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At least 541 records · Page 30

Thermal Pressure in the Thermal Equation of State for Solid and a Proposed Substitute

Abstract The thermal equation of state (TEOS) for solids is a mathematic model among pressure, temperature and density, and is essential for geophysical, geochemical, and other high pressure–temperature (high P–T) researches. However, in the last few decades, there has been a growing concern about the accuracy of the pressure scales of the calibrants, and efforts have been made to improve it by either introducing a reference standard or building new thermal pressure models. The existing thermal equation of state, P ( V , T ) = P ( V , T 0 ) + P th ( V , T ), consists of an isothermal compression and an isochoric heating, while the thermal pressure is the pressure change in the isochoric heating. In this paper, we demonstrate that, for solids in a soft pressure medium in a diamond anvil cell, the thermal pressure can neither be determined from a single heating process, nor from the thermal pressure of its calibrant. To avoid the thermal pressure, we propose to replace the thermal pressure with a well-known thermal expansion model, and integrate it with the isothermal compression model to yields a Birch–Murnaghan-expansion TEOS model, called VPT TEOS. The predicted pressure of MgO and Au at ambient pressure from Birch–Murnaghan-expansion VPT TEOS model matches the experimental pressure of zero (0) GPa very well, while the pressure prediction from the approximated Anderson PVT TEOS exhibit a big deviation and a wrong trend.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Shock Response of Commercial Purity Polycrystalline Magnesium Under Uniaxial Strain at Elevated Temperatures

Here, results of plate impact experiments designed to investigate the onset of incipient plasticity in commercial purity polycrystalline magnesium (99.9%) under weak uniaxial strain compression and elevated temperatures up to melt are presented. The dynamic stress at yield and post yield of magnesium, as inferred from the measured normal component of the particle velocity histories at the free (rear) surface of the target plate, are observed to decrease progressively with increasing test temperatures in the range from 23 to 500 °C. At (higher) test temperatures in the range 500–610 °C, the rate of decrease of dynamic stress with temperature at yield and post-yield in the sample is observed to weaken. At still higher test temperatures (617 and 630 °C), a dramatic increase in dynamic yield as well as flow stress is observed indicating a change in dominant mechanism of plastic deformation as the sample approaches the melt point of magnesium at strain rates of ~105/s. In addition to these measurements at the wavefront, the plateau region of the free surface particle velocity profiles indicates that the longitudinal (plastic) impedance of the magnesium samples decreases continuously as the sample temperatures are increased from room to 610 °C, and then reverses trend (indicating increasing material longitudinal impedance/ strength) as the sample temperatures are increased to 617 and 630 °C. Lastly, electron back scattered diffraction analysis of the as-received and annealed pre-test magnesium samples reveal grain coarsening as well as grain re-orientation to a different texture during the heating process of the samples.

36 MATERIALS SCIENCE↗

Electrochemical grand potential-based phase-field simulation of electric field-assisted sintering

Here, an electrochemical grand potential functional was proposed to describe the sintering of an ionic ceramic green body. The resultant phase-field description enables simulation of the consolidation of an arbitrary number of granular particles and their interactions with the surrounding void phase. The model includes the effects of charged vacancies and the associated interactions between internal and applied electric fields. Defect segregation to grain boundaries is also accounted for, as well as enhanced interfacial defect mobilities. The model was parameterized for Y 2 O 3 . Simulations of two-particle systems showed that the applied electric field had an increasingly important impact on neck growth as particle size increased. A sudden rapid increase in temperature occurred for larger field strengths, which has been reported to be correlated to the onset of a flash event in flash sintering. Simulations of many particles showed that internal heat generation by Joule heating was localized at particle–particle contacts (grain boundaries), even though their conductivities were lower than nearby internal particle-void interfaces. A percolative path for ionic charge across the green body and the ceramic sintered solid was thus defined, accelerating the Joule heating process as the porosity of the green body is removed.

