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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 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Laser ultrasonic imaging of subsurface defects with the linear sampling method

Laser ultrasonics is a remote nondestructive evaluation technique suitable for real-time monitoring of fabrication processes in semiconductor metrology, advanced manufacturing, and other applications where non-contact, high fidelity measurements are required. Here we investigate laser ultrasonic data processing approaches to reconstruct images of subsurface side drilled holes in aluminum alloy specimens. We demonstrate through simulation that the model-based linear sampling method (LSM) can perform accurate shape reconstruction of single and multiple holes and produce images with well-defined boundaries. We experimentally confirm that LSM produces images that represent the internal geometric features of an object, some of which may be missed by conventional imaging.

42 ENGINEERING↗
DOE OSTI2020

Fused filament fabrication of polymer composites for extreme environments

Vast improvements have been made to the capabilities of advanced manufacturing (AM), yet there are still limitations on which materials can effectively be used in the technology. To this end, parts created using AM would benefit from the ability to be developed from feedstock materials incorporating additional functionality. A common three-dimensional (3D) printing polymer, acrylonitrile butadiene styrene, was combined with bismuth and polyvinylidene fluoride via a solvent treatment to fabricate multifunctional composite materials for AM. Composites of varying weight percent loadings were extruded into filaments, which were subsequently 3D printed into blocks via fused filament fabrication. Investigating the material properties demonstrated that in addition to the printed blocks successfully performing as radiation shields, the chemical, thermal, and mechanical properties are suitable for AM. Thus, this work demonstrates that it is possible to enhance AM components with augmented capabilities while not significantly altering the material properties which make AM possible.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Assessing atomically thin delta-doping of silicon using mid-infrared ellipsometry

Hydrogen lithography has been used to template phosphine-based surface chemistry to fabricate atomic-scale devices, a process we abbreviate as atomic precision advanced manufacturing (APAM). In this work, we use mid-infrared variable angle spectroscopic ellipsometry (IR-VASE) to characterize single-nanometer thickness phosphorus dopant layers (δ-layers) in silicon made using APAM compatible processes. A large Drude response is directly attributable to theδ-layer and can be used for nondestructive monitoring of the condition of the APAM layer when integrating additional processing steps. Furthermore, the carrier density and mobility extracted from our room temperature IR-VASE measurements are consistent with cryogenic magneto-transport measurements, showing that APAM δ-layers function at room temperature. Finally, the permittivity extracted from these measurements shows that the doping in the APAM δ-layers is so large that their low-frequency in-plane response is reminiscent of a silicide. However, there is no indication of a plasma resonance, likely due to reduced dimensionality and/or low scattering lifetime.

2D material↗
DOE OSTI2020

Low-cost & Energy Dense Batteries for Transportation

The project sought to explore development of novel polymer separator materials and additives for Li-S and Li-ion batteries that would solve critical failure modes and performance bottlenecks for these chemistries. This technology presented significant advanced manufacturing challenges and opportunities in getting to scale, including materials synthesis scale-up, large-area polymer processing techniques, electrode formulation, and the development of coin and pouch cells for electrochemical energy storage. Specific accomplishments included synthesis of organic molecular and polymer materials designed to solve outstanding challenges in electrochemical cells. The primary focus of new materials design was aimed at improving longevity, power, cost reduction, and environmental sustainability of said electrochemical devices. The project also involved assembly and characterization of electrochemical devices with standard galvanostatic and potentiostatic techniques as well as electrochemical impedance spectroscopy.

25 ENERGY STORAGE↗
DOE OSTI2020

Plastics for a Circular Economy Workshop: Summary Report

This report summarizes the results of a public workshop sponsored by the Bioenergy Technologies Office, the Advanced Manufacturing Office, and Mars held on December 11–12, 2019 in Golden, Colorado. The Plastics for a Circular Economy Workshop brought together experts from industry, academia, and national laboratories to discuss opportunities and challenges facing the development of new technologies to address plastic waste.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Inkjet Printing to Scale Perovskite and Silicon Tandem Solar Cell: Cooperative Research and Development Final Report, CRADA Number CRD-17-00690

The proposed project seeks to develop a method for inkjet printing of the active layer in perovskite solar cells for application in stand-alone products or added to conventional silicon solar cells in a mechanically-stacked tandem configuration. This technology presents significant advanced manufacturing challenges and opportunities in getting to scale, including development of novel uses for printing technologies and development of predictive quality control techniques.

