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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 685 records · Page 38

Scale-up of Next Generation Nano-Enhanced Composite Materials for Longer Lasting Consumer Goods

The objective for this project was to create an industrial-scale manufacturing operation for Vertically Aligned Carbon Nanotube Forests (VACNTs), which make up N12 Technologies’ (N12) NanoStitch® product, a prepreg additive that makes advanced composites tougher, lighter, and more durable. This was achieved using University of Dayton Research Institute’s (UDRI) 60-inch Nano Adaptive Hybrid Fabric (NAHF-X) reactor system. N12 had a unique and effective nanomaterial-based product that they were manufacturing on small-scale 1-inch wide substrate machines in Boston, MA. UDRI had a large-scale 60-inch wide nanomaterial growth reactor available for scaling up 2nd party products in Dayton, OH. Thanks to the successful cooperation between both parties, this project resulted in the world’s first industrial-scale continuous VACNT film pilot plant in Dayton, OH with an increase in VACNT supply production rate of >10X. This scale up enabled market validation via testing programs and pilot manufacturing operations with a number of customers.

36 MATERIALS SCIENCE↗

Comparison of DTRA/NACT Next Generation Digitizer Evaluations

Sandia National Laboratories has tested and evaluated three digitizers, the Affinity, manufactured by Guralp Systems, the Centaur, manufactured by Nanometrics, and the Q330M+, manufactured by Quanterra, a division of Kinemetrics. These digitizers are used to record sensor output for seismic and infrasound monitoring applications. The purpose of this document is to highlight various results and observations collected during comprehensive evaluations conducted on each unit.

42 ENGINEERING↗

Microbiome to Function: Next Generation Eco-Microbiology Workshop Report

The Biological and Environmental Research (BER) program champions the predictive understanding of complex biological systems to enable energy and infrastructure security. To support this challenging endeavor, BER began funding Science Focus Area (SFA) projects at the national labs a decade ago in order to foster scientific advances that are more easily achieved by sustained team research. BER has recently encouraged collaboration among SFAs as a means to accelerate innovation and scientific impact. To facilitate BER’s vision, the Bioscience Division at Los Alamos National Laboratory (LANL) proposed an annual pan-SFA workshop that would rotate among the National Labs. LANL hosted the first workshop in September 2019 to explore a common challenge—understanding how microbiomes function—and to promote collaboration opportunities among SFAs in BER’s Microbial Genomics Program. The workshop comprised overview presentations of the eight SFAs and two SFA pilots and discussions of near- and midterm opportunities to foster collaboration. These opportunities include 1) sharing isolates, 2) sharing data and storage, 3) establishing common standards and best practices, and 4) fostering scientific exchanges.

59 BASIC BIOLOGICAL SCIENCES↗

Plasma Processing of SRF Cavities for the Next Generation of Particle Accelerators

What are the major goals of the project? Goal 1: Optimize interactively processing of the single-cell cavity by combining plasma treatment and vertical cold bath testing. Continue using single cell cavity as the test bed for new applications. Goal 2: Work on upgrading the plasma etching technology for multi-cell SRF cavities. Goal 3: Develop and adapt discharge configurations to critical cavity regions including the electron beam weld (EBW) and iris areas. Goal 4: Develop tailored methods to prepare surface properties for a specific function prior to any additional modification, such as (but not limited to) surface passivation in preparation of other superconducting materials and structures.

43 PARTICLE ACCELERATORS↗

Effect of GPS Manipulation to Traditional and Next Generation Relay Protection

This project’s objective is to test the effect of GPS timing variations on relay protection algorithms to determine vulnerabilities and the associated hazards to the electric grid. This will focus on differential protection which utilizes peer to peer communication between substations to determine if the current is not equivalent. This requires the use of GPS to sync the two substations and can be vulnerable to GPS manipulation. However, the effects of GPS manipulation are not a commonly known risk. Therefore, this LDRD will address the risks of GPS manipulation for such a widely implemented technology. For differential protection a GPS resilient architecture was implemented and tested for differential protective relays through a direct serial fiber connection between the two relays. This allows for one relay to be the master and provide synchronization outside of timestamp for differential protection.

24 POWER TRANSMISSION AND DISTRIBUTION↗

3D printing of High Precision Radiation Filters for next generation Cosmic Background (CMB) studies (Final Report)

The terahertz (THz) spectral range is the part of the electromagnetic spectrum between 0.1–10 THz or 0.03–3 mm wavelength. For a long period, the terahertz band was relatively unexplored due to the unavailability of cost-effective and powerful sources. Due to the evolution of these devices in the mid-1980s, however, terahertz radiation has attracted much more attention. Since this part of the spectrum is between the infrared (IR) and microwave frequency ranges, the development of waveguides, filters, polarizers, lenses, and other optical components. Since terahertz waves to penetrate most dielectric materials offers the possibility of many applications. Since terahertz radiation can pass through organic tissue without causing damage, and it can be safely applied for biomedical applications. Radio astronomy and wireless communication are also fields with great interest in this spectral range. For example, terahertz waves could be used to detect cold bodies and debris in space or to increase data transmission using the larger bandwidth of the terahertz band.