36 MATERIALS SCIENCE↗

Electrification potential of U.S. industrial boilers and assessment of the GHG emissions impact

Electrification is a key strategy for decarbonizing the industrial sector. Industrial process heating, which still relies heavily on fossil fuel combustion and accounts for the majority of sector wide GHG emissions, is a particularly attractive electrification target. Electrifying industrial boilers represents a cross-cutting opportunity for GHG emissions reductions, given their widespread use in most manufacturing industries. Yet, there are gaps in the understanding of the current population of conventional industrial boilers in the United States that preclude a characterization of boiler electrification's technical potential to reduce fuel consumption and GHG emissions. In this study, we develop an up-to-date dataset of the industrial boiler population in the U.S. and quantify the county-level electricity requirements and net changes in fuel use and GHG emissions under the current electric grid and theoretical future grid scenarios. Our results show an increase of 105 MMmtCO 2 e and 73 MMmtCO 2 e in GHG emissions from boiler electrification, with and without the replacement of byproduct fuels, respectively, under the current electric grid, and a reduction of 19 MMmtCO2e and 7 MMmtCO2e in GHG emissions under a future high renewables electric grid. GHG emissions savings are currently possible only in certain regions of the U.S. unless future grids are decarbonized. We also provide discussion that could be useful for policy makers and manufacturing facilities for advancing the electrification of industrial boilers in locations and industries toward fuel savings and GHG emissions reductions.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Mechanical properties and strain localization of WA-DED printed P91 steel

This paper discusses a P91 steel block that was additively manufactured by wire arc direct energy deposition (WA-DED) followed by two types of post-process heat treatment (PPHT). Vickers microhardness and digital image correlation tensile tests were performed along the building direction. The global mechanical properties (i.e., microhardness and tensile properties) and the local mechanical responses (i.e., hardness fluctuation and strain localization) were systematically investigated. Results showed that (1) all P91 specimens showed higher strengths than American Society of Mechanical Engineers standard requirements for wrought P91 steel, (2) the as-printed P91 exhibited much higher average hardness and fluctuations than that after PPHT, (3) PPHT reduced P91 strengths but improved the ductility significantly, and (4) strain localization presented in the as-printed specimen during uniform deformation in tensile tests. The hardness fluctuation and strain localization along the building direction of the AP P91 were caused by different thermal histories received during WA-DED. The study indicated that PPHT, ideally tempering-only heat treatment, is necessary for the WA-DED printed P91 steel.

Mechanical properties↗

Multi-scale characterization of supersolidus liquid phase sintered H13 tool steel manufactured via binder jet additive manufacturing

Additive manufacturing (AM) of H13 tool steel by binder jet 3D printing (BJ3DP) followed by pressureless supersolidus liquid phase sintering (SLPS) provides a low-cost alternative manufacturing method for components with intricate geometric features. However, the microstructure-mechanical property relationships for BJ3DP-SLPS produced H13 tool steel are not well understood, which makes it challenging to develop printing and post-processing methods that maximize part performance. In this work, we leverage atom probe tomography and transmission electron microscopy along with thermodynamic calculations to rationalize the microstructure-mechanical property relationships in as-sintered BJ3DP H13 tool steel. Here, we report for the first time, the presence of a continuous eutectic film-like carbide in H13 along with the more commonly observed cuboidal MX carbides in the prior liquid channels of the microstructure. Further, atom probe tomography revealed the interconnected nature of the MX carbides that appear to be discrete in two-dimensional micrographs. These continuous eutectic carbides and interconnected MX carbides result in brittle failure of the material. Characterization of these microstructural features will be critical in developing appropriate post-processing heat treatments for the improved mechanical performance of BJ3DP H13.