14 SOLAR ENERGY↗
DOE OSTI2020

Physical Sciences Vistas (Issue 3 2020)

In this issue, highlights of our outstanding R&D supporting the Laboratory’s nuclear security mission include the following. 1. The essential nuclear materials science contributions of MST’s Materials Properties Team to a range of Lab missions, operations, and initiatives. 2. Work in the Sigma Complex supporting NNSA’s Advanced Manufacturing Development milestones by members of Sigma Division and colleagues across the Laboratory and other NNSA sites. 3. Greg Dale’s role in the Lab’s molybdenum program and today as a technical lead on the Scorpius project. 4. Measurements that reveal the role thermal interfaces play in dynamic compression experiments. 5. The first-ever synthesis of an actinide framework, which offers opportunities for understanding these structures as potential radioactive waste forms and provides new models of actinide species transport in the environment. This issue also showcases, as part of our commitment to simultaneous excellence in mission operations and community relations, the successful high-hazard repair of the LANSCE accelerator, which resulted in a large team Laboratory Distinguished Performance Award, and a virtual Summer Physics Camp for Young Women that brought together participants from around the world, even as COVID kept them socially distant in their homes.

36 MATERIALS SCIENCE↗
DOE OSTI2021

In Situ High Energy X-ray Diffraction Characterization of Phase Transformations and Mechanical Behaviors in Rapidly Solidified Titanium and Stainless Steel Alloys [Thesis]

Advanced manufacturing techniques like additive manufacturing (AM) have poised themselves to revolutionize metal manufacturing. A wide range of AM techniques are capable of manufacturing metal components with unique, complex geometries and hastening the scientific-engineering-development cycle. Metal AM relies on a layer-by-layer rapid manufacturing process to build components from the substrate up. Rapid solidification is a large departure from traditional metal manufacturing due to its complex physics. Characterization of rapid solidification is difficult, stemming from the small volumes used in AM and the fast dynamics of the process. High energy X-ray diffraction (HEXRD) is a solution to the characterization problems of rapidly solidified alloys and AM. HEXRD can probe small volumes at fast rates and provides a wide range of thermomechanical and kinetic information. This thesis presents the application of HEXRD to rapidly solidified titanium and stainless steel alloys through a series of case studies. In the first two studies, HEXRD is applied to rapidly solidified titanium and stainless steel welds. The materials are characterized for their temperature history, phase changes, kinetics, and microstructural evolution. In the next case study, HEXRD is applied to characterize phase changes in elastocaloric NiTi shape memory alloys (SMAs) under thermomechanical load. HEXRD, in conjunction with other tools, is used to explain the superior performance of the additively manufactured SMAs. In the final two case studies, HEXRD is used to measure the mechanical response of AM parts with complex geometries; namely, the octet truss lattice. Diffraction reveals a wide range of materials information about the AM microstructure including unexpected phases, texture, and mechanical response to loading. The mechanical results from HEXRD and then compared with theoretical predictions about the performance of octet truss lattices. Summarily, HEXRD is a diverse tool that is poised to address the complex characterization problems of many aspects of the additive manufacturing process.

36 MATERIALS SCIENCE↗
DOE OSTI2021

TCR Postulated Accident and MHA Dose Assessment

Oak Ridge National Laboratory (ORNL) is engaged in regulatory activities to gain US Department of Energy (DOE) approval to build and operate a small high-temperature gas reactor, the Transformational Challenge Reactor (TCR). ORNL uses advanced manufacturing techniques to produce select reactor components. The TCR is unique in its mission: the reactor’s at-power operating lifetime will be less than one effective full-power day to limit the radiological source term to very low values, thus facilitating approval to operate. The primary regulatory documents governing construction and operation of the facility are NUREG-1537, “Guidelines for Preparing and Reviewing Applications for the Licensing of Non-Power Reactors” and DOE-STD-3009, “Preparation of Nonreactor Nuclear Facility Documented Safety Analysis.” Although this document is not a safety basis document, it provides a conservative indication of the magnitude of onsite and offsite radiological doses for specific scenarios, thus informing future design and regulatory activities. As required by NUREG-1537, scenarios included in this analysis are (1) a worstcase depressurized loss-of-forced-circulation accident, and (2) a maximum hypothetical accident. Details on the analysis of dose consequences with various system configurations are also provided.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Future of Water Infrastructure and Innovation Summit

