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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 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Frequency domain measurements of melt pool recoil force using modal analysis

Recoil pressure is a critical factor affecting the melt pool dynamics during Laser Powder Bed Fusion (LPBF) processes. Recoil pressure depresses the melt pool. When the recoil pressure is low, thermal conduction and capillary forces may be inadequate to provide proper fusion between layers. However, excessive recoil pressure can produce a keyhole inside the melt pool, which is associated with gas porosity. Direct recoil pressure measurements are challenging because it is localized over an area proportionate to the laser spot size producing a force in the mN range. This paper reports a vibrationbased approach to quantify the recoil force exerted on a part in a commercial LPBF machine. The measured recoil force is consistent with estimates from high speed synchrotron imaging of entrained particles, and the results show that the recoil force scales with applied laser power and is inversely related to the laser scan speed. These results facilitate further studies of melt pool dynamics and have the potential to aid process development for new materials.

42 ENGINEERING↗
DOE OSTI2024

Outcomes and Conclusions from the 2022 AM Bench Measurements, Challenge Problems, Modeling Submissions, and Conference

The Additive Manufacturing Benchmark Test Series (AM Bench) provides rigorous measurement data for validating additive manufacturing (AM) simulations for a broad range of AM technologies and material systems. AM Bench includes extensive in situ and ex situ measurements, simulation challenges for the AM modeling community, and a corresponding conference series. In 2022, the second round of AM Bench measurements, challenge problems, and conference were completed, focusing primarily upon laser powder bed fusion (LPBF) processing of metals, and both material extrusion processing and vat photopolymerization of polymers. In all, more than 100 people from 10 National Institute of Standards and Technology (NIST) divisions and 21 additional organizations were directly involved in the AM Bench 2022 measurements, data management, and conference organization. The international AM community submitted 138 sets of blind modeling simulations for comparison with the in situ and ex situ measurements, up from 46 submissions for the first round of AM Bench in 2018. Analysis of these submissions provides valuable insight into current AM modeling capabilities. The AM Bench data are permanently archived and freely accessible online. The AM Bench conference also hosted an embedded workshop on qualification and certification of AM materials and components.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Two-photon absorption laser induced fluorescence measurements of absolute neutral deuterium density, temperature, and bulk flow in Proto-MPEX

Neutral particle control is critical for fusion fueling and confinement. Neutral diagnostics for fusion-relevant plasmas are commonly restricted to line-integrated or ex situ methods. A non-perturbative, two-photon absorption laser induced fluorescence (TALIF) diagnostic is implemented on the Prototype Material Plasma Exposure eXperiment (Proto-MPEX) to probe neutral atomic deuterium in a fusion-relevant plasma at 1 cm intervals along the radius of the vacuum vessel. The diagnostic is situated ~20 m from the vacuum vessel, and a signal is collected along the laser injection axis, requiring only one line-of-sight. TALIF measurements are absolutely calibrated using xenon and krypton. Absolute atomic densities derived from xenon calibration are compared to absolute atomic densities derived from krypton calibration. In this work, preliminary measurements of absolute atomic deuterium density, temperature, and local bulk flow dependence on radial location and input power in Proto-MPEX are presented. Neutral atomic deuterium velocity distribution functions are measured throughout a one-second plasma pulse with a time resolution of 250 ms.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Real-time cure monitoring of fiber-reinforced polymer composites using infrared thermography and recursive Bayesian filtering

Despite the desirable characteristics of fiber-reinforced polymer (FRP) composites, their utilization in high volume production industries is limited by a lack of efficient manufacturing techniques. Monitoring the curing process of these composites can help with improving the quality and efficiency of the manufacturing process. This article discusses a method that uses Kalman-filter-based fusion of the information obtained from infrared thermography (surface temperature measurements) and a heat conduction model to estimate degrees of cure and internal temperatures of curing FRP composite parts in real time. The effectiveness of the methodology is demonstrated by successfully monitoring the curing of an FRP composite part in a laboratory experiment. Finally, the proposed methodology is a crucial step towards identifying anomalies in the curing process that negatively impact the quality of FRP composite parts.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Synthesis and thermophysical property determination of NaCl-PuCl3 salts

