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DOE OSTI2022

Elastic Lattice Enabling Reversible Tetrahedral Li Storage Sites in a High-Capacity Manganese Oxide Cathode

The key to breaking through the capacity limitation imposed by intercalation chemistry lies in the ability to harness more active sites that can reversibly accommodate more ions (e.g., Li + ) and electrons within a finite space. However, excessive Li-ion insertion into the Li layer of layered cathodes results in fast performance decay due to the huge lattice change and irreversible phase transformation. Here, in this study, an ultrahigh reversible capacity is demonstrated by a layered oxide cathode purely based on manganese. Through a wealth of characterizations, it is clarified that the presence of low-content Li 2 MnO 3 domains not only reduces the amount of irreversible O loss; but also regulates Mn migration in LiMnO 2 domains, enabling elastic lattice with high reversibility for tetrahedral sites Li-ion storage in Li layers. This work utilizes bulk cation disorder to create stable Li-ion-storage tetrahedral sites and an elastic lattice for layered materials, with a reversible capacity of 600 mA h g –1 , demonstrated in th range 0.6–4.9 V versus Li/Li + at 10 mA g –1 . Admittedly, discharging to 0.6 V might be too low for practical use, but this exploration is still of great importance as it conceptually demonstrates the limit of Li-ions insertion into layered oxide materials.

25 ENERGY STORAGE↗

DOE OSTI2023

Status of CEBAF Upgrades

Extending CEBAF energy reach by increasing the number of recirculations, while using the existing SRF system is being explored. Proposed energy upgrade is based on a new approach to multi-pass acceleration of electrons in a single Fixed Field Alternating Gradient (FFA) beam line, configured with Halbach-style permanent magnets. Encouraged by recent success of CBETA, a proposal was formulated to nearly ?double? CEBAF energy by replacing the highest energy arcs with a pair of FFA arcs. The new non-scaling FFA arcs would support simultaneous transport of additional 6 passes with energies spanning a factor of two. One of the challenges of the multi-pass (11) linac optics is to assure uniform focusing in a vast range of energies, in a fixed field lattice. Here, we propose a triplet lattice that would provide a stable periodic solution covering energy ratio of 1:33. The current CEBAF injection at 123 MeV, makes optical matching in the first linac virtually impossible due to extremely high energy span ratio (1:175). Replacement of the current injector with a 650 MeV recirculating injector will alleviate that problem. Orbital and optical matching from the FFA arcs to the linacs is implemented as a compact non-adiabatic insert. Presented scheme would promise to deliver a 22 GeV beam with normalized emittance of 76 mm·mrad and with a relative energy spread of 1×10-3. Further recirculation beyond 22 GeV is limited by large, 974 MeV per electron, energy loss due to synchrotron radiation

Bogacz, Alex↗

DOE OSTI2025

Probing Operando Electrochemical Strain Generation in α-NaFeO 2 Composite Cathodes during Cycling of Na-Ion Batteries

The transition metal oxide (TMO) cathodes in Na-ion batteries suffer from low-capacity retention. Chemo-mechanical instabilities lead to the deterioration of the electrochemical performance of TMO cathodes in Li-ion batteries. However, there is not much known about the chemo-mechanical instabilities in the TMO cathodes for Na-ion batteries. Understanding the governing forces behind the interplay between the electrochemical performance and mechanical stability in TMO cathodes is critical for the development of Na-ion batteries. Here, we synchronize the digital image correlation (DIC) technique with electrochemical analysis to capture the real-time deformation behavior of the α-NaFeO 2 cathodes during cycling. When the charge cutoff voltage is 3.6 V, the cathode experiences reversible deformations (except for the first cycle). There is negative strain (shrinkage) generation during Na extraction and positive strain (expansion) generation during the subsequent Na insertion. A detailed analysis of the potential-dependent strain rate evolution points out complicated phase transformations and nonequilibrium conditions in the α-NaFeO 2 cathodes during cycling. When the charge cutoff voltage was increased to 4.2 V, there was a rapid capacity loss and large plastic deformations in the α-NaFeO 2 cathodes. We provide an in-depth discussion about the possible mechanisms behind the chemo-mechanical instabilities in the α-NaFeO 2 . In conclusion, the correlation is critical to develop material-based strategies to mitigate instability mechanisms in TMO cathodes for Na-ion batteries.