36 MATERIALS SCIENCE↗

Exploring the tempering behaviour of additively manufactured high-alloy tool steel using synchrotron X-ray and neutron techniques

Post-processing heat treatment provides a critical pathway toward the commercialisation of additively manufactured (AM) S390 high-speed steel, which is a representative high-alloy tool steel employed in precision manufacturing, offering up to 1.5 times longer tool life and over 20% higher cutting speeds compared to conventional grades. In this study, the phase evolution of AM S390 steel during heat treatment, with particular emphasis on carbide precipitation behaviour, was systematically investigated using a combination of synchrotron X-ray and neutron techniques. The metastable M2C carbides were found to dissolve during austenitisation, while the stable primary carbides MC and M6C experienced coarsening with an average size increase of about 60 nm after just 2 min of tempering. Moreover, the austenite lattice parameters reduced from 3.618 to 3.608 Å within the first 10 min of tempering, suggesting carbon depletion in the steel matrix was likely associated with the formation of secondary carbides. This interpretation was substantiated by small-angle scattering results, which revealed the presence of nanoscale precipitates with a volume fraction of 3.1% after 60 min of tempering. These microstructural evolutions collectively accounted for the observed peak hardness of 921 HV. Furthermore, a comparative analysis of synchrotron and neutron small-angle scattering data highlighted the complementary strengths of each technique, offering critical insight into their suitability for characterising nanoscale features in AM high-alloy steels.

Synchrotron X-ray diffraction↗

System design and analysis of thermal power dispatch systems for boiling water reactors

Nuclear power plants are crucial to meeting net zero emission goals and achieving energy sustainability. Integrating these plants with clean energy technologies such as high-temperature steam electrolysis (HTSE) may improve the efficiency and economic competitiveness of these plants. Here, the current study investigates the design and operation of a thermal power dispatch (TPD) system for coupling boiling water reactors (BWRs) to HTSE plants. The TPD system extracts a portion of the steam from the reactor’s main steam line and transfers its thermal energy to an HTSE plant through a power transport loop. A TPD system for 5 % steam extraction has been designed and the system performance during steady and transient operations has been analyzed. The TPD system dispatched a total of 197 MW thermal energy to the HTSE plant under nominal design conditions. Saturated steam at 7.17 MPa from the BWR plant was condensed and subcooled to a temperature of 168 °C, while a mass flow rate of 91.1 kg/s of superheated steam was dispatched to the HTSE plant. Furthermore, the system performance during transient operation showed a continuous transition from the initial hot standby mode to the nominal power dispatch level. The transient simulation results emphasized the importance of investigating component level performance for the TPD system design. The current results will guide future works on the development of integrated energy systems for hydrogen production or process heat applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Experimental evaluation of a prototype hybrid CPV/T system utilizing a nanoparticle fluid absorber at elevated temperatures

Novel approaches for solar energy conversion continue to garner interest as a potential thermal and electrical energy source. Additionally, the need for systems capable of producing thermal energy at temperatures up to 300 °C is growing as a means to provide process heat to industry and distributed generation for small communities. An approach that has seen recent increased interest is the hybrid concentrating photovoltaic/thermal collector that can co-produce electricity and heat energy above 100 °C. A technique for this is to use nanoparticles in the heat transfer fluid to spectrally filter off wavelengths poorly utilized by the photovoltaic component. Here, we have demonstrated the first on-sun operation of a nanoparticle based hybrid CPV/T solar collector at temperatures exceeding 100 °C using a combination of gold and indium tin oxide nanoparticles in Duratherm S flowing in the receiver, with an aperture area a full order of magnitude larger than other tests. At 14× concentration the system achieved a photovoltaic efficiency of 4% while achieving a peak thermal efficiency of 61% with an outlet temperature of the fluid of 110 °C.

