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Results for “material flows”

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 505 records · Page 28
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Active learning of a crystal plasticity flow rule from discrete dislocation dynamics simulations

Continuum-scale material deformation models, such as crystal plasticity (CP), can significantly enhance their predictive accuracy by incorporating input from lower-scale (i.e. mesoscale) models. The procedure to generate and extract the relevant information is however typically complex and ad hoc, involving decision and intervention by domain experts, leading to long development times. In this study, we develop a principled approach for calibration of continuum-scale models using lower scale information by representing a CP flow rule as a Gaussian process model. This representation allows for efficient parameter space exploration, guided by the uncertainty embedded in the model through a process known as Bayesian optimization (BO). We demonstrate a semi-autonomous BO loop which instantiates discrete dislocation dynamics simulations whose initial conditions are automatically chosen to optimize the uncertainty of a model CP flow rule. Our self-guided computational pipeline efficiently generated a dataset and corresponding model whose error, uncertainty, and physical feature sensitivities were validated with comparison to an independent dataset four times larger, demonstrating a valuable and efficient active learning implementation readily transferable to similar material systems.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Flow behavior characterization of biomass Feedstocks

With the advancement of renewable energy, the processing and handling of biomass feedstocks has drawn enormous research interest. The key to economically viable and operationally reliable biomass handling processes involves a complete understanding of the flow behavior of different feedstocks as functions of the inherent critical material properties environmental conditions, and critical processing parameters. This review introduces the basic principles and methods in bulk solids flow and highlights recent efforts to understand the flow behavior of biomass feedstocks. The effects of inherent properties, environmental parameters, and handling equipment on the flow behavior of biomass feedstocks are presented. Particle size, shape, moisture, consolidation stress, temperature, storage time at rest, chemical treatment, and the material and geometry of the handling equipment all substantially influence biomass flowability. The limitations of current studies and the potential methods to overcome them are presented. Finally, an outlook for future research effort is provided, with proposed opportunities for improving the characterization of biomass flow.

Bulk solids testing↗
DOE OSTI2024

An integrated high-throughput robotic platform and active learning approach for accelerated discovery of optimal electrolyte formulations

Solubility of redox-active molecules is an important determining factor of the energy density in redox flow batteries. However, the advancement of electrolyte materials discovery has been constrained by the absence of extensive experimental solubility datasets, which are crucial for leveraging data-driven methodologies. In this study, we design and investigate a highly automated workflow that synergizes a high-throughput experimentation platform with a state-of-the-art active learning algorithm to significantly enhance the solubility of redox-active molecules in organic solvents. Our platform identifies multiple solvents that achieve a remarkable solubility threshold exceeding 6.20 M for the archetype redox-active molecule, 2,1,3-benzothiadiazole, from a comprehensive library of more than 2000 potential solvents. Significantly, our integrated strategy necessitates solubility assessments for fewer than 10% of these candidates, underscoring the efficiency of our approach. Our results also show that binary solvent mixtures, particularly those incorporating 1,4-dioxane, are instrumental in boosting the solubility of 2,1,3-benzothiadiazole. Beyond designing an efficient workflow for developing high-performance redox flow batteries, our machine learning-guided high-throughput robotic platform presents a robust and general approach for expedited discovery of functional materials.

25 ENERGY STORAGE↗
DOE OSTI2025

SAVY O-ring characterization for lifetime extension

Los Alamos National Laboratory and Nuclear Filter Technology, Inc. developed the SAVY-4000 nuclear material storage container, named after the designers Stone, Anderson, Viers, and Yarbro. The SAVY 4000 meets the requirements of Department of Energy (DOE) M 441.1-1,2 Nuclear Material Packaging Manual, to protect workers who handle nuclear materials against radiation exposures resulting from the leakage of stored materials. The SAVY-4000 is an innovative and creative design: it can be opened and closed in a few seconds without using torque wrenches and instead only a tire iron or equivalent prying tool; has a built-in, fire-rated filter that prevents the build-up of hydrogen gas yet retains 99.97% of plutonium particulates at 200 ACCM rated flow; and prevents the release of stored materials upon a 12- foot drop.

