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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

Experimental and numerical investigation of flame stabilization and pollutant formation in matrix stabilized ammonia-hydrogen combustion

Ammonia (NH 3 ) is a carbon-free fuel that offers an attractive alternative for reducing greenhouse gas emissions. However, the slow flame speed, low heating value, and emissions of nitrogen-containing pollutants present significant issues for practical combustion applications. To address these issues, we investigate the use of matrix stabilized combustion. In this type of burner, combustion is performed within an inert porous ceramic foam, heat is recirculated by solid conduction and radiation, which enhances flame speed and combustion stabilization, thereby permitting combustion over a wide range of equivalence ratio conditions. We present a new porous media burner (PMB) capable of stabilizing NH 3 /air flames at ambient conditions. An extensive experimental characterization of the stability of this burner is conducted with up to 30% by volume of hydrogen (H 2 ) in the fuel stream. A 15:1 turndown ratio is demonstrated, with a high thermal power density of 62 MW m -3 . Concentrations of NO, unburnt NH 3 , and H 2 in the exhaust stream are measured. Two regimes are identified for low NO operation: rich and very lean. For rich conditions, NO emissions decrease with increasing equivalence ratio and decreasing H 2 blending. Unburnt NH 3 emissions follow opposite trends. These measurements are complemented by simulations in which the burner is represented by a coupled solid-gas reactor network. In conclusion, this model captures the burner’s pollutant emissions to good accuracy and is used to analyze the mechanisms of pollutant formation.

42 ENGINEERING↗
DOE OSTI2025

Myna: Connecting powder bed fusion build data to simulation tools for digital twin applications

Additive manufacturing (AM), as a digital process, can generate a detailed digital thread linking a part’s design and manufacturing to its operational performance. As AM systems advance, an increasing amount of process data is stored in manufacturing databases. In principle, this data can be utilized by simulation-based digital twin approaches, such as real-time process control and asynchronous post-processing guidance. However, few tools currently exist for systematically integrating digital thread data with computational tools. Here, in this study, we propose a software package, called Myna, for connecting data from powder bed fusion processes to simulation tools. The utility of such a platform is demonstrated using build data from the Oak Ridge National Laboratory Manufacturing Demonstration Facility “Peregrine v2023-10” public dataset to automatically configure and run 54 semi-analytical 3DThesis melt pool simulations, 78 numerical Additive FOAM melt pool simulations, and 3 ExaCA microstructure simulations. The simulated, spatially registered microstructures are then compared directly with electron backscatter diffraction characterization of the corresponding as-built part locations. The resulting simulated microstructure showed variation as a function of process parameters, particularly stripe width; however, the experimental data had little variation between the microstructure texture and grain size resulting from different processing conditions. Analysis of the discrepancies suggest that it is possible a two-phase ferritic-austenitic solidification model is needed to accurately predict grain size and texture for certain stainless steel 316L feedstock compositions under powder bed fusion conditions, providing direction for future research. As illustrated here, due to the number and complexity of the simulations involved in AM process-structure–property predictions, automated methods to connect process data and simulations will remain necessary tools for testing hypotheses and implementing digital twin applications.

Knapp, Gerald L. [Oak Ridge National Laboratory (O↗
DOE OSTI2020

Innovative large overbraided carbon fiber composite beams in historical Friendship Bell Pavilion

The International Friendship Bell Pavilion located in the City of Oak Ridge, Tennessee symbolizes the spirit of the peace and friendship shared by the city of Oak Ridge and city of Naka, Japan. The Bell Pavilion features an 8000-pound bronze cast bell along with futuristic materials and advanced manufacturing technologies. The team has developed innovative overbraided carbon fiber arched beams in conjunction with the bronze bell. Carbon fiber was utilized in these beams because of its lightweight, strong, stiff, and durable characteristics. A sandwich design used a high-performance foam core, overbraided with triaxial carbon fibers. This is the world’s largest overbraided composite structure for parks and recreation. For the first time in such an application, 17 free floating, 33-foot (10 m) long arched carbon fiber composite beams cantilever from a central concrete-steel superstructure over the bronze bell. The arc radius of the bottom of each beam is uniquely different giving an appearance of an open dome when standing underneath the structure.