Wable, Minal [University of Maryland Baltimore Cou↗

NASA NTRS1987

Design, fabrication and delivery of a miniature Cassegrainian concentrator solar array system

The optical design of the miniature Cassegrainian concentrator (MCC) element was improved for both offpoint and onpoint power capability. The cell stack design has shown no losses under the high short term thermal stresses imposed by component level test and is projected to be capable of greater than five years thermal cycle life in low Earth orbit. The structural design met all requirements for stiffness and flatness and requires adjustable inserts for fine tuning of the GFRP structure to meet flatness goals. The completed, fully populated small and large MCC panels deliverable under this contract perform electrically as expected. A solid acceptance inspection program to guarantee quality of all purchased parts, and continued manufacturing process improvements will make the MCC design a viable low cost alternative to standard flat panel technology. Minor improvements to the cell stack design of the MCC element can make significant improvements in both the performance and manufacturability of the MCC system.

Kruer, Mark A.↗

NASA NTRS2009

Lunar Reconnaissance Orbiter (LRO) Rapid Thermal Design Development

The Lunar Reconnaissance Orbiter (LRO) project had a rapid development schedule starting with project conception in spring of 2004, instrument and launch vehicle selection late in 2005 and then launch in early 2009. The lunar thermal environment is one of the harshest in our solar system with the heavy infrared loading of the moon due to low albedo, lack of lunar atmosphere, and low effective regolith conduction. This set of constraints required a thermal design which maximized performance (minimized radiator area and cold control heater power) and minimized thermal hardware build at the orbiter level (blanketing, and heater service). The orbiter design located most of the avionics on an isothermalized heat pipe panel called the IsoThermal Panel (ITP). The ITP was coupled by dual bore heat pipes to an Optical Solar Reflector (OSR) covered heat pipe radiator. By coupling all of the avionics to one system, the hardware was simplified. The seven instruments were mainly heritage instruments which resulted in their desired radiators being located by their heritage design. This minimized instrument redesigns and therefore allowed them to be delivered earlier, though it resulted in a more complex orbiter level blanket and heater service design. Three of the instruments were mounted on a tight pointing M55J optical bench that needed to be covered in heaters to maintain pointing. Two were mounted to spacecraft controlled radiators. One was mounted to the ITP Dual Bores. The last was mounted directly to the bus structure on the moon facing panel. The propulsion system utilized four-20 pound insertion thrusters and eight-5 pound attitude control thrusters (ACS) in addition to 1000 kg of fuel in two large tanks. The propulsion system had a heater cylinder and a heated mounting deck for the insertion thrusters which coupled most of the propulsion design together simplifying the heater design. The High Gain Antenna System (HGAS) and Solar Array System (SAS) used dual axis actuator gimbal systems. HGAS required additional boom heaters to cool the approximately 10 W of RF losses thru the rotary joints and wave guides from the 40 W Ka system. By design this module needed a fair amount of heater, blanketing, and radiator complexity. The SAS system required a separate cable wrap radiator to help cool the Solar Array harness which dissipated 30 W thru the actuators and cable wraps. This module also was complex.