Currently, a knowledge gap exists in the available data and understanding of thermophysical properties relating to fresh fuel salts, especially those containing plutonium. These data are necessary for designing, constructing, and licensing future commercial molten-salt reactors. Thermophysical properties, such as melting temperature, salt stability, density, and heat capacity were ascertained using NaCl-PuCl3 (36 mol% PuCl3) and a more sodium rich composition containing 25 mol% PuCl3. The NaCl-PuCl3 salt mixture was synthesized for this study and contained 63.4 mol% NaCl, 36.3 mol% PuCl3 and was 99.7% pure. Upon heating, the NaCl–PuCl3 eutectic was stable at temperatures up to 800 °C. The onset of melting occurred at 451 ± 3 °C, and the enthalpy of fusion was determined to be 23.0 ± 1.4 kJ/mol. Heat capacity measurements in the liquid phase ranged from 107.7 to 91.3 J/mol.K, with an average value of 104.6 ± 11.4 J/mol.K between 500 and 650 °C. Three independent trials of the molten NaCl-PuCl3 salt found the density to be ?(T) = 3.8589 – 9.5342·10-4 T(°C). In addition, ab initio molecular dynamic simulations to calculate density and heat capacity values are included.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Characterizing secondary neutrons at BLIP for isotope production applications

Fast secondary neutrons created at the Brookhaven Linac Isotope Producer (BLIP) facility following proton irradiation were characterized by the foil activation technique and compared with FLUKA Monte Carlo simulations. The FLUKA-simulated neutron flux was spectrally adjusted following the maximum entropy formalism using the International Reactor Dosimetry and Fusion File (IRDFF-II), with predictions agreeing with experimental measurements to within 9 % following the adjustment procedure. Here, a multitude of degrader configurations were simulated to assess the feasibility of improving the fast (E n > 20 MeV) secondary neutron yield at the proposed neutron target position (“N-slot”). A configuration where the N-slot is closest to the proton degrader produced the highest fast neutron yield, with tungsten degraders achieving the best performance. Assuming the optimized target-degrader configuration proposed in this work, we discuss potential isotope production opportunities with secondary neutrons. In most cases the yields are in the order of several mCi.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2021

Assessing laser powder bed fusion system geometric errors through artifact-based methods

Additive manufacturing (AM) machines have developed more rapidly than standardized frameworks needed for the qualification of their geometric capabilities. While some manufacturer-specific methods exist to test capabilities and perform some calibration tasks, standardization efforts have only recently been undertaken in the form of ISO/ASTM 52902. In this study, the recommended methodology prescribed by the standard was implemented by building geometric artifacts with a laser powder bed fusion (LPBF) system and performing dimensional inspection with a coordinate measurement machine (CMM), amongst other methods. Typical dimensional capabilities of the LPBF system are identified and commentary is made on applying metrology methods, detecting geometric error, and diagnosing base causes in the LPBF system. In doing so, favored metrology practices and measurement analysis methods auxiliary to the standard are proposed. Artifact measurements were used to characterize beam positioning error and beam offset error. Methods for decoupling the effects of error sources are proposed. Difficulties in the inspection of AM components are identified, and the effects of various CMM measurement strategies are evaluated. Insights on the application of the new standard are presented, along with commentary as to its fitness for the LPBF process.

Berez, J.↗
DOE OSTI2022

High-energy-density plasma in femtosecond-laser-irradiated nanowire-array targets for nuclear reactions

In this work, the high-energy-density plasmas (HEDP) evolved from joule-class-femtosecond-laser-irradiated nanowire-array (NWA) targets were numerically and experimentally studied. The results of particle-in-cell simulations indicate that ions accelerated in the sheath field around the surfaces of the nanowires are eventually confined in a plasma, contributing most to the high energy densities. The protons emitted from the front surfaces of the NWA targets provide rich information about the interactions that occur. We give the electron and ion energy densities for broad target parameter ranges. The ion energy densities from NWA targets were found to be an order of magnitude higher than those from planar targets, and the volume of the HEDP was several-fold greater. At optimal target parameters, 8% of the laser energy can be converted to confined protons, and this results in ion energy densities at the GJ/cm 3 level. In the experiments, the measured energy of the emitted protons reached 4 MeV, and the changes in energy with the NWA’s parameters were found to fit the simulation results well. Experimental measurements of neutrons from 2 H(d,n) 3 He fusion with a yield of (24 ± 18) × 10 6 /J from deuterated polyethylene NWA targets also confirmed these results.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Phase-space sensitivity (weight functions) of 3 MeV proton diagnostics

