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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 OSTI2020

Top Loading Helium Cryostat Integrated with High-Pressure Cell with Fast Remote Pressure Control (Final Report for SBIR Phase 1)

A large number of physical phenomena, such as superconductivity and quantum critical phenomena, often appear only at very low temperatures below 5 K. There is an immense interest to investigate these phenomena at high pressure as a means of tuning interatomic distances, and thus the interaction parameters controlling these phenomena, in a continuous and controlled fashion. The current P-T condition for neutron scattering experiments are limited to either relatively low pressures of about 2 GPa at temperatures below 5 K, or to relatively high temperatures at pressures or tens of GPa. The purpose of this research is to develop neutron sample environment instrumentation for reaching 10-20 GPa at 1-2K with rapid and reliable online pressure and temperature control (i.e. without having to interrupt the experiment). The ultimate goal of the project is to design an integrated fast-cooling low-temperature sample environment cryogenic system compatible with state of the art neutron diamond anvil cells suitable for single-crystal neutron scattering experiments for temperatures down to 2K and pressures of several tens of GPa. The integrated system will consist of top-loading Helium flow cryostat with in-situ sample alignment mechanisms, large-volume diamond anvil cells (DAC) made from novel superalloy Pascalloy and optimized for fast cooling and heating, and a compact remote pressure control mechanism for the DAC based on a novel concept of inflatable bellows integrated with a lever-arm based force amplifier. In Phase I, we have designed, manufactured, and tested prototypes of the novel compact force-amplified pneumatic pressure control mechanism for Neutron Diamond Anvil Cell (nDAC), which allows to use pneumatic bellows system for smooth remote pressure control in the nDAC inside a top-loading cryostat with bore size of 70 mm or larger. This allows significant minimum temperature decrease in remotely controlled nDAC from 5-10 K down to 2 K. We also studied mechanical properties of a novel non-magnetic superalloy Pascalloy with different heat-treatment conditions and preliminary results indicate that up to date this is probably the strongest and most suitable material for making more compact and lightweight cryogenic nDACs for neuron scattering experiments at extreme conditions, allowing much faster cooling and heating. Potential applications: The new developments will allow to create a wide range of compact Diamond Anvil Cells for neutron diffraction which can reach several tens of GPA pressure at 2-4 K while preserving accurate remote pressure control capabilities. The new concepts can be used for developing sample environment instrumentation outside the neutron scattering field. The new development have very strong potential for expanding experimental capabilities in materials sciences and have high commercialization potential. The proposed new cryogenic high-pressure system or any of its individual components will be in high demand not only in neutron scattering facilities, but also at synchrotron beamlines and other high-pressure research facilities around the world.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fluidization of Group A Glass Particles: Experiments and Preliminary Validation

This work is aimed at providing reliable high-quality data from fluidization experiments. Geldart Group A glass beads are used as bed material. The fluidizing medium is air at atmospheric pressure which enters the system at 40% relative humidity. The air inlet velocity is varied over a broad range from 2 U mf to 26 U mf , where the minimum fluidization velocity, U mf , is 0.608 cm/s. There is not a significant change in the mean values of differential pressure; however, there are noticeable trends in their standard deviation values. Preliminary validation studies are performed using the open-source software Multiphase Flow with Interphase eXchanges (MFiX) developed by the National Energy Technology Laboratory (NETL). The results from Eulerian-Eulerian (MFiX-TFM, two-fluid model) and Eulerian-Lagrangian (MFiX-PIC, particle-in-cell) formulations are compared. The work presented in this report highlights the applicability of MFiX-PIC for large-scale applications, and reveals that PIC simulation offers a suitable alternative to TFM simulation when effects due to multiple components or polydispersity are significant. PIC modeling provides a readily extendible framework for such systems. However, PIC models do rely on an empirical closure for inter-particle stress. Some solution discrepancies were evident in MFiX-PIC predictions which require further analysis. As such, the study underlines the need for a systematic approach to quantify the sources of numerical uncertainty within the PIC model. However, even with known empiricism, MFiX-PIC has demonstrated considerable potential in analyzing gas-solid systems. The results obtained are encouraging and warrant further investigation to improve the predictive capability of MFiX-PIC.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Cooperative Research and Development Agreement between National Energy Technology Laboratory and Birla Carbon U.S.A., Inc. [Abstract]

