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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Evaluation of Thermal & Mechanical Properties of Additively Manufactured Monolithic SiC for Solar Receiver Applications

Increasing the operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Owing to its high temperature stability combined with excellent thermal and optical properties, SiC has been the material of choice for application in high-temperature solar receivers. State-of-the-art SiC volumetric concentrating solar air receivers such as the honeycomb design have successfully demonstrated in field exit air temperatures approaching 800oC. However, a successful application of CST systems for the decarbonization of heat reliant industrial sectors requires significant increases in the temperature capability of SiC receiver technology. Supported by an award from the Solar Technology Office (SETO), US Department of Energy (DOE), GE Research in collaboration with Heliogen Holdings Inc, is engaged in the development of an ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. The program objective is to design and demonstrate a techno-economically viable SiC air receiver technology that can achieve exit air temperatures up to 1100oC for CST applications. We report and discuss the results of our testing and evaluation of thermal and mechanical properties of reaction-bonded SiC fabricated via binder jet printing to support the receiver component design, development, and analyses.

14 SOLAR ENERGY↗
DOE OSTI2025

Environmentally Friendly Use of Carbon Ore for Advanced Building Materials for Homes and Commercial Buildings

Through this effort, X-MAT CCC sought to confirm the utility and commercialization potential of carbon-derived building materials (CDBM) technology licensed from our partner, Semplastics. These CDBM products contain at least 52% coal-derived carbon by mass. Including the binders within the resin, the products contain at least 71% carbon by mass overall, meeting a key criterion for DE-FOA-0002185 – Area of Interest (AOI) 5 – Design Research and Development, Validation, and Fabrication of a Prototype Carbon-Based Building. The Phase II project has resulted in a technology demonstrator prototype structure, a detailed design for a carbon-based building, and updated techno-economic analysis (TEA) including detailed market surveys to show the commercial viability of CDBM products. We pursued the following objectives in Phase II: (1) construction of a partial building shell as a technology demonstrator, (2) testing of CDBM products, individually and in assemblies, (3) demonstration of bonding of CDBM and traditional building materials (TBM) in structural applications, (4) production of a detailed design for a carbon-based building, and (5) an update of the TEA that was performed in Phase I. In Phase II, X-MAT CCC and our industry team performed the development and testing needed to improve the maturity of the technology from a Technology Readiness Level (TRL) of 5 to TRL 6. CDBM have been shown by our partner Semplastics to exhibit a number of high-performance characteristics, including high strength (five times the flexure strength of the best commercial brick, and more than twice the compressive strength of construction-grade concrete block), lower density, improved mechanical durability and abrasion resistance, very high temperature stability, and resistance to chemicals, acids, salts, and water. These properties offer significant improvements over conventional building materials. Phase II built upon the work accomplished in Phase I by performing technical and economic research and development to confirm the viability of CDBM as commercial products in various markets. Acknowledgment: This material is based upon work supported by the Department of Energy under Award Number DE-FE0031985.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

TCF - Sustainable Well Cement for Geothermal, Thermal Recovery, and Carbon Storage wells

Primary cementing is the most important operation performed on a subterranean well. Cement, placed in the annulus between the casing and the formations, serves as a hydraulic seal preventing fluids and gas migrations, protecting steel casing from corrosion, and supporting the well structure. Poor cementing jobs can be directly responsible for wells not reaching their full capacity, casing corrosion, compromised well integrity and, in the worst-case scenarios, well collapse. Geothermal, thermal recovery, and carbon storage wells offer environments that are especially difficult for cements to survive while the required lifespan of these wells can be years. In these wells currently used cements cannot provide durable well integrity, and new solutions are necessary. The necessity of stabilizing the electric grid, increasing its flexibility, and providing energy on demand will further expand the market of durable cement solutions for applications in high-temperature underground reservoir thermal energy storage wells (HT RTES). The design challenges of special cement systems for such wells originate from chemistry limitations of currently used well cements, aggressive environments, temperature and repeated shock conditions associated with them, and very weak formations that are not uncommon in these wells. During the last 70 years the most common systems for thermal-well construction have been Ordinary Portland Cement (OPC) (absolute majority of the wells), silica-lime system, and high aluminum cement-containing formulations. The major issues of calcium-silicate hydrates, that form during the hydration of OPC resulting in hardened material, are their poor chemical resistance to acids due to the calcium interactions with acid anions followed by its eventual dissolution, even in mild acids, such as carbonic acid from CO 2 dissolution, and inadequate bonding to the steel causing serious casing corrosion problems (Sugama & Pyatina, 2019). Performance of OPC-based cement may be significantly improved with organic additives; however, those are limited by their temperature stability. An alternative to calcium-silicate cement was developed by BNL and commercialized by Halliburton as ThermaLock TM cement. Calcium-aluminate-phosphate-based chemistry of the material allowed overcoming acid-resistance problems of OPC, especially in CO 2 -rich geothermal environments. In 2012-2015, building upon this experience, BNL developed Thermal Shock Resistant Cement (TSRC) with the support of Geothermal Technology Office (GTO) of DOE. TSRC has high-temperature stable chemistry, superior properties of cement-metal casing bond and corrosion protection (4-times better than currently used OPC-based formulation), significantly outperforms common well-cements in thermal-shock tests, has self-healing properties, and like ThermaLock TM is CO 2 resistant incorporating carbonate ions into stable hydrates (Gill et al., 2012).