14 SOLAR ENERGY↗

Technical and economic feasibility of solar flat-plate collector thermal energy systems for small and medium manufacturers

Manufacturing industries require process heating for a wide variety of operations, such as drying, cooking, washing, and sterilizing. Studies of industrial energy consumption have shown that more than 50% of industrial heating demand is in the low (<60 °C), medium (60-150 °C), and medium-high (<250 °C) temperature ranges. A significant fraction of this low temperature thermal energy could be generated by commercially available solar flat-plate collector thermal energy systems, which would reduce the use of fossil fuels, energy cost volatility, and carbon emissions. However, manufacturing industries have not been able to take advantage of solar flat-plate collector systems for two main reasons: First, information is not readily available about when and what flat-plate collector system sizes can be economically applied and, second, manufacturers often do not have appropriate personnel or analysis tools to make decisions about installation of solar flat-plate collector systems. The goal of this research is to provide design decision support to small- and medium-sized manufacturers in conducting feasibility analysis for the application of solar flat-plate collector systems in their operations. The $\bar{φ}, f$-chart method and modified $\bar{φ}, f$-chart design method are used to predict the amount of energy collected by solar flat-plate collectors. A simplified model is proposed to assess the cost of solar flat-plate collector energy systems. To demonstrate the presented feasibility analysis methodology, a decision support software application is developed. What-if scenarios are presented for several geographic locations of varying climates. A sensitivity analysis of savings-to-investment ratio (SIR) was performed by changing selected input parameters by ±30% from the base case. It was found that SIR is sensitive to natural gas price, followed by collector area dependent cost, discount rate, cost of the auxiliary gas heater, and cost of the preheating system.

14 SOLAR ENERGY↗

How low can you go? The importance of quantifying minimum generation levels for renewable integration

One of the significant limitations of solar and wind deployment is declining value caused by the limited correlation of renewable energy supply and electricity demand as well as limited flexibility of the power system. Limited flexibility can result from thermal and hydro plants that cannot turn off or reduce output due to technical or economic limits. These limits include the operating range of conventional thermal power plants, the need for process heat from combined heat and power plants, and restrictions on hydro unit operation. To appropriately analyze regional and national energy policies related to renewable deployment, these limits must be accurately captured in grid planning models. In this work, we summarize data sources and methods for U.S. power plants that can be used to capture minimum generation levels in grid planning tools, such as production cost models. We also provide case studies for two locations in the U.S. (California and Texas) that demonstrate the sensitivity of variable generation (VG) curtailment to grid flexibility assumptions which shows the importance of analyzing (and documenting) minimum generation levels in studies of increased VG penetration.

17 WIND ENERGY↗

Performance response of packed-bed thermal storage to cycle duration perturbations

Packed-bed thermal stores are integral components in numerous bulk electricity storage systems and may also be integrated into renewable generation and process heat systems. In such applications, the store may undergo charging and discharging periods of irregular durations. Previous work has typically concentrated on the initial charging cycles, or on steady-state cyclic operation. Understanding the impact of unpredictable charging periods on the storage behavior is necessary to improve design and operation. Here in this paper, the influence of the cycle duration (or 'partial-charge' cycles) on the performance of such thermal stores is investigated. The response to perturbations is explained and provides a framework for understanding the response to realistic load cycles.

14 SOLAR ENERGY↗

Life-cycle analysis of fuels from post-use non-recycled plastics

Plastic-to-fuel (PTF) technology uses pyrolysis to convert plastic waste—especially non-recycled plastics (NRP)—into ultra-low sulfur diesel (ULSD) fuel. To assess the potential energy and environmental benefits associated with PTF technology, we calculated the energy, water consumption, and greenhouse gas emissions of NRP-derived ULSD and compared the results to those metrics for conventional ULSD fuel. For these analyses, we used the Greenhouse gases, Regulated Emissions and Energy use in Transportation (GREET®) model. Five companies provided pyrolysis process product yields and material and energy consumption data. Co-products of the process included char and fuel gas. Char can be landfilled, which, per the company responses, is the most common practice for this co-product, or it may be sold as an energy product. Fuel gas can be combusted to internally generate process heat and electricity. Sensitivity analyses investigated the influence of co-product handling methodology, product yield, electric grid composition, and assumed efficiency of char combustion technology on life-cycle greenhouse gas emissions. The sensitivity analysis indicates that the GHG emissions would likely be reduced up to 14% when it is compared to conventional ULSD, depending on the co-product treatment method used. NRP-derived ULSD fuel could therefore be considered at a minimum carbon neutral with the potential to offer a modest GHG reduction. Moreover, this waste-derived fuel had 58% lower water consumption and up to 96% lower fossil fuel consumption than conventional ULSD fuel in the base case. In addition to the comparison of PTF fuels with conventional transportation fuels, we also compare the results with alternative scenarios for managing NRP including power generation and landfilling in the United States.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Conversion of food waste to renewable energy: A techno-economic and environmental assessment