NETL researchers will be collaborating with Birla Carbon, U.S.A., Inc. (Birla Carbon) to leverage NETL's patented catalyst work on methane decomposition to commercialize an efficient and a cost-effective process for production of hydrogen and valuable carbon from natural gas. This catalytic methane decomposition is a promising technology, however, finding an appropriate catalyst to perform all the functions has been a challenge. NETL has developed a suitable catalyst for the process which has shown promising results. The heat required for this endothermic catalytic decomposition process is provided by combustion of a portion of the hydrogen. This process is cost effective, energy efficient, and environmentally friendly with minimal CO 2 mitigation costs. The objectives of the project include evaluation of the effect of feed gas composition on the performance, reduction of the catalyst production cost, and conduction of an in-depth large-scale cost analysis for a process suitable for applications at Birla Carbon.

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

Shrubland Restoration

The shrubland at Fermilab is an area home to many species such as songbirds, insect and a variety of plant life. While it has its inhabitants many native songbirds are decreasing in population and this may be because the area is not suitable for these birds anymore. The three specific birds impacted the most are the yellowbreasted chat, bells vireo, and the willow flycatcher. The area is currently not offering a suitable habitat for these native birds for many reasons.

Lopez, Ruben↗
DOE OSTI2022

Transient superconductivity at nano- and meso-scales

High-T c superconductivity is surpassed by few, if any, other unsolved problems in contemporary physics in terms of its richness, complexity, impact on other fields, and potential technological importance in energy applications. Recent discoveries reveal that the highest transition temperatures emerge under extraordinary experimental conditions such as the strong perturbation of a single atomic layer material by the underlying substrate, application of ~200 GPa pressure or ~MV/cm static electric fields, or irradiation by intense femtosecond optical fields. Research in superconductivity under extreme experimental conditions is challenging and requires the development of novel experimental methods and new theoretical tools suitable to tackle the problem. Our team has approached the challenges of transient superconductivity under intense optical fields by rethinking the types of experimental observables that are best suited to elucidate the physics of light-induced effects. This exercise has identified the need for: i) ultra-fast spatio-temporal probes enabling access to plasmonic properties and also nano-scale inhomogeneities that are ubiquitous in unconventional superconductors; ii) meso-scale structures and hybrid meta-surfaces imperative for strong enhancement of optical fields and iii) theoretical approaches suitable to explain and predict the response of superconductors under ultra-fast photo-excitation. Co-PIs have already made major advances with developing capabilities i)-iii). Therefore, our team is poised to make significant progress in transient superconductivity by exploring novel spatio-temporal effects that currently remain unattainable. Co-investigators will search for light-induced superconductivity in the high-T c cuprates to build upon spectacular recent results still lacking independent confirmations. Novel data acquisition methods combined with nano-plasmonic imaging will allow our team to test the hypothesis of photo-induced superconducting pairing. Spatio-temporal experiments will provide insights into the interplay between superconductivity and competing orders in the cuprates. Co-PIs will also investigate strong light-matter interaction and superconductivity in FeSe monolayers. Finally, we will study spatio-temporal electrodynamics of planar Josephson junctions. This latter direction will allow our team to thoroughly characterize one of the most fundamental examples of inhomogeneity in all of unconventional superconductivity. The proposed experiments in combination with theoretical analysis will provide information that is difficult to obtain using alternative methods. Basov and Averitt will carry out pump-probe spectroscopy and nano-imaging experiments. Averitt and Hone will design and fabricate state-of-the-art meta-surfaces. Theoretical and computational studies of ultrafast transient phenomena will be carried out by Millis and Fogler. Modeling of time-resolved nano-optical effects will be done by Fogler. The bulk of the requested budget will be used to support graduate students at Columbia & UCSD that will be co-supervised by co-PIs. The proposed program is transformative, since it will enable an entire suite of experiments previously either impossible or technically implausible. It will deliver critically important insights not only into mechanisms of unconventional superconductivity but also to many other correlated quantum materials.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Materials Development and Advanced Process Simulation for Additive Manufacturing with Fiber-Reinforced Thermoplastics (Final Technical Report)