Abstract The weight function W ( X ) is a diagnostic sensitivity to phase-space variables X that relates the measured signal C to the distribution function F ( X ) through the equation C = ∫ W ( X ) F ( X ) d X . In the present work, an algorithm to calculate W for a diagnostic that measures 3 MeV protons produced in d(d,p)t fusion reactions between a fast ion and a thermal deuteron is developed. The emitted protons escape the tokamak on curved orbits and are detected. These curved orbits constitute effective diagnostic ‘sightlines’. The presented algorithm accounts for the complications associated with these curved sightlines. An initial calculation of time-reversed proton orbits computes effective solid angles and sightlines for the relevant range of incident proton velocity vectors. These precomputed orbits are then used within the framework of FIDASIM (2020 Plasma Phys. Cont. Fusion 62 105008) to calculate the reactivity averaged over the thermal distribution of the ‘target’ deuterons and the probability that a fast ion of specified energy and pitch has a gyroangle that is consistent with the kinematic equations along each of the sightlines. Comparisons with analytic formulas and with independent calculations for the Mega Amp Spherical Tokamak 3 MeV proton diagnostic verify the algorithm.

Physics↗
DOE OSTI2024

Top Yukawa coupling measurement at the muon collider

We have presented a detailed study about the prospects for the measurement of the top Yukawa coupling in the vector boson fusion production of a top quark pair at high energy muon colliders. By employing the effective W approximation and the high energy limit for the helicity amplitudes of the subprocess W + W − → t t ¯ , we have derived the energy scaling of the statistical signal significance in the presence of the anomalous couplings by focusing on the interference term only. The sensitivity on the top Yukawa coupling decreases as the bin energy increases. For the anomalous triple gauge boson couplings and the gauge-boson-fermion couplings with E 2 energy growing behavior, the signal significance has mild increase at the beginning and starts to decrease for s ^ t t ¯ ∼ 0.2 s μ + μ − . The 95% CL on the anomalous top Yukawa coupling is projected to be 5.6% (1.7%) at a 10 (30) TeV muon collider, which is comparable to the sensitivity of 2% at the 100 TeV collider. Published by the American Physical Society 2024

Astronomy & Astrophysics↗
DOE OSTI2020

Microscale thermophoresis as a powerful tool for screening glycosyltransferases involved in cell wall biosynthesis

Background: Identification and characterization of key enzymes associated with cell wall biosynthesis and modification is fundamental to gain insights into cell wall dynamics. However, it is a challenge that activity assays of glycosyltransferases are very low throughput and acceptor substrates are generally not available. Results: We optimized and validated microscale thermophoresis (MST) to achieve high throughput screening for glycosyltransferase substrates. MST is a powerful method for the quantitative analysis of protein-ligand interactions with low sample consumption. The technique is based on the motion of molecules along local temperature gradients, measured by fluorescence changes. We expressed glycosyltransferases as YFP-fusion proteins in tobacco and optimized the MST method to allow the determination of substrate binding affinity without purification of the target protein from the cell lysate. The application of this MST method to the β-1,4-galactosyltransferase AtGALS1 validated the capability to screen both nucleotide-sugar donor substrates and acceptor substrates. We also expanded the application to members of glycosyltransferase family GT61 in sorghum for substrate screening and function prediction. Conclusions: This method is rapid and sensitive to allow determination of both donor and acceptor substrates of glycosyltransferases. MST enables high throughput screening of glycosyltransferases for likely substrates, which will narrow down their in vivo function and help to select candidates for further studies. Additionally, this method gives insight into biochemical mechanism of glycosyltransferase function.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Solar Steam on Demand

