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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Revealing transient powder-gas interaction in laser powder bed fusion process through multi-physics modeling and high-speed synchrotron x-ray imaging

Laser powder bed fusion (LPBF) is an emerging metal additive manufacturing process. The gas-driven powder motions in laser powder bed fusion have significant influence on the build quality. However, the transient powder-gas interaction has not been well understood due to the challenges in quantitative experiment measurements. In this work, the powder-gas interaction for a single pulse laser illuminating on the powder bed is studied. We establish a multi-physics model to simulate the complex liquid/gas flow as well as the gas-driven powder motions, which is substantiated by high-speed synchrotron x-ray imaging. We identify and quantify four characteristic modes of powder-gas interaction in LPBF. The motion of a powder is controlled by one or multiple interaction modes collectively. As revealed by simulations and confirmed by experiments, powders can merge into the molten pool from its rim, be ejected at different divergence angles (powder spattering), or dive into the molten pool to cause significant molten pool fluctuation. Overall, our results provide insights toward the driving forces controlling the dynamic powder behavior, which pave the way for reducing structure defects during the build process.

36 MATERIALS SCIENCE↗
DOE OSTI2020

High Speed In-situ X-ray Imaging of 3D Freeze Printing of Aerogels

3D freeze printing (3DFP) combines drop-on-demand (DOD) inkjet printing with freeze casting to fabricate lightweight and multifunctional aerogels with customized geometries. Freeze casting is an efficient and easily implemented method capable of fabricating porous, sponge-like structures for many different applications. This process enables tailoring the microstructure of the final product (i.e., pore morphology, alignment, average size distribution, etc.) by controlling the fabrication conditions and freezing kinetics. Furthermore, its combination with DOD printing provides the capability of engineering the macrostructure without relying on a mold as reported for 3D freeze-printed aerogels made from graphene, silver nanowires, and other nanocomposites. In this paper, we performed in-situ X-ray imaging to understand the inside process dynamics in 3DFP using a commercially available colloidal silica ink. We investigated the 3DFP process with the following hierarchy: first, single droplets; then, uniform lines obtained from coalescence of droplets; and finally, three consecutive lines deposited layer by layer. With the help of X-ray imaging, the importance of the balance between material deposition and freezing rates was shown in-situ by the observation inside of the freeze front following the tip of the printed line. The effects of the substrate temperature on the elimination of undesired interfacial boundaries were also shown by the observed ice crystals penetrating from lower to upper layer.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Remarkable enhancement in thermal conductivity of stainless-steel leveraging metal composite via laser powder bed fusion: 316L-Cu composite

This work aimed to significantly enhance the thermal conductivity of the SS matrix by fabricating a metal composite SS-Cu system utilizing a laser powder bed fusion process. The impact of process parameters on the microstructure of SS-Cu samples is investigated. Here, the processing and post-processing factors that influence the effective thermal conductivity of the metal composite SS-Cu system are discussed. Then, the effective thermal conductivity and mechanical properties of the SS-Cu composite are measured at room temperature and operating temperature of 300 °C. The optimized laser powder bed fusion parameters led to low Marangoni convection, high cooling rate, greater macro-segregation, and higher thermal conductivity values albeit at the cost of ductility in SS-Cu metal composite likely due to the presence of the unmelted powder particles. As-printed SS-60 vol % Cu and annealed SS-60 vol % Cu had 2.5X and 6.6X thermal conductivity enhancement, respectively. During annealing, phase separation, partial melting of Cu, and formation of a continuous network of Cu surrounding SS play a key role in enhancing the thermal conductivity of the SS-Cu metal composite structure.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A review of SWAT applications, performance and future needs for simulation of hydro-climatic extremes