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

A Method for Dynamic Kolsky Bar Compression at High Temperatures: Application to Ti-6Al-4V

Abstract An experimental apparatus for measuring the dynamic behavior of materials subjected to strain rates on the order of 10 $$^3$$ 3 s $$^{-1}$$ - 1 and temperatures up to 800°C with a unique triple actuation system is developed in this work. This system is based on the traditional Kolsky (or split-Hopkinson pressure) bar design, with the addition of an external furnace used to heat the specimen to the desired temperature. A synchronized triple pneumatic actuation system is used to control the motion and timing of the the sample, incident, and transmitted bars. The cold contact time (CCT), or the time during which the heated sample is in contact with the room temperature bars before compression, is measured experimentally and carefully controlled to minimize the development of a temperature gradient across the sample and avoid heating of the bars. Experiments are performed in conjunction with ultra high speed imaging and 2D digital image correlation (DIC), as well as high speed thermal imaging. To verify the viability of the proposed system, experiments were conducted on Ti-6Al-4V (wt.%) at temperatures from 25°C up to and 800°C at an average strain rate of approximately 1200 s $$^{-1}$$ - 1 .

36 MATERIALS SCIENCE↗
DOE OSTI2020

NDMAS System and Process Description

The U. S. Department of Energy (DOE) has made a significant investment in research to develop the next generation of reactor technologies as well as to improve the performance and lengthen the life cycle of existing nuclear reactors. Data collected to demonstrate new concepts may also be used in the future to support licensing of these technologies. Provenance of these data must be preserved. The Nuclear Data Management and Analysis System (NDMAS) was established to manage and preserve data collected by fuels and materials research conducted by the high-temperature, gas-cooled reactor program. The scope of NDMAS is expanding to include other nuclear research programs that have the shared need to preserve the provenance of research data. Nuclear research funded by DOE is conducted by Idaho National Laboratory (INL), universities, other national laboratories, foreign research partners, and private companies. This research will generate a large amount of data from a variety of sources over a period of many years. Managing the data generated by the research and development projects presents a significant challenge for retaining data integrity and availability.

+↗
DOE OSTI2025

Testing piezoelectric sensors in a nuclear reactor environment

Several Department of Energy Office of Nuclear Energy (DOE-NE) programs, such as the Fuel Cycle Research and Development (FCRD), Advanced Reactor Concepts (ARC), Light Water Reactor Sustainability, and Next Generation Nuclear Power Plants (NGNP), are investigating new fuels, materials, and inspection paradigms for advanced and existing reactors. A key objective of such programs is to understand the performance of these fuels and materials during irradiation. In DOE-NE’s FCRD program, ultrasonic based technology was identified as a key approach that should be pursued to obtain the high-fidelity, high-accuracy data required to characterize the behavior and performance of new candidate fuels and structural materials during irradiation testing. The radiation, high temperatures, and pressure can limit the available tools and characterization methods. In this work piezoelectric transducers capable of making these measurements are developed. Specifically, three piezoelectric sensors (Bismuth Titanate, Aluminum Nitride, and Zinc Oxide) are tested in the Massachusetts Institute of Technology Research reactor to a fast neutron fluence of 8.65x1020 nf/cm2. It is demonstrated that Bismuth Titanate is capable of transduction up to 5 x1020 nf/cm2, Zinc Oxide is capable of transduction up to at least 6.27 x1020 nf/cm2 , and Aluminum Nitride is capable of transduction up to at least 8.65x x1020 nf/cm2.