Parks and Recreation↗
DOE OSTI2022

Transcriptional pathways linked to fetal and maternal hepatic dysfunction caused by gestational exposure to perfluorooctanoic acid (PFOA) or hexafluoropropylene oxide-dimer acid (HFPO-DA or GenX) in CD-1 mice

Per- and polyfluoroalkyl substances (PFAS) comprise a diverse class of chemicals used in industrial processes, consumer products, and fire-fighting foams which have become environmental pollutants of concern due to their persistence, ubiquity, and associations with adverse human health outcomes, including in pregnant persons and their offspring. Multiple PFAS are associated with adverse liver outcomes in adult humans and toxicological models, but effects on the developing liver are not fully described. Here we performed transcriptomic analyses in the mouse to investigate the molecular mechanisms of hepatic toxicity in the dam and its fetus after exposure to two different PFAS, perfluorooctanoic acid (PFOA) and its replacement, hexafluoropropylene oxide-dimer acid (HFPO-DA, known as GenX). Pregnant CD-1 mice were exposed via oral gavage from embryonic day (E) 1.5-17.5 to PFOA (0, 1, or 5 mg/kg-d) or GenX (0, 2, or 10 mg/kg-d). Maternal and fetal liver RNA was isolated (N = 5 per dose/group) and the transcriptome analyzed by Affymetrix Array. Differentially expressed genes (DEG) and differentially enriched pathways (DEP) were obtained. DEG patterns were similar in maternal liver for 5 mg/kg PFOA, 2 mg/kg GenX, and 10 mg/kg GenX (R2: 0.46-0.66). DEG patterns were similar across all 4 dose groups in fetal liver (R2: 0.59-0.81). There were more DEGs in fetal liver compared to maternal liver at the low doses for both PFOA (fetal = 69, maternal = 8) and GenX (fetal = 154, maternal = 93). Upregulated DEPs identified across all groups included Fatty Acid Metabolism, Peroxisome, Oxidative Phosphorylation, Adipogenesis, and Bile Acid Metabolism. Transcriptome-phenotype correlation analyses demonstrated > 1000 maternal liver DEGs were significantly correlated with maternal relative liver weight (R 2 >0.92). These findings show shared biological pathways of liver toxicity for PFOA and GenX in maternal and fetal livers in CD-1 mice. The limited overlap in specific DEGs between the dam and fetus suggests the developing liver responds differently than the adult liver to these chemical stressors. This work helps define mechanisms of hepatic toxicity of two structurally unique PFAS and may help predict latent consequences of developmental exposure.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Effect of strain rate on the deformation of hollow CoS nanoboxes and doubly porous self-assembled films

Nanomaterials with multiscale porosity are attractive as lightweight structural materials because unique deformation mechanisms can be programmed at different length scales. Here, we explore this concept by investigating the mechanics of hollow nanoboxes, as well as films self-assembled from nanoboxes. Hollow CoS nanoboxes with lengths of 900 nm and <30 nm wall thickness are synthesized using colloidal methods. Individual nanoboxes are compressed inside a scanning electron microscope at strain rates of 0.001 s –1 , 0.01 s –1 , and 0.1 s –1 . Nanoboxes are found to have a first peak stress of 15 MPa and loading modulus of ~240 MPa regardless of strain rate. The nanoboxes deform through ductile, plastic bending of side walls at 0.001 s –1 strain rate, while brittle fracture occurs at the higher strain rates. Self-assembly of these nanoboxes results in films with relative density of <0.1. Nanoindentation shows strain rate independent behavior with average modulus and hardness of ~15 MPa and ~230 kPa, respectively. Furthermore, the mechanical behavior of the film is compared to that of the nanobox building blocks, cellular foams and granular materials.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Performance evaluation of a dynamic wall integrated with active insulation and thermal energy storage systems