42 ENGINEERING↗
DOE OSTI2023

The influence of temperature history and flow mixing on the vapor-phase speciation of uranium oxide nanoparticles

The transport of radioactive material following a nuclear event depends heavily on fallout characteristics (e.g., composition, shape, and size), which in turn are controlled by the conditions under which the fallout forms. To this end, we use a novel plasma flow reactor (PFR) to explore how conditions including temperature history and gas mixing influence the chemical speciation and physical characteristics of uranium oxide nanoparticles. The PFR consists of a glass tube attached to an inductively coupled plasma (ICP) torch via an adaptor piece (ring flow injector) located downstream of the plasma-generating RF coil. We increase the gas flow rates from normal ICP operating conditions to higher values both upstream at the RF coil and downstream at the ring flow injector to create four distinct temperature profiles and two distinct gas flow mixing conditions (normal and higher Ar atomic ratios). Ex situ transmission electron microscopy (TEM) analysis is used to determine the crystal structure, morphology, and size distribution of the synthesized particles as a function of temperature and mixing. The particles display a striking dependence on these conditions in terms of the resulting speciation of uranium oxide: lower temperature (higher upstream) and slower cooling (normal downstream with normal Ar atomic ratio mixing) favor the formation of α-UO 3 particles, while faster cooling (higher downstream with higher Ar atomic ratio mixing) and higher temperature (normal upstream) favor the formation of UO 2 particles. The extent of gas mixing dictates particle aggregation: better mixing encourages the particles to aggregate more extensively. Here these results demonstrate the sensitivity of uranium to initial local conditions and can be used to improve our understanding of the kinetics that drive uranium speciation and ultimately inform fallout transport models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Characterizing the Impact of Oligomerization on Redox Flow Cell Performance

Abstract Redox flow batteries (RFBs) are hindered by complex failure modes, particularly crossover through the membrane, resulting in capacity fade and reduced cycling efficiencies. Redox‐active oligomers (RAOs) have recently been proposed for mitigating this phenomenon while maintaining sufficient transport properties; however, to date, few studies have quantified how the chemical and electrochemical properties of RAOs influence their performance in redox flow cells. Here, we demonstrate that oligomeric derivatives of 2,2,6,6‐tetramethylpiperidine 1‐oxyl (TEMPO) exhibit lower diffusivities than the monomeric species but retain facile charge transfer characteristics. The size‐dependent variations in mass transport rates directly translate to differences in flow cell polarization and symmetric cycling performance. Post‐mortem analyses reveal that oligomerization does not meaningfully alter decay processes as evinced by similar capacity fade across all species. Broadly, these findings corroborate and extend upon previously developed relationships between molecular size, electrochemical properties, and flow cell performance.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Catalytic converters having non-linear flow channels

Disclosed is a honeycomb catalyst substrate core having geometrically non-linear flow channels. In an embodiment, the honeycomb catalyst substrate core includes helical flow channels. In another embodiment, the honeycomb catalyst substrate core includes sinusoidal flow channels. In yet another embodiment, the honeycomb catalyst substrate core includes helical plus sinusoidal flow channels. The honeycomb catalyst substrate core comprises a plurality of parallel non-linear flow channels formed along a longitudinal axis of symmetry of the catalyst substrate core, each non-linear flow channel configured such that a turbulent vortical flow occurs during engine exhaust gas flow. Also disclosed is a method for manufacturing a ceramic honeycomb having non-linear flow channels, comprising the steps extrusion soft ceramic material through a die whilst the die moves through six degrees of freedom along its axis of symmetry. Disclosure includes a method for manufacturing a ceramic honeycomb having non-linear flow channels using three-dimensional printing.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Catalytic converters having non-linear flow channels