DuPont, Local Motors, and the Composites Manufacturing and Simulation Center (CMSC) at Purdue worked together to advance process simulation capabilities for Additive Manufacturing (AM) and develop printable short fiber reinforced semi-crystalline engineering thermoplastics suitable for vehicle components. DuPont provided one candidate thermoplastic material, which was evaluated against the following three criteria: 1) Printability using extrusion additive manufacturing processes. 2) Suitability for vehicle applications based on mechanical coupon screening tests. 3) Predictive capability of process simulations. Indiana Manufacturing Institute provided modeling and simulation technology and access to Purdue’s lab scale AM printer. Local Motors provided mechanical property requirements and printed demonstration prototype components using their Thermwood Large Scale Additive Manufacturing (LSAM) printer. To meet the performance and cost requirements of the automotive industry, high fiber content semi-crystalline engineering materials are required. Printing experience and property data for a 50% by weight short glass fiber reinforced material were gathered. Further, material properties required for simulating the printing process with the glass-fiber reinforced material were characterized. Knowledge was acquired with regards to the processability and performance of this thermoplastic material. Predictions of part deformation and crystallinity level were verified against experimental observations. Any significant results other than verification of simulation, e.g., novel material identified here would be impactful.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Road Map for Developing Iron Phosphate Waste Forms for Salt Wastes

In this report, issues that must be addressed to advance the technology readiness level of phosphate glass waste forms being developed to immobilize high-level radioactive salt waste streams are identified, the states of understanding various technical aspects of formulation, processing, and performance are summarized, and approaches supporting further development are recommended. Processing results in dehalogenation of the waste salt, capture of the gaseous halide-bearing species, and immobilization of the residual salt components in a phosphate glass waste form. The approach is suitable for high-level salt waste from electrochemical reprocessing and molten salt reactors. The technology has been demonstrated for chloride-based salts and may also be suitable for the treatment and immobilization of fluoride-based and iodide-bearing waste salts. Aspects of the process requiring further development are identified and approaches recommended.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Nevada National Security Site Demonstration Reactor Siting and Capability Study

The study’s purpose is to identify suitable testbeds within the NNSS for the demonstration of advanced and emerging reactor technologies. These testbeds are envisioned to be existing structures, facilities, or sites that may be suitable for advanced reactor demonstrations, advanced reactor fuel fabrication, or other experimental support for advanced reactor demonstrations. This study examines siting alternatives at NNSS with the objective of identifying locations for near term ARD projects. Included in the outcomes is an evaluation of the quantitative and qualitative factors that must be addressed for each site if selected to host an ARD sponsored demonstration.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Application of Refractory High-Entropy Alloys for Higher-Reliability and Higher-Efficiency Brayton Cycles and Advanced Nuclear Reactors

An exceptional set of newly-discovered advanced superalloys known as refractory high-entropy alloys (RHEAs) can provide near-term solutions for wear, erosion, corrosion, high-temperature strength, creep, and radiation issues associated with supercritical carbon dioxide (sCO2) Brayton Cycles and advanced nuclear reactors. In particular, these superalloys can significantly extend their durability, reliability, and thermal efficiency, thereby making them more cost-competitive, safer, and reliable. For this project, it was endeavored to manufacture and test certain RHEAs, to solve technical issues impacting the Brayton Cycle and advanced nuclear reactors. This was achieved by leveraging Sandia’s patents, technical advances, and previous experience working with RHEAs. Herein, three RHEA manufacturing methods were applied: laser engineered net shaping, spark plasma sintering, and spray coating. Two promising RHEAs were selected, HfNbTaZr and MoNbTaVW. To demonstrate their performance, erosion, structural, radiation, and hightemperature experiments were conducted on the RHEAs, stainless steel (SS) 316 L, SS 1020, and Inconel 718 test coupons, as well as bench-top components. The experimental data is presented, analyzed, and confirms the superior performance of the HfNbTaZr and MoNbTaVW RHEAs vs. SS 316 L, SS 1020, and Inconel 718. In addition, to gain more insights for larger-scale RHEA applications, the erosion and structural capabilities for the two RHEAs were simulated and compared with the experimental data. The experimental data confirm the superior performance of the HfNbTaZr and MoNbTaVW RHEAs vs. SS and Inconel. Most importantly, the erosion and the coating material experimental data show that erosion in sCO2 Brayton Cycles can be eliminated completely if RHEAs are used. The experimental suite and validations confirm that HfNbTaZr is suitable for harsh environments that do not include nuclear radiation, while MoNbTaVW is suitable for harsh environments that include radiation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Phasor-Measurement-Unit-Based Data Analytics Using Digital Twin and PhasorAnalytics Software