Baker, Charles↗

NASA NTRS2011

Electrical Connector Mechanical Seating Sensor

A sensor provides a measurement of the degree of seating of an electrical connector. This sensor provides a number of discrete distances that a plug is inserted into a socket or receptacle. The number of measurements is equal to the number of pins available in the connector for sensing. On at least two occasions, the Shuttle Program has suffered serious time delays and incurred excessive costs simply because a plug was not seated well within a receptacle. Two methods were designed to address this problem: (1) the resistive pin technique and (2) the discrete length pins technique. In the resistive pin approach, a standard pin in a male connector is replaced with a pin that has a uniform resistivity along its length. This provides a variable resistance on that pin that is dependent on how far the pin is inserted into a socket. This is essentially a linear potentiometer. The discrete approach uses a pin (or a few pins) in the connector as a displacement indicator by truncating the pin length so it sits shorter in the connector than the other pins. A loss of signal on this pin would indicate a discrete amount of displacement of the connector. This approach would only give discrete values of connector displacement, and at least one pin would be needed for each displacement value that would be of interest.

Arens, Ellen↗

NASA NTRS2001

Acoustic Issues in Human Spaceflight

NASA is concerned about acute effect of sound on crew performance on International Space Station (ISS), and is developing strategies to assess and reduce acute, chronic, and delayed effects of sound. High noise levels can cause headaches, irritation, fatigue, impaired sleep, headache, and tinnitus and have resulted in an inability to hear alarms. Speech intelligibility may be more impaired for crew understanding non-native language in a noisy environment. No hearing loss occurred, but significant effects on crew performance and communication occurred. Permanent Threshold Shifts (PTS) have not been observed in the US shuttle program. Russian specification for noise in spacecraft is 60 dBA (awake) and 50 dBA (asleep) while the U.S. noise specification on ISS is NC 50 (awake) and NC 40 (asleep) with a 85 dBA hazard limit. Background noise levels of ISS modules have measured 56-69 dBA. Treadmill exercise operations measure 77 dBA. Alarms are required to be 20 dBA above ambient. Hearing protection is recommended when noise exceeds 60 dB 24 hour Leq. Countermeasures include hearing protection and design/ engineering controls. Advanced composite materials with excellent low frequency attenuation properties could be applied as a barrier protection around noisy equipment, or used on personal protective equipment worn by the crew. Hearing protection countermeasures include foam ear inserts, passive muff headsets, and active noise reduction headsets. Oto-acoustic emissions (OAE) could be used to monitor effectiveness of hearing protection countermeasures and tailor hearing protection countermeasures to individual crewmembers. Micro-gravity, vibration, toxic fumes, air quality/composition, stress, temperature, physical exertion or some combination of the above factors may have interacted with moderate long-term noise exposure to cause significant hearing loss. Longitudinal studies will need to address what co-morbidity factors, such as radiation, toxicology, microgravity effects (fluid shift), aging, are involved with hearing loss.

Clark, Jonathan B.↗

DOE OSTI2024

Biosensors for the detection of chorismate and cis,cis -muconic acid in Corynebacterium glutamicum

Abstract Corynebacterium glutamicum ATCC 13032 is a promising microbial chassis for industrial production of valuable compounds, including aromatic amino acids derived from the shikimate pathway. In this work, we developed two whole-cell, transcription factor based fluorescent biosensors to track cis,cis-muconic acid (ccMA) and chorismate in C. glutamicum. Chorismate is a key intermediate in the shikimate pathway from which value-added chemicals can be produced, and a shunt from the shikimate pathway can divert carbon to ccMA, a high value chemical. We transferred a ccMA-inducible transcription factor, CatM, from Acinetobacter baylyi ADP1 into C. glutamicum and screened a promoter library to isolate variants with high sensitivity and dynamic range to ccMA by providing benzoate, which is converted to ccMA intracellularly. The biosensor also detected exogenously supplied ccMA, suggesting the presence of a putative ccMA transporter in C. glutamicum, though the external ccMA concentration threshold to elicit a response was 100-fold higher than the concentration of benzoate required to do so through intracellular ccMA production. We then developed a chorismate biosensor, in which a chorismate inducible promoter regulated by natively expressed QsuR was optimized to exhibit a dose-dependent response to exogenously supplemented quinate (a chorismate precursor). A chorismate–pyruvate lyase encoding gene, ubiC, was introduced into C. glutamicum to lower the intracellular chorismate pool, which resulted in loss of dose dependence to quinate. Further, a knockout strain that blocked the conversion of quinate to chorismate also resulted in absence of dose dependence to quinate, validating that the chorismate biosensor is specific to intracellular chorismate pool. The ccMA and chorismate biosensors were dually inserted into C. glutamicum to simultaneously detect intracellularly produced chorismate and ccMA. Biosensors, such as those developed in this study, can be applied in C. glutamicum for multiplex sensing to expedite pathway design and optimization through metabolic engineering in this promising chassis organism. One-Sentence Summary High-throughput screening of promoter libraries in Corynebacterium glutamicum to establish transcription factor based biosensors for key metabolic intermediates in shikimate and β-ketoadipate pathways.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