Thermal energy storage systems in buildings can store cooling/heating energy during non-peak load hours or when renewable energy sources are available for later use when demanded. Using the building envelope as a thermal battery can help to shave the peak load, reduce the burden in electric grids, and enhance the occupant's thermal comfort. Sensible energy storage on wall systems such as thermally activated building systems can provide an active thermal storage strategy. However, most of the stored energy is used through passive means directed by the thermal lag, which can impede the on-demand release of the stored energy. Integrating active insulation systems with building thermal storage systems can increase the flexibility of charging and discharging time and duration. In this study, a wall system equipped with an active insulation system and thermally activated storage system was designed, and its performance on active cooling energy contribution was studied. The performances of energy storage (charging), release (discharging) of the thermal energy storage energy, and the active insulation system were studied separately and together as an integrated system. Results showed that the thermal properties of the thermal energy storage core material and the pipe spacing of both embedded pipes in the thermal energy storage and hydronic pipes used in the active insulation system affected the wall performance the most out of all the tested wall system parameters. During discharging, the heat flux into the wall was as high as 81.92 W/m 2 . This active insulation system's dynamic R-value varied between less than 1ft 2 •°F•h/BTU (0.18 m 2 •K/W) to 98% of the equally thick foam insulation's R-value.

25 ENERGY STORAGE↗
DOE OSTI2026

Preliminary neutronic and thermal analysis of Inertial Fusion Energy systems with a focus on thick liquid wall concepts

This paper provides an assessment of the neutronic behavior of Inertial Fusion Energy systems using the Serpent 2 Monte Carlo code. The study explores different types of reactor concepts, including dry-wall and thick liquid wall systems. In particular, it characterizes the tritium breeding and energy multiplication performance, as well as the effect of long-term irradiation on structural materials. For this purpose, the displacement per atom (DPA) and the gas production rate in structural materials are calculated. A simplified geometry with varying geometrical parameters is used as a representation for the different kinds of devices. Additionally, the case of the HYLIFE-II concept is used to assess modeling inaccuracies arising from certain approximations. A comparison between the simplified geometry and a realistic one is performed, thanks to Serpent’s capability to run transport calculations on unstructured meshes. The study then addresses the impact of these discrepancies on the temperature distribution in the first wall using the GeN-Foam code for conjugate heat transfer analysis. The results highlight the necessity to consider the heterogeneous nature of the liquid wall, as simplified models tend to underestimate radiation damage metrics and heat loads.

Conjugate heat transfer↗
DOE OSTI2020

Platform development for dE/dx measurements on short-pulse laser facilities

We illustrate generating benchmark data on charged-particle stopping power in dense plasma is a challenge, motivating new experimental platforms for facilities such as short-pulse lasers. We report on several experiments that aimed to develop a platform for high-precision stopping power measurements at OMEGA EP, specifically developing target-normal sheath acceleration (TNSA) sources, proton isochoric heating, and radiatively heated foams. Integrated experiments were performed to measure stopping power, but several phenomena have been identified that would need to be mitigated for a stopping-power measurement, including irreproducibility of the TNSA sources, spurious electromagnetic fields around proton-heated targets, and cross-talk between the source and subject targets. This work provides a basis for potential future work towards mitigating these problems and performing stopping-power measurements, and is also valuable data for general understanding of TNSA and proton isochoric heating experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Optimization of a short-pulse-driven Si He-α soft x-ray backlighter

High backlighter brightness is important to maximize the number of detected photons in radiography experiments and to minimize the background while backlighting high-energy density plasmas with strong self-emission. Here, several different configurations were tested to improve the brightness of the Si He-α x-ray line emission at a photon energy of 1865 eV from high-energy (>1 kJ), short-pulse (~20-ps), laser-driven backlighter targets. The emission from low-density SiO 2 foam targets, the effects of a laser prepulse, and Si targets with a CH “shield” that form a small cavity were compared to solid-density, flat Si targets. The CH “shield” targets showed the best performance with a >5× improvement in time integrated emission and an x-ray pulse duration of ~25 ps with no measurable spectral shift of the Si He-α emission line. A conversion efficiency from laser light into Si He-α photons of the order of 1 × 10 –5 was inferred from the data.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

