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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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Determination of the Basic Parameters of Impact Interaction of Abrasive Particles Against the Blades of the Rotor Accelerator of a Centrifugal Mill

Ways to improve the efficiency with which materials are pulverized in impact centrifugal mills as well as ways of preventing wear of the blades are proposed. The problem is solved using equations that describe the motion of particles on the surface of the rotor in a polar coordinate system. It is discovered that the rate of impact of the particles against a blade increases linearly with increasing angular velocity. The angle of attack and radius of contact of a particle with the blade are independent of this velocity, though they are substantially affected by the initial position of the particles. The nature of the variation of the rate of impact and the angle of attack is determined, based on which possible wear of the blades may be predicted and measures taken to reduce wear.

42 ENGINEERING↗
DOE OSTI2019

Structural and Magnetic Properties of La-Substituted M-Type Hexagonal Sr–Ni Ferrites Synthesized by Ball-Milling-Assisted Ceramic Process

Sr{sub 0.5}Ni{sub 0.5}La{sub x}Fe{sub 12 − x}O{sub 19} (x = 0, 0.08, 0.16, and 0.24) hexaferrites have been synthesized by ball-milling-assisted ceramic process. The calcined samples are characterized by X-ray powder diffraction (XRD), scanning electron microscopy (SEM), Fourier transform infrared spectra (FTIR), and vibrating sample magnetometry (VSM). XRD reveals that all samples consist of the main M-type hexagonal Sr ferrite phase and a low amount of rhombohedral Fe{sub 2}O{sub 3} as secondary phase, and a continuous increase of the hexagonal lattice parameters with substitution content (x). Magnetic characterization indicates that all Sr{sub 0.5}Ni{sub 0.5}La{sub x}Fe{sub 12 − x}O{sub 19} samples have a hard magnetic property. Substitution of Fe{sup 3+} ions by La{sup 3+} ions can obviously improve the specific saturation magnetization, remanence, magnetic moment, and effective anisotropy constant. Specific saturation magnetization, remanence, and the magnetic moment reach a maximum at x= 0.24 and calcination temperature of 1050 {sup ∘}C.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Use of Industrial Waste (Al-Dross, Red Mud, Mill Scale) as Fluxing Agents in the Sulfurization of Fe-Ni-Cu-Co Alloy by Carbothermic Reduction of Calcium Sulfate

The use of industrial waste [mill scale (MS), red mud (RM), Al-dross (AD)] as fluxing agents in the sulfurization of Fe-Ni-Cu-Co alloy to matte (Fe-Ni-Cu-Co-S) by carbothermic reduction of CaSO{sub 4} was investigated at 1673 K (1400 °C). The sulfurization efficiency (SE) was 76 (± 2) pct at RM or AD single fluxing. However, SE drastically increased to approximately 89 pct at a ‘5AD + 5MS’ combination, which was equivalent to reagent-grade chemical ‘5Al{sub 2}O{sub 3} + 5Fe{sub 2}O{sub 3}’ fluxing (SE = 88 pct). The present results can be used to improve the cost-effective recovery of rare metals (Ni and Co) from deep sea manganese nodules.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Tensile Properties and Fracture Characteristics of Nanostructured Copper and Cu-SiC Nanocomposite Produced by Mechanical Milling and Spark Plasma Sintering Process

The presence of large grains within nanometric and ultrafine grain matrix is an effective method in order to enhance strength while keeping the high ductility of metals. For this purpose, in this research, spark plasma sintering (SPS) was used to consolidate milled Cu and Cu-SiC powders. In SPS process, local sparks with high temperature between particles take place and locally lead to intense grain growth, and therefore, this method has the ability to produce bimodal grain structures in copper and copper-based composites. Microstructural and mechanical studies showed ≈ 185 and ≈ 437 nm matrix grain sizes, high tensile yield strength values of ≈ 188.4 and ≈ 296.9 MPa, and fracture strain values of 15.1 and 6.7% for sintered Cu and Cu-4 vol.% SiC nanocomposite materials, respectively. The presence of nanoparticles promoted the occurrence of static recrystallization and decreased the fraction of coarse grains in microstructure. The high tensile properties of the produced materials are attributed to fine grain size, homogenous dispersion of nanoparticles and retarded grain boundary migration during sintering.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2013