CEBAF 22 GeV FFA energy upgrade

Extending the energy reach of CEBAF by increasing the number of recirculations, while using the existing linacs is explored. This energy upgrade is based on the multi-pass acceleration of electrons in a single non-scaling Fixed Field Alternating Gradient (FFA) beam line, using Halbach-style permanent magnets. Encouraged by the recent successful demonstration of CBETA, a proposal was formulated to nearly double the energy of CEBAF from 12 to 22~GeV by replacing the highest energy arcs with FFA transport. The new FFA arcs would support simultaneous transport of an additional 6 passes spanning roughly a factor of two in energy. One of the challenges of the multi-pass (11) linac optics is to assure uniform focusing over a wide range of energies. Here, we propose a triplet lattice that provides a stable periodic solution covering an energy ratio of 1:33. The current CEBAF injection at 123 MeV, makes optical matching in the first linac impossible due to the extremely high energy ratio (1:175). Replacement of the current injector with a 650 MeV recirculating injector will alleviate this issue. Orbital and optical matching from the FFA arcs to the linacs is implemented as a compact non-adiabatic insert. The design presented here is anticipated to deliver a 22 GeV beam with normalized emittance of 76 mm·mrad and a relative energy spread of 1×10\textsuperscript{-3}. Further recirculation beyond 22 GeV is limited by the large (974 MeV per electron) energy loss due to synchrotron radiation.

Benesch, J.↗

DOE OSTI2023

CEBAF 22 GeV FFA energy upgrade

Benesch, J.↗

DOE OSTI2023

Mining the Penicillium expansum Genome for Virulence Genes: A Functional-Based Approach to Discover Novel Loci Mediating Blue Mold Decay of Apple Fruit

Blue mold, a postharvest disease of pome fruits, is caused by the filamentous fungus Penicillium expansum. In addition to the economic losses caused by P. expansum, food safety can be compromised, as this pathogen is mycotoxigenic. In this study, forward and reverse genetic approaches were used to identify genes involved in blue mold infection in apple fruits. For this, we generated a random T-DNA insertional mutant library. A total of 448 transformants were generated and screened for the reduced decay phenotype on apples. Of these mutants, six (T-193, T-275, T-434, T-588, T-625, and T-711) were selected for continued studies and five unique genes were identified of interest. In addition, two deletion mutants (Δt-625 and Δt-588) and a knockdown strain (t-434 KD ) were generated for three loci. Data show that the Δt-588 mutant phenocopied the T-DNA insertion mutant and had virulence penalties during apple fruit decay. We hypothesize that this locus encodes a glyoxalase due to bioinformatic predictions, thus contributing to reduced colony diameter when grown in methylglyoxal (MG). This work presents novel members of signaling networks and additional genetic factors that regulate fungal virulence in the blue mold fungus during apple fruit decay.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS2011

Thermal Protection System Aerothermal Screening Tests in HYMETS Facility

The Entry, Descent, and Landing (EDL) Technology Development Project has been tasked to develop Thermal Protection System (TPS) materials for insertion into future Mars Entry Systems. A screening arc jet test of seven rigid ablative TPS material candidates was performed in the Hypersonic Materials Environmental Test System (HYMETS) facility at NASA Langley Research Center, in both an air and carbon dioxide test environment. Recession, mass loss, surface temperature, and backface thermal response were measured for each test specimen. All material candidates survived the Mars aerocapture relevant heating condition, and some materials showed a clear increase in recession rate in the carbon dioxide test environment. These test results supported subsequent down-selection of the most promising material candidates for further development.

