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At least 559 records · Page 31

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DOE OSTI2023

Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing: Expedited Powder Development in the Area of Aluminum Powder Alloys and their End Use (Final Report)

The overall Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development (“X-P4AM”) project objective is to drastically reduce the time-to-market barriers for new additive alloys of interest in automotive and aerospace applications, through computational alloy design with rapid screening and down- selection via synthesis of candidate alloys with rapid solidification. The project will also refine the technology in high pressure gas atomization to improve the production of commercial quantities of selected powders with high powder yields and enhanced powder quality. A new aluminum (Al) alloy based on high entropy composition, enhanced powder production, and optimized AM build parameterization provided a critical step in widespread adoption of AM technology for automotive applications, in this case. The individual backgrounds and capabilities of the Parties are ideally suited to the successful execution of this work. The included work enhanced the Contractors’ AM capabilities, a core competency of the Contractors, and develop a close working relationship with the Participant in the area of aluminum powder alloys and their end use.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development and Additive Manufacturing Deployment in the Area of Aluminum Alloys for AM Powder Production (Final Report)

The overall Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development and Additive Manufacturing Deployment (“X-P4AM”) project objective is to drastically reduce the time-to-market barriers for new additive alloys of interest in automotive and aerospace applications, through computational alloy design with rapid screening and down- selection via synthesis of candidate alloys with rapid solidification. The project will also refine the technology in high pressure gas atomization to improve the production of commercial quantities of selected powders with high powder yields and enhanced powder quality. A new aluminum (Al) alloy based on an Al-Ce-X composition, enhanced powder production, and optimized AM build parameterization provided a critical step in widespread adoption of AM technology for automotive applications, in this case. The individual background and capabilities of the Party are ideally suited to the successful execution of this work. The included work enhanced the Contractors’ AM capabilities, a core competency of the Contractors, and developed a close working relationship with the Participant in the area of aluminum powder alloys and their end use.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Science-Based Acceleration of the Full Value Stream for Metal Additive Manufacturing: Expedited Powder Development and Additive Manufacturing Deployment in the Areas of Ni-Base Superalloy and Custom Alloy Powders for AM

The overall Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development and Additive Manufacturing Deployment (“X-P4AM”) project objective is to drastically reduce the time-to-market barriers for new additive alloys of interest in automotive and aerospace applications, through computational alloy design with rapid screening and down- selection via synthesis of candidate alloys with rapid solidification. The project will also refine the technology in high pressure gas atomization to improve the production of commercial quantities of selected powders with high powder yields and enhanced powder quality. Production of modified nickel-based superalloys and a Ni-containing alloy based on a high entropy composition, enhanced powder production methods, and optimized AM build parameterization provided critical steps in widespread adoption of AM technology for aerospace applications, in this case. The individual backgrounds and capabilities of the Parties are ideally suited to the successful execution of this work. The included work enhanced the Contractors’ AM capabilities, a core competency of the Contractors, and develop a close working relationship with the Participant in the areas of nickel-based powder superalloys and custom alloys and their end use.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Science-Based Acceleration of the Full Value Stream for Metal Additive Manufacturing: Expedited Powder Development and Additive Manufacturing Deployment in the Areas of Ni-Base Superalloy and Custom Alloy Powders for AM

The overall Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development and Additive Manufacturing Deployment (“X-P4AM”) project objective is to drastically reduce the time-to-market barriers for new additive alloys of interest in automotive and aerospace applications, through computational alloy design with rapid screening and down- selection via synthesis of candidate alloys with rapid solidification. The project will also refine the technology in high pressure gas atomization to improve the production of commercial quantities of selected powders with high powder yields and enhanced powder quality. Production of modified nickel-based superalloys and a Ni-containing alloy based on a high entropy composition, enhanced powder production methods, and optimized AM build parameterization provided critical steps in widespread adoption of AM technology for aerospace applications, in this case. The individual backgrounds and capabilities of the Parties are ideally suited to the successful execution of this work. The included work enhanced the Contractors’ AM capabilities, a core competency of the Contractors, and develop a close working relationship with the Participant in the areas of nickel-based powder superalloys and custom alloys and their end use.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development and Additive Manufacturing Deployment in the Area of Aluminum Powder Alloys

