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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 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Techno-Economic Comparison of Molten-Salt Electrolysis and Carbothermic Reduction for the Production of Metallurgical-Grade Silicon

Metallurgical-grade silicon (MG-Si) is an important source material for many industrial applications, including the manufacture of alloys, solar photovoltaics, and electronics. The process to refine raw materials into MG-Si is energy-intensive, with the predominant method of submerged-arc furnaces requiring energy consumption of approximately 11–13 kWh/kg Si. Recent research has discussed promising methods for reducing the energy required for the silicon production process, including the use of molten-salt electrolysis (MSE), a technique that offers potential savings in energy consumption without requiring carbon inputs for the process. This paper presents a techno-economic study of a potential industrial-scale MSE plant for MG-Si production to evaluate the trade-offs between capital and operating costs of the system. Capital costs are sourced from recent MG-Si plants and an existing cost model developed for MSE processes that includes the size of the plant and the operating temperature among its inputs. The results show that MSE technology has the potential to be an economically cost-competitive option for MG-Si production if the technology successfully scales to industrial production and matures enough to allow for financing costs similar to that of a comparably sized submerged-arc furnace plant.

14 SOLAR ENERGY↗
DOE OSTI2020

Transient Microstructure Evolutions and Local Properties of Dual-Phase 980 MPa Grade Steel Via Friction Stir Spot Processing

Friction stir processing is a novel solid-state process to modify microstructures and their properties by intense, localized plastic deformation. However, little research has been reported for microstructure evolutions of advanced high-strength steels during the process. The present work focuses on the study of transient microstructure changes and local mechanical properties for friction stir spot processed dual-phase (DP) 980 MPa grade steel (DP980) under different peak temperatures. A pinless silicon nitride ceramic tool was used to produce relatively simple material deformation and flow near the tool. Friction stir spot processed steel samples were characterized by optical and electron microscopies. Furthermore, Vickers microhardness and nano-indentation measurements were used to study local mechanical properties for correlation with microstructures. A swallow layer of refined grains (<0.6 µm) was obtained with a low peak temperature (under 400 °C), whereas higher peak temperatures (>Ac 1 ) led to a change in grain size with different microstructures (fine-grained DP or martensite). Electron back-scattered diffraction characterizations revealed a large deformation in the as-received microstructures (mixture of ferrite and tempered martensite) induced by friction stir spot processing, leading to recrystallization and grain refinement around the stirred zone. Also, nano-indentation measurements showed a higher hardness than the hardness of the as-received DP980. Friction stir processing with different process conditions effectively changed microstructures and local mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Automated Process Planning for Embossing and Functionally Grading Materials via Site-Specific Control in Large-Format Metal-Based Additive Manufacturing

The potential for site-specific, process-parameter control is an attribute of additive manufacturing (AM) that makes it highly attractive as a manufacturing process. The research interest in the functionally grading material properties of numerous AM processes has been high for years. However, one of the issues that slows developmental progress in this area is process planning. It is not uncommon for manual programming methods and bespoke solutions to be utilized for site-specific control efforts. This article presents the development of slicing software that contains a fully automated process planning approach for enabling through-thickness, process-parameter control for a range of AM processes. The technique includes the use of parent and child geometries for controlling the locations of site-specific parameters, which are overlayed onto unmodified toolpaths, i.e., a vector-based planning approach is used in which additional information, such as melt pool size for large-scale metal AM processes, is assigned to the vectors. This technique has the potential for macro- and micro-structural modifications to printed objects. A proof-of-principle experiment is highlighted in which this technique was used to generate dynamic bead geometries that were deposited to induce a novel surface embossing effect, and additional software examples are presented that highlight software support for more complex objects.

36 MATERIALS SCIENCE↗
DOE OSTI2020

LiDAR-Aided Interior Orientation Parameters Refinement Strategy for Consumer-Grade Cameras Onboard UAV Remote Sensing Systems

Unmanned aerial vehicles (UAVs) are quickly emerging as a popular platform for 3D reconstruction/modeling in various applications such as precision agriculture, coastal monitoring, and emergency management. For such applications, LiDAR and frame cameras are the two most commonly used sensors for 3D mapping of the object space. For example, point clouds for the area of interest can be directly derived from LiDAR sensors onboard UAVs equipped with integrated global navigation satellite systems and inertial navigation systems (GNSS/INS). Imagery-based mapping, on the other hand, is considered to be a cost-effective and practical option and is often conducted by generating point clouds and orthophotos using structure from motion (SfM) techniques. Mapping with photogrammetric approaches requires accurate camera interior orientation parameters (IOPs), especially when direct georeferencing is utilized. Most state-of-the-art approaches for determining/refining camera IOPs depend on ground control points (GCPs). However, establishing GCPs is expensive and labor-intensive, and more importantly, the distribution and number of GCPs are usually less than optimal to provide adequate control for determining and/or refining camera IOPs. Moreover, consumer-grade cameras with unstable IOPs have been widely used for mapping applications. Therefore, in such scenarios, where frequent camera calibration or IOP refinement is required, GCP-based approaches are impractical. To eliminate the need for GCPs, this study uses LiDAR data as a reference surface to perform in situ refinement of camera IOPs. The proposed refinement strategy is conducted in three main steps. An image-based sparse point cloud is first generated via a GNSS/INS-assisted SfM strategy. Then, LiDAR points corresponding to the resultant image-based sparse point cloud are identified through an iterative plane fitting approach and are referred to as LiDAR control points (LCPs). Finally, IOPs of the utilized camera are refined through a GNSS/INS-assisted bundle adjustment procedure using LCPs. Seven datasets over two study sites with a variety of geomorphic features are used to evaluate the performance of the developed strategy. The results illustrate the ability of the proposed approach to achieve an object space absolute accuracy of 3–5 cm (i.e., 5–10 times the ground sampling distance) at a 41 m flying height.

47 OTHER INSTRUMENTATION↗
NASA NTRS1969

Computer grading of examinations

A method, using IBM cards and computer processing, automates examination grading and recording and permits use of computational problems. The student generates his own answers, and the instructor has much greater freedom in writing questions than is possible with multiple choice examinations.

Frigerio, N. A.↗
NASA NTRS1972

Analysis and design of on-grade reinforced concrete track support structures

For the improvement of rail service, the Department of Transportation, Federal Rail Administration, is sponsoring a test track on the Atchison, Topeka, and Santa Fe Railway. The test track will contain nine separate rail support structures, including one conventional section for control and three reinforced concrete structures on grade, one slab and two beam sections. The analysis and design of these latter structures was accomplished by means of the finite element method, NASTRAN, and is presented.

Mclean, F. G.↗