thermal protection systems (TPS)↗

NASA NTRS2006

Dielectric Heaters for Testing Spacecraft Nuclear Reactors

A document proposes the development of radio-frequency-(RF)-driven dielectric heaters for non-nuclear thermal testing of the cores of nuclear-fission reactors for spacecraft. Like the electrical-resistance heaters used heretofore for such testing, the dielectric heaters would be inserted in the reactors in place of nuclear fuel rods. A typical heater according to the proposal would consist of a rod of lossy dielectric material sized and shaped like a fuel rod and containing an electrically conductive rod along its center line. Exploiting the dielectric loss mechanism that is usually considered a nuisance in other applications, an RF signal, typically at a frequency .50 MHz and an amplitude between 2 and 5 kV, would be applied to the central conductor to heat the dielectric material. The main advantage of the proposal is that the wiring needed for the RF dielectric heating would be simpler and easier to fabricate than is the wiring needed for resistance heating. In some applications, it might be possible to eliminate all heater wiring and, instead, beam the RF heating power into the dielectric rods from external antennas.

Sims, William Herbert↗

DOE OSTI2024

Failure investigation and mitigation after experimental research reactor fuel plate deformation in an irradiation device

Experimental research reactor fuel testing is conducted in the Belgian Reactor 2 (BR2) of the Belgian Nuclear Research Centre (SCK CEN) in dedicated irradiation vehicles or rigs. One such vehicle allows flat full-size fuel plates to be irradiated by inserting them into slotted baskets that captures a narrow portion of the longitudinal edges of the plates. The motion of the fuel plates within the baskets is possible within the narrow slots and thus, the plate is considered to be unattached. The design intentionally omits fixing mechanisms of the fuel plates to the baskets to facilitate the inspection and repositioning of the plates between the irradiation cycles and the accommodation of thermal expansion of the plates in the lateral direction. However, loosely inserted fuel plates have weak structural boundary conditions allowing for larger out-of-plane deflections caused by hydrodynamic loads exerted by the flowing coolant, as compared to those of fixed plates. Unexpected large deformations of plates occurred in several irradiation cycles that further resulted in a loss of cladding integrity. These deformations could not be attributed to a single source. This triggered a series of thermal hydraulic, structural, and fluid-structure interaction analyses aiming at understanding the observed phenomenon. The analyses revealed that, for a certain combination of unfavorable manufacturing and assembly tolerances, fuel plate edges could escape out of the slots in the irradiation basket due to the hydrodynamic load. Subsequently, the plate could become wedged inside the basket coolant channel opening. This resulted in reduced coolant flow and accelerated temperature increase and thermal expansion of the plate while under irradiation. This unfavorable feedback loop could then lead to excessive plate surface temperatures, deformed plates and cladding failure, as was observed in the experiments. These analyses not only provided a probable cause of the fuel plate failures, but also resulted in a new and improved design of the irradiation basket to avoid these issues in the future. In conclusion, a series of recent successful irradiations confirm that the sources of failures were identified correctly, and the implemented mitigations were adequate.

BR2↗

NASA NTRS1990

Flight control issues of the next generation space transportation launch vehicles

Some of the issues that affect the flight control and guidance system designs for vertical-takeoff and horizontal-takeoff vehicles were investigated. A two-stage all-rocket vehicle was used to represent the vertical-takeoff system and a generic aerospace plane concept to represent the horizontal-takeoff vehicle. Two flight control issues for the vertical-takeoff rocket were uncovered. The first was the large gimbal angle range required for pitch trim when using parallel mated vehicles. The second was control during staging. Two issues were also identified for the air-breathing vehicle. The first is that the drag losses due to aerodynamic trim are a significant fraction of the total ideal velocity required to achieve orbit. The second issue is that since the vehicle flies at high dynamic pressure for most of the ascent, the guidance system design will be more difficult to ensure accurate insertion than that for the vertical-takeoff rocket system.