A multiphase flow model of water droplets dielectrophoretic-induced air dehumidification phenomena

Air humidity in indoor spaces plays a critical role in human comfort and health. Dehumidification systems are used for building humidity controls, but they can take significant energy consumption, especially in geographic locations with high outdoor humidity and warm climates. Consequently, there is a growing demand for innovative dehumidification processes that consume minimal energy. Dielectrophoretic air dehumidification represents one such promising approach. However, it has not garnered significant attention due to the absence of engineering models and simulation tools capable of evaluating its performance and limitations at large-scale airflows. A new numerical multiphase CFD model, which is also experimentally validated, is developed in a customized Reacting Foam solver based on OpenFOAM® version 9. The newly developed model seeks to decrease substantial energy consumption and lower costs by leveraging the dielectrophoretic phenomenon to regulate moisture levels in the air. The solver integrates a hybrid Eulerian-Lagrangian framework to track the droplet's trajectory and growth rate while solving the continuum equations for the moist air. An electrospray produces electrically charged droplets, which grow during their in-flight trajectories as water vapor condenses onto their surfaces. The role of electrostatic forces in promoting vapor condensation within a high-gradient electrical field is investigated, and the dielectrophoretic vapor nucleation process on charged water droplets is discussed. The CFD model was validated against results from the literature and from proof-of-concept experiments conducted by the authors, which showed a 2 % air dehumidification with a single electrospray and airflow rate of 5 cubic feet per minute. The simulation results indicated that augmenting the number of electrically charged spray droplets increased the dehumidification of the air to 25 %. The initial mean droplet diameter, the orientation of the injector and relative humidity significantly influence the assessment of dehumidification. As a result, scaling up this approach to larger airflow volumes is identified as a potential future research direction.

42 ENGINEERING↗
DOE OSTI2022

Effective thermal conductivity of insulation materials for cryogenic LH 2 storage tanks: A review

An accurate estimation of the effective thermal conductivity of various insulation materials is essential in the evaluation of heat leak and boil-off rate from liquid hydrogen storage tanks. In this work, we review the existing experimental data and various proposed correlations for predicting the effective conductivity of insulation systems consisting of powders, foams, fibrous materials, and multilayer systems. We also propose a first principles-based correlation that may be used to estimate the dependence of the effective conductivity as a function of temperature, interstitial gas composition, pressure, and structural properties of the material. We validate the proposed correlation using available experimental data for some common insulation materials. Further improvements and testing of the proposed correlation using laboratory scale data obtained using potential LH 2 tank insulation materials are also discussed.

08 HYDROGEN↗
DOE OSTI2026

Two-phase flow numerical analysis of electrode geometry for alkaline water electrolyzers

Hydrogen is a promising component of a future energy-secure and efficient economy, but its competitiveness depends on reducing production costs. One strategy is to operate alkaline water electrolyzers at higher current densities to increase output. However, this intensifies performance losses due to gas bubble accumulation, which blocks transport pathways and deactivates electrochemically active surfaces. Enhancing bubble evacuation through electrode design is therefore essential. Previous studies have explored various approaches — such as modifying surface morphology, applying sonication or pressure modulation, and introducing surfactants — but these efforts have addressed a limited range of conditions due to the complexity of two-phase flow and electrode geometries. Experiments have also largely been focused on either cell level improvements, which lack the information necessary to isolate each contributing factor, or on modified geometries that are not relevant to practical cell operation. From a modeling perspective, conventional Eulerian multiphase models do not track the complex gas–liquid interfacial dynamics and often neglect surface tension and contact angle effects, reducing their predictive accuracy. To provide insights on the effects of different electrode geometries on the performance of alklaine water electrolyzers this work employs an immersed boundary volume-of-fluid method to simulate bubble behavior in 3D porous electrodes. Multiple base electrode geometries, typically used in practice, with varying porosity are evaluated under a constant surface gas generation rate. Simulation data is analyzed to quantify electrode gas coverage, bubble size dynamics and other relevant metrics. Results show that porosity strongly influences bubble accumulation on electrode surfaces, with higher porosity reducing gas coverage, and its not strictly dependent on the electrode geometry. However, the electrode’s base geometry significantly affects gas accumulation at the separator gap, independent of porosity. A foam electrode geometry resulted in the lowest gas coverage of all electrodes with a median volumetric gas coverage of 11%, but at the cost of a 70% reduction in active area compared with the largest surface area electrode, while gyroid electrodes showed the best trade-off between gas coverage, particularly at the separator surface, and electrochemically active area. In conclusion, the results highlight the need for holistic electrode design strategies.

