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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Electrochemical cleaning: An in-Situ method to reverse chromium poisoning in solid oxide fuel cell cathodes

Chromium poisoning is one of the primary factors that affect solid oxide fuel cell (SOFC) durability. In this study, an electrochemical cleaning method has been employed to reverse the effects of chromium poisoning. Two cells were fabricated and poisoned under identical conditions by operating them at 800°C in the presence of a Cr source. Both poisoned cells exhibited a significant reduction in maximum power density and an increase in polarization resistance. One of the poisoned cells, designated as the baseline cell, was cooled to room temperature after poisoning. Microstructural observation of the baseline cell showed significant contamination of the cathode active layer by chromium oxide and (Cr,Mn) spinel deposits. The other poisoned cell was electrochemically cleaned for two hours under a mild electrolytic condition. As a result of the electrochemical cleaning process, the chromium oxide deposits were substantially removed leading to a significant reduction of Cr concentration in the cathode, especially at the cathode/electrolyte interface. Furthermore, a substantial fraction of the cell performance loss was also reversed. To the best of our knowledge, this is a first demonstration of reversing the effects of chromium poisoning using a rapid in-situ process.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

In Situ Attenuated Total Reflectance Infrared Spectroelectrochemistry (ATR-IR-SEC) for the Characterization of Molecular Redox Processes on Surface-Proximal Doped Silicon ATR Crystal Working Electrodes

In situ mid-infrared spectroscopy is a powerful technique for understanding the mechanism of CO 2 reduction (CO 2 R) catalysts because it enables the direct detection of catalytic intermediates and products. Moreover, spectroelectrochemistry (SEC), the coupling of spectroscopy with electrochemistry, allows spectroscopic changes to be correlated with applied potentials to reveal potential-dependent intermediates that are often relevant to photoelectrochemical reactions. Hybrid photoelectrodes, comprised of a narrow bandgap semiconductor, like silicon (Si), with a covalently-linked molecular catalyst, are a promising platform for sunlight-driven catalysis, but characterization of the catalytic mechanism(s) is challenging under photoelectrochemical conditions, particularly when the catalyst is present in monolayer or less concentrations. Here, we have developed a new strategy to use multiple-reflection attenuated total reflectance IR spectroscopy (ATR-IR) coupled with electrochemistry to characterize catalysts directly integrated with a semiconductor surface under applied potential. We show that by surface-proximal n-type or p-type doping of the top ~100-200 nm of the crystal surface, Si ATR crystals can be used simultaneously as the internal reflection element and semiconductor working electrode for ATR-IR-SEC measurements. The surface-proximal doping strategy yields a quasi-equipotential surface with excellent infrared transparency that would have been compromised by free carrier absorption if the crystal was uniformly doped. This approach permits the catalytically-active functionalized surface to be directly probed without modification and overcomes signal-to-noise limitations of other strategies that use separately deposited working electrodes on Si ATR crystals. Proof-of-concept ATR-IR-SEC spectra were collected during the reduction and oxidation of monolayers of Re- and Ru-based transition metal carbonyl complexes, respectively, verifying the viability of the technique to probe redox processes associated with CO 2 R catalysts on Si electrode surfaces with high sensitivity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Non-equilibrium reducing flame aerosol process to create supported high-entropy alloy nanoparticles

High-entropy alloy (HEA) nanomaterials provide opportunities and property combinations for energy and electronic applications, but their practical synthesis faces challenges of elemental immiscibility, metal reducibility, and particle aggregation during their synthesis. Herein, we report a broadly applicable non-equilibrium, scalable, and in-situ reducing flame aerosol process for synthesis of supported HEA nanoparticles. This versatile process can directly load a high concentration of 2 ~ 4 nm HEA nanoparticles on various 1- to 3-dimensional supports. Notably, simultaneous formation of HEA nanoparticles and a mesoporous silica support was successfully realized in a single step. Exploration of this process demonstrates the role of kinetics and entropy on decreasing alloy particle size and altering the reducibility of elements. We propose an entropy-induced reduction mechanism to incorporate oxidizable elements into HEAs, which extends the compositional space of HEA nanoparticles. As a representative catalytic application, we present a RuPdOsIrPt/graphene electrocatalyst with high activity and stability for hydrogen oxidation reaction. Our findings open horizons for high-performance HEA design and applications in diverse fields such as catalysis, electrochemistry, and sensing.

