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DOE OSTI2021

Additively Manufactured Compliant Hybrid Gas Thrust Bearing for Supercritical Carbon Dioxide Turbomachinery: Design and Proof of Concept Testing

The following paper presents a new type of gas lubricated thrust bearing that utilizes additive manufacturing or also known as direct metal laser melting (DMLM) to fabricate the bearing. The motivation for the new bearing concept is derived from the need for highly efficient supercritical carbon dioxide (sCO2) turbomachinery in the mega-watt power range. The paper provides a review of existing gas thrust-bearing technology, outlines the need for the new DMLM concept, and discusses proof-of-concept testing results. The new concept combines hydrostatic pressurization with individual tilting pads that are flexibly mounted using hermetic squeeze film dampers (HSFD) in the bearing-pad support. This paper describes the thrust-bearing concept and discusses the final design approach. Proof-of-concept testing in air for a 6.8 in. (173 mm) outer diameter thrust gas bearing was performed; with thrust loading, up to 1500 lbs (6.67 kN) and a thrust runner speed of 10krpm (91 m/s tip speed). The experiments were performed with a bent shaft resulting in thrust runner axial vibration magnitudes of 2.9 mils (74 μm) p-p and dynamic thrust loads of 270 lbs (1.2 kN) p-p. In addition, force deflection characteristics and stiffness coefficients of the bearing system are presented for an inlet hydrostatic pressure of 380 psi (2.62 MPa). Results at 10 krpm show that the pad support architecture was able to sustain high levels of dynamic misalignment equaling 6 times the nominal film clearance while demonstrating a unit load-carrying capacity of 55 psi (0.34 Mpa). Gas-film force deflection tests portrayed nonlinear behavior like a hardening spring, while the bearing pad support stiffness was measured to be linear and independent of gas film thickness.

Engineering↗

DOE OSTI2024

Identification of Dynamic Force Coefficients for an Additively Manufactured Hermetic Squeeze Film Bearing Support Damper Utilizing a Pass-Through Channel

Abstract The following paper presents breakthrough experimental results for a new hermetic squeeze film damper (HSFD) concept that is integrally designed within an externally pressurized tilting-pad radial gas bearing support. The flexibly damped gas bearing module was designed for a 7.2″ (183 mm) diameter shaft and fabricated using direct metal laser melting (DMLM); also known as additive manufacturing. The bearing and HSFD were sized based on ongoing studies for oil-free supercritical carbon dioxide (sCO2) power turbines in the 8.5 MW–10 MW power range. The development of the new damper concept was motivated by past dynamic testing on HSFD, which generated frequency-dependent stiffness and damping force coefficients. In efforts to eliminate the frequency dependency, a new HSFD architecture was conceived that adds accumulator volumes and a pass-through channel to previously conceived HSFD flow network designs. The other motivation for the work is the need to develop a cost-effective and reliable oil-free bearing technology that is scalable to large power turbomachinery applications. There were several objectives for the following work. The first objective was to successfully design and fabricate a single piece bearing-damper using additive manufacturing, while dimensionally controlling critical design features. The paper discusses the manufacturing steps and shows cut-ups that reveal adequate clearance control capability with internal damper clearances. The second objective was to perform experimental testing with the new HSFD design in efforts to extract stiffness and damping coefficients for excitation frequencies within 20–160 Hz and peak vibration amplitudes between 0.25 mils (6.35 microns) to 1 mil (25.4 microns). The test results for a single HSFD bearing module indicated that the design modifications to the HSFD architecture were successful in eliminating nearly all the frequency dependencies for the stiffness force coefficient. The dynamic tests yielded a stiffness coefficient that varied between 112 klb/in. (19.6 MN/m) and 96 klb/in. (16.8 MN/m). The damping force coefficient however, exhibited relatively more variation with frequency with values residing between 175 lb-s/in. (31 kN-s/m) to 214 lb-s/in. (37 kN-s/m). Finally, the paper advances a three-dimensional fluid-structure interaction (FSI) model using transient finite element analysis (FEA) coupled to a computational fluid dynamics (CFD) model. The FSI analysis performed between 20 Hz and 80 Hz was used to predict the stiffness and damping of the HSFD using a quarter-section model of the damper. The FSI analysis was able to support test results by showing only a 6–7.4% change in the magnitude of force coefficients. Stiffness predictions agree reasonably well with experiments whereas damping is underpredicted.