A top-down assessment of energy, water and land use in uranium mining, milling, and refining

Land, water and energy use are key measures of the sustainability of uranium production into the future. As the most attractive, accessible deposits are mined out, future discoveries may prove to be significantly, perhaps unsustainably, more intensive consumers of environmental resources. A number of previous attempts have been made to provide empirical relationships connecting these environmental impact metrics to process variables such as stripping ratio and ore grade. These earlier attempts were often constrained by a lack of real world data and perform poorly when compared against data from modern operations. This paper conditions new empirical models of energy, water and land use in uranium mining, milling, and refining on contemporary data reported by operating mines. It shows that, at present, direct energy use from uranium production represents less than 1% of the electrical energy produced by the once-through fuel cycle. Projections of future energy intensity from uranium production are also possible by coupling the empirical models with estimates of uranium crustal abundance, characteristics of new discoveries, and demand. The projections show that even for the most pessimistic of scenarios considered, by 2100, the direct energy use from uranium production represents less than 3% of the electrical energy produced by the contemporary once-through fuel cycle.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2026

Synergistic effects of chemical-free hydrothermal pretreatment on the recovery of cellulosic sugars and pectin from sugar mill-derived sugar beet pulp

Sugar mills processing sugar beet generate large amounts of sugar beet pulp (SBP), a carbohydrate-rich byproduct composed of 22–30% cellulose, 24–32 % hemicellulose, and 15-20% pectin. Mild, chemical-free hydrothermal pretreatment offers a promising approach to recover these compounds while minimizing pectin degradation, reducing chemical use, and lowering operating costs for value-added applications. This study evaluates the effects of chemical-free hydrothermal pretreatment on cellulosic sugars recovery and its synergy with subsequent pectin extraction under pretreatment conditions ranging from 80°C to 120°C for 15-45 min. Results show that increasing pretreatment severity preserved most glucans with 4% decrease in galacturonan content. Optimal pretreatment (100°C for 45 min) followed by enzymatic hydrolysis achieved the best glucose (95%) and pentose (74%) yields, while galacturonan remained concentrated in the residual solids. Subsequent citric acid extraction at 80°C for 3 hr and a solid-to-liquid ratio of 1:15 yielded up to 85% pectin, significantly lowering water, chemical, and energy requirements compared to conventional industrial extraction. The integration of mild hydrothermal pretreatment with enzymatic hydrolysis thus maximized sugar recovery and enabled efficient downstream pectin extraction without compromising product yields. These findings advance low-impact valorization strategies to reinforce SBP’s values in biorefinery.

09 - BIOMASS FUELS↗
DOE OSTI2020

Stability boundary and optimal operating parameter identification in milling using Bayesian learning

Here, this paper describes a novel Bayesian learning approach for stability boundary and optimal parameter identification in milling without the knowledge of the underlying tool dynamics or material cutting force coefficients. The paper is divided into two parts. First, a Bayesian learning method for stability lobe identification using test results is described. Each axial depth and spindle speed combination is characterized by a probability of stability which is updated using Bayes’ rule when a test result (stable or unstable) is made available. A novel likelihood function is defined which incorporates knowledge of the stability behavior. Numerical results show convergence to the analytical stability lobe diagram. Second, an adaptive experimental strategy to identify optimal operating parameters that maximize material removal rate is described. Numerical evaluation shows convergence to the optimal operating point with error less than 15 % within ten tests on average. The approach is validated using experimental results. Results show that the proposed method is an efficient and robust learning method to identify the stability lobe diagram and optimal operating parameters with a limited number of tests/data points.

Bayesian machine learning↗
DOE OSTI2023

Effects of magnetic field annealing on the hard magnetic properties of milled Nd-Fe-B powders

In this study, we report the effect of magnetic field annealing (MA) in relieving the stress induced during the milling of Nd-Fe-B sintered magnets. The effect of MA processing parameters and particle size on the magnetic properties were investigated. Based on the results, magnetic field annealing is more effective in improving the magnetic properties of larger size particles, compared to finer particles. Our computational study on the role of particle surface defects in bi-modal particle distribution agrees with results obtained experimentally. In conclusion, magnetic field annealed powder has been successfully used to develop 4.6 g.cm -3 density bonded magnets with 75 vol% of magnetic powder and polyamide 12 (nylon 12) polymer binder resulting in 11.3 MGOe energy product.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Hybrid data-driven and model-informed online tool wear detection in milling machines