Alkaline↗
DOE OSTI2020

Superior Fischer-Tropsch Performance of Uniform Cobalt Nanoparticles Deposited into Mesoporous SiC

Electrochemically-derived well-crystalline mesoporous silicon carbide (pSiC) was used to host cobalt nanoparticles and to show superior catalytic performance during the CO hydrogenation according to Fischer-Tropsch. Colloidal metal particles (9 ± 0.4 nm) were prepared independently before depositing them into pSiC and, for comparison purposes, into commercially available silica (Davisil) and foam-like MCF-17 supports. The Co/pSiC catalyst demonstrated the highest catalytic activity of 117 ?molCO gCo-1 s-1 at 220 °C in the Fischer-Tropsch reaction, while the silica supported cobalt samples showed about one order of magnitude less activity. A significant increase in the C5+ hydrocarbons selectivity for Co/pSiC was observed. The stable performance of the catalyst is attributed to the high dispersion of the active phase and the use of silicon carbide acting as a thermally conductive and chemically inert porous support.

lablokou, V. S.↗
DOE OSTI2023

Geophysical signatures of soil AFFF contamination from spectral induced polarization and low field nuclear magnetic resonance methods

Few field methods are available for characterizing source zones contaminated with aqueous film forming foam (AFFF). Non-invasive geophysical characterization of AFFF source zone contamination in situ could assist with the delineation and characterization of these sites, allowing for more informed sampling regimes aimed at quantifying subsurface poly- and perfluoroalkyl substances (PFAS) contamination. In this study, we present initial results from the investigation of the sensitivity of two existing surface and borehole-deployable geophysical technologies, spectral induced polarization (SIP), and low field nuclear magnetic resonance (NMR), to soils impacted with AFFF. To investigate the sensitivity of these methods to AFFF-impacted soil, bench-scale column experiments were conducted on samples consisting of natural and synthetic soils and groundwater. While our findings do not show strong evidence of NMR sensitivity to soil PFAS contamination, we do find evidence that SIP has sufficient sensitivity to detect PFAS sorption to soils. This finding is based on evidence that AFFF constituents associated with the pore surface produce a measurable polarization response in both freshly contaminated synthetic soils and in soils historically impacted with AFFF.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

In situ high-temperature Raman spectroscopy for online EAF slag analysis

Real-time monitoring of slag chemistry is critical for optimizing Electric Arc Furnace (EAF) steelmaking operations, where dynamic variations in slag composition directly influence slag foaming, refractory degradation, and thermal efficiency. Conventional techniques such as X-ray fluorescence (XRF), Fourier-transform infrared (FTIR), and scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy (SEM-EDS) are commonly used to analyze slag composition, but their offline nature and equipment constraints limit their applicability for online monitoring in harsh industrial environments. To address this challenge, we present an in situ, high-temperature analytical approach that integrates Raman spectroscopy with a custom designed fiber-optic probe for real-time slag characterization at 1550 °C. The system enables non destructive spectral acquisition from molten slags, providing molecular-level insights into silicate polymerization and iron oxidation states. Eight synthetic slag samples were evaluated, and key Raman features—such as Q n silicate units and FeO₄/FeO₆ coordination environments—were identified and quantitatively correlated with slag basicity and Fe₂O₃ content. The results demonstrate agreement between Raman spectral ratios and bulk slag chemistry, validating the method’s capability to track compositional and structural changes under molten temperature. This work establishes the feasibility of deploying fiber-optic Raman probe for online EAF slag monitoring and highlights their potential to support closed-loop control strategies, thereby enhancing process stability, refractory protection, and steel quality in industrial steelmaking applications.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