36 MATERIALS SCIENCE↗

NASA NTRS2012

An Examination of Unsteady Airloads on a UH-60A Rotor: Computation Versus Measurement

An unsteady Reynolds-averaged Navier-Stokes solver for unstructured grids is used to simulate the flow over a UH-60A rotor. Traditionally, the computed pressure and shear stresses are integrated on the computational mesh at selected radial stations and compared to measured airloads. However, the corresponding integration of experimental data uses only the pressure contribution, and the set of integration points (pressure taps) is modest compared to the computational mesh resolution. This paper examines the difference between the traditional integration of computed airloads and an integration consistent with that used for the experimental data. In addition, a comparison of chordwise pressure distributions between computation and measurement is made. Examination of this unsteady pressure data provides new opportunities to understand differences between computation and flight measurement.

Biedron, Robert T.↗

NASA NTRS2016

Design of a Two-Stage Light Gas Gun for Muzzle Velocities of 10 - 11 km/s

Space debris poses a major risk to spacecraft. In low earth orbit, impact velocities can be 10 - 11 km/s and as high as 15 km/s. For debris shield design, it would be desirable to be able to launch projectiles of known shape and mass to these velocities. The design of the proposed 10 - 11 km/sec gun uses, as a starting point, the Ames 1.28”/0.22” two stage gun, which has achieved muzzle velocities of 10 - 11.3 km/sec. That gun is scaled up to a 0.3125” launch tube diameter. The gun is then optimized with respect to maximum pressures by varying the pump tube length to diameter ratio (L/D), the piston mass and the hydrogen pressure. A pump tube L/D of 36.4 is selected giving the best overall performance. Piezometric ratios for the optimized guns are found to be ~2.3, much more favorable than for more traditional two stage light gas guns, which range from 4 to 6. (The piezometric ratio for a gun is defined as the maximum projectile base pressure divided by the constant projectile base pressure which, acting over the entire barrel length, would produce the same muzzle velocity.) The maximum powder chamber pressures are 20 to 30 ksi. To reduce maximum pressures, the desirable range of the included angle of the cone of the high pressure coupling is found to be 7.3 to 14.6 degrees. Lowering the break valve rupture pressure is found to lower the maximum projectile base pressure, but to raise the maximum gun pressure. For the optimized gun with a pump tube L/D of 36.4, increasing the muzzle velocity by decreasing the projectile mass and increasing the powder loads is studied. It appears that saboted spheres could be launched to 10.25 and possibly as high as 10.8 km/sec, and that disc-like plastic models could be launched to 11.05 km/s. The use of a tantalum liner to greatly reduce bore erosion and increase muzzle velocity is discussed. With a tantalum liner, CFD code calculations predict muzzle velocities as high as 12 to 13 km/s.

Bogdanoff, David W.↗

DOE OSTI2021

Synergistic foam stabilization and transport improvement in simulated fractures with polyelectrolyte complex nanoparticles: Microscale observation using laser etched glass micromodels