INTRODUCTION: This Report summarizes the research and development project performed by Sunvapor and the subrecipient National Renewable Energy Laboratory (NREL) during the period of 10/01/2018-9/30/2021. The work was aimed at the economic integration of solar steam with an industrial process, and in particular, the advantages that a novel type of thermal energy storage and collector design could bring to the system. The completed work includes experimental research on the storage material, design of the collector, engineering of a complete solar steam plant, and economic analysis. The plant was, in the end, not constructed, due to COVID-19 impacts to the project host. PURPOSE: The purpose of the project was to test the hypothesis that a levelized cost of heat (LCOH) of 2¢/kWh delivered to a steam-consuming process, including energy discharged from storage, could be feasibly achieved. PROJECT OBJECTIVES: For Budget Period 1 our objectives were to engineer a prototype industrial solar steam generation system, and design and test a Latent Heat Energy Storage (LHES) lab-scale system. For Budget Period 2 our objectives were to construct and test the solar steam prototype plant, and to build and factory-test a full LHES module. For Budget Period 3 our objective was to integrate the storage module with the solar steam generator, show successful long duration energy tests of the combined system, and use the results to project the LCOH of delivered steam to a second-generation plant. PROJECT OUTCOMES: Various phase change materials (PCMs) for the LHES were tested for compatibility with industrial steam uses as measured by phase change temperature, stability of latent heat of fusion, and their corrosive effects on steel (the heat exchanger material). Two of these materials (sodium formate and sodium/ potassium) showed potential to meet the technical criteria. The estimated cost of a complete LHES module with these materials did not meet economic targets. The developmental collector design builds from previous work to exploit the potential cost advantages of a spaceframe of lumber construction. Design improvements were achieved in assembly efficiency and structural performance. A complete engineering package was completed for the solar steam system without storage that included the developmental as well as commercial arrays. The plant was permitted for construction. The storage CAPEX for a reference plant was estimate to be greater than $\$ 57$/kWh. The LCOH of the system without storage and with developmental collectors of lumber construction was projected to be 2¢/kWh, assuming a FCR of 8.2% over thirty years. PROJECT MILESTONES: The Milestones fully achieved in the first Budget Period includes obtaining a Letter of Intent from an industrial steam-consuming project host, issuance of a construction permit, and corrosion resistance. The Milestone that was partly achieved was the degradation in the latent heat of fusion. Milestones associated with Budget Periods 2 and 3, related to the construction and operation of the plant were not achieved as a result of the host shutting down the plant due to COVID-19 impacts. CONCLUSIONS: Sunvapor was able to secure an agreement with a host to build a fully engineered and permitted solar steam plant that met the host’s economic goals. As a basis for comparison, the solar field design was comprised of eight commercial collector arrays and one developmental Green Parabolic Trough Collector (GPTC) array. The projected LCOH with a solar field entirely populated with a second generation GPTC met the goal of 2¢/kWh. The experimental program concerning the PCM indicated the feasibility of meeting their technical requirements for industrial steam uses. The cost of the complete LHES exceeded its $\$ 14$/kWh target, and therefore the inclusion of LHES could not be economically justified. Due to COVID-19 impacts on the host, the solar steam plant was not constructed.

14 SOLAR ENERGY↗
NASA NTRS1987

Fabrication of imaging X-ray optics

The design, fabrication, and performance of optics for X-ray astronomy and laboratory applications are described and illustrated with diagrams, drawings, graphs, photographs, and sample images. Particular attention is given to the Wolter I telescope developed for spectroscopic observation of 8-30-A cosmic X-ray sources from a rocketborne X-ray Objective Grating Spectrometer; this instrument employs three nested paraboloid-hyperboloid mirrors of 5083 Al alloy, figured by diamond turning and covered with a thin coating of acrylic lacquer prior to deposition of a 40-nm-thick layer of Sn. In calibration tests at NASA Marshall, the FWHM of the line-spread function at 1.33 nm was found to be 240 microns, corresponding to 21 arcsec. Also presented are the results of reflectivity measurements on C and W multilayers sputtered on Si and fusion glass substrates.

Catura, R. C.↗
NASA NTRS2021

The Effect of Composition on Microstructure and Properties for Additively Manufactured Superalloy 718

Additive manufacturing (AM) represents an exciting new approach towards producing metallic aerospace components. The ability to make complex geometries that were impossible to create using conventional manufacturing methods has sparked interest from the aerospace community, including NASA. The use of AM components for crucial and human rated space missions necessitates a full characterization of the differences between AM and more conventional wrought and cast processes. For this study, sixteen different commercially available superalloy 718 powder feedstocks were obtained, built using laser powder bed fusion(L-PBF), and microstructurally and mechanically analyzed. These measurements revealed a wide range of build qualities and microstructures despite all powder lots falling within the 718chemical specification and being processed using the same prescribed build and heat treatment parameters. Statistical analysis found a strong correlation of the amount of carbon in the powder with the final grain size and strength of the heat-treated 718 part. Ultimately, this study highlights the need of a refined superalloy 718 chemical specification for powder lots to be used in AM.

Timothy M Smith↗
NASA NTRSDate not supplied

A14H-04 Analysis of Simulated and Observed Trends in Global Surface PM2.5 and Aerosol Optical Properties from 1958 to 2018 Using the NASA GEOSCCM