A major objective of this project was to apply GE’s commercial machine learning and data analytics toolsets to large-scale, real-world, anonymized Phasor Measurement Unit (PMU) datasets in order to extract signatures, correlated and/or causal factors, and precursor patterns associated with significant power system phenomena. The project had a particular emphasis on extraction of insights relevant to asset health monitoring, real-time load modeling and cybersecurity monitoring. Additionally, the team was directed to undertake a comprehensive data quality analysis for the provided datasets and encouraged to estimate the ‘machine-learning readiness’ of the datasets by documenting any major obstacles to the application of commercial machine learning algorithms. To accomplish the aforementioned objectives, the project team’s work centered around the identification of key event signatures and application of the identified event signatures for event detection and event classification. The industry-validated, semi-supervised machine learning strategy employed for event signature identification involved several major tasks, including data-preprocessing, generation of an overabundance of features, normal data identification, normality modeling, and event signature identification through a methodical, quantitative ranking of features in order of relevance to each studied event type. Throughout the project, data quality issues and mitigation techniques were investigated. In this report, insights are provided regarding the readiness of the provided synchrophasor datasets for application of machine learning and data analytics. The methodologies employed for this technical strategy are summarized in this report. With regards to data preprocessing and feature generation, the provided Training and Test Datasets were ingested into GE’s big data environment. Subsequently, the team applied bad data cleansing and data imputation scripts, event detection scripts, and application programming interfaces (APIs) to the datasets for convenient data access. The project team completed development and validation of dozens of physics-based, statistics-based and transformation-based feature functions used for the extraction of over 60 synchrophasor features. Using a new parallel feature generation technology developed on this project, over 60 features have been rapidly generated for the full two years’ worth of Training and Test Dataset data associated with both the Eastern and Western interconnects. Even accommodating for temporal down-sampling inherent to the feature extraction procedure, this parallel feature generation activity resulted in a massive feature set with a storage requirement approximately equal to that of the raw training dataset itself. With regards to normal data identification and normality modeling, a normality model was built using the feature data extracted from the Training Dataset and iteratively refined subsequent to incremental adjustments and expansions of the Training Dataset feature data. With respect to event characterization and signature identification, an event signature identification pipeline was developed and used in conjunction with the normality model to identify over 15 event signatures for key event categories within the Training Dataset. The identified event signatures were used to characterize hundreds of key events in terms of relative severity, duration, and location of the event. An investigation was undertaken to identify correlated and causal factors involved in transformer events. A separate investigation into temporal trends in ring-down analysis results was undertaken to determine possible associations between system dynamics and various other factors such as loading, season or year. To validate the identified event signatures, additional work was undertaken to develop signature-based anomaly detection and classification tools suitable for convenient application to the synchrophasor datasets. The anomaly detection and classification tools, suitable for online application, were then applied to the entirety of the Eastern Interconnect Training and Test Datasets. Performance of the event detection and classification tools was evaluated upon receipt of the Test Dataset event logs (i.e., the labels for events contained in the Test Dataset), and promising results were obtained despite several challenges (documented herein) associated with application of supervised or semi-supervised machine learning methods to large-scale, anonymized datasets. Finally, the detection and classification tools were used to detect, classify, and characterize thousands of new events not included in the original event logs provided by the DOE within both the Training and Test Datasets.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

A Short-Term Solar Forecasting Platform Using a Physics-Based Smart Persistence Model and Data Imputation Method