Energy and water systems are interdependent, and the U.S. Department of Energy (DOE) has invested in energy and water for several years, including the Energy-Water Desalination Hub (led by the National Alliance for Water Innovation, NAWI), and research and development (R&D) in resource recovery from wastewater, among other areas. The Advanced Manufacturing Office (AMO) at the U.S. Department of Energy (DOE) held The Future of Water Infrastructure and Innovation Summit to inform the understanding of future opportunities in the water space. The virtual summit was held on October 27 and 28, 2020. The organizers gathered information from a diverse group of relevant water and wastewater stakeholders representing academia, industry, government, nongovernmental organizations, and local/regional utilities. Topics from Day 1 discussions included: desalination, water and wastewater treatment/recovery, produced water, industrial management of water, and hydropower, conveyance, and water systems.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

INECP Country Engagement Plans and Transformational Events [Slides]

The International Nonproliferation Export Control Program (INECP) harnesses the expertise of the U.S. Department of Energy (DOE) national laboratories to assist partners internationally in implementing and adopting strategic trade control measures that can effectively counter WMD procurement efforts. This presentation includes discussion of work with LANL INECP technical leads to update the engagement plan for Turkey, which involved researching Turkey’s WMD related legal framework, relevant export control agencies, and WMD-relevant industries (e.g. advanced manufacturing and aerospace).

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2021

An Integrated High Pressure SOFC and Premixed Compression Ignition (PCI) Engine System

Components for a transformative, high pressure, intermediate temperature solid oxide fuel cell (SOFC) and premixed compression ignition (PCI) engine system were developed. The resulting system is a 1 MWe natural gas fueled hybrid SOFC and reciprocating internal combustion engine system capable of achieving over 70% electrical efficiency at a cost of $0.87/W. To achieve 70% electric efficiency, the SOFC system operates at 80% fuel utilization; however, when operating at this high level of fuel utilization, fuel to the engine (anode tailgas) is extremely dilute. Accordingly, a substantial portion of the effort focused on development and assessment of the combustion strategy capable of consuming this dilute fuel mixture. The engine testing effort showed that pre-chamber assisted compression ignition provides the best combination of controllability, efficiency and emissions. The engine experiments showed that high efficiency combustion can be achieved with near zero criteria pollutants. It is likely that the engine system could operate with minimal aftertreatment requirements, reducing complexity, cost, and precious metal usage. System level modeling was used to assess the overall efficiency, determine cost and efficiency tradeoffs, and demonstrate the potential to perform load following with the hybrid system. Finally, advanced manufacturing was used to demonstrate the potential to fabricate heat exchangers needed for the hybrid system from low chromium materials, which addresses the issue of chromium poisoning of the SOFC stack material.

03 NATURAL GAS↗
DOE OSTI2021

Advanced Syngas Cleanup Using Radically Engineered Modular Systems

The overall objective of this project was to address key knowledge gaps and develop modular sorbent-based warm syngas cleanup designs that will enable 1- to 5-MW REMS-based plants to be cost-competitive with large state-of-the-art commercial plants utilizing all of our abundant domestic coal reserves. We proposed to develop two potential new desulfurization process designs specifically targeted for REMS plants for combined heat and power or polygeneration from coal gasification. The first design is a modification of our commercially offered dual transport reactor design based Warm-gas Desulfurization Process (WDP) where the transport-reactor regenerator is replaced with a fluidized-bed regenerator. This design leverages the learnings obtained from our pre-commercial demonstration testing of the WDP technology for over 3,000 hours and conclusions from the lessons learned workshop. The second design is a fixed-bed process that leverages the successful composition and chemistry of our WDP sorbent to develop an effective fixed-bed sorbent formulation and fixed-bed process design. These two potential desulfurization process designs have a strong technical likelihood of success and offer the best opportunity to effectively employ design standardization, mass production and advanced manufacturing techniques to enable cost competitiveness for syngas cleanup at smaller scale.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Sandia / IBM Discussion on Machine Learning for Materials Applications [Slides]