Disclosed is a honeycomb catalyst substrate core having geometrically non-linear flow channels. In an embodiment, the honeycomb catalyst substrate core includes helical flow channels. In another embodiment, the honeycomb catalyst substrate core includes sinusoidal flow channels. In yet another embodiment, the honeycomb catalyst substrate core includes helical plus sinusoidal flow channels. The honeycomb catalyst substrate core comprises a plurality of parallel non-linear flow channels formed along a longitudinal axis of symmetry of the catalyst substrate core, each non-linear flow channel configured such that eddies occurs during engine exhaust gas flow. Also disclosed is a method for manufacturing a ceramic honeycomb having non-linear flow channels, comprising the steps extrusion soft ceramic material through a die whilst the die moves through six degrees of freedom along its axis of symmetry. Disclosure includes a method for manufacturing a ceramic honeycomb having non-linear flow channels using three-dimensional printing.

Masoudi, Mansour↗
DOE OSTI2021

Advanced Multi-Tube Mixer Combustion for 65% Efficiency (Final Report)

This project targeted advanced low NOx combustion for advanced gas turbines capable of 65%, or greater, efficiency in combined cycle application. This technology advancement has further potential to benefit gas turbines used in coal based IGCC applications with pre-combustion carbon capture and hydrogen as the resulting fuel. The program developed and synthesized the most advanced combustion system capable of achieving low NOX emissions up to turbine inlet temperatures of 3100F while also supporting the load-following needs of a modern grid. The combustion system contributes to the overall gas turbine efficiency goal by setting the maximum cycle temperature achievable for a given NOX level and by minimizing the through-combustor air flow pressure drop. Focus areas for this project targeted maximizing the turbine inlet temperature entitlement, as constrained by emissions considerations. The design also minimized parasitic air flow pressure drop by using advanced cooling techniques and performance materials selections and by minimizing hot surface area. These two technology objectives (maximum, emissions-compliant cycle temperature and minimum air flow pressure drop) were integrated into a prototype design. The primarily analytical project sought to identify the most promising technologies to meet these objectives. Additional critical “jugular” data were obtained from multi-tube mixer tests to realize the potential of leveraging “micro flames” for minimizing overall hot surface area. This data was used, in conjunction with an understanding of advanced material and cooling design technologies, to analytically develop multiple design concepts. Phase I focused on in-depth engineering analysis and design, with minimal supporting laboratory testing to enable a selection of the top three combustion architectures for achieving these overall objectives. Phase II of the program developed the selected design through a combination of sub-scale testing and analytical efforts. Early tests included a cold-flow cascade to establish aerodynamic performance characteristics and a sub-scale fired test at GE Global Research in Niskayuna, NY, to establish cooling and heat transfer characteristics in conjunction with combustion performance. The data from these tests validated the analytical models to ultimately design a full-scale, test article to evaluate at prototypical pressure and temperature conditions at GE Gas Power’s Gas Turbine Technology Laboratory in Greenville, SC. GE Gas Power also developed, tested, and recommended a suitable seal design to be applied to the unique features of the combustor. To assess the technology challenges from prospective future production of the combustor from a ceramic matrix composite material, screening tests of Environmental Barrier Coatings were completed.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Flow-Assisted Selective Mineral Extraction from Seawater

The sustainable production of critical materials from natural sources requires a paradigm shift away from currently used resource-intensive processes. In this paper, we report a single-step, laminar co-flow method (LCM) that leverages non-equilibrium conditions to selectively extract pure Mg(OH) 2 from natural seawater. Conventional seawater-based Mg extraction involves adding individual or a combination of precipitants to obtain Mg(OH) 2 , but the co-existence of Ca 2+ unavoidably results in CaCO 3 impurities requiring additional purification steps. Here we show that the non-equilibrium conditions in LCM achieved using a microfluidics device and by simply co-injecting a NaOH solution with seawater can result in improved selectivity for Mg(OH) 2 unlike in conventional bulk mixing method. The resulting precipitates are characterized for composition and the process yield and purity are optimized through systematic variations of the reaction time and the concentration of NaOH. This is the first demonstration of LCM for selective separation, and as a one-step process that does not rely on novel sorbents, membranes, or external stimuli, it is easy to scale-up. LCM has the potential to be broadly relevant to selective separations from complex feed streams and diverse chemistries—enabling more sustainable materials extraction and processing.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Enhanced Stability and Sensitivity for CA-125 Detection Under Microfluidic Shear Flow Using Polyethylene Glycol-Coated Biosensor