Engineering↗

DOE OSTI2020

MECHANICAL AND CORROSION ASSESSMENT OF FRICTION SELF-PIERCING RIVET JOINT OF CARBON FIBER-REINFORCED POLYMER AND MAGNESIUM ALLOY AZ31B

In the present work, thermoset carbon fiber–reinforced polymer (CFRP) was spot joined to magnesium alloy AZ31B by a friction self-piercing riveting (F-SPR) process. Lap shear tensile and cross-tension testing were used to evaluate the mechanical joint performance. An average lap shear tensile load of 5.18 kN was achieved, while an average of 2.81 kN was found from cross-tension testing. All F-SPR samples showed pull-out of AZ31B after mechanical testing, indicating good mechanical interlocking between the steel rivet and AZ31B. Corrosion potential was measured for each material to establish the galvanic corrosion characteristics. As expected, AZ31B was found to be the most active, while thermoset CFRP was the most noble. The steel rivet fell between the AZ31B (active) and the thermoset CFRP (noble). Salt fog corrosion testing (ASTM B-117) was performed to evaluate the corrosion performance of the uncoated F-SPR joint. With up to 200 h of exposure, the post-corroded F-SPR joint integrity retained 81.2% of the pre-exposure F-SPR joint strength with AZ31B pull-out failure mode. From cross-sectional analysis of the F-SPR joint, extensive corrosion of AZ31B was observed at the joint and other exposure areas. However, steel rivet was not significantly corroded potentially due to sacrificial anode effect by which AZ31B corroded first in the galvanic couple.

Lim, Yong Chae↗

DOE OSTI2021

Investigation of Surface Skidding Response of PBX 9501 and PBX 9502

Introduction: Assess the hazards of handling polymer bonder explosives(PBX) for the case of skidding with grit particles in the frictional interface. High explosive (HE) materials tested: PBX 9501 and 9502. High melting point materials at the skidding interface between HE and a substrate is known to increase the probability of ignition by creating hot spots not subject to reduced heating from the melting of HE material. Skidding occurred at peak forces of 6-26 kN normal force, and 0.6-3.4 kN of frictional force. Velocities for skidding range from 5-30 m/s, see figure 7. Sparse amounts of 300 μm silica grit is applied loosely to the HE surface before testing. Previous works have tested ignition by grit. Testing parameters include angle of impact, drop height, grit size, grit density, substrate material. This study focuses on pre ignition conditions and detailed thermal imaging of the frictional interface. Conclusions: Temperature hot spots were observed at high points in HE surface topology. These high points may be created by grit particles. Since these points impact first high frictional work is concentrated and quickly increases temperature. Small amounts of grit do not affect the overall frictional force but do concentrate the frictional work to create hot spots.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Light Curves and Spectra from Kilonova Models [Poster]

White dwarf-neutron star merger simulations show a Ca IR line feature in spectra, pointing to Ca-rich transients as a possible observation (Kaltenborn et al 2024, Gillanders et al 2024). Supernova and new/old kilonova (KN) models have been compared to recent peculiar long gamma-ray burst (GRB) with KN-like signal (Troja et al 2022).

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2024

Anchoring Strategies for Marine Renewable Energy at the Sandia Water Impact Facility

This report documents the formulation and preliminary analysis of potential anchoring strategies for use in future WEC testing at the Sandia Water Impact Facility given the existing 5-ton and 10-ton concrete blocks at the facility. Three anchoring strategies are created that are applicable to different mooring configurations for existing WECs of interest for testing. The three anchoring strategies have a maximum allowable load of between 24.57 kN and 281.17 kN, depending on whether the 5-ton or 10-ton blocks are used, with Strategy 3 with 10-ton blocks having the highest allowable load. The AquaHarmonics and CalWave xWave WECs can be tested up to a 1:1.5 and 1:1.15 scale, respectively, while maintaining a mooring configuration very close to the one used in ocean deployment. The requirements for the mooring lines, shackles, and triplates needed to support the three strategies are also calculated, with commercially available products specified. Finally, the padeyes connected to the existing concrete blocks are assessed and determined to be satisfactory for the loading expected with these anchoring strategies.

