymers.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Development of a Solvent-Free Process to Prepare DNAN

Objectives: Additive-free, solvent-free chemical reactions are generally more environmentally benign than alternative processes that involve these reaction components. 2,4-Dinitroanisole (DNAN) is of interest to the military and to industry as a replacement for trinitrotoluene (TNT) in melt-cast explosives. As anisole is a widely used feedstock chemical, the development of an efficient, additive-free, solvent-free method for its dinitration could lead to adoption of a new “green” synthetic route for DNAN manufacture. Technical Approach: Our goal is the scale-up (from the previously demonstrated one gram scale to a 500 gram scale) of the additive-free, solvent-free dinitration of anisole using the equipment and facilities available at the Los Alamos National Laboratory. Results: Through a series of simple optimization process, we have been successful at scaling demonstrating the development of a solvent-free process for the synthesis of 2,4-dinitroanisole using a batch process. The overall method involves the use of a mixture of propionic anhydride and 98% nitric acid to form the reactive nitrating species, proprionyl nitrate. This nitrating reagent is then added to a highly concentrated solution mixture of anisole and proprionic anhydride slowly over time to produce the desired 2,4-dinitroanisole product. This batch process could be scaled-up to the 270g scale. Flow-reaction methods should allow for larger scale production of DNAN. Benefits: This work has addressed the SERDP SEED Statement Of Need regarding environmentally benign methods for the synthesis of DNAN. Having achieved our goal, the next step will be to partner with a commercial manufacturer of explosive materials to scale the synthesis up to production levels.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