Electrical energy plays vital role in our socio-economic activity and therefore ensuring the reliability of the electric grid, from the generation, transmission and distribution level is critical. In order to maintain the power system parameter viz., frequency, voltage, etc., optimally, balancing of generation and consumption is very much essential. However, solar energy is infirm power by nature this is due to cloud cover / other local phenomena. Hence, Photovoltaic (PV) power generation brings a significant challenge to the grid operator due to the variability of the solar energy. The complexity of this challenge in terms of planning and dispatch ability of PV resources, aggravates with the high penetration of solar energy into the electric grid. In this setting, reliable solar radiation forecasting models based on accurate and quality input data become essential. In order to develop a suitable model for predicting solar radiation, quality historical / real time measurement is also needed. Under this study NIWE and NREL jointly developed / tested short-term solar forecasting frameworks using a smart persistence and physics-based smart persistence models for intra-hour forecasting of solar radiation (PSPI) and benchmarked 9 different data imputation techniques in 15 Solar Radiation Resource Assessment (SRRA) stations, located at different parts of India. During any measurement campaign, due to various technical reasons, we may miss few observations. However, the missing observation often reduce the performance of any forecasting model. Therefore, suitable data imputation method would assist us to obtain continuous observation of solar radiation. A station-by-station and method-by-method analysis was carried out to understand the performance of each model. Based on our analysis, among all the data imputation methods, the Kalman data imputation method is better for Indian Weather condition. In addition, Kalman StructTS, Linear, Stine and Arima methods yield slightly inferior accuracy compared to Kalman, but outperform the other methods. The extended solar radiation data are used by solar forecasting models to provide the prediction of solar radiation at 15 SRRA stations. As far as short term forecasting model is concerned, the PSPI model outperforms the Smart Persistence model. However, the forecast error is increases with the forecasting horizon.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

NASNF Processing and Packaging Technical Study

The ABD program will require development of a strategy for the dispositioning the Non-Aluminum Spent Nuclear Fuel (NASNF), some of which will be very challenging to handle and dissolve as described in this report. Not all the NASNF is suitable for processing through the electrolytic dissolver. The strategy may involve dissolution of the majority of the NASNF inventory in the electrolytic dissolver combined with some other disposition alternative(s) for the fraction that is not suitable for electrolytic dissolution. This report highlights the risks and challenges associated with the baseline approach of using the electrolytic dissolver to process all of the NASNF. In addition, the characteristics of the NASNF and how those characteristics relate to the risks associated with electrolytically dissolving the specific fuel types.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

An Integrated Multiscale Modeling Framework for Unconventional Stimulation and Production (Final Report)

The production of oil and gas from unconventional reservoirs largely depends upon two main features operating at different scales: (1) the establishment of a reservoir scale stimulated fracture network that effectively communicates with the rock volume, enhancing permeability and transport to the wellbore and (2) the coupled multi-phase flow, chemical and mechanical processes affecting the migration of hydrocarbons from the low permeability country rock adjacent to the stimulated fracture network. To date, there has been no simulation framework that allows seamless and integrated prediction of these features across spatial scales extending from the pore structure of the reservoir rock to the volume of the reservoir. In addition, there has been a lack of suitable field measurements to test such models, as stimulation and production data are often proprietary and not freely available to national laboratories and academic institutions. New multi-scale simulation capabilities are needed that are validated against suitable field-based research experiments on hydraulic fracturing and shale production.