16 TIDAL AND WAVE POWER↗

DOE OSTI2024

Submerged Fatigue Testing of Marine Energy Advanced Materials

Marine energy structures are typically made of advanced composite materials and are subjected to extreme ocean environments in service. In extreme ocean environments, seawater currents and waves load structures repeatedly, which cause two environmental conditions: water intrusion and mechanical fatigue. In prior research, the two environmental conditions were applied sequentially, where composite specimens were aged and then mechanically tested. To understand the combined effects of dynamic loading and water intrusion on composite materials, the present study involves the static and fatigue four-point bend testing of composite coupons in a water tank. The water tank was designed and built to fit either a 100 kN or a 250 kN load frame. Flexural strength value, cycles to failure, and failure mode results from submerged fatigue testing will be used to inform marine energy structure designs. The coupon-scale test method will be used to scale up to and inform methods for subsequent subcomponent testing and standards development. The benefits of designing marine energy structures to informed standards are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite materials↗

DOE OSTI2024

Submerged Fatigue Testing of Marine Energy Advanced Materials

Marine energy structures are typically made of advanced composite materials and are subjected to extreme ocean environments in service. In extreme ocean environments, seawater currents and waves load structures repeatedly, which cause two environmental conditions: water intrusion and mechanical fatigue. In prior research, the two environmental conditions were applied sequentially, where composite specimens were aged and then mechanically tested. To understand the combined effects of dynamic loading and water intrusion on composite materials, the present study involves the static and fatigue four-point bend testing of composite coupons in a water tank. The water tank was designed and built to fit either a 100 kN or a 250 kN load frame. Flexural strength value, cycles to failure, and failure mode results from submerged fatigue testing will be used to inform marine energy structure designs. The coupon-scale test method will be used to scale up to and inform methods for subsequent subcomponent testing and standards development. Finally, the benefits of designing marine energy structures to informed standards are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

13 HYDRO ENERGY↗

DOE OSTI2023

Chitosan Coating Functionalized with Flaxseed Oil and Green Tea Extract as a Bio-Based Solution for Beef Preservation

Ecological and safe packaging solutions arise as pivotal points in the development of an integrated system for sustainable meat production. The aim of this study was to assess the effect of a combined chitosan (Ch) + green tea extract (GTE) + essential oil (thyme oil, TO; flaxseed oil, FO; or oregano oil, OO) coating on the safety and quality of vacuum-packaged beef during storage at 4 °C. An optimized bio-based coating formulation was selected (2% Ch + 2% GTE + 0.1% FO) to be applied to three fresh beef cuts (shoulder, Sh; knuckle, Kn; Striploin, St) based on its pH (5.8 ± 0.1), contact angle (22.3 ± 0.4°) and rheological parameters (viscosity = 0.05 Pa.s at shear rate > 20 s−1). Shelf-life analysis showed that the Ch–GTE–FO coating delayed lipid oxidation and reduced total viable counts (TVC) and Enterobacteriaceae growth compared with uncoated beef samples over five days. In addition, Ch–GTE–FO coating decreased total color changes of beef samples (e.g., ∆E* = 9.84 and 3.94, for non-coated and coated Kn samples, respectively) for up to five days. The original textural parameters (hardness, adhesiveness and springiness) of beef cuts were maintained during storage when Ch–GTE–FO coating was applied. Based on the physicochemical and microbial characterization results, the combination of the Ch–GTE–FO coating developed was effective in preserving the quality of fresh beef cuts during refrigerated storage along with vacuum packaging.

Mendes, Cíntia G.↗

DOE OSTI2025

The Gravity Collective: A Comprehensive Analysis of the Electromagnetic Search for the Binary Neutron Star Merger GW190425

We present an ultraviolet to infrared search for the electromagnetic (EM) counterpart to GW190425, the second ever binary neutron star merger discovered by the LIGO-Virgo-KAGRA Collaboration. GW190425 was more distant and had a larger localization area than GW170817, so we use a new tool, Teglon, to redistribute the GW190425 localization probability in the context of galaxy catalogs within the final localization volume. We derive a 90th percentile area of 6688 deg 2 , a ∼1.5× improvement relative to the LIGO/Virgo map, and show how Teglon provides an order-of-magnitude boost to the search efficiency of small (≤1 deg 2 ) field-of-view instruments. We combine our data with a large, publicly reported imaging data set, covering 9078.59 deg 2 of unique area and 48.13% of the LIGO/Virgo-assigned localization probability, to calculate the most comprehensive kilonova (KN), short gamma-ray burst (sGRB) afterglow, and model-independent constraints on the EM emission from a hypothetical counterpart to GW190425 to date under the assumption that no counterpart was found in these data. If the counterpart were similar to AT 2017gfo, there would be a 28.4% chance of it being detected in the combined data set. We are relatively insensitive to an on-axis sGRB, and rule out a generic transient with a similar peak luminosity and decline rate as AT 2017gfo to 30% confidence. Finally, across our new imaging and publicly reported data, we find 28 candidate optical counterparts that we cannot rule out as being associated with GW190425, finding that four such counterparts discovered within the localization volume and within 5 days of merger exhibit luminosities consistent with a KN.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2026