T. Reinhardt, Brian↗
DOE OSTI2023

Binder Jet Additive Manufacturing Process and Material Characterization for High Temperature Heat Exchangers Used in Concentrated Solar Power Applications

The U.S. Department of Energy’s (DOE) Sunshot 2030 initiative has a goal of reducing the cost of concentrating solar power (CSP) to 5 cents per kWh for baseload power plants. One of the potential pathways to this goal includes a reduction in the cost of the supercritical CO2 (sCO2) power block to 0.9 cents per kWh. Recuperators—high and low temperatures, used in the sCO2 power cycle, contribute to >50% of the cost of the power cycle. This work studies the feasibility towards a ≥10% cost reduction for High Temperature Recuperators (HTR) used in the sCO2 power cycle. One way to address the cost reduction is by leveraging low-cost additive manufacturing, specifically, Binder Jet Additive Manufacturing (BJAM) to 3D print HTRs at scale. This study focuses on the development of a BJAM process towards 3D printing HTR cores using Stainless Steel alloy 316L (SS316L). To evaluate the suitability of the BJ process towards the HTR, high level specifications of the application are translated to materials capability requirements. Subsequently, at-temperature materials testing is conducted on as-printed and sintered additively manufactured coupons. Data from the coupons are compared against cast and wrought SS316L data obtained from the literature. Results show that the tensile properties from the BJ process compare well against cast properties. Furthermore, a baseline analysis of creep testing data is established for the BJ process, and insights are drawn from the results towards future improvements of the process.

14 SOLAR ENERGY↗
DOE OSTI2025

Nanoindentation’s imprint on an advanced society: Toward application conditions at the extremes

Abstract As society strives for a more sustainable future, key technologies depend on advanced materials development. Nanoindentation enables highly localized nanoscale measurement of mechanical properties, crucial for optimizing the performance of functional materials. Coupled with chemical charging, variable temperatures, or high deformation speeds, it offers insights into pressing materials science challenges necessary for sustainable energy transitions. This article explores the role of nanoindentation in advancing vital next-generation technologies. Graphical abstract

36 MATERIALS SCIENCE↗
DOE OSTI2025

Direct Air Reactive Capture and Conversion for Utility-Scale Energy Storage (Final Report)

This final report for FEW0277 summarizes the work performed over the project performance period of October 2021 – March 2025. This project was funded under the “Reactive Capture and Conversion R&D” lab call released in FY2021. The goal of the project was to develop dual-function materials and process for capturing CO 2 from the atmosphere and converting it into CH 4 . The work was organized into four parallel tracks in 1) direct air capture materials synthesis and characterization, 2) catalysts for CO 2 conversion, 3) mechanistic investigations via ab initio simulations, and 4) process modeling, technoeconomic analysis, and lifecycle assessment. The project was split into two budget periods. The first budget period focused on development of amine-based materials, due to their known performance for CO 2 direct air capture and their potential to act synergistically with metal catalysts to enable a low-temperature methanation pathway. The second budget period focused on development of alkali-based materials and a simulated-moving-bed process for high conversion catalytic reduction of captured CO 2 to CH 4 . All project milestones were completed during the project performance period and are summarized in this report. Our work resulted in publication of eight peer-reviewed manuscripts, one patent application, and numerous presentations given at domestic and international conferences and invited academic department seminars.

03 NATURAL GAS↗
DOE OSTI2024

High-Field Magnets for Future Hadron Colliders

Recent strategy updates by the international particle physics community have confirmed strong interest in a next-generation energy frontier collider after completion of the High-Luminosity LHC program and construction of a e + e - Higgs factory. Both hadron and muon colliders provide a path toward the highest energies, and both require significant and sustained development to achieve technical readiness and optimize the design. For hadron colliders, the energy reach is determined by machine circumference and the strength of the guiding magnetic field. To achieve a collision energy of 100 TeV while limiting the circumference to 100 km, a dipole field of 16 T is required and is within the reach of niobium–tin magnets operating at 1.9 K. Magnets based on high-temperature superconductors may enable a range of alternatives, including a more compact footprint, a reduction of the cooling power, or a further increase of the collision energy to 150 TeV. The feasibility and cost of the magnet system will determine the possible options and optimal configurations. In this article, I review the historical milestones and recent progress in superconducting materials, design concepts, magnet fabrication, and test results and emphasize current developments that have the potential to address the most significant challenges and shape future directions.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2026

Post-Mortem Characterization of Cerium Speciation in Molten Calcium Chloride

Abstract Advancing radiochemistry and nuclear materials science requires understanding actinide interactions with molten salts, which are used in next-generation nuclear reactors and for processing of actinides to recover useful fissile material. Understanding chemical interactions of actinides with molten salts has been limited by challenges in developing spectroscopic and X-ray techniques that are compatible with the high temperatures necessary to study molten salts. In this work, interactions of CeO2 (serving as a nonradioactive surrogate for uranium and plutonium) with CaCl2 are characterized following heating. Scanning electron microscopy indicates CeO2 morphological changes from small (<1 μm) particles to 3–5 μm sheets. Powder X-ray diffraction and infrared and Raman spectroscopies show the formation of CeOCl at higher (850–1050 °C) temperatures. In the absence of a chemical reducing agent, it was found that a high-temperature, low-oxygen environment is the key to the formation of oxychloride and that oxychloride formation is inhibited by annealing the CeO2 starting material. Lastly, thermal analysis revealed lowering of the melting point of CaCl2 after heating with CeO2. In all, this work identifies applicable spectroscopic techniques to target studies of heavy elements in molten salt environments and highlights the relationship between chemical speciation and melting behavior, a key thermophysical property.