79 ASTRONOMY AND ASTROPHYSICS↗

Artificial Photosynthesis with Next Generation Molecular Catalysts

The objective of this project was to develop a new class of molecular photocatalysts for CO 2 reduction that will enable breakthrough advances in artificial photosynthesis. A major limitation of existing photocatalytic assemblies is that only a small fraction of absorbed photons are converted into fuel due to inefficiencies in electron transport between the different system components. In the case of molecular catalysts for reduction of CO 2 , highly reducing electron equivalents are required for catalysis. As a result, the electron flux between the photosensitizer and CO 2 reduction catalyst is heavily biased towards the photosensitizer. One method to direct the electron flux towards productive photocatalysis is to design molecular catalysts for CO 2 reduction that operate at more favorable potentials than existing catalysts. The conventional approach is to tune the potential of the catalyst through selection of the supporting ligands, however, this only leads to incremental improvements due to the existence of an unfavorable scaling relationship between the rate and potential of catalysis. Our hypothesis is that the catalytic rate and potential can be simultaneously enhanced using bimetallic catalysts in which one metal improves the potential of catalysis and the second metal increases the rate of catalysis. During the course of this project, a few studies reported some success in improving photocatalytic CO 2 reduction with heterobimetallic complexes, demonstrating the potential of this approach to catalyst design.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Evaluation of Ceramic Heat Exchanger for Next-Generation Concentrated Solar Power

The U.S. Department of Energy has identified a third generation of concentrated solar power (Gen3 CSP) technologies to minimize cost of CSP produced electricity. By developing these technologies further, it is forecasted that Gen3 CSP will meet the levelized cost of electricity (LCOE) SunShot target of 6 cents/kWh to compete with dominant, conventional nonrenewable energy sources (1). The focus for advancing CSP systems for Gen3 is to increase overall system efficiency. Thus, reevaluating second-generation systems, superheated steam-turbine power cycles, and implementing more advanced power cycles is essential. Specifically, it has been identified that a supercritical carbon dioxide (sCO 2 ) Brayton cycle can increase the net thermal-to-electric efficiency to over 50% for CSP power tower configurations (2). Compared to conventional superheated steam Rankine cycle systems, more extreme operating conditions are required and pose critical barriers to overcome in the field of materials and manufacturing for Gen3 CSP.

14 SOLAR ENERGY↗

Systems Level Study of a Novel Fast-Growing Cyanobacterial Strain for Next Generation Biofuel Production

The overall objective of this project is to use an integrated systems biology approach to develop a fast growing cyanobacterial strain as a platform organism for photobiological production of advanced biofuels and other useful chemicals. Cyanobacteria are oxygenic photosynthetic microbes that use light and CO 2 as feedstocks, and hence offer enormous promises for sustainable bioenergy production. One of the key issues in cyanobacterial biofuel production is the growth rates of these microbes. Compared to other oxygenic photosynthetic organisms such as plants and eukaryotic algae, many cyanobacterial strains have superior growth properties. However, they grow significantly slower than heterotrophic microbes such as E. coli and yeast that are commonly used in biofuel research. We have recently identified Synechococcus elongatus UTEX 2973, a unicellular cyanobacterium that has the ability of rapid photoautotrophic growth comparable to that of the yeast Saccharomyces cerevisiae. In this project, we will pursue a systems approach to develop Synechococcus 2973 as a versatile and useful model cyanobacterial host to be used by the bioenergy research community during the coming era. The knowledge base generated during this project will also be helpful for sustainable biofuel production by other cyanobacterial as well as eukaryotic photosynthetic hosts that use sunlight and CO 2 as renewable feedstocks.

09 BIOMASS FUELS↗

Revolutionizing observations and predictability of Arctic system dynamics through next-generation dense, heterogeneous and intelligent wireless sensor networks with embedded AI

The Arctic region is a complex and dynamic system, where changes in temperature and partitioning between water in solid, liquid and vapor phase are fundamentally reshaping hydro-biogeochemical fluxes from the bedrock to the atmosphere. The increasing temperature and frequency of extreme heat, precipitation and fire events (Wang et al., 2017; Meredith et al., 2019) have critical consequences for the Arctic ecosystems and people, as well as for the global climate system. Although many observational and remote sensing activities have been on-going, detailed ecosystem processes – particularly related to controls on and impacts of permafrost thaw – are difficult to detect or measure. To improve the understanding and prediction of these extreme events and their consequences, we need a revolution in the way we collect ground-based observations from hillslope to pan-Arctic scales and couple them with satellite imagery and models to deliver rich, actionable, and scale-appropriate data.