Precision machining tool wear is responsible for low product throughput and quality. Monitoring the tool wear online is vital to prevent degradation in machining quality. However, direct real-time tool wear measurement is not practical. This paper presents residual-based anomaly detection models, combining a hybrid model comprised of a physics-based model and a data-driven model (a decision tree or a neural network) to predict signals of interest (e.g., power or forces) under nominal conditions, followed by Page’s cumulative sum test for detecting tool wear on-line using the computer numerical control machine measurements. The most informative features are ranked using dynamic programming and its approximation variants from real-time measurements and machine settings, such as the width of cut, depth of cut, feed rate and spindle speed, that serve as inputs to the predictive models. The baseline nominal model is incrementally updated with experimental data via a gradient boosted adaptation model to generate the residuals that account for discrepancies between the actual machine data under normal conditions and the baseline nominal model predictions. The hybrid model is validated against 20 Mazak milling machine experimental tests and one Haas run-to-failure experiment. The proposed anomaly detector is applied to synthetic data from simulations of the physics-based model at different operating conditions, measurement noise levels, and tool wear levels, and the methods were able to achieve an overall 92% accuracy in data with 1% noise. The anomaly detection methods based on hybrid model reduced the false alarms of either the data-driven or physical-based models alone, and are found to be capable of good online detection of tool wear.

42 ENGINEERING↗
DOE OSTI2025

Cascading from $\mathscr{N}$ = 2 supersymmetric Yang–Mills theory to confinement and chiral symmetry breaking in adjoint QCD

We argue that adjoint QCD in 3 + 1 dimensions, with any SU(N) gauge group and two Weyl fermion flavors (i.e. one adjoint Dirac fermion), confines and spontaneously breaks its chiral symmetries via the condensation of a fermion bilinear. We flow to this theory from pure $\mathscr{N}$ = 2 SUSY Yang–Mills theory with the same gauge group, by giving a SUSY-breaking mass M to the scalars in the $\mathscr{N}$ = 2 vector multiplet. This flow can be analyzed rigorously at small M, where it leads to a deconfined vacuum at the origin of the $\mathscr{N}$ = 2 Coulomb branch. The analysis can be extended to all M using an Abelian dual description that arises from the N multi-monopole points of the $\mathscr{N}$ = 2 theory. At each such point, there are N −1 hypermultiplet Higgs fields h$^{i=1,2}_m$, which are SU(2) R doublets. We provide a detailed study of the phase diagram as a function of M, by analyzing the semi-classical phases of the dual using a combination of analytic and numerical techniques. The result is a cascade of first-order phase transitions, along which the Higgs fields h i m successively turn on, and which interpolates between the Coulomb branch at small M, where all h$^{i}_m$ = 0, and a maximal Higgs branch, where all h$^{i}_m$ ≠ 0, at sufficiently large M. We show that this maximal Higgs branch precisely matches the confining and chiral symmetry breaking phase of two-flavor adjoint QCD, including its broken and unbroken symmetries, its massless spectrum, and the expected large-N scaling of various observables. The spontaneous breaking pattern SU(2) R → U(1) R , consistent with the Vafa–Witten theorem, is ensured by an intricate alignment mechanism for the h$^{i}_m$ in the dual, and leads to a CP 1 sigma model of increasing radius along the cascade.

D’Hoker, Eric [Univ. of California, Los Angeles, C↗
DOE OSTI2023

Particle size and shape effect of Crumbler® rotary shear-milled granular woody biomass on the performance of Acrison® screw feeder: A computational and experimental investigation

Physical experiments and discrete element model (DEM) simulations are conducted to evaluate particle characteristics and operation parameter effects on screw feeding performance for rotary shear-milled Douglas fir. Three performance metrics are used: mass flow rate, shaft driving torque, and specific energy consumption. The impact of particle size, particle size distribution (PSD), shaft rotational speed (rpm), and hopper dimensions on the performance are investigated. All employed performance metrics reveal the superior flowability of the 2-mm particles in contrast to the larger 6-mm counterpart. Remarkably, wider PSD results in poorer flowability than the two mono-sized particles, proving the flowability enhancement achieved by narrower PSD of the woody feedstock. More importantly, DEM simulations unveil PSD-induced degradation in flowability is attributed to mechanical interlocking and particle segregation effects. Furthermore, higher shaft rpm causes higher mass flow rate at the cost of higher specific energy consumption due to viscous dissipation and changes in flow pattern.