Increasing quantities of food waste have become a concern due to high disposal costs in landfills and high greenhouse gas emissions. With this increase in food waste generation, there is also an increasing demand for renewable natural gas to supplement traditional fossil fuel combustion and offset the impacts of climate change. Collecting food waste from landfills and turning it into renewable natural gas using anaerobic digestion could be a win-win option for both food waste disposal and renewable energy production. While some literature exists on the energy potential, economic feasibility, and environmental benefit of food waste disposal via anaerobic digestion, no existing study simultaneously evaluates the energy, economic and environmental effect of food waste to renewable energy via anaerobic digestion, especially on a plant and city scale. Further, this study is focused on the techno-economic and environmental assessment of food waste to energy via anaerobic digestion in order to fill this gap. Four anaerobic digestion pathways are considered in this study: flare, pipeline natural gas, combined heat and power, and combined cycle for efficient power generation. Using a city of 1M people the results show that renewable natural gas from food waste could supply the natural gas usage for 1.9% of residential use, 2.7% of commercial use, 1.1% of industrial use, 167.5% of the compressed natural gas vehicle fleet, 0.7% of electric power generation, or 2.5% of industrial high-temperature heating processes. All pathways except pipeline natural gas will have a positive net present value in the baseline scenario, and the pipeline natural gas pathway will become economically viable with a net present value of 31 USD/t of food waste with renewable energy credits. Lastly, all of the pathways achieve negative greenhouse gas emissions, which indicates that anaerobic digestion is a more environmentally friendly method for the handling of food waste than landfills.

03 NATURAL GAS↗

Microstructural heterogeneities in additively manufactured refractory alloy C103 and their implications for room and elevated temperature mechanical behavior

Considering the vast component design space enabled by fusion-based additive manufacturing (F-BAM) processes, e.g., directed energy deposition (DED), the scale-up manufacturing of Nb-alloys with F-BAM is advantageous for structural applications. However, varying thermokinetic parameters-induced microstructural heterogeneities are prevalent within the F-BAM processed alloys. Such microstructural heterogeneities can have significant implications for the room and elevated temperature mechanical behavior. While a few studies investigating F-BAM processed alloy C103 are available, none of these studies investigate the microstructural heterogeneities – including those associated with solidification growth modes and second phase particles – and the effect thereof on the mechanical behavior. To this end, we investigate the microstructurally heterogeneous regions with varying solidification growth morphologies, segregation behavior, and second phase particle attributes within the laser-DED processed alloy C103. The implications of such heterogeneous regions for room- and elevated-temperature tensile behavior and damage mechanisms are revealed. Particularly, the interface between the cellular and planar region is identified as susceptible to deformation localization. The implications of hot isostatic pressing (HIP) for the consolidation behavior, microstructural evolution, and resulting mechanical behavior are also discussed. Although the recrystallization and grain growth led to a reduced yield strength in the HIPed condition, the homogenization of microstructure alleviated the deformation localization sites, such as the planar/cellular interface within the melt pool. The homogenized microstructure alongside the enhanced consolidation upon HIP led to an enhanced elongation to failure. Findings establish microstructural design considerations in F-BAM processed Nb alloys and also facilitate design of post-processing heat treatments for achieving improved mechanical properties.