54 ENVIRONMENTAL SCIENCES↗

Quantum system engineering for a next-generation search for axion dark matter. Final report

This project pursued two major experimental goals related to the quantum engineering of the ensemble of nuclear spin qubits, as a potential sensing platform for axion-like dark matter: (1) control the fidelity of spin ensemble state preparation, (2) characterize the coherence time of the spin ensemble under different drive conditions. We have successfully achieved these goals. We have experimentally demonstrated control over the polarization of the 207 Pb nuclear spin ensemble, using light-induced transient paramagnetic centers. We have also performed NMR measurements on the 207 Pb spin ensemble in solid ferroelectric PMN-PT, demonstrating the T 2 coherence time of 16.7 ms. We have used this approach to set new experimental limits on the EDM and the gradient interactions of axion-like dark matter in the mass range 162 neV to 166 neV. In addition, having characterized the magnetic resonance properties of the 207 Pb spin ensemble in solid ferroelectric PMN-PT, we have formulated the technical requirements needed to reach the quantum sensitivity limits in a magnetic resonance-based search for axion-like dark matter.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Highly Integrated Wide Bandgap Power Module for Next Generation Plug-In Vehicles (Final Report)

Wide bandgap devices are key enablers for high power density traction inverters. A highly integrated wide bandgap (WBG) power module enables higher temperature operation, higher inverter efficiency and overall smaller die area with the same power delivery. However, it requires careful design of the power module to take advantage of all the superior material properties that silicon carbide (SiC) provides over conventional silicon (Si) Insulated Gate Bipolar Transistor (IGBT) based design. This project developed an efficient and densely packed SiC power module for an automotive traction inverter application. Extensive study was performed to select the best performing SiC die considering a wide range of temperature variation, suitability to integrate into target packaging, robust body diode performance and overall high electrical efficiency. Multiple design ideas were explored to achieve lower stray inductance for both power loop and signal loop, uniform current distribution, compact form factor, and very high thermal performance. The final power module package includes all six inverter switches in the same module (six-pack) with die sintered at both bottom and top surfaces utilizing high performance substrate to achieve high electrical and thermal performance. Two power module variants were developed using 900 V and 1200 V devices for operating at two different high voltage levels (> 600 V HV battery). Both power modules were comprehensively characterized, and high efficiency operation of the inverter was confirmed through analysis. Finally, a complete functional inverter was built with the 1200V power modules using other essential components (HV capacitors, gate driver board, controller board, current sensor, connectors etc.) and tested using GM’s standard test procedure. There are several challenges associated with adopting WBG devices for high voltage operation. In order to assess and mitigate those challenges, GM and subrecipients of this project have conducted multiple detailed studies. This includes phase current reconstruction using integrated Rogowski coil, device junction temperature estimation using on-state gate resistance, modeling and testing the effect of high voltage and fast switching on motor insulation and bearings, partial discharge inception voltage measurement under different environmental conditions. Findings of all these studies are summarized in this report.

33 ADVANCED PROPULSION SYSTEMS↗

Next-Generation Metal-Supported SOFC Phase 1 (CRADA Final Report)

This project is a paper study of Metal-Supported Solid Oxide Fuel Cell (MS-SOFC) development. The literature from 2017-2021 regarding MS-SOFCs and SOFCs was reviewed and analyzed. The findings were used to develop a set of ideas for improving MS-SOFCs. If implemented, improved MS-SOFCs will contribute to increased fuel efficiency and reduced greenhouse gas emissions in the transportation sector.

30 DIRECT ENERGY CONVERSION↗

Corrosion Protection and Dissimilar Material Joining for Next Generation Lightweight Vehicles

The Arconic Technology Center working with Honda R&D Americas, LLC and the Ohio State University evaluated the corrosion performance of several multi-material conditions and demonstrated the production worthiness of the Resistance Spot Riveting (RSR™) process. RSR is a new technology being developed by Howmet Fastening Systems (formerly Arconic, Inc.) that employs a fastener that is installed using conventional resistance spot welding equipment to produce multi-material joints. The goal of the 3-year project was to demonstrate the use of RSR to join aluminum to steel and aluminum to carbon fiber composites on a prototype scale. Deployment of this technology would help the automotive industry achieve an additional 10 to 20% weight reduction over high strength steels. These weight-savings to the body in white generally translates to 2.5-5.0% of overall vehicle curb weight. The resulting total weight-savings could provide a 1.5% to 3.0% total improvement in fuel efficiency for vehicles that incorporate RSR for multi-material joining. The RSR technology addresses several production barriers to achieving DOE’s fuel efficiency targets including eliminating the need of additional capital for new joining technologies and the flexibility to process conventional steel and multi-material structures with the same equipment. Additionally, the trend towards ultra-high strength steels limits the availability of conventional joining technologies that can effectively process these multi-material combinations. In order to accomplish these goals, the following program milestones were completed by the team: 1) Developed RSR process parameters, producing multi-material joints for mechanical testing and corrosion assessments. 2) Conducted corrosion evaluation of RSR and baseline joints assembled between automotive type aluminum alloys, steels, and carbon fiber using several corrosion mitigation strategies. 3) Developed a production ready feed system and integrate into a robotic resistance spot welding station to simulate automotive production conditions. 4) Produced demonstration assemblies for testing and evaluation.

36 MATERIALS SCIENCE↗