09 BIOMASS FUELS↗
DOE OSTI2010

Exploitation of olive mill wastewater and liquid cow manure for biogas production

Co-digestion of organic waste streams is an innovative technology for the reduction of methane/greenhouse gas emissions. Different organic substrates are combined to generate a homogeneous mixture as input to the anaerobic reactor in order to increase process performance, realize a more efficient use of equipment and cost-sharing by processing multiple waste streams in a single facility. In this study, the potential of anaerobic digestion for the treatment of a mixture containing olive mill wastewater (OMW) and liquid cow manure (LCM) using a two-stage process has been evaluated by using two continuously stirred tank reactors (CSTRs) under mesophilic conditions (35 {sup o}C) in order to separately monitor and control the processes of acidogenesis and methanogenesis. The overall process was studied with a hydraulic retention time (HRT) of 19 days. The digester was continuously fed with an influent composed (v/v) of 20% OMW and 80% LCM. The average removal of dissolved and total COD was 63.2% and 50%, respectively. The volatile solids (VS) removal was 34.2% for the examined mixture of feedstocks operating the system at an overall OLR of 3.63 g CODL{sub reactor}{sup -1}d{sup -1}. Methane production rate at the steady state reached 0.91 L CH{sub 4}L{sub reactor}{sup -1}d{sup -1} or 250.9 L CH{sub 4} at standard temperature and pressure conditions (STP) per kg COD fed to the system.

09 BIOMASS FUELS↗
DOE OSTI2020

Nanoscale Mg–B via Surfactant Ball Milling of MgB 2 : Morphology, Composition, and Improved Hydrogen Storage Properties

Metal borides have attracted the attention of researchers due to their useful physical properties and unique ability to form high hydrogen-capacity metal borohydrides. We demonstrate improved hydrogen storage properties of a nanoscale Mg–B material made by surfactant ball milling MgB 2 in a mixture of heptane, oleic acid, and oleylamine. Transmission electron microscopy data show that Mg–B nanoplatelets are produced with sizes ranging from 5 to 50 nm, which agglomerate upon ethanol washing to produce an agglomerated nanoscale Mg–B material of micron-sized particles with some surfactant still remaining. X-ray diffraction measurements reveal a two-component material where 32% of the solid is a strained crystalline solid maintaining the hexagonal structure with the remainder being amorphous. Fourier transform infrared shows that the oleate binds in a “bridge-bonding” fashion preferentially to magnesium rather than boron, which is confirmed by density functional theory calculations. The Mg–B nanoscale material is deficient in boron relative to bulk MgB 2 with a Mg–B ratio of ~1:0.75. The nanoscale MgB 0.75 material has a disrupted B–B ring network as indicated by X-ray absorption measurements. Hydrogenation experiments at 700 bar and 280 °C show that it partially hydrogenates at temperatures 100 °C below the threshold for bulk MgB 2 hydrogenation. In addition, upon heating to 200 °C, the H–H bond-breaking ability increases ~10-fold according to hydrogen–deuterium exchange experiments due to desorption of oleate at the surface. This behavior would make the nanoscale Mg–B material useful as an additive where rapid H–H bond breaking is needed.

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

Volumetric Shaping of Nanoparticle-DNA Crystals by Light-Induced Milling

DNA-programmable self-assembly enables the formation of nanoparticle crystals with controlled lattice symmetry. While this approach offers the formation of complexly ordered nanostructures for optical, mechanical, and biological applications, a mesoscale control over such nanomaterials is limited. Directing the material formation process through the assembly pathway or external fields allows for modulating crystal morphology, but achieving arbitrary morphology remains challenging. Here, we present a photothermal method for shaping 3D DNA-programmable crystals of gold nanoparticles. Through local heating of nanoparticles due to plasmonic light absorption, we induce targeted volumetric dissolution of specifically defined crystal areas with micron-scale accuracy. This technique effectively prescribes crystal shaping and creates arbitrarily shaped voids within crystals. We further investigate both computationally and experimentally the key factors governing volumetric material subtraction. The developed automated light-milling platform enables the fabrication of nanomaterials exhibiting both DNA-programmable nanoscale order and custom-designed mesoscale architecture.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Optical interference for the guidance of cryogenic focused ion beam milling beyond the axial diffraction limit