The microfluidic-based point-of-care (POC) diagnostic tool has garnered significant interest in recent years, offering rapid and cost-effective disease detection. There is a growing trend toward integrating microfluidic platforms with biosensors, aligning lab-on-a-chip technologies with POC diagnostic devices. Despite numerous efforts to incorporate biosensors into microfluidic systems, researchers have performed very limited investigations on the stability of biomarker detection when biosensors operate under microfluidic shear flow conditions. Gold nanoparticles (AuNPs) are a widely employed material in capacitive biosensors for antibody immobilization and sensitivity enhancement. However, AuNPs have limitations in providing stable detection of biomarkers within microfluidic shear flow due to their agglomeration nature. This study addresses these limitations by employing 2 kDa polyethylene glycol (PEG) as an intermediate biofunctional layer to immobilize CA-125 antibodies on gold-interdigitated electrodes for the stable and accurate detection of CA-125 antigens. The stabilities and sensitivities of AuNPs and PEG-coated biosensors are evaluated under both static drop and microfluidic shear flow conditions for CA-125 antigen detection. The experimental results demonstrate a capacitive signal response (5660 pF at 10 kHz) 2.2 times higher using the PEG-coated biosensor than the signal (2551 pF at 10 kHz) measured by the AuNP-coated biosensor in the detection of CA-125 antigen–antibody conjugation under static drop conditions, indicating the higher sensitivity of the PEG-coated biosensor. Additionally, the PEG-coated biosensor exhibits better consistency for the CA-125 antigen detection between static drop and microfluidic shear flow conditions (Cp decrease in percentage (ΔCp%↓) = 2.9% at 10 kHz) compared to the electrical signals measured using the AuNP-coated biosensor (ΔCp%↓ = 32.4% at 10 kHz), which suggests that the PEG-coated biosensor demonstrates higher stability for CA-125 antigen detection under microfluidic shear flow conditions. With these significant improvements brought by the PEG-coated biosensor, especially under microfluidic conditions, a substantial hurdle in developing electrical biosensors for POC diagnostic applications has been overcome, expediting further advancements in the field.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Mechanistic Study of Controlled Zinc Electrodeposition Behaviors Facilitated by Nanoscale Electrolyte Additives at the Electrode Interface

Nanoparticle organic hybrid materials (NOHMs) are liquid-like materials composed of an inorganic core to which a polymeric canopy is ionically tethered. NOHMs have unique properties including negligible vapor pressure, high oxidative thermal stability, and the ability to bind to reactive species of interest due to the tunability of their polymeric canopy. This makes them promising multifunctional materials for a wide range of energy and environmental technologies, including electrolyte additives for electrochemical energy storage (e.g., flow batteries) and the electrochemical conversion of CO 2 to chemicals and fuels. Due to their unique transport behaviors in fluid systems, an understanding of the near-electrode surface behavior of NOHMs in electrolyte solutions and their effect on electrochemical reactions is still lacking. In this work, the complexation of zinc (Zn) by NOHMs with an ionically tethered polyetheramine canopy (HPE) (NOHM-I-HPE) was studied using attenuated total reflectance Fourier transform infrared and Carbon-13 nuclear magnetic resonance spectroscopy. Additionally, various electrochemical techniques were employed to discern the role of NOHM-I-HPE during zinc electrodeposition, and the results were compared to those of the electrochemical system containing untethered HPE polymers. Our findings confirmed that NOHM-I-HPE and HPE reversibly complex zinc in the aqueous electrolyte. NOHM-I-HPE and HPE were found to block some of the electrode active sites, reducing the overall current density during electrodeposition, while facilitating the formation of smooth zinc deposits, as revealed by surface imaging and diffraction techniques. Observed variations in the current density responses and the degree of passivation created by the NOHM-I-HPE and HPE adsorbed on the electrode surface revealed that their different packing behaviors at the electrode–electrolyte interface influence the zinc deposition mechanism. The presence of the nanoparticle and ordering offered by the NOHMs as well as the structured conformation of the polymeric canopy allowed the formation of void spaces and free volumes for enhanced transport behaviors. Furthermore, these findings provided insights into how structured electrolyte additives such as NOHMs can allow for advancements in electrolyte design for controlled deposition of metal species from energy-dense electrolytes or for other electrochemical reactions.

25 ENERGY STORAGE↗
DOE OSTI2020

Elucidating the G″ overshoot in soft materials with a yield transition via a time-resolved experimental strain decomposition

Significance The yielding transition in soft materials manifests macroscopically as a reversible transition from solid-like deformation to liquid-like flow under sufficiently large loading or deformation. Despite the ubiquity of materials that exhibit yielding, an understanding of the transition has remained elusive due to experimental limitations of the simple rheological tests typically used to study it. We present here a more thorough understanding of yielding, obtained via an iterative test protocol and analysis that allow for the separation of solid-like and liquid-like behaviors in the response of these materials. We show that yielding is a gradual transition, occurring to an increased extent as the deformation increases.

Donley, Gavin J.↗
DOE OSTI2022

A method for generating moving, orthogonal, area preserving polygonal meshes

A new method for generating locally orthogonal polygonal meshes from a set of generator points is presented in which polygon areas are a constraint. The area constraint property is particularly useful for particle methods where moving polygons track a discrete portion of material. Because Voronoi polygon meshes have some very attractive mathematical and numerical properties for numerical computation, a generalization of Voronoi polygon meshes was formulated that enforces a polygon area constraint. Area constrained moving polygonal meshes allow one to develop hybrid particle-mesh numerical methods that display some of the most attractive features of each approach. It is shown that this mesh construction method can continuously reconnect a moving, unstructured polygonal mesh in a pseudo-Lagrangian fashion without change in cell area/volume, and the method's ability to simulate various physical scenarios is shown. Overall, the advantages are identified for incompressible fluid flow calculations, with demonstration cases that include material discontinuities of all three phases of matter and large density jumps.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Modeling of Sagging for 3D Printed Layers During the Curing Process

Here, a printed layer of silica-enforced poly(dimethylsiloxane)-co-(diphenylsiloxane) is modeled as a two-phase system consisting of air and polymer with an interface set up during the printing process. The structural geometry changes mostly due to the action of surface tension, while all material properties are strongly temperature dependent. Polymer flow is described using equations of the extended Herschel–Bulkley model, with parameters strongly dependent on temperature and degree of curing. Parameters of the model are determined using flow sweep measurements and separate experiments with vertical structure sagging at different temperatures. The curing process is modeled using dependencies between the curing rate, degree of curing, and temperature obtained in studies by differential scanning calorimetry. The developed model is used for simulations of printed structure deformations with different initial and boundary conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A laboratory-scale compression feed screw for characterizing continuous feeding of dense granular materials

Compression feed screws are commonly used in biorefineries for the continuous feeding of biomass feedstock into reactors. Developing methods to assess the feasibility of feeding granular materials in a compression feed screw is critical for reducing solids handling issues during operation. A laboratory-scale compression feed screw has been built to measure critical process parameters of the feeding operation, namely the driving torque and the mass flow rate. The process parameters of two granular materials, microcrystalline cellulose Avicel PH-200 and milled corn stover are measured using the laboratory-scale feeder. The results show that a larger torque is required to feed corn stover than Avicel PH-200, even though the former consists of more compressible particles. Further, the device can capture real-time fluctuations in the process parameters during operation. Here, the laboratory-scale feeder can be used to compare the feeding of different granular materials and the measured parameters can be used to validate predictive models for a compression screw feeding process.

09 BIOMASS FUELS↗