Hydro-climatic extremes, such as droughts and floods, have most likely increased due to climatic change and could lead to severe impacts on socio-economic, structural and environmental sectors. With nearly 4000 publications, the Soil and Water Assessment Tool (SWAT) is clearly one of the most extensively used ecohydrological models worldwide. The model has been widely used for projecting the impacts of future hydro-climatic changes, but application for extreme streamflow conditions is still rarely reported. To date, SWAT application reviews have focused on compilations of SWAT studies for specific or relatively new applications such as eco-hydrological modelling, ecosystem services, sub-daily simulations, and pesticide fate and transport simulations. However, no existing SWAT review studies have focused on simulation of hydro-climatic extremes. Furthermore, this research aims to bridge this gap by compiling and reviewing the findings of studies reporting SWAT hydro-climatic extremes including highlighting the performance and future research needs. A total of 111 articles have been identified since 1999; most of these studies were conducted in the United States and China. These articles can be divided into extreme flow assessments, drought studies, flood studies, drought and flood studies, SWAT coupling with other models, and SWAT improvements. Most of the extreme performance assessment studies reported “satisfactory ”performance, with a particular emphasis on peak flow comparisons. Future research needs regarding this topic include: (1) a unified SWAT extreme performance assessment framework; (2) SWAT improvements that result in improved replication of peak and low flows; (3) reliability assessment of global and satellite products for SWAT extreme simulations; (4) bias correction of CMIP6 and regional climate projections; (5) comparison of SWAT + and SWAT for extreme flow simulations in different types of basins; (6) development of an extreme flow module within an overall SWAT modelling system; and (7) integration of artificial intelligence within SWAT modelling.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Advances in hexagon mesh-based flow direction modeling

Watershed delineation and flow direction representation are the foundations of streamflow routing in spatially distributed hydrologic modeling. A recent study showed that hexagon-based watershed discretization has several advantages compared to the traditional Cartesian (latitude–longitude) discretization, such as uniform connectivity and compatibility with other Earth system model components based on unstructured mesh systems (e.g., oceanic models). Despite these advantages, hexagon-based discretization has not been widely adopted by the current generation of hydrologic models. One major reason is that there is no existing model that can delineate hexagon-based watersheds while maintaining accurate representations of flow direction across various spatial resolutions. In this study, we explored approaches such as spatial resampling and hybrid breaching-filling stream burning techniques to improve watershed delineation and flow direction representation using a newly developed hexagonal mesh watershed delineation model (HexWatershed). We applied these improvements to the Columbia River basin and performed 16 simulations with different configurations. The results show that (1) spatial resampling modulates flow direction around headwaters and provides an opportunity to extract subgrid information; and (2) stream burning corrects the flow directions in mountainous areas with complex terrain features.

58 GEOSCIENCES↗
DOE OSTI2021

Visually resolving the direct Z-scheme heterojunction in CdS@ZnIn 2 S 4 hollow cubes for photocatalytic evolution of H 2 and H 2 O 2 from pure water

We report the direct Z-scheme heterojunction has been recently emerging as an appealing architecture for photocatalysts design. Its efficiency depends on the interfacial and structural features of the photocatalysts. Herein, the two-dimensional ZnIn 2 S 4 nanosheets are grown on the surface of CdS hollow cubes to construct the CdS@ZnIn 2 S 4 hierarchical hollow photocatalysts with chemically bonded interface. The visualized measurements based on spatial-resolved surface photovoltage spectroscopy, combined with other spectroscopic and simulation investigations, clearly disclose that the CdS@ZnIn 2 S 4 hollow cubes constitute a highly efficient direct Z-scheme system. This accounts for the stoichiometric generation of H 2 and H 2 O 2 from pure water observed for the CdS@ZnIn 2 S 4 sulfide-only photocatalysts under visible light irradiation with an apparent quantum efficiency of 1.63 % at 400 nm. The present work demonstrates an effective protocol to achieve comprehensive insights into the charge transfer route at semiconductor heterojunction, and offers a viable way for constructing efficient sulfide-only photocatalysts for driving water splitting reaction.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

In-situ monitoring of atomically dispersed Pt sites supported on OMS-2 during CO 2 activation