Inaccessibility to direct pore scale observation in hydrocarbon recovery of tight shale formations poses a great challenge to water-energy nexus initiatives and necessitates the use of high throughput technologies to emulate environmentally friendly processes. Herein, we employ a precise glass micromodel fabrication and visualization method to isolate the supercritical CO 2 bubbles surrounded by CO 2 -water lamella prepared in saline produced water stabilized with molecular complexation of zwitterionic surfactants (ZS) and polyelectrolyte complex nanoparticles (PECNP). The Selective Laser Enhanced Etching (SLE) technique was selected for micromodel simulation of high-pressure flow. Two representative designs, (1) fracture/micro-crack network 28 and (2) fracture/matrix were etched on fused silica glass with a laser printing machine and scCO 2 foam was injected to study the foamability, propagation, stability, and fluid loss properties. The highly monodispersed and uniformly distributed array of scCO 2 bubbles were detected in flow of scCO 2 foam in highly saline brine containing ionic complexes of positively charged PECNPs and ZS, whereas foam flow with the lamella containing ZS in fractures offered a noticeably large and polydisperse array of scCO 2 bubbles. scCO 2 bubble motion and deformation were traced, and local description of foam flow was visually examined. The confined array of scCO 2 bubbles stabilized by ZS in microcracks was affected by bubble growth and coalescence, whereas the super-populated array of monodispersed scC O2 bubbles with lamella containing complexes of PECNP and ZS were able to fill the channels with stable configurations within the timeframe of comparative stability measurements. The ability of complex fluid to prevent the formation damage was evaluated through fluid loss visualization in micromodels. Probing scCO 2 foam transport in homogenous porous media revealed smaller volume leak-off for scCO 2 foam containing PECNP-ZS ionic complexes.

04 OIL SHALES AND TAR SANDS↗

NASA NTRS1985

Analysis of cavitation damage on the Space Shuttle main engine high pressure oxidizer turbopump

The performance of the Space Shuttle Main Engines (SSME) has met or exceeded specifications. However, the durability for selected components has not met the desired lifetime criteria. Thus, the High-Pressure Oxidizer Turbopump (HPOTP) has experienced cavitation erosion problems in a number of locations in the pump. An investigation was conducted, taking into account an analysis of the cavitation damage, the development of a flow model for the pump, and the recommendation of design changes which would increase the life expectancy of the unit. The present paper is concerned with the cavitation damage analysis. A model is presented which relates the heavy damage on the housing and over the inducer blades to unsteady blade surface cavitation. This cavitation occurs on the inducer blades in the wakes downstream of the pump inlet housing vanes.

Stinebring, D. R.↗

DOE OSTI2021

Effect of Pressure and Temperature on Carbon Dioxide Reduction at a Plasmonically Active Silver Cathode

Here, carbon dioxide reduction at a plasmonically active silver cathode was investigated by varying the pressure and temperature at multiple applied potentials under both dark and illuminated conditions to understand the mechanism of selectivity changes driven by plasmon-enhanced electrochemical conversion. Carbon dioxide partial pressures (P Co 2 ) from 0.2 to 1 atm were studied during linear sweep voltammetry and chronoamperometry at -0.7, -0.9, and -1.1 V RHE . At a given applied overpotential the total current density increased with increasing P Co 2 in both the dark and the light, but there were significant differences in the Tafel behavior between dark and illuminated conditions. The reduction of CO 2 to carbon monoxide (CO) was found to have first-order behavior with respect to P Co 2 at all applied potentials in both the dark and the light, likely indicating no change in the rate-determining step upon illumination. Activity for the hydrogen (H 2 ) evolution reaction decreased with increasing P Co 2 at slightly different rates in the dark and the light at each applied potential, making it unclear if light is influencing CO or H 2 intermediate adsorbate coverage. Both formate and methanol production showed no dependence on P Co 2 under any conditions, but the true reaction orders may be masked by the much higher activity for CO and H 2 at the silver cathode. The investigation of product distribution with temperature at 14, 22, and 32°C at -0.7, -0.9, and -1.1 V RHE in both the dark and the light demonstrated that the selectivity changes observed upon illumination are not caused by local heating of the cathode surface.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Rhodium‐Catalyzed Oxidative Alkenylation of Naphthalene: Factors That Influence Reaction at the β‐ versus α‐Position

The catalyst precursor [(η 2 -C 2 H 4 ) 2 Rh(μ-OAc)] 2 and in situ oxidant Cu(OPiv) 2 (OPiv = t-BuCOO – ) convert naphthalene and olefins (i.e., ethylene and propylene) to alkenylnaphthalenes. Under all reaction conditions tested, the functionalization is selective for the β-position of naphthalene with the highest observed β:α ratio >20:1. The β-selectivity is catalyst controlled, but oxidant identity, ethylene pressure, and olefin identity influence the ratio of β-alkenylation to α-alkenylation. The concentration of HOPiv and naphthalene do not have an effect on the β:α ratio under the reaction conditions tested. Arenes similar to naphthalene (i.e., o-xylene and 1,2,3,4-tetrahydronaphthalene) give quantitative selectivity for alkenylation at the position β to the substituent. Using propylene as the olefin for naphthalene alkenylation, the β:α ratio is 32(7):1. and the anti-Markovnikov to Markovnikov ratio is 16(2):1.