A Comparison of Three Neodymium Atomic Data Sets for Kilonova Modeling

We examine the impact of input neodymium (Nd) atomic data on the light curves and spectra of kilonovae (KNe), probing the sensitivity of kilonova observables to the atomic physics of this important lanthanide element. We use the SuperNu Monte Carlo radiative transfer code, simulating a simple semianalytic 1D kilonova (KN) with a pure Nd atmosphere, fixing the radiative transfer method while using input atomic data generated by three different codes: the LANL suite of atomic physics codes, HULLAC, and Autostructure. We see that the choice of atomic data significantly shapes the resulting light curves and spectra. Peak bolometric luminosities differ by a ratio of nearly 1.5 between HULLAC/Autostructure and LANL data sets. Moreover, we observe significant near- to mid-IR differences in the structure of the spectra. We specifically attribute these differences to the choice of atomic data for neutral Nd I. Many of the results here have been adapted from a presentation at “Radiative Transfer and Atomic Physics of Kilonovae” in Stockholm, 2023. We additionally present a LANL data set with energies calibrated to available values in the NIST Atomic Spectra Database, and demonstrate that this calibration also significantly affects IR spectral structure at late time. The substantial differences in KN observables that arise from tuning the atomic data of just one lanthanide element highlight the special attention that must be paid to atomic physics uncertainties when modeling KNe, from AT2017gfo to beyond.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2024

Submerged Fatigue Testing of Marine Energy Advanced Materials: Preprint

composite materials↗

DOE OSTI2024

Submerged Fatigue Testing of Marine Energy Advanced Materials

composite materials↗

DOE OSTI2023

Extent of interlocking and metallurgical bonding in friction riveting of aluminum alloy to steel

In this study, the joining of 6061-T6 aluminum alloy and DP590 steel using a M42 steel rivet via friction riveting technique is investigated. The surface morphology and microstructure characterization reveal the formation of an anchor zone that imparts mechanical interlock as well as the formation of metallurgical bonds at the interface of aluminum and steel. A combination of interlocking and bonding results in the achievement of a high load-carrying capacity of 5.7 kN during lap shear testing at room temperature. A finite element-based computational model was developed which accurately predicted the lap shear response of the joint. The model revealed that the metallurgical bond formed during fric-riveting adds 39% peak load strength to the joint. An extensive microstructural investigation, post-lap-shear fractography, and the modeling results, together provided insights on the joint failure mechanism. In conclusion, this study highlights that friction riveting is a promising method for aluminum-to-steel dissimilar joining, which is important for lighweighing automotive vehicles for energy efficiency.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Molecular pathways for learning in the single-cell Stentor coeruleus

The single-cell Stentor coeruleus contracts in response to mechanical taps but habituates and learns to ignore the taps after repeated stimulation. Here, we explored the molecular changes that occur during the formation of this cellular memory in order to improve our understanding of non-synaptic learning. We impaired cellular protein synthesis with cycloheximide and puromycin and found that, contrary to the effects of such treatments on metazoa, these drugs accelerate habituation and prolong memory retention in Stentor . Exploratory proteomic and transcriptomic analyses identified candidate proteins and genes that changed over the course of habituation and response recovery, pointing toward the regulation of Stentor learning by calcium signaling and protein phosphorylation. Building on these results, we found that using RNA interference to knock down the calcium-binding, EF-hand domain-containing protein SteCoe_6763 accelerated habituation. Furthermore, increased extracellular calcium improved Stentor learning, while treatment with kinase and phosphatase inhibitors impaired learning. In particular, KN-93, a drug known to inhibit calcium/calmodulin-dependent kinase II and voltage-gated calcium channels, decreased both the rate and extent of habituation in Stentor , similar to its effects on learning in metazoa. We also discovered that habituation memory can be maintained in progeny following cell division. Taken together, these results suggest that response recovery in Stentor requires new protein synthesis and that memory formation involves the modification of delocalized mechanoreceptors by phosphorylation and calcium signaling. This is consistent with our previous model of Stentor learning, in which habituation occurs through the inactivation of cell-surface receptors.