Powell, Richard W.↗

DOE OSTI2021

Significant life extension of lithium-ion batteries using compact metallic lithium reservoir with passive control

Both traditional graphite-based lithium-ion batteries and next generation silicon-based chemistries suffer significant capacity fade from loss of cyclable lithium due to continued solid-electrolyte interphase growth. A possible engineering solution to maintaining the capacity of cells is incorporating a metallic lithium reservoir and discharging the reservoir into a working electrode to make up for lost cyclable lithium. Here, metallic lithium reservoirs are inserted into both pouch- and cylindrical-format cells. Significant capacity recovery and lifetime extension are demonstrated for traditional graphite and Si/graphite-based cells. In this work, a combination of post-mortem characterization and modeling provide insight into how the lithium distribution as a function of position from reservoir vary with recovery rate. The potential of using passive control to potentially eliminate the need for extra wiring for the third electrode is explored using a simple resistor.

25 ENERGY STORAGE↗

DOE OSTI2021

Differentiable programming for online training of a neural artificial viscosity function within a staggered grid Lagrangian hydrodynamics scheme

Lagrangian methods to solve the inviscid Euler equations produce numerical oscillations near shock waves. A common approach to reducing these oscillations is to add artificial viscosity (AV) to the discrete equations. The AV term acts as a dissipative mechanism that attenuates oscillations by smearing the shock across a finite number of computational cells. However, AV introduces several control parameters that are not determined by the underlying physical model, and hence, in practice are tuned to the characteristics of a given problem. We seek to improve the standard quadratic-linear AV form by replacing it with a learned neural function that reduces oscillations relative to exact solutions of the Euler equations, resulting in a hybrid numerical-neural hydrodynamic solver. Because AV is an artificial construct that exists solely to improve the numerical properties of a hydrodynamic code, there is no offline ‘viscosity data’ against which a neural network can be trained before inserting into a numerical simulation, thus requiring online training. We achieve this via differentiable programming, i.e. end-to-end backpropagation or adjoint solution through both the neural and differential equation code, using automatic differentiation of the hybrid code in the Julia programming language to calculate the necessary loss function gradients. A novel offline pre-training step accelerates training by initializing the neural network to the default numerical AV scheme, which can be learned rapidly by space-filling sampling over the AV input space. We find that online training over early time steps of simulation is sufficient to learn a neural AV function that reduces numerical oscillations in long-term hydrodynamic shock simulations. These results offer an early proof-of-principle that online differentiable training of hybrid numerical schemes with novel neural network components can improve certain performance aspects existing in purely numerical schemes.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Testing of a 15 kA Superconducting Transformer

Here, the manufacturing of superconducting magnets for High Energy Physics (HEP) and Fusion Energy Sciences (FES) applications requires high-current conductors to generate stronger magnetic fields without increasing the inductance of the magnet. Increased inductance is undesirable due to the associated AC losses, which reduce the temperature margin; and the quench protection also becomes complicated. Testing high-current conductors with a direct current (DC) room temperature power supply is unfeasible for two primary reasons: 1) the limited capacity to supply large currents, and 2) the significant heat load losses at the current leads. A superconducting transformer offers a solution to both challenges. A 50-kA superconducting transformer is planned for manufacturing and commissioning at Brookhaven National Laboratory as part of its user facility upgrade. This transformer will facilitate the testing of superconducting cables, conductors, joints, and insert coils under high magnetic field conditions (10 T) and with currents up to 50-kA. To evaluate the manufacturing process and validate the theoretical models, the magnet division has developed and tested a 15-kA prototype transformer. A control loop has been implemented to ensure precise current delivery to the sample. This paper presents the coil design, manufacturing, and experimental results from the cold tests.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