02 PETROLEUM↗
DOE OSTI2022

Low-Cost Preform and Molding Processes

The entry cost for prototyping a composite component for manufacture using automated, high rate processes is prohibitively expensive in many cases, especially for small business, where tooling costs may be several $100k. Discussions with industry also indicate that many small companies, tier 1 and 2 suppliers, have an interest to mold composite parts but do not want to deal with the capital cost, material handling issues, and labor associated with dry fiber preforming operations. While the molders may locate near the end user for logistics reasons, it may be more cost effective for the performer to remain regional and invest in capital equipment to support preform automation, thus keeping costs to a minimum. This project was designed to explore and demonstrate several options to meet these industry needs. Dry fiber preforming approaches were evaluated which allow for low pressure resin infusion, single sided tooling options such a vacuum assisted resin transfer molding (VARTM) or low pressure resin transfer molding (RTM-light). Unlike sheet molding compound, SMC compression molding where typical molding pressures of 1000 psi are required to push material into the desired location; positioning of a dry fiber preform into the desired location on the tool allows for low molding pressures of 10-50 psi. Lower molding pressures allow for use of low cost, additive fabrication of polymeric tooling. Polymeric tooling is suitable for rapid part prototyping and limited production. Dry fiber preforming approaches evaluated included use of commercial chopped strand mat, robotic chopper gun deposition, and continuous fiber preform augmentation using tailored fiber placement (TFP). Use of chopped strand mat does not require a robotic deposition method, however a cutting table is generally required and there is typically 20-30% scrap generation. While various fiber areal weights are available, the preform is not readily optimized for minimal fiber use or weight savings. In contrast, a robotic chopper gun approach allows for localized deposition where fiber is required to meet structural requirements. The robotic method is highly automated and minimizes fiber scrap, however the capital cost of the equipment and engineering labor for programming can result in higher preform cost compared to chopped strand mat in certain cases depending on preform complexity. Dry fiber preforming using the robotic chopper gun method allows for creation of three dimensional forms. This approach may be ideal for molding in-house, or if the preforms stack together densely to allow for efficient shipping. Applications evaluated for this program considered trade-off between fabrication of a fully 3D preform versus production of a flat preform which is designed to readily drape into the final desired shape. Such a preform design greatly simplifies robotic programming and requires no specialized tooling. The flat preforms are easily stacked and shipped to the final molding location. Flat preforms are much easier to augment with TFP continuous fiber to provide local reinforcement. The demonstration and evaluation of these preforming and tooling methods were completed on three component applications. The first application was a battery box cover for an electric vehicle which was highly three dimensional. The second demonstrator article was comprised of complex contours and was used to demonstrate the use of TFP and RTM-light molding process. The third demonstration article was the roof of an operator’s cab for large construction equipment. The roof is relatively flat however it is comprised of complex changes in thickness which clearly demonstrate the advantage of robotic chopper gun approach as compared to using numerous preform layers of chopped strand mat. The cost trades for the various preforming methods are summarized to help guide the reader as to preforming method considerations. Finally, these demonstrations all used glass fiber roving. A fourth, exploratory task was added to evaluate the ability to make preforms using Zoltek’s carbon fiber split tow roving. We were able to adapt the chopper gun to make flat preforms for laminate testing, but further development effort would be required to make suitable preforms.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Aerosol Inlets for a Mid-Sized Uncrewed Aerial System (UAS)

The purpose of this technical report is to document the efforts to design and test two inlet systems for aerosol sampling suitable for deployment on a medium-sized fixed-wing Uncrewed Aerial System (UAS). This work, which was supported by the U.S. Department of Energy’s Atmospheric Radiation Measurement (ARM) user facility, was conducted at the Pacific Northwest National Laboratory (PNNL) for the ARM Aircraft Facility (AAF) starting in November 2017. The current work is a part of AAF efforts to instrument the ArcticShark (a mid-sized UAS owned and operated by the AAF) for atmospheric research and develop a scientific payload for deployment on a similar-sized UAS with minimal adaptation and integration. An aerosol inlet system is necessary to sample and transport ambient air sample to the scientific instrumentation with minimal distortions to the aerosols. Two isokinetic aerosol inlets were designed: the first is a simple passive system for a single instrument suitable to be installed in a wing pylon; the second is a system with active control designed to sample and distribute air among several heterogeneous instruments and to provide basic humidity control of the air sample so that the measured aerosol parameters should correspond to “dry” conditions (a common requirement). Both systems could be easily adapted for deployment on another platform and/or with a different set of instrumentation. Several conducted flight tests showed that the inlets’ performance met our design goals.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Aluminization Coatings and Glass Seals for High Temperature System: CRADA 536 [Abstract Only]

The proposed work will demonstrate the suitability of PNNL Reactive Air Aluminization (RAA) coatings (US Patent Numbers 10,577,694, 10,378,094, and 9,481,923) for use in high-temperature systems. In particular, the Participant and Contractor will explore applicability of these coatings in Participant’s high-temperature hydrogen reactors where they would be used to prepare the sealing surfaces of the reactor technology. Utility Global will also instruct PNNL regarding their needs relating to the further development of glass seal technologies that are suitable for use in their systems. This effort will entail alkaline earth-based silicate glass development and characterization; evaluation and characterization of reliability and compatibility of the coatings with glass seals, working environments, and substrates; performance demonstrations of representative cells and intermediate cells sealed using the glass seals and/or coatings of interest; and incorporation of the aluminization coatings and glass seals into the reactor for full-scale testing.