Atomically dispersed catalysts have drawn great interest lately, as they showcase a high density of active sites, selectivity, and high turnover frequencies in oxidation chemistry due to labile oxygen activation. In contrast, the applications of these catalysts have lagged in reduction reactions due to the ambiguity caused by the sintering and restructuring of active sites. To bridge this gap, the evolution of Pt 4+ isomorphically substituted into an octahedral molecular sieve structure (OMS-2) under reductive conditions was correlatively characterized using multiple in-situ analytical techniques such as ambient pressure X-ray photoelectron spectroscopy, environmental transmission electron microscopy, and solid-state nuclear magnetic resonance. The surface dynamics of the Pt single atoms were revealed during the Reverse Water Gas Shift (RWGS) reaction, where the active sites were identified as two-coordinated platinum single atoms. Under reaction, we show nonbinding atoms adjacent to the single atoms restructured the motif of the single atoms to Pt 2+ via ion mobility of potassium, increasing the activation energy by 25.6 kJ/mol. Here, this work also highlights the potential for increased stability of the single atom sites via isomorphic substitution of the metal oxide support, since the Pt-OMS-2 catalyst retained activity for about 33 h before deactivation, after which nanoparticles were observed in TEM images. This work offers a new perspective in single atom synthesis using the metal oxide as the host for the single atom site, instead of adatoms on the surface

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

A forecast-driven decision-making model for long-term operation of a hydro-wind-photovoltaic hybrid system

Hydro-wind-photovoltaic (PV) hybrid system has the potential to increase the integration of renewable energy sources into an existing grid. For the long-term operation of the system, due to the non-storable nature of wind and PV power, it is essentially to decide the optimal long-term carryover storage of cascade reservoirs. However, it remains a challenge due to high uncertainties of long-term forecasts and complicated hydraulic/electrical relationships between cascade reservoirs. Here in this study, a forecast-driven decision-making model is proposed for the hybrid system, which converts the multi-stage long-term operation process into a two-stage operation problem (including current stage and carryover stage) to avoid using longer-horizon forecast information with lower accuracy. First, the carryover stage energy surfaces (CESs) considering the forecast uncertainties of wind, solar and hydro resources are proposed to characterize carryover stage benefit quantitatively. Then a CESs-based forward decision-making optimization model is developed to guide the long-term operation of a hydro-wind-photovoltaic hybrid system. The applications in a hydro-wind-PV hybrid system of Yalong River basin results show that: compared with conventional operation, 1) power generation increases 9.03%; 2) in terms of the carryover storages control, the reservoir impounding and drawdown timing are delayed, and the drawdown depth is increased, which can be used to formulate better reservoir operation rules.

13 HYDRO ENERGY↗
DOE OSTI2021

Design of a 2 MW ZrC/W-based molten-salt-to-sCO 2 PCHE for concentrated solar power

To increase the power cycle efficiency and lower the levelized cost of electricity (LCOE) of concentrated solar power (CSP) plants, printed circuit heat exchangers (PCHEs) capable of operating above 700 °C with molten chloride salt and a sCO 2 -based fluid are needed. In this paper, the design of a high-pressure, high-temperature, 2 MW PCHE comprised of a thermomechanically-robust, zirconium carbide/tungsten (ZrC/W) composite is conducted for CSP plants. The ZrC/W composite is a material with high thermal conductivity, high stiffness, and high failure strength at high temperatures, along with excellent resistance to thermal cycling and thermal shock. In this work, a thermomechanical design analysis was conducted to select appropriate material thicknesses of the ZrC/W plates, and to determine the geometrical dimensions and the thermal performance of the PCHE. The influences of the plate number and heat exchanger length on power density and pressure drop have also been systematically investigated. Economic analyses were conducted to compare the cost of ZrC/W-based PCHEs to those comprised of IN740H (a state-of-the-art, nickel-based superalloy) and 316 stainless steel (316SS). Finally, at a sufficiently high plate production rate, the manufacturing cost of ZrC/W-based PCHEs can be significantly lower, while achieving a much higher power density, compared with state-of-the-art, nickel alloy-based and stainless steel-based PCHEs.