Kelly, Sheridon N. [Lawrence Livermore National La↗
DOE OSTI2022

Magnetic field screening in hydrogen-rich high-temperature superconductors

In the last few years, the superconducting transition temperature, T c , of hydrogen-rich compounds has increased dramatically, and is now approaching room temperature. However, the pressures at which these materials are stable exceed one million atmospheres and limit the number of available experimental studies. Superconductivity in hydrides has been primarily explored by electrical transport measurements, whereas magnetic properties, one of the most important characteristic of a superconductor, have not been satisfactory defined. Here, we develop SQUID magnetometry under extreme high-pressure conditions and report characteristic superconducting parameters for Im-3m-H 3 S and Fm-3m-LaH 10 —the representative members of two families of high-temperature superconducting hydrides. We determine a lower critical field H c1 of ~0.82 T and ~0.55 T, and a London penetration depth λ L of ~20 nm and ~30 nm in H 3 S and LaH 10 , respectively. The small values of λ L indicate a high superfluid density in both hydrides. These compounds have the values of the Ginzburg-Landau parameter κ ~12–20 and belong to the group of “moderate” type II superconductors, rather than being hard superconductors as would be intuitively expected from their high T c s.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Advanced Moderator Material Handbook

High hydrogen density moderators such as metal hydrides are an important research topic within the DOE NE Microreactor Research, Development, and Deployment (RD&D) Program due to their ability to retain hydrogen to much higher temperatures than other hydrogenous media. This class of moderators, which includes yttrium dihydride (YH 2 ), thermalizes neutrons in the system such that the overall fuel mass or the required uranium enrichment in the system can be significantly reduced. Knowledge of material properties, both in the as-fabricated and irradiated state, are important to understanding moderator performance during steady-state and transient reactor operation. Provided in this document is the Advanced Moderator Material Handbook, which provides a detailed summary of the literature data on yttrium dihydride, thermomechanical and other property data, and a critical evaluation of that data. This handbook also provides a description of ongoing experiments to understand in-reactor performance, such as irradiations in ATR, as well as nuclear data from an integral critical experiment at NCERC. The majority of this report focuses on measured values but also includes some modeling results for comparison where applicable.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A NEA review on innovative structural materials solutions, including advanced manufacturing processes for nuclear applications based on technology readiness assessment

The Nuclear Energy Agency (NEA) Expert Group on Innovative Structural Materials (EGISM) was established in 2008 under the guidance of the Nuclear Science Committee (NSC). Its objectives are to conduct joint and comparative studies to support the development, selection and characterisation of innovative structural materials that can be implemented in advanced nuclear fuel cycles, under long service lifetime and extreme conditions, such as high temperature, high dose/dose rate and corrosive chemical environments. In this context of growing interest and initiatives, the EGISM initiated at the beginning of 2018 an activity among its members to: Identify, in a non-exhaustive way, the currently existing programs on innovative materials and fabrication processes in NEA member countries and China; Establish a first cartography of the activities that are underway on these topics and identify common subjects and thematic; Propose a Technology Readiness Level scale to estimate the maturity of both innovative materials and fabrication processes; Carry out a reflection on what the enablers are to quickly climb this TRL scale, as well as the obstacles, in order to identify solutions to overcome them. This paper first gives definitions shared between the EGISM members on what are considered as advanced structural materials solutions. Next, some international initiatives for the accelerated development of high performance materials are presented both in non-nuclear and nuclear fields. Then, the methodology adopted for technology readiness assessment is explained. A non-exhaustive synthesis of the projects identified among the EGISM members on innovative structural materials and advanced manufacturing solutions such as additive manufacturing is presented. The TRL level of these projects is evaluated. A focus is also made on some of these projects to illustrate and explain the TRLs chosen as well as highlighting enablers or obstacles identified to climbing up the TRL scale.