08 HYDROGEN↗
DOE OSTI2022

Roll to Roll (R2R) Manufacturing of Electrolysis Electrodes for Low Cost Hydrogen Production: Cooperative Research and Development Final Report, CRADA Number CRD-18-00780

NREL, Argonne National Laboratory (ANL) and Oak Ridge National Laboratory (ORNL), which are also referred to collectively herein as the "Contractors" will perform electrode ink development and characterization, focusing on 1) inks with appropriate properties for R2R (gravure and slot-die) coating onto PFSA membrane and 2) catalysts suitable for electrolysis. Participant will develop acceptance criteria and characterization methods for direct coating on the membrane. The purpose of this project is to show feasibility for cost reduction of the electrode through increased throughput and improved material utilization. Successful completion of this project will result in more affordable hydrogen production via proton exchange membrane (PEM) electrolysis by substantially reducing the anode precious metal content and catalyst-coated membrane processing costs. Assists laboratory in achieving programmatic scope, adds new capability to the laboratory's core competencies. This project uses and enhances the laboratory's core competencies, and enhances U.S. competitiveness by utilizing DOE developed intellectual property and/or capabilities. This project will benefit the Fuel Cell subprogram within the EERE Fuel Cell Technologies Office (FCTO) by actively developing materials, formulations, components, and processes for PEM electrolyzer stacks for overcoming critical technical barriers to widespread hydrogen production for zero-emission transportation applications. Through this JWS, NREL, ANL and ORNL are assisting a key domestic industry partner, Proton Energy Systems, Inc., in the area of low-cost electrolyzer electrode formulation and coating technology. After completion of this project, NREL, ANL and ORNL will be able to verify whether the direct deposit coating processes investigated are suitable for producing CCMs for PEM electrolyzers, which is of great interest and benefit to the DOE EERE Fuel Cell Technologies Office (FCTO) and H2@Scale missions.

08 HYDROGEN↗
DOE OSTI2022

Completion of initial reduced-order model for flammable refrigerant dispersal in residential spaces

Environmental regulations aimed at reducing global warming impacts of HVAC&R refrigerants have resulted in the phase-out of chlorofluorocarbons (CFCs) in 2010 and hydrochlorofluorocarbons (HCFCs) by 2030 in developed countries with additional restrictions on the use of hydrofluorocarbons (HFCs) set to take effect in 2036. Many of the remaining alternative refrigerants that have lower global warming potential (GWP) and that are suitable for use in HVAC&R systems (e.g., propane, difluoromethane) are flammable to some degree. Flammable refrigerants introduce new challenges and hazards to property and personal safety related to potential deflagration during system maintenance or due to leakage of the refrigerant accumulating in the conditioned space. Standards have been developed to set maximum charge limits for flammable refrigerants in HVAC&R systems; however, existing safety standards and codes still restrict their use. The bodies that maintain and update these codes need publicly available, science-based information to enable credible guidelines for setting safe charge limits for different flammable refrigerants in different HVAC&R applications. In 2016, the Alliance for Responsible Atmospheric Policy, the Air-Conditioning Heating and Refrigeration Institute (AHRI), ASHRAE, the U.S. Department of Energy (DOE), and the State of California began efforts to develop such information. As part of this effort, Oak Ridge National Laboratory (ORNL) began the current, ongoing project to examine imposed charge limits for flammable refrigerants and identify reasonable adjustments to these limits when found appropriate. Past tasks under this project have included development of experimentally vetted, computational fluid dynamics (CFD) simulation approaches to study the results of leakage of flammable refrigerants from various HVAC&R systems into different types of commercial and residential spaces. In this report, we discuss recent efforts to develop a predictive model of the flammable volume fraction and accumulated refrigerant mass in a single-room residential space resulting from the leak of a flammable refrigerant from a small room air conditioning (RAC) unit. The eventual goal is development of a model suitable for public release which could simulate a range of scenarios. In discussions with the AHRTI Flammable Refrigerant Subcommittee (FRS) at the beginning of this effort, a total of 9 input parameters were chosen for consideration including room area, room/door opening area, ventilation fan flow rate, unit/leak height, leak area, leak rate, total refrigerant charge, refrigerant molecular weight, and state of the unit fan.

42 ENGINEERING↗