Modeling of long-term trends of aerosols and their properties is important for constraining aerosol-climate forcing, and for characterizing changes in particulate matter pollution speciation and exposure. Here we study global and regional long-term trends in surface fine particulate matter (PM ) and aerosol optical properties for 60 years from 1958 to 2018, using simulations performed with the NASA Goddard Earth Observing System Chemistry Climate Model (GEOSCCM), and evaluate the model hindcast with observations for the last three decades. Comparing the modeled aerosols with a diverse set of observations helps interpret observed and simulated trends, and serves as a benchmark for future GEOSCCM developments and input datasets improvements. We first characterize modeled global and regional temporal changes in surface PM and its components, aerosol optical depth (AOD) and single scattering albedo (SSA) and we interpret their link with emissions drivers. We then compare modeled surface PM with ground-based observations from monitoring networks and with global reconstructed PM datasets from observations-model data fusion. Total AOD is compared with long-term satellite measurements from the Moderate Resolution Imaging Spectroradiometer (MODIS) and measurements from the ground-based Aerosol Robotic Network (AERONET). Additional aerosol optical properties, such as absorption and scattering coefficients, are evaluated with ground-based observations from the Global Atmosphere Watch (GAW) records.

aerosols↗
DOE OSTI2024

Safe Operations at Roadway Junctions: Intelligent Roadway Infrastructure as Functional Interlocking

Automated vehicle (AV) technology is quickly maturing, and the corresponding infrastructure systems that evaluate traffic and communicate to vehicles requires sophisticated sensing and perception technologies, referred to as intelligent roadway infrastructure (IRI), to complement emerging AV capabilities. IRI provides signals to vehicles, indicating right-of-way for vehicles and communicating to approaching AVs that no other vehicle is failing to yield. This capability, denoted as safety-affirmative signaling, provides a green light or a green arrow as appropriate and affirms through communication links to connected vehicles when it is safe to proceed. About 36% of collisions occur at intersections, with most occurring upon left turns (22.2%) or crossing over (12.6%), and only a small percentage (1.2%) while turning right at an intersection. Of all intersection crashes about half (52.5%) of those vehicles were traveling through a signalized intersection 2. Safety-affirmative signaling would guarantee safety of AV fleet vehicles, by providing the interlocking principle, a term from automated train control that only allows progression through a railway intersection after affirming no opportunity for a crash exists. IRI through safety-affirmative signaling would bring performance and safety to complex roadway intersections where AV transit fleet service is most needed, as well as safety benefits to traditional, non-automated vehicles and vulnerable road users. The implementation of IRI has functional, programmatic, and technical challenges. Research work performed at the National Renewable Energy Laboratory (NREL) in an integrative approach encapsulating these themes, and termed infrastructure perception and control (IPC) is motivated by improved performance (travel time), improved safety (reduced collisions), and improved energy efficiency (less fuel burned and minimized production of greenhouse gases). IPC is intended not only for roadway and intersection applications but also in extension to inform complementary buildings and grid systems to enable better co-management, as vehicles and their charging needs become increasingly integrated into the built environment. The NREL IPC project presents an open-source framework, architecture, and supporting technology to implement IRI, addressing critical issues such as fusion of data, reliability, standardization of data interfaces, and confidence of detection. The framework is informed by previous experience in U.S. Department of Defense research technology, specifically in the use of radar to detect, identify, and track aerial threats. These principles combined with multi-sensor fusion provides for a complete digital twin with known and measurable confidence and accuracy from which safety-affirmative signaling can be developed and deployed.

ADVANCED PROPULSION SYSTEMS,MATHEMATICS AND COMPUT↗
DOE OSTI2023

Qualification and Commissioning of Helium Flow Loop Experiment for Blanket Design Measurements

Sufficient cooling of plasma-facing materials remains an outstanding challenge in the design of fusion reactor blankets in commercial power demonstration plants. Due to its chemical inertness and low neutron interaction cross section, pressurized helium is a candidate coolant fluid for such systems; however, helium has a small thermal mass compared to liquid coolants, potentially reducing heat removal performance. To address this need, a number of heat transfer enhancements have been proposed to improve the cooling efficiency of such components, thereby decreasing pumping power needs and improving overall plant efficiency. Toward this end, a helium flow loop experiment (HFLE) has been designed and commissioned to test advanced passive heat transfer enhancements in unit-cell test sections, providing necessary data for model validation and subsequent system design. The HFLE is designed to provide flow of pressurized (up to 4 MPa) helium at flow rates up to 80 g/s, enabling heat transfer and pressure drop measurements in test pieces at Reynolds numbers in excess of 180 000. To explore the effects of novel and complex heat transfer enhancements, test sections are produced via additive manufacturing, providing geometries not typically obtainable by conventional machining. Here in this work, we present results from HFLE commissioning and the initial thermal-hydraulic tests of an additively manufactured rifled-rib test section. Results are compared to smooth pipe correlations, and plans are described for future HFLE measurements. These preliminary experiments indicate the utility of the HFLE for heat transfer enhancement testing and simulation validation activities.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