Alkenes↗

NASA NTRS1984

Advanced on-site power plant development technology program

A 30-cell, full area short stack containing advanced cell features was tested for 2900 hours. A stack acid addition approach was selected and will be evaluated on the stack at 5000 hours test time. A brassboard inverter was designed and fabrication was initiated. Evaluation of this brassboard inverter will take place in 1984. A Teflon coated commercial heat exchanger was selected as the preferred approach for the acid condenser. A reformer catalyst with significantly less pressure drop and equivalent performance relative to the 40-K baseline catalyst was selected for the development reformer. The early 40-kW field power plant history was reviewed and adjustments were made to the On-Site Technology Development Program to address critical component issues.

Source record↗

NASA NTRS1977

Tripropellant engine study

Work conducted was devoted to three main tasks. Thermochemical equilibrium performance data were assembled to establish the expected performance calculations of the mode 1 engine propellant combinations and thermodynamic and transport data for the products of combustion. Turbine drive gas characteristics were also established. Thrust chamber and nozzle cooling studies were devoted to the evaluation of H2, C3H8, CH4, and RP-1 as coolants in the existing SSME cooling circuit geometry. It was found that all these candidate coolants are feasible without limiting the desired operating conditions with the exception of RP-1, which would limit the maximum P(c) to 2000 psia. RP-1 could be used, however, to cool the nozzle only without imposing the chamber pressure limit. A total of 15 candidate engine system cycles were selected and a preliminary engine system balance was conducted for 12 of these systems to establish component operating flowrates, pressures and temperatures. It was found that the staged combustion cycles employing fuel rich LOX/hydrocarbon turbine drive gases are power limited.

Wheeler, D. B.↗

DOE OSTI2024

Bicarbonate-Carbonate Selectivity through Nanofiltration for Direct Air Capture of Carbon Dioxide

Direct air capture (DAC) of carbon dioxide is one approach among many proposed that is capable of offsetting hard-to-avoid emissions. In previous work, we developed the alkalinity concentration swing (ACS) method, which is driven through concentrating an alkaline solution that has been loaded with atmospheric CO 2 by desalination technologies, such as reverse osmosis or capacitive deionization. Though the ACS is promising in terms of energy usage and implementation, its absorption rate and water requirements are infeasible for a large-scale DAC process. Here, we propose an improvement on the ACS, the bicarbonate-enriched alkalinity concentration swing (BE-ACS), which selects bicarbonate ions from a stream of aqueous alkaline solution that has absorbed atmospheric CO 2 . The bicarbonate-rich stream is then concentrated, which greatly increases its CO 2 partial pressure, and then CO 2 is extracted from solution. We experimentally investigate the use of pressure-driven nanofiltration (NF) membrane-based separation to select bicarbonate ions over carbonate ions. We screen commercial membranes and select one high-performance membrane for detailed studies, quantifying its bicarbonate-carbonate selectivity factor and bicarbonate-passage factor. Feed pH, the combined concentration of aqueous CO 2 , bicarbonate, and carbonate species (or dissolved inorganic carbon), alkalinity, and permeation flux are systematically varied to study NF separation properties. We find that the selectivity factor, which exceeds 30 times in certain regimes, increases with higher feed pH and higher alkalinity. Lastly, the performance metrics of the selected NF membrane are input into a theoretical BE-ACS cycle analysis, and the required energy input and cycle capacity output are evaluated. Ideal cycle energy is found to be as low as around 250 kJ/mol, with opportunities identified for further decreases through process engineering and forward osmosis energy recovery.