36 MATERIALS SCIENCE↗
DOE OSTI2022

SOFIA: Spectrometer Optimized for Facility Integrated Applications

Los Alamos National Laboratory researchers developed the Spectrometer Optimized for Facility Integrated Applications (SOFIA) for new capabilities in non-destructive nuclear material analysis, nuclear data measurements, and actinide science. SOFIA is the first ultra-high resolution gamma spectrometer technology based on low-temperature microcalorimeter designs. By precisely measuring the gamma rays passively emitted from radioactive and nuclear materials, SOFIA provides rapid, completely nondestructive analysis to improve the economics and timeliness of nuclear material analysis by reducing reliance on costly sampling and destructive analysis. By developing the first compact instrument based on ultrahigh resolution microcalorimeter gamma spectroscopy, the researchers intended to bring this technology into practical use in nuclear facilities and analytical laboratories.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Development of a Gibbs Energy Minimiser for the MOOSE-based Corrosion Modelling App Yellowjacket and Validation of MSTDB

Nuclear materials are highly complex multiscale, multiphysics systems,and an effective prediction of nuclear reactor performance and safety requires simulation capabilities that tightly couple different physical phenomena. The Idaho National Laboratory’s Multiphysics Object Oriented Simulation Environment (MOOSE) provides the computational foundation for performing such simulations. With the move towards advanced reactors, such as the Molten Salt Reactor (MSR), that employ high temperature fluids compared to conventional reactors, corrosion has become a problem of great interest. A new application called Yellowjacket is currently under development to directly couple thermodynamic equilibrium and kinetics with phase field models in order to model corrosion in MSRs. As part of Yellowjacket, a Gibbs energy minimiser is being developed to perform thermochemical equilibrium calculations for a range of different materials, which is currently in its infancy. This report describes the further progress towards the development of Yellowjacket Gibbs energy minimiser. Ontario Tech University is developing a new Gibbs energy minimiser for Yellowjacket which is the primary contribution of this work. The aim to develop a thermochemistry solver for the MOOSE framework following the same development philosophy and using the same tools and libraries. A special focus is on performance, documentation and SQA. Furthermore through a scope extension partway through the fiscal year a thorough assessment of the MSTDB-TC v1.3 was performed at Ontario Tech University in the context of continuous improvement and quality assurance. The objective of the work was to have an arm’s length review of the database to give confidence that the database is performing as it was intended while assessing its current state to give recommendations to future developments. This assessment involved two parts: A) a quantitative assessment, and B) a qualitative assessment. Part A involved developing an automated test-suite that would compute values from the database using Thermochimica with comparisons to experimental measurements for validation purposes, which gives confidence to the database’s stakeholders that its functioning properly. Part B involved reviewing all binary systems in the database and making a qualitative assessment with two performance indicators: comprehensiveness and overall confidence. It is important to note that the models in the database are empirical, which is to say that the quality of any model is highly dependent on the experimental data used to inform its development.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Additive Manufacturing of Corrosion Resistant UHTC Materials for Chloride Salt-to-sCO2 Brayton Cycle Heat Exchangers

The objectives of the project include: (1) screen high-purity, high density ultra-high-temperature ceramics (UHTCs) for chloride salt corrosion resistance, (2) develop binder-jet additive manufacturing and sintering for ZrB 2 -MoSi 2 blends using literature and experiments to demonstrate feasibility, and (3) evaluate chloride salt corrosion resistance of additively manufactured ZrB 2 -MoSi 2 . These initial objectives support the development of a durable and reliable ultra-compact high-efficiency salt-to-sCO 2 heat exchanger for closed-loop Brayton power cycles based on corrosion resistant, high-strength, thermally conductive UHTC materials and novel designs enabled by additive manufacturing. The UHTC materials are also abrasion resistant so that they could be applicable to all three thermal carrier media pathways identified in the CSP Gen3 Roadmap.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Microstructure and 77K mechanical properties of electron beam welded Cu101- Inconel 625 joints

In developing large-scale next-generation superconducting radio frequency (SRF) linear accelerators using superconducting films on Cu, the design and development of dissimilar welding and joining metals, such as Cu to Inconel, stainless steel, and Nb, are essential. In this talk, we present the development of procedures for electron-beam welding of Cu¿Inconel 625 and evaluation of the microstructure and 77K mechanical properties of the weld and base material in the welded condition and heat treatments in the 750°C ¿950°C heat treatment range. The results will be presented in the context of developing joining techniques for low-temperature applications where high conductivity and strength, vacuum hygiene, and magnetic properties of the material need consideration. The methods presented here are being deployed to thin film SRF Cu cavities at Jefferson Lab. Acknowledgment: This material is based upon work supported by the U.S. Department of Energy, Office of Science, Office of Nuclear

Khanal, Bashu↗