36 MATERIALS SCIENCE↗

Laser powder bed fusion of ODS Fe–Cr–Al (0.3Zr, 0.3Y 2 O 3 ): Unveiling processing-microstructure- mechanical property relationships

Here, this study investigates the fabrication of oxide dispersion strengthened (ODS) Fe-Cr-Al alloys via laser powder bed fusion (LPBF) with strategic additions of 0.3 wt% Zr and 0.3 wt% Y 2 O 3 for enhanced mechanical performance in nuclear applications. Systematic processing parameter optimization yielded three distinct conditions: one low-density product with significant defects and two near-full-density materials with improved consolidation. Comprehensive characterization confirmed single-phase α-ferrite matrix formation with successful incorporation of Y-, Zr-, O-, and C-rich precipitates characteristic of ODS alloys. However, precipitate density remained low (∼10 7 cm −3 ), resulting in sink strength values substantially below optimal levels for radiation resistance. Microhardness values (mid-200s HV) correlated inversely with grain size following the Hall-Petch relationship, indicating grain boundary strengthening as the dominant mechanism rather than precipitation strengthening. The optimized processing conditions achieved excellent mechanical properties with room temperature yield strength of approximately 500 MPa and 30 % elongation, demonstrating superior strength-ductility synergy compared to other additively manufactured ODS materials and performance consistent with literature values for LPBF-processed ODS-FeCrAl alloys. This investigation reveals both the potential and limitations of LPBF processing for ODS Fe-Cr-Al alloys. While successful defect-free fabrication was achieved, results highlight the critical need for systematic optimization of processing parameters and post-processing heat treatments to enhance precipitate density for effective dispersion strengthening and radiation resistance while maintaining additive manufacturing advantages.

Additive manufacturing↗

Innovative laser-based methods for monitoring fuel retention in ITER

This paper addresses the challenge of tritium inventory management in ITER and future fusion reactors, highlighting the importance of accurate tritium measurement and its spatial distribution within the vacuum vessel. Given ITER’s operational constraints, especially the limit on tritium retention, precise measurement is essential for both safety and regulatory compliance. To tackle these questions, the paper presents the T-monitor diagnostic system developed by Forschungszentrum Jülich, which uses Laser-Induced Desorption (LID) in combination with Diagnostic Residual Gas Analysis (DRGA) to measure hydrogen isotope concentrations on the surface of divertor tiles. The system integrates a high-power laser, advanced optical components, and a Fast Scanning Mirror Unit (FSMU) for accurate laser spot positioning with rapid response. Designed to measure in situ tritium retention, the diagnostic provides high-resolution spatial mapping, vital for evaluating detritiation strategies. The laser heating process increases the divertor surface temperature to 1600 K within the laser spot, promoting hydrogen isotope desorption. Accurate measurements require the precise control of laser parameters, including pulse duration and spot size, with a target relative accuracy of 20%. The optical design includes both in-vessel and ex-vessel components, such as durable high-reflectivity mirrors made of gold and copper, selected not only for their infrared performance but also for their transmission of visible wavelengths for observation purposes. To protect optical components from contamination, a pneumatic shutter is used.

Hydrogen isotopes↗

Optimal design of phase change material storage for steam production using annual simulation

A direct steam generation (DSG) solar collector can be an efficient process-heat application compared to electricity generation, and it can significantly reduce dependence on non-renewable energy sources for steam generation. Due to intermittency of the sun, thermal energy storage is required to increase the capacity factor or the yearly utilization of the system. For this study, phase change material (PCM) is used to store the heat from the steam produced in the solar collector. Sodium formate is selected as the PCM material on a cost basis. A detailed off-design analysis is carried to predict the annual performance of the system. Fins are used to enhance the thermal performance of the PCM, and an simplified method is derived to predict the required fin mass. With an increase in the number of fins, the thermal performance of the system increases significantly at design point. Furthermore the fins are expensive, so an annual simulation and techno-economic analysis is carried to calculate the optimal number of fins and other operating parameters.

14 SOLAR ENERGY↗