CaMKII↗

DOE OSTI2024

Graviton-photon oscillations in an expanding universe

Through the Gertsenshtein effect, the presence of a large external B-field may allow photons and gravitons to mix in a way that resembles neutrino oscillations and is even more similar to axion-photon mixing. Assuming a background B-field (or any field that behaves like one), we examine the Gertsenshtein mechanism in the context of FLRW expanding universe models, as well as de Sitter space. The conformal invariance of Maxwell’s equations and the conformal noninvariance of the Einstein equations preclude the operation of the Gertsenshtein effect at all scales. In general we find for the matter- and radiation-dominated cases, graviton-oscillations are possible only at late conformal times or when the wavelengths are much shorter than the horizon (kn $\gg$ 1), but that the time-dependent oscillations eventually damp out in any case. Further, the presence of charged particles additionally damps out the oscillations. For the de Sitter universe, we find that oscillations are possible only at early conformal times (n $\ll$ H -1 ) and for wavelengths short compared to the Hubble radius, but eventually freeze in when wavelengths become longer than the Hubble radius. In principle a Gertsenshtein-like mechanism might influence the balance of particle species in an inflationary phase before freezing in; however, we find that in all our models the mixing length is larger than the Hubble radius. We discuss several possible remedies to this situation.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2024

Monotonic testing of single shear-plane CLT-to-CLT joint with hardwood dowels

Reducing embodied carbon emissions in buildings and striving for carbon neutrality through sustainable design has become a primary goal in the construction industry. The industry is expanding its use of wood-engineered products, such as cross-laminated timber (CLT) to achieve those sustainability goals. Furthermore, replacing steel fasteners with lower embodied carbon alternatives is gaining increased attention in timber engineering. This paper aims to quantify the mechanical behavior of single shear-plane CLT-to-CLT joints using hardwood dowels. The study includes 154 single shear-plane experimental tests with four different CLT species, two hardwood dowel species, and two dowel diameters. Further, the test specimens were subjected to cyclic and monotonic loading until failure, and mechanical properties such as yielding and ultimate strength, serviceability and yielding stiffness, and ductility were quantified. The hardwood dowel CLT-to-CLT joints demonstrated high strength with up to 10.3 kN (2.3 kips) capacity per dowel and lateral stiffness of up to 5.2 kN/mm (30.8 k/in) per dowel. This strength and stiffness are roughly equivalent to or exceed values for mass timber wood screws, making hardwood dowels a good alternative. In addition, the observed mean ductility of joints ranged from 2.4 to 4.5. Finally, analytical equations for the joints' yielding strength, lateral serviceability stiffness, and yielding stiffness were derived with non-linear regression analysis and validated using the experimental test results.

42 ENGINEERING↗

DOE OSTI2025

Friction surface layer deposition of triple-phase Al 10 Cr 12 Fe 35 Mn 23 Ni 20 high entropy alloy: Process optimization and microstructural evolution

A high-strength Co-free triple-phase Al 10 Cr 12 Fe 35 Mn 23 Ni 20 high-entropy alloy (HEA) was successfully fabricated using Friction Surface Layer Deposition (FSLD), a bulk manufacturing method. Multiple single-layer deposits were produced by varying forging force (F) and traverse speeds (T r ) to optimize the process parameters. The optimized conditions (F = 40 kN & T r = 200 mm/min) were then applied to manufacture a scaled-up multi-layer specimen. The initial microstructure of the HEA consisted of coarse grains of the soft FCC-phase, long columnar dendrites of the hard BCC-phase, and small precipitates of the harder B2-phase within the BCC-dendrites. During FSLD, the FCC-matrix underwent continuous dynamic recrystallization due to high-temperature severe plastic deformation, forming finer equiaxed grains. Simultaneously, the BCC-dendrites fractured into smaller fragments, some of which experienced partial growth and coarsening under applied stress, resulting in an hourglass morphology. In contrast, the small B2-precipitates within the BCC-fragments dissolved during the elevated temperatures of FSLD and reprecipitated as substantially finer precipitates during continuous cooling post-FSLD. Additionally, the orientation relationships between the FCC and BCC/B2 phases were completely destroyed by the severe thermoplastic deformation inherent to FSLD. The microstructural refinements led to a substantial improvement in hardness from 177 HV to 283 HV, driven by Hall-Petch strengthening. The increased number of interfaces, including coherent BCC-B2 interfaces, potentially enhances the sink strength and radiation tolerance of the HEA, making it a promising candidate for nuclear applications. In conclusion, this study also highlights FSLD as a versatile technique for achieving tunable properties in HEAs, with detailed schematics illustrating the complex mechanisms of phase transformations during processing.

Additive Manufacturing↗