animal feed↗

NASA NTRS1994

STOVL CFD model test case

The transitional flight characteristics of a geometrically simplified Short Take-Off Vertical Landing (STOVL) aircraft configuration have been measured in the NASA Ames 7- by 10-Foot Wind Tunnel. The experiment is the first in a sequence of tests designed to provide detailed data for evaluating the capability of computational fluid dynamics methods to predict the important flow parameters for powered lift. The model consists of a 60 deg cropped delta wing platform, blended fuselage and two circular in-line jets that exit perpendicularly from the flat lower surface. The measured flows have a maximum freestream Mach number of 0.2. Model angle of attack is varied between -10 and +20 deg. The flow is ambient temperature in both jet exits and the nozzle pressure ratios are varied between 1 and 3. The data presented includes forces and moments, pressures measured at 281 surface pressure ports and the pressures of the jets. Measurements of the flow are also made in the tunnel test section upstream and downstream of the model and at the jet exits to guide boundary condition selection for the planned computations. Flow visualization and total pressure measurements in the jet plumes provide a description of the three-dimensional jet efflux flowfield.

Roth, Karlin R.↗

DOE OSTI2026

A Review on Direct Air Capture of Carbon Dioxide: Sorbent Materials, Process Engineering, Industrial Scale-Up, and Future Perspectives

The relentless accumulation of anthropogenic greenhouse gases has driven atmospheric carbon dioxide concentrations to approximately 426 ppm, necessitating the aggressive deployment of negative-emission technologies to achieve net zero by 2050. Direct air capture (DAC) offers a scalable, location-independent approach to atmospheric carbon removal; however, it is fundamentally constrained by the significant thermodynamic barriers associated with capturing CO 2 from ultradilute ambient conditions, requiring minimum thermodynamic energy inputs substantially higher than those for postcombustion point sources. This comprehensive review critically examines the technological landscape of DAC, focusing on the interdependent triad of sorbent material design, contactor engineering, and regeneration thermodynamics. We evaluate the fundamental boundaries of adsorption, emphasizing that an optimal adsorption enthalpy and isosteric heat of adsorption must balance the high CO 2 uptake capacity with the energetic penalties of sorbent regeneration. A systematic, comparative analysis of state-of-the-art sorbents is presented, encompassing mesoporous silicas, zeolites, carbon-based materials (CBMs), metal−organic frameworks (MOFs), porous organic polymers (POPs), and polymeric membranes. Special attention is devoted to surface functionalization strategies, particularly amine grafting and impregnation, which transition capture mechanisms from physisorption to chemisorption to enhance selectivity under ambient moisture and low partial pressures. Furthermore, we assess the operational merits of various reactor configurations, including gas−solid, gas−liquid, and membrane contactors, alongside regeneration cycles such as temperature, vacuum, pressure, and moisture swing adsorption. Finally, the review bridges fundamental materials science with industrial application by chronicling the scale-up milestones of pioneering entities and providing a strategic roadmap for advancing DAC technology readiness levels toward global deployment.

Adsorption↗

DOE OSTI2024

Aldol condensation of mixed oxygenates on TiO 2

Kinetic studies of aldol condensation of mixtures on TiO 2 reveal strong suppression of acetone self-condensation in the presence of acetaldehyde.

Oliphant, Brandon Elliott↗

NASA NTRS1973

Determination of the temperature of gas mixtures by using laser Raman scattering

A theoretical model for the Raman rotational spectrum of air was formulated, yielding the spectral temperature dependence; and an error analysis of temperature measurement accuracies was performed. The theoretical spectra and the predicted temperature measurement error of + or - 20 K (7 percent) compared well with experimental data. These experimental data consisted of Raman spectra of air obtained for temperatures ranging from 243 to 313 K at a pressure of 1 atmosphere. The use of selected lines resulted in an experimental accuracy of + or - 13 K (-5 percent).

Coney, T. A.↗