Cryogenic focused ion beam (Cryo-FIB) milling has become a standard step in the cryogenic electron tomography (Cryo-ET) workflow and is required to thin cells to electron-semitransparency. However, this destructive process removes the vast majority of the cellular material and raises a critical question: what thin section should be preserved for Cryo-ET analysis? Using a tri-coincident cryogenic FIB-SEM-LM system, we identify an interferometric optical response that can be used for targeting lamella production to fluorescently labeled structures with accuracy beyond the diffraction limit. Here we demonstrate this approach using synthetic samples of fluorescent beads embedded in micron-scale droplets of amorphous ice. We then apply the approach to capture virions inside host cells. Successful targeting is confirmed by Cryo-ET revealing clusters of virions in intracellular vesicles. The method does not require any fluorescent fiducials or axial registration and can be performed on any fluorescently labeled structure that is visible in widefield fluorescence microscopy.

Cryoelectron microscopy↗
DOE OSTI2018

Probing flow-induced nanostructure of complex fluids in arbitrary 2D flows using a fluidic four-roll mill (FFoRM)

Abstract Engineering flow processes to direct the microscopic structure of soft materials represents a growing area of materials research. In situ small-angle neutron scattering under flow (flow-SANS) is an attractive probe of fluid microstructure under simulated processing conditions, but current capabilities require many different sample environments to fully interrogate the deformations a fluid experiences in a realistic processing flow. Inspired by recent advances in microfluidics, we present a fluidic four-roll mill (FFoRM) capable of producing tunable 2D flow fields for in situ SANS measurements, that is intended to allow characterization of complex fluid nanostructure under arbitrary complex flows within a single sample environment. Computational fluid dynamics simulations are used to design a FFoRM that produces spatially homogeneous and sufficiently strong deformation fields. Particle tracking velocimetry experiments are then used to characterize the flows produced in the FFoRM for several classes of non-Newtonian fluids. Finally, a putative FFoRM-SANS workflow is demonstrated and validated through the characterization of flow-induced orientation in a semi-dilute cellulose nanocrystal dispersion under a range of 2D deformations. These novel experiments confirm that, for steady state straining flows at moderate strain rates, the nanocrystals orient along the principal strain-rate axis, in agreement with theories for rigid, rod-like Brownian particles in a homogeneous flow.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Alkaline mineral residues from pulp mills as a sustainable and economical alternative to lime fertilizers

Lime is typically comprised of calcium carbonate (CaCO 3 ) or calcium magnesium carbonate (CaMg(CO 3 ) 2 ) and is needed to maintain a proper pH in agriculture and forestry soils, but it represents a major cost to growers and results in significant greenhouse gas emissions due to the mining, crushing, and transport required. There is a need to identify existing sources of alkaline mineral wastes and assess their potential as sustainable and cost-effective alternatives to lime. Dregs and grits (DGs) are highly alkaline mineral residues from biomass pulp mills that form during the recovery of pulping chemicals and are mostly comprised of CaCO 3 . For the first time, we assess the efficacy of industrially sourced DGs on 22 acidic soils across the Southeastern United States that are currently used in either agriculture or forestry operations. The application of DGs was found on average to result in the same soil pH response as calcite over multiple soil incubations (0 day to 120 days). An analysis of the carbon content of the soils after the incubation revealed that soils incubated with DGs experienced a statistically significant increase in soil carbon relative to control soils and those incubated with CaCO 3 . The generation and application of DGs emits 0.35 tonnes of CO 2 for every tonne of DGs, which compares favorably to the 0.86 tonnes of CO 2 for every tonne of agricultural lime generated and $85 per tonne lime reported in the literature. DGs prove to be a sustainable and economical substitute for agricultural lime in the acidic soils of the Southeastern United States.

54 ENVIRONMENTAL SCIENCES↗