organic↗
DOE OSTI2021

Exploring OpenSNAPI Use Cases and Evolving Requirements [Slides]

Emerging system architectures are rapidly transforming in order to meet shifting requirements. Motivated by expanding data volumes, energy efficiency concerns, and the omnipresent need to improve performance, architectures are increasingly adopting a data-centric approach. At the core of this concept is the goal of minimizing data motion and instead processing data in-situ to the greatest degree possible. Therefore, data-centric designs, in contrast to conventional CPU-centric models, typically distribute compute capabilities throughout the architecture. As part of this paradigm shift, a novel class of devices known as data processing units (DPUs), alongside CPUs and GPUs, are quickly forming a third pillar of data-centric systems. These devices, which include smart network adapters and switches, seek to offload computation on data at the network edge as well as in-flight within the network fabric. The Open Smart Network API (OpenSNAPI) project seeks to develop a unified API for DPU devices. In our previous talks, we introduced the OpenSNAPI project and detailed our investigations regarding the viability of offloading compute intensive kernels to BlueField DPUs. In contrast, in this talk we detail our efforts to offload application-level file I/O to the DPU. We also discuss plans and early efforts to explore in-network compute capabilities. Finally, we describe our observations with respect to the evolving design of OpenSNAPI.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2005

A Viable Scheme for Elemental Extraction and Purification Using In-Situ Planetary Resources

NASA's new strategic direction includes establishing a self-sufficient, affordable and safe human and robotic presence outside the low earth orbit. Some of the items required for a self-sufficient extra-terrestrial habitat will include materials for power generation (e.g. Si for solar cells) and habitat construction (e.g. Al, Fe, and Ti). In this paper we will present a viable elemental extraction and refining process from in-situ regolith which would be optimally continuous, robotically automated, and require a minimum amount of astronaut supervision and containment facilities, The approach is based on using a concentrated heat source and translating sample geometry to enable simultaneous oxide reduction and elemental refining. Preliminary results will be presented to demonstrate that the proposed zone refining process is capable of segregating or refining important elements such as Si (for solar cell fabrication) and Fe (for habitat construction). A conceptual scheme will be presented whereby such a process could be supported by use of solar energy and a precursor robotic mission on the surface of the moon.

Sen, S.↗
NASA NTRS1994

Laser-Induced Fluorescence Helps Diagnose Plasma Processes

Technique developed to provide in situ monitoring of rates of ion sputter erosion of accelerator electrodes in ion thrusters also used for ground-based applications to monitor, calibrate, and otherwise diagnose plasma processes in fabrication of electronic and optical devices. Involves use of laser-induced-fluorescence measurements, which provide information on rates of ion etching, inferred rates of sputter deposition, and concentrations of contaminants.

Beattie, J. R.↗
NASA NTRS2024

Correlations of Additive Manufacturing Model-Based Process Metrics With Spatter-Induced Porosity in the Powder Bed Fusion-Laser Beam/Metallic Process

Components fabricated using the powder bed fusion laser beam metallic (PBF-LB/M) additive manufacturing (AM) process comprise a multitude of sequential weld passes. Qualifying materials for components in critical applications requires a thorough understanding of pertinent processing-microstructure-property relationships. Porosity defects have a strong adverse effect on the mechanical properties of a material. The morphology of porosity defects created by lack of fusion in PBF-LB/M often exhibit high aspect ratios that can act as stress concentrators and become crack initiation sites. The occurrence of spatter induced porosity is studied using synchronized AM model-based process metrics and porosity measured by high-resolution X-ray computed tomography. A novel AM process metric is introduced to quantify the relative exposure to spatter ejecta impacts and incorporation throughout the sequence of the PBF-LB/M process. Further characterization using optical metallography and scanning electron microscopy indicated that both keyhole and lack of fusion porosity correlated statistically with the spatter ejecta impact field of the PBF-LB/M process. Both keyhole and lack of fusion porosity can be predicted by the spatter exposure process metric, which can be exploited to control the fusion sequence.

Additive Manufacturing↗
NASA NTRSDate not supplied

A Novel Additive Manufacturing Process Metric for Predicting Spatter-related Porosity in Laser Powder Bed Fusion

Components fabricated using the powder bed fusion laser beam metallic (PBF) additive manufacturing (AM) process comprise a multitude of sequential weld passes. Porosity defects resulting from weld pass inconsistencies are a concern for PBF materials and have a strong adverse effect on the mechanical properties. In an effort to understand and avoid spatter induced porosity, this work aims to provide a novel computational technique that can be used to quantify and predict the sequence-sensitive impact of spatter upon the PBF process stability and consequential porosity in as-printed material. A novel spatter impact AM model-based process metric (AM-PM) is introduced to model and quantify the impact that spatter has on the PBF process. The occurrence of spatter induced porosity is studied using thermal rise, lack of fusion, and spatter impact AM-PMs synchronized with porosity measured by high-resolution X-ray computed tomography. Six cylindrical specimens were designed to compare the AM-PM correlations with porosity across two different laser powers and three hatch scanning strategies. A point field based computational approach is shown to be effective for testing the influence of the different AM-PMs and interrogating the physical process conditions underlying the porosity formation. Further, characterization using optical metallography and scanning electron microscopy indicated that both keyhole and lack of fusion porosity correlated with the spatter impact AM-PM, which can be exploited to predict and control spatter related porosity by the hatch strategy. Efforts to predict porosity composition within PBF material should incorporate the PBF process disturbances that can result from spatter. The spatter impact AM-PM can be readily incorporated into the development of defect prediction models at the part scale.

Additive Manufacturing↗
NASA NTRS2006

Evaluating Trichloroethylene Degradation Using Differing Nano- and Micro-Scale Iron Particles

Trichioroethylene, or TCE, is a central nervous system depressant and possible carcinogen, as well as a persistent groundwater pollutant. TCE exists in the aquifer either as free product in the form of a dense non-aqueous phase liquid (DNAPL) or as a dissolved-phase constituent. It is only slightly soluble in water, so dissolution of the contaminant is a long-term process and in-situ remediation is difficult. To remedy this, NASA and the University of Central Florida developed Emulsified Zero-Valent Iron, or EZVI. The emulsion droplet contains ZVI particles and water encapsulated by an oil/surfactant membrane, and effectively penetrates to degrade DNAPL-phase TCE. To maximize the efficiency of this process, several commercially available ZVIs of radically different particle sizes and morphologies both in emulsion and as neat (unemulsified) metal were evaluated for relative effectiveness at TCE degradation.

Berger, Cristina M.↗
DOE OSTI2025

Multiscale investigation of thermomechanical and compositional developments in Ni alloy 718 under laser processing

Laser processing has been widely employed in various applications due to its exceptional spatial resolution. However, the rapid temperature gradients generated in localized areas present significant challenges for experimental characterization using conventional instruments. To characterize Ni alloy 718 during laser processing, we employed in-situ synchrotron X-ray diffraction with a high-speed detector, a method particularly well-suited for probing processes with high temporal and spatial resolution. Through a series of in-situ experiments, we investigated the local variations in the evolution of microstructures and thermomechanical behaviors within a keyhole mode melt pool. The in situ macroscopic thermomechanical behaviors were quantified using an empirical model derived from diffraction patterns, with experimental results showing reasonable agreement with finite element analysis. Various laser parameters were tested to assess their influences on the residual strains in the melt pools. The results revealed that the residual strain in the keyhole mode melt pool is relatively insensitive to variations in the parameters and is smaller than that in the melt pool created under conduction mode laser scanning. Additionally, we analyzed the shapes of individual diffraction spots, providing insights into the plastic behaviors and compositional developments in the resolidified alloy. The analysis confirmed that compositional variations in a dendritic microstructure manifest as asymmetric broadening of the diffraction spots.

Ni alloy 718↗
DOE OSTI2021

Catalysts by pyrolysis: Direct observation of chemical and morphological transformations leading to transition metal-nitrogen-carbon materials

Transition metal-nitrogen-carbon materials (M-N-C catalysts) are promising electrocatalysts in polymer electrolyte fuel cells (PEFCs) and electrolyzer applications. High temperature treatment in inert atmosphere (pyrolysis) is the essential, most common method for the synthesis of M-N-C catalysts and critical to achieve high electrocatalytic activity and electronic conductivity. To this day, despite many uses and successful implementations in materials manufacturing, pyrolysis has been an entirely empirical technology, with process control and optimization relying exclusively on “Edisonian” approach. The knowledge gap in the mechanism about how the precursor is being transformed into catalysts hinders further development of the M-N-C catalysts regardless of the precursor class and processing protocols. In this work, we probed the morphological evolution and chemical transformation of a nitrogen-containing charge transfer organic salt, mixed with transition metal (iron) salt and amorphous silica powder (precursor) during the pyrolysis process via a combination of in situ synchrotron and laboratory-based diagnostic techniques. The pyrolysis process is found to be divided into three stages. During a controlled temperature ramp, the selected organic N-C precursor (nicarbazin) began melting and decomposing just below 400 °C, forming a certain number of micrometer-scale pores and pathways. With increase in temperature from 400 °C to 900 °C, amorphous carbon domains started forming, and reduced (metallic) iron nanoclusters appeared, being dispersed uniformly throughout the carbonaceous matrix. When temperature advanced above 900 °C, graphitization of carbon commenced, associated with appearance and evolution of atomically dispersed metal-nitrogen moieties in the carbonaceous matrix. As the graphitization advanced further, a secondary process of agglomeration of metal nanoparticles occurred. Multi-analytical technique observations conducted here provide a base for rational design and optimization of M-N-C electrocatalysts via pyrolysis.

36 MATERIALS SCIENCE↗
NASA NTRS2004

Minimizing Launch Mass for ISRU Processes

The University of Dayton and the Jet Propulsion Laboratory are developing a methodology for estimating the Earth launch mass (ELM) of processes for In-Situ Resource Utilization (ISRU) with a focus on lunar resource recovery. ISRU may be enabling for both an extended presence on the Moon, and for large sample return missions and for a human presence on Mars. To accomplish these exploration goals, the resources recovered by ISRU must offset the ELM for the recovery process. An appropriate figure of merit is the cost of the exploration mission, which is closely related to ELM. For a given production rate and resource concentration, the lowest ELM - and the best ISRU process - is achieved by minimizing capital equipment for both the ISRU process and energy production. ISRU processes incur Carnot limitations and second law losses (irreversibilities) that ultimately determine production rate, material utilization and energy efficiencies. Heat transfer, chemical reaction, and mechanical operations affect the ELM in ways that are best understood by examining the process's detailed energetics. Schemes for chemical and thermal processing that do not incorporate an understanding of second law losses will be incompletely understood. Our team is developing a methodology that will aid design and selection of ISRU processes by identifying the impact of thermodynamic losses on ELM. The methodology includes mechanical, thermal and chemical operations, and, when completed, will provide a procedure and rationale for optimizing their design and minimizing their cost. The technique for optimizing ISRU with respect to ELM draws from work of England and Funk that relates the cost of endothermic processes to their second law efficiencies. Our team joins their approach for recovering resources by chemical processing with analysis of thermal and mechanical operations in space. Commercial firms provide cost inputs for ELM and planetary landing. Additional information is included in the original extended abstract.

England, C.↗
DOE OSTI2021

Low-cost sensors and analytics for a digital factory

ORNL Manufacturing Demonstration Facility and Perisense worked on a low-cost solution for machining process monitoring to enable a digital factory. Enabling machine connectivity for digital factors is expensive for many small to medium manufacturers. The hypothesis for the research project is that a lowcost sensor suite, which can be retrofitted to a legacy machine tool or a new machine tool, can effectively provide real-time, in-situ sensing for manufacturing processes, which can enable improvements in process performance and efficiency. The Perisense sensor node was installed on the Haas TM1 machine with a current sensor and an accelerometer. Cutting tests were performed at different process parameters and sensor data was recorded. Results show a correlation of the current sensor to the spindle load. The accelerometer, mounted on the machine base, showed a correlation to the spindle speed as well as the spindle load. The sensor data can be used to monitor the machining process and provide insights on the machine spindle load utilization.

42 ENGINEERING↗
DOE OSTI2022

Leveraging Multiple Raman Excitation Wavelength Systems for Process Monitoring of Nuclear Waste Streams

Processing nuclear waste from sites such as Hanford is a significant environmental cleanup need while being a significant logistical challenge. Integration of process monitoring tools, that can provide in situ and real-time feedback about the process, can significantly alleviate needs to collect grab samples for process control and product characterization. Raman spectroscopy paired with chemometric analysis is one process monitoring tool that can provide chemical composition information on a large number of chemical targets in nuclear waste streams. However, methods to improve limits of detection as well as drop uncertainty in quantification are needed. Optimizing instrument specifications can achieve this, here this is demonstrated by comparing limits of detection for key analytes when using Raman systems with 671 nm, 532 nm, and 405 nm excitation wavelengths. Generally, limits of detection decease (allowing the measurement of lower salt concentrations) with decreasing wavelength. Similarly, data collection times and averaging were optimized. Finally, multiple chemometric modeling approaches were leveraged, including multiblock methods that combined data from all three Raman systems to simultaneously quantify targets with improved sensitivity.

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

Scalable, In-situ Data Clustering Data Analysis for Extreme Scale Scientific Computing (Final Report)

The objective of this project is to address challenges in the design and development of scalable in-situ data clustering and analytics algorithms and software. Our goal is to develop parallel software consisting of a set of spatio-temporal data clustering and anomaly detection functions, both of which are very important for large-scale analysis and have wide applicability for in-situ runs as well as post-processing analysis. Our design principles for in-situ analysis consider the following: (1) identify parts of the computation can be done close to the data within the nodes, while it is still in memory; (2) extract analysis components can (and should) be performed in remote staging and analysis nodes; (3) develop error-bound approximation methods for applications tolerable for small errors; (4) identify the type of derived distributions and statistics, for spatio-temporal data, that can be kept locally in order to both accelerate computations and meet energy constraints in subsequent iterations and phases; (5) use a self-describing data format so that data can be consistent and understood among local storage (memory and SSDs) and at staging and analysis nodes, thereby providing portability and flexibility; (6) develop service-oriented functions that can schedule in-situ and post-hoc analysis tasks based on the dynamic requirements of applications. Our development focus is to produce the parallel data analysis software/library that will be scalable, reusable, extensible, and generic for applications in different disciplines. The software will be able to run in-situ with the simulations as well as post-hoc analysis. This approach will satisfy many synergistic requirements for data intensive applications executed on data coming from instruments and experiments. In particular, the proposed multilevel approach is directly applicable to perform design tradeoffs for running part of the algorithms near the instruments and the rest on remote (analysis) systems.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

In situ Visible Light and Thermal Imaging Data from a Laser Powder Bed Fusion Additive Manufacturing Process Co-Registered to X-ray Computed Tomography and Fatigue Data

This dataset is comprised of in situ sensing data collected during a laser-based powder bed fusion additive manufacturing process, as well as rasterized scan path information, post-build X-ray computed tomography (XCT), and fatigue test results. A total of 64 cylinders, approximately 15 mm in diameter and 102 mm tall, were printed out of stainless steel 316H on a Colibrium Additive Concept Laser M2 Series 5 machine. Parameters known to produce dense material were used to construct 56 of these cylinders, while the remaining 8 cylinders were printed with relatively high energy density parameters prone to producing keyhole pores. In addition, two spatter generation blocks were constructed upstream of the 64 cylinders such that ejecta produced during the melting of the spatter generators were stochastically seeded onto the 64 cylinders. Based on previous experiments, these spatter particles were theorized to produce stochastic lack-of-fusion pores. During the construction of the build, high-resolution images of reflected light in the visible spectrum were captured both before and after recoating for each print layer. Additionally, temporally integrated thermal imaging in the near infrared spectrum produced integrated sum and max images on a layerwise basis. The multimodal in situ data has been co-registered to the build plate coordinate system, allowing for identification of process anomalies (e.g., spatter particles) apparent in the two sensors. Following construction of the build, the cylinders were subjected to XCT to identify internal flaws, and the resulting data have also been registered to the build plate coordinate system. Finally, 60 of the 64 cylinders were machined into fatigue coupons conforming to ASTM E466 and subsequently subjected to either high- or -low-cycle fatigue testing. The results of the fatigue tests have also been included in the dataset, and the XCT data corresponded to the approximate location of the gauge sections of the machine fatigue specimen geometry.

42 ENGINEERING↗
NASA NTRS2012

Cassegrain Solar Concentrator System for ISRU Material Processing

A 0.5 m diameter Cassegrain concentrator was constructed as a means of providing highly concentrated sunlight for the demonstration processing of lunar simulated regolith and other NASA In-Situ Resource Utilization Project (ISRU) reaction processes. The concentrator is constructed of aluminum with a concentration ratio of approximately 3000 to 1. The concentrator focuses solar energy into a movable tray located behind the concentrator. This tray can hold simulated regolith or any other material and or device to be tested with concentrated solar energy. The tray is movable in one axis. A 2-axis extended optical system was also designed and fabricated. The extended optical system is added to the back of the primary concentrator in place of the moveable test tray and associated apparatus. With this optical system the focused sunlight can be extended from the back of the primary concentrator toward the ground with the added advantage of moving the focal point axially and laterally relative to the ground. This allows holding the focal point at a fixed position on the ground as the primary concentrator tracks the sun. Also, by design, the focal point size was reduced via the extended optics by a factor of 2 and results in a concentration ratio for the system of approximately 6,000 to 1.The designs of both optical systems are discussed. The results from simulated regolith melting tests are presented as well as the operational experience of utilizing the Cassegrain concentrator system.

Colozza, Anthony J.↗
NASA NTRS2011

Generalized Software Architecture Applied to the Continuous Lunar Water Separation Process and the Lunar Greenhouse Amplifier

This innovation provides the user with autonomous on-screen monitoring, embedded computations, and tabulated output for two new processes. The software was originally written for the Continuous Lunar Water Separation Process (CLWSP), but was found to be general enough to be applicable to the Lunar Greenhouse Amplifier (LGA) as well, with minor alterations. The resultant program should have general applicability to many laboratory processes (see figure). The objective for these programs was to create a software application that would provide both autonomous monitoring and data storage, along with manual manipulation. The software also allows operators the ability to input experimental changes and comments in real time without modifying the code itself. Common process elements, such as thermocouples, pressure transducers, and relative humidity sensors, are easily incorporated into the program in various configurations, along with specialized devices such as photodiode sensors. The goal of the CLWSP research project is to design, build, and test a new method to continuously separate, capture, and quantify water from a gas stream. The application is any In-Situ Resource Utilization (ISRU) process that desires to extract or produce water from lunar or planetary regolith. The present work is aimed at circumventing current problems and ultimately producing a system capable of continuous operation at moderate temperatures that can be scaled over a large capacity range depending on the ISRU process. The goal of the LGA research project is to design, build, and test a new type of greenhouse that could be used on the moon or Mars. The LGA uses super greenhouse gases (SGGs) to absorb long-wavelength radiation, thus creating a highly efficient greenhouse at a future lunar or Mars outpost. Silica-based glass, although highly efficient at trapping heat, is heavy, fragile, and not suitable for space greenhouse applications. Plastics are much lighter and resilient, but are not efficient for absorbing longwavelength infrared radiation and therefore will lose more heat to the environment compared to glass. The LGA unit uses a transparent polymer antechamber that surrounds part of the greenhouse and encases the SGGs, thereby minimizing infrared losses through the plastic windows. With ambient temperatures at the lunar poles at 50 C, the LGA should provide a substantial enhancement to currently conceived lunar greenhouses. Positive results obtained from this project could lead to a future large-scale system capable of running autonomously on the Moon, Mars, and beyond. The software for both applications needs to run the entire units and all subprocesses; however, throughout testing, many variables and parameters need to be changed as more is learned about the system operation. The software provides the versatility to permit the software operation to change as the user requirements evolve.

Perusich, Stephen↗