A level set approach for the computational study of a yield stress fluid filling a thin mold

Many important engineering and scientific applications such as cement slurries, foams, crude oil, and granular avalanches involve the concept of yield stress. Therefore, modeling yield stress fluids in different flow configurations, including the accurate prediction of the yield surface, is important. In this paper, we present a computational model based on the finite element method to study the flow of yield stress fluids in a thin mold and compare the results with data from flow visualization experiments. Here, we use the level set method to describe the interface between the filling fluid and air. We use polypropylene glycol as a model Newtonian fluid and Carbopol for the model yield stress fluid, as the Carbopol solution demonstrates yielding without thixotropy. To describe the yielding and shear-thinning behavior, we use a generalized Newtonian constitutive equation with a Bingham–Carreau–Yasuda form. We compare the results obtained from the mold filling experiments with the results from the three-dimensional (3D) model and from a reduced-order Hele-Shaw (HS) model that is two-dimensional, including the effect of shear-thinning along the thin direction only approximately. We show that both the 3D and the HS model can capture the experimental meniscus shape reasonably well for all the fluids considered at three different flow rates. This indicates that the shape evolution is insensitive to the dimensionality of the model. However, the viscosity and yield surfaces predicted by the 3D and HS models are different. The HS model underestimates the high viscosity and unyielded regions compared to the estimation by the 3D model.

42 ENGINEERING↗
DOE OSTI2022

Effect of sucrose on the oxidation-reduction conditions and retention of rhenium during vitrification of low-activity waste

Technetium speciation and solubility during nuclear waste vitrification are affected by oxygen partial pressure in the melt. Thus, reducing agents such as sucrose, which are routinely added to nuclear waste feeds to repress foaming, can significantly affect the volatilization of Tc and increase its retention in glass. Using Re as a surrogate for Tc, we measured the effect of sucrose addition to two low-activity waste melter feeds on the Re retention, oxygen partial pressure, and iron redox as functions of temperature. As expected, Re retention in glass increased as the sucrose content increased. Furthermore, this is attributed to sucrose reaction with nitrates and nitrites in the feed. Destruction of nitrates and nitrites reduces the salt phase fraction and thus likely promotes Re diffusion into the glass-forming melt. In agreement with available literature, we discuss that a modest increase in the sucrose content (compared to current practice) can significantly improve the Tc retention without reducing Fe 2+ to metal.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Ultra-stable trimetallic phosphide heterostructure with regulated electronic structure for overall water splitting at high current densities

Developing ultra-stable electrocatalysts for highly efficient overall water splitting at high current density (HCD) is critical for renewable hydrogen/oxygen production in the industry. However, the most active electrocatalysts for large current-driven water splitting are seriously handicapped by insufficient electrical contact kinetics due to the intensive bubble overflow. Herein, we demonstrate the ultra-stable trimetallic phosphides of NiFeP/NiCoP catalysts on a hydrophilic Ni foam skeleton via a corrosion-hydrothermal-phosphating strategy. The optimized NiFeP/NiCoP catalyst stabilizes for 600 h at -1 A cm -2 for hydrogen evolution reaction (HER) and oxygen evolution reaction (OER) in alkaline solution, and it only needs low overpotentials of 237 and 314 mV to drive HER and OER at 1 A cm -2 , respectively. As expected, the optimized NiFeP/NiCoP electrode maintains 1000 h at 0.5 A cm -2 for water splitting, ranking among the top performers among reported catalysts. Such excellent performance could be attributed to the fast electron transfer for electrochemical reactions, the electron-deficient Fe/Ni sites contribute to forming robust metal oxyhydroxide during OER, and electron-rich Co sites facilitate H adsorption during HER. In conclusion, the findings present a highly promising candidate for ultra-stable non-noble metal electrocatalysts, offering a viable option for hydrogen/oxygen supply for fuel cells and metal-air batteries.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