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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 703 records · Page 39
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogenities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Characterization of Saltstone Grout Line Samples

During a prestart recirculation operation in the Saltstone Processing Facility (SPF), operations staff noticed hardened scaling falling into the hopper. As a result, SPF operators and Saltstone Engineering decided to postpone operation and conduct a process room hopper cleanout. During the cleanout effort personnel noted greater than normal buildup of damp solid material in the transfer line. A borescope investigation was conducted and confirmed buildup was present throughout the transfer line to the downstream valves. Savannah River National Laboratory personnel were asked to characterize the scale material and samples collected from the saltstone grout line and provide recommendations and/or further guidance as to whether additional corrosion testing is needed for useful equipment operating life information. Based on the samples characterized results, the plug material contained only the 60:40 slag:fly ash saltstone. Portland cement in the original 10:45:45 Portland cement:slag:fly ash mix may result in a less abrasive slurry compared to the 60:40 slag:fly ash mix because the slag is > 95 % crushed angular, sharp edged glass. Saltstone grout erosion and corrosion testing of A36 carbon steel is needed to determine if the 60:40 mix is more abrasive and corrosive for A36 carbon steel than the 10:45:45 mix.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Integration of a Wigner effect-based energy storage system with an advanced nuclear reactor

In this work, an innovative energy storage concept based on the purposeful creation of defects in crystalline material by neutron irradiation is presented. Lattice defects are generated when heavy particles collide with the atoms in a crystal structure, i.e., if the incoming particles have enough energy, recoil atoms are displaced from their initial lattice sites. Most of the displaced atoms will eventually combine with nearby vacancies, but some of them will come to rest in non-ideal locations. The energy held by displaced atoms is called Wigner energy. Lattice defects can migrate and form clusters, and the Wigner energy can be released from these groupings if sufficient activation energy is provided. In the nuclear industry, this effect is well-known since it represented an issue for graphite-moderated reactors. This work presents the conceptual design of an engineering system that exploits this physical process to store the energy of neutrons in advanced reactor concepts. In the first part of the paper, the theoretical performance of an energy storage system based on the Wigner effect is described. Given the lattice properties and the compatibility with the harsh reactor environment, graphite was selected as the candidate material for the irradiation targets. Both experimental data and molecular dynamics simulations confirmed that this system can achieve performance comparable with state-of-the-art batteries in terms of stored energy density. In the second part of the paper, the engineering challenges of this innovative technology and the proposed solutions are described. After defining the optimal irradiation conditions, the different steps of the operation of the proposed energy system (from energy storing to energy harvesting) were defined. Finally, the integration of this concept with advanced reactor designs, i.e., a Sodium-cooled Fast Reactor and a Molten Salt-cooled Reactor, was investigated and the corresponding performance was evaluated.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Constructing a Simulation Surrogate with Partially Observed Output

Gaussian process surrogates are a popular alternative to directly using computationally expensive simulation models. When the simulation output consists of many responses, dimension-reduction techniques are often employed to construct these surrogates. However, surrogate methods with dimension reduction generally rely on complete output training data. This article proposes a new Gaussian process surrogate method that permits the use of partially observed output while remaining computationally efficient. The new method involves the imputation of missing values and the adjustment of the covariance matrix used for Gaussian process inference. The resulting surrogate represents the available responses, disregards the missing responses, and provides meaningful uncertainty quantification. In conclusion, the proposed approach is shown to offer sharper inference than alternatives in a simulation study and a case study where an energy density functional model that frequently returns incomplete output is calibrated.

42 ENGINEERING↗
DOE OSTI2025

Cyber-Informed Engineering (CIE) Integration into Model- Based Systems Engineering (MBSE)

Engineering design in the field of industrial engineering, such as designing automated factories or warehouses, is critical for the effective operation of facilities. Any design flaws introduced early can result in significant capital expenses to correct. However, early-stage engineering design is inherently complex. The systems are not yet built, requiring designers to integrate various aspects, including digital engineering and cybersecurity, to support virtual representations throughout the design process. In this study, we propose an approach to integrate Cyber-Informed Engineering (CIE) principles into model-based systems engineering (MBSE). This approach facilitates the development of a digital thread for engineering systems, ensuring secure digital artifacts in the design of industrial engineering systems.