This report includes a compilation of several slide presentations: 1) Interatomic Potentials for Materials Science and Beyond–Advances in Machine Learned Spectral Neighborhood Analysis Potentials (Wood); 2) Agile Materials Science and Advanced Manufacturing through AI/ML (de Oca Zapiain); 3) Machine Learning for DFT Calculations (Rajamanickam); 4) Structure-preserving ML discovery of a quantum-to-continuum codesign stack (Trask); and 5) IBM Overview of Accelerated Discovery Technology (Pitera)

36 MATERIALS SCIENCE↗
DOE OSTI2021

Assessment of Cold Spray Technology for Nuclear Power Applications

This report provides an overview of cold spray (CS) technology as it relates to repair and fabrication of metal alloys in the nuclear power industry. CS is a relatively new technology with applications established in other industries (e.g., aerospace, defense), and greater use of CS is anticipated within the nuclear power industry. This report is prepared in support of the United States Nuclear Regulatory Commission (NRC) Action Plan for Advanced Manufacturing Technologies (AMTs) Rev. 1, which includes objectives to identify the AMTs most likely to be used for nuclear power applications that require NRC approval, and to prepare NRC staff to review regulatory submittals containing components manufacturing using AMTs. In addition to providing an overview of CS technology, this report highlights engineering and scientific knowledge gaps of CS and rates the size of the knowledge gaps. It also assesses importance rankings of the knowledge gaps as they relate to several application categories. The application categories considered in this exercise include factory-applied CS for chloride induced stress corrosion cracking (CISCC) mitigation, field CISCC repair, light water reactor (LWR) factory structural fabrication, and LWR field dimensional restoration and corrosion protection. The combination of a knowledge gap size rating and importance ranking for an application can be used to prioritize additional data or information gathering efforts.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

High Temperature CMC Nozzles for 65% Efficiency

GE Gas Power has executed a development project that targeted cooled high-temperature ceramic matrix composite (CMC) nozzles as an innovative turbomachinery component that contributes toward the DOE’s goal for advanced gas turbines that are capable of at least 65% efficiency in combined cycle application. This technology advancement has potential to also benefit gas turbines used in coal-based IGCC applications with pre-combustion carbon capture and hydrogen as the resulting fuel. The development of this technology built upon CMC capability advancements made under earlier DOE programs. The objective for this project was to develop the application of ceramic matrix composite for nozzle application in an industrial gas turbine hot gas path. The CMC component development activity done in this project facilitates high firing temperatures through improved cooling designs and concepts, better sealing, reduced leakage, advanced manufacturing processes to facilitate high performing turbomachinery, and revolutionary component architecture to improve the gas turbine performance in a combined cycle application.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Theory-guided Design of Refractory MPEAs for High-Temperature, Harsh-Service Conditions

Focusing on novel materials for harsh-service environments (oxidation, corrosion, and load), durability, higher operational temperature, and direct impact on power-generation technology, the goal was, using a quantitative theory-guided design approach integrated with high-throughput synthesis and characterization for validation, to accelerate by 50% the development of high temperature, refractory-based multi-principal element alloys (MPEAs) materials platforms (with co-designed oxidation-resistant, self-healing coatings) that demonstrate phase-stable operation with desired properties at 10-20% higher temperatures in oxidizing environments over state-ofthe- art systems (like Ni-stainless steels, i.e., Haynes 282 – used in critical gas turbine applications, and refractory TZM, i.e., molybdenum-rich Mo99.4-Ti0.5-Zr0.08-C0.02 in wt%). Notably, refractory MPEAs may achieve higher operational temperatures with superior creep strength and offer 50-100% larger thermal conductivity (140-170 W/m-K) than Ni-based systems, potentially eliminating active cooling, reducing system weight, complexity, and cost. Achieving this goal addresses DOE material challenges in energy generation and efficiency (higher-temperature operation), reduced lifecycle energy (waste-heat recovery), and accelerating materials development in support of AMO’s Strategic Plan and QTR goals. DOE’s Advanced Manufacturing Office (AMO) goal of reducing industrial energy intensity and GHG emissions is addressed by development of coated refractory MPEAs exhibiting 20%+ higher operational temperature (direct increase of Carnot efficiency), higher melting temperatures (better phase stability), superior creep strength (better lifetime with creep rate lower by factor of 10), larger (50-100%) thermal conductivity (improved cooling without active cooling), reduced complexity (single-phase alloys), self-healing coating (reliable oxidation-resistance) and cost.

36 MATERIALS SCIENCE↗