14 SOLAR ENERGY↗
DOE OSTI2026

SAF: a promising approach to meet growing jet fuel demand

SAF provides a promising approach to aid the rising jet fuel demand from increased travel around the world and reduce the lifecycle emissions from the aviation sector. Although the feasibility of SAF pathways has been demonstrated through economic and environmental metrics quantification, the models used to quantify these variables have a high degree of variability in terms of accuracy and thereby reliability. To understand how to adopt and commercialize SAF, we need to harmonize these process models and assess metrics and technical limitations related to their production technologies. We find the production cost of SAF using hydro processed fatty acids and esters (HEFA), Fischer-Tropsch (FT), and alcohol-to-jet (ATJ) to be $\$$3-$\$$6/gallon gasoline equivalent (gge) and life cycle emissions to be lower than Jet A, except for ATJ using corn grain (≤25%). HEFA utilizing oil feedstocks has the lowest production cost (~$\$$2.9/gge) and highest jet yield (>150 gge/dry ton), while FT has the largest emission reduction (94%) compared to fossil jet. A unique contribution of this study is a comparative analysis of metrics related to SAF processes across technical, economic, and sustainability aspects. A cross-comparison of these metrics shows HEFA using fats, oils, and grease have the most favorable ratings, while HEFA using algae and ATJ using corn stover have more neutral and unfavorable ratings, respectively. These ratings can be improved by implementing the right combination of practical and technological advancements.

09 BIOMASS FUELS↗
DOE OSTI2025

Benchmark of numerical modeling approaches on the systematic performance evaluation of wave energy converters

Different numerical modeling methods have been developed and applied to evaluate a variety of performance indicators of wave energy converters (WECs), including the power performance, structural loads, levelized cost of energy, etc. Based on the modeling fidelity, the commonly used numerical modeling approaches can be classified as linear modeling, weakly nonlinear modeling and fully nonlinear modeling approaches. Each method differs in accuracy and computational efficiency, making them suitable for different stages of WEC design. However, the selection of modeling approach could significantly impact evaluation outcomes. For instance, simplified linear models may underestimate structural loads or overestimate energy production in some operational conditions, potentially leading to less cost-effective designs. Given the widespread utilization of these models, it is essential to understand the uncertainties brought by them in performance evaluations. This work is dedicated to benchmarking different linear-potential-flow-based numerical models for evaluating the systematic performance of WECs. Three representative numerical modeling approaches are considered in this work, including linear frequency-domain modeling, statistically linearized spectral-domain modeling and Cummins equation-based nonlinear time-domain modeling. A generic point absorber WEC is considered as the research reference in this work, and different sea sites are taken into account. The numerical models are utilized to predict critical performance indicators, including power performance, the annual energy production, the capacity factor, the levelized cost of energy and the PTO fatigue loads. By comparing the results, this work identifies the uncertainties associated with different modeling approaches in evaluating WEC performance.

Fatigue↗
DOE OSTI2023

Accurate activity determination of a californium neutron source

Accurately counting analog events requires constructing an electronics chain that produces one count for each input pulse. Here, in this work, we review the use of Nuclear Instrumentation Module electronic units for counting neutron capture events in a 3He tube. We identify two unique types of false trigger events in a leading-edge discriminator and show how a dual timer module can be used to produce a veto window to exclude these events. We use the constructed electronics chain to build an apparatus to measure neutron pulses from a 252 Cf neutron source. We compare the measurements with a Monte Carlo N-Particle (MCNP) model to determine the activity of the neutron source. Furthermore, by making additional measurements with borated polyethylene attenuators between the source and detector, we are able to determine the boron concentration of the polyethylene. This technique provides accurate determination of the source activity to a precision of 2.8% at the k=1 level. The method used is simple, inexpensive, and requires no additional calibrated instruments.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