42 - ENGINEERING↗
DOE OSTI2021

Utilizing the unique charge extraction properties of antimony tin oxide nanoparticles for efficient and stable organic photovoltaics

Simultaneously enhancing device performance and longevity, as well as balancing the requirements on cost, scalability, and simplification of processing, is the goal of interface engineering of organic solar cells (OSCs). In our work, we strategically introduce antimony (Sb 3+ ) cations into an efficient and generic n-type SnO 2 nanoparticles (NPs) host during the scalable flame spray pyrolysis synthesis. Accordingly, a significant switch of conduction property from an n-type character to a p-type character is observed, with a corresponding shift in the work function (WF) from 4.01 ± 0.02 eV for pristine SnO 2 NPs to 5.28 ± 0.02 eV for SnO 2 NPs with 20 mol. % Sb content (ATO). Both pristine SnO 2 and ATO NPs with fine-tuned optoelectronic properties exhibit remarkable charge carrier extraction properties, excellent UV resistance and photo-stability being compatible with various state-of-the-art OSCs systems. The reliable and scalable pristine SnO 2 and ATO NPs processed by doctor-blading in air demand no complex post-treatment. Our work offers a simple but unique approach to accelerate the development of advanced interfacial materials, which could circumvent the major existing interfacial problems in solution-processed OSCs.

14 SOLAR ENERGY↗
DOE OSTI2021

The IDAES process modeling framework and model library—Flexibility for process simulation and optimization

Abstract Energy systems and manufacturing processes of the 21st century are becoming increasingly dynamic and interconnected, which require new capabilities to effectively model and optimize their design and operations. Such next generation computational tools must leverage state‐of‐the‐art techniques in optimization and be able to rapidly incorporate new advances. To address these requirements, we have developed the Institute for the Design of Advanced Energy Systems (IDAES) Integrated Platform, which builds on the strengths of both process simulators (model libraries) and algebraic modeling languages (advanced solvers). This paper specifically presents the IDAES Core Modeling Framework (IDAES‐CMF), along with a case study demonstrating the application of the framework to solve process optimization problems. Capabilities provided by this framework include a flexible, modifiable, open‐source platform for optimization of process flowsheets utilizing state‐of‐the‐art solvers and solution techniques, fully open and extensible libraries of dynamic unit operations models and thermophysical property models, and integrated support for superstructure‐based conceptual design and optimization under uncertainty.

42 ENGINEERING↗
DOE OSTI2021

Equalization of Intensity-Modulated Fiber-Optic Voltage Sensors for Power Distribution Systems

We test fiber-optic voltage sensors based on optical reflection from a piezoelectric transducer. Our specific devices possess a 2 kHz fundamental resonance, and we verify a readily usable frequency band from approximately 10 Hz to 3 kHz, with a dynamic range of 60 dB for a detection system integrating over this entire band. Additionally, we demonstrate a digital signal processing approach to equalize the measured frequency response, enabling accurate retrieval of short-pulse inputs. These results suggest the value and applicability of intensity-modulated fiber-optic voltage sensors for measuring both steady-state waveforms and broadband transients which, coupled with the straightforward and compact design of the sensors, should make them effective tools in electric grid monitoring.

42 ENGINEERING↗
DOE OSTI2023

RAPID Manufacturing Institute Final Report

The Rapid Advancement of Process Intensification Deployment (RAPID) Manufacturing Institute, founded in 2017, is a public/private partnership between the U.S. Department of Energy and the American Institute of Chemical Engineers (AIChE). RAPID promotes the development, deployment and commercialization of Process Intensification (PI) and Modular Chemical Process Intensification (MCPI) technologies, enabling U.S. manufacturing to reduce energy consumption, improve process efficiencies and lower investment and operating costs. This mission was carried out through parallel work breakdown structure elements including the establishment of committees to guide the operations and technical direction of RAPID, the establishment of management practices and institute processes, education and workforce development (EWD), and six technical focus areas for the development of technologies to advance PI and MCPI. Throughout the initial six-year cooperative agreement, RAPID worked to meet performance metrics which focused on the operation and sustainment of the institute, education and workforce development and the development of PI and MCPI for the advancement of U.S. manufacturing. All these metrics were successfully met through a total of 43 projects which leveraged $\$$70M Federal with $\$$90M cost share. As a result of these efforts, 84 private and public organizations were brought together by RAPID as members to co-invest in R&D, commercialization and deployment of innovative technologies. In the research portfolio, 82% of the 38 projects achieved > 20% energy efficiency improvement. A RAPID Test Network was developed with 51 testbed facilities to enable access to resources, facilities, tools, and expertise. Eight EWD programs were also developed with over 13,000 impressions. RAPID’s efforts to research, develop, demonstrate, and deploy high-impact PI and modular process technology solutions have enabled reduced energy use, increased sustainability, and improved profitability for U.S. manufacturing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Experimental Measurements of NOx Emissions in a Rotating Detonation Engine

An experimental study of NOx emissions in a rotating detonation engine is presented in this paper. Rotating detonation engines produce a pressure gain in the combustion process which leads to increased efficiency compared to conventional constant pressure, deflagration based combustion. However, in order for rotating detonation engines to become a viable alternative to conventional combustion, they must meet NOx emissions regulations. Emissions from rotating detonation engines are not currently well understood. A parametric study was performed to determine time averaged NOx emissions in a rotating detonation engine over a range of operating conditions. The effects of inlet pre-heat, equivalence ratio, flow rate, and fuel composition are investigated.

Ferguson, Donald↗
DOE OSTI2022

Energetic Materials

Energetic materials comprise explosives, pyrotechnics, and propellants. The science of energetic materials is dedicated to developing a means to predict performance and safety characteristics with high fidelity. This is a particular challenge and is predicated on materials science and engineering, physics, chemistry, and dynamic response in extreme conditions. Fundamental elements of these complicated composite materials remain grand challenges—from the design of high-energy metastable molecules, to the engineering of composite formulations, to the processing parameters that link to safety and performance characteristics in as-yet undetermined ways. Key elements include crystalline mechanics, grain dynamics, multiphase interfaces, thermal and mechanical damage, and failure—all linked to multistep and high-rate chemistry and shock physics. A future revolution in our understanding and predictive capability for energetic materials behavior and responses is dependent upon sustained focus and advances in materials research and development.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Binder Effects on Processing, Mechanical Properties, and Performance of Thin Sulfide Solid‐State Electrolytes

All‐solid‐state batteries (ASSBs) offer enhanced safety and energy density compared to conventional lithium‐ion batteries by replacing flammable liquid electrolytes with solid‐state electrolytes (SSEs). Among SSEs, sulfide‐based electrolytes exhibit high ionic conductivity and mechanical deformability, making them promising candidates for next‐generation energy storage. However, their practical implementation is hindered by interfacial instability, mechanical brittleness, and challenges in fabricating ultrathin electrolyte membranes (<30 μm) with robust mechanical integrity. Here, this study systematically examines the influence of polymeric binders—polyisobutylene, hydrogenated nitrile butadiene rubber, and styrene–ethylene–butylene–styrene (SEBS)—on the structural, mechanical, and electrochemical performance of thin sulfide SSE membranes. Key findings reveal that SEBS enables the fabrication of ultrathin, uniform membranes, while binder elasticity significantly affects structural stability during cycling. Operando stack pressure measurements indicate that binder properties directly influence adhesion force for LPSCl particles, influencing their stabilizing cycling period. These results underscore the critical role of polymer binders beyond mechanical reinforcement, positioning them as essential design variables in sulfide SSE engineering. By linking binder chemistry to processability and electrochemical performance, this study provides insights into optimizing sulfide SSEs, advancing their commercial viability in ASSBs.

argyrodite sulfide electrolyte↗
DOE OSTI2021

A 3D FPGA Track Segment Seeding Engine Based on the Tiny Triplet Finder

A 3D track segment seeding engine core based on the Tiny Triplet Finder has been implemented and tested in a low-cost FPGA device. The seeding engine is designed to preselect and group hits (stubs) from cylindrical detector layers to feed subsequent track fitting stage. The seeding engine consists of a Hough transform space for r-z view and a Tiny Triplet Finder for r-phi view to implement 3D constraints. The seeding engine is organized as a pipeline so that each hit is processed in a single clock cycle. Test results show that the seeding engine operates as expected.

Wu, Jinyuan↗
DOE OSTI2022

Copper Single Atom-Triggered Niobia–Ceria Catalyst for Efficient Low-Temperature Reduction of Nitrogen Oxides

To reduce nitrogen oxide (NO x ) emission from diesel engines in the cold-start process benefitting the atmospheric environment, catalysts with superior low-temperature NO x removal efficiency are highly demanded. Herein, we report an efficient Nb 2 O 5 /CuO/CeO 2 (NbCuCe) oxide catalyst for the selective catalytic reduction (SCR) of NO x , showing much higher DeNO x activity below 200 °C, superior sulfur resistance, faster response, and much less NH 3 slip than the state-of-the-art Cu-CHA zeolite catalyst. Additionally, atomically dispersed Cu species facilitate the strong interaction between Cu and the Nb/Ce base catalyst, which significantly improves the low-temperature redox properties at Cu–O–Ce sites and NH 3 adsorption/activation at Nb–O–Cu sites, thus contributing to the superior SCR performance of NbCuCe at low temperatures. The developed NbCuCe catalyst is highly promising for efficient DeNO x from cold-start diesel engines and can be coupled with Cu-CHA to achieve a broad operation temperature window.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Hybrid magnonics in hybrid perovskite antiferromagnets

Abstract Hybrid magnonic systems are a newcomer for pursuing coherent information processing owing to their rich quantum engineering functionalities. One prototypical example is hybrid magnonics in antiferromagnets with an easy-plane anisotropy that resembles a quantum-mechanically mixed two-level spin system through the coupling of acoustic and optical magnons. Generally, the coupling between these orthogonal modes is forbidden due to their opposite parity. Here we show that the Dzyaloshinskii–Moriya-Interaction (DMI), a chiral antisymmetric interaction that occurs in magnetic systems with low symmetry, can lift this restriction. We report that layered hybrid perovskite antiferromagnets with an interlayer DMI can lead to a strong intrinsic magnon-magnon coupling strength up to 0.24 GHz, which is four times greater than the dissipation rates of the acoustic/optical modes. Our work shows that the DMI in these hybrid antiferromagnets holds promise for leveraging magnon-magnon coupling by harnessing symmetry breaking in a highly tunable, solution-processable layered magnetic platform.

14 SOLAR ENERGY↗
DOE OSTI2025

Expanding market opportunities: cogeneration strategies for integrated PWR and thermal energy storage systems

We assess the economic viability of nuclear cogeneration by investigating three different modes—fixed dispatch, fully flexible dispatch, and flexible dispatch with minimum heat supply requirements. The analysis focuses on an existing pressurized water reactor (PWR) integrated with thermal energy storage (TES). Heat production costs are estimated under these modes for two U.S. electricity markets: the Electric Reliability Council of Texas (ERCOT) and the Pennsylvania–New Jersey–Maryland Interconnection (PJM). A sensitivity analysis examines profitability at varying heat market prices. Results indicate that fixed heat dispatch inflates heat production costs, often rendering projects economically feasible only at higher heat price levels. Fully-flexible dispatch lowers heat production costs by an average of 43 % compared to fixed dispatch. However, the current 30 % thermal dispatch limit may be insufficient to serve high baseline industrial demands cost‐effectively; higher maximum dispatch rates could enhance project economics. Markets with higher and more volatile electricity prices (e.g., ERCOT) offer greater total energy sales potential (i.e., heat and electricity), but also increase opportunity costs when heat production scheduling restrictions are imposed. In contrast, lower-price, less volatile markets (e.g., PJM) experience smaller impacts from such constraints and provide greater flexibility in accommodating varying cogeneration modes. In conclusion, these findings provide a framework to guide nuclear plant operators in aligning cogeneration strategies with industrial process requirements and electricity market conditions.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Solar Heat for Industrial Processes: Integration with Chemical Reactors

The integration of solar thermal systems with chemical reactors has been proposed as part of a larger effort to develop and deploy solar heat for industrial processes (SHIP) technologies. A strong motivation for SHIP processes and technologies is the potential for high thermal efficiency coupled with low-cost thermal energy storage (TES) which can enable commercial deployment of such systems. While there are different ways to categorize SHIP technologies, one important such distinction is between directly irradiated systems and indirect off-sun process driven by a SHIP system. While directly irradiated systems can provide high thermal efficiencies and high fluxes, they usually require complex engineering solutions due to the need for redesigning the established processes and unit operations. In most cases, it is also more challenging to couple such a process to a TES system, losing some of the benefits of SHIP. On the other hand, using a SHIP system to drive an industrial process off-sun can allow better integration with existing process chains, easier TES capabilities, and potential for more applications fitting a specific SHIP technology. However, the integration of SHIP systems with the industrial processes is not fully explored in detail, especially in the case of high-temperature processes such as reforming, cracking, cement manufacturing, and iron/steelmaking. Many of these systems require heating fluxes of >50 kW/m^2, supplied via combustion of hydrocarbons in a fire box and benefitting from radiative heat transfer between the flue gases and the reaction zones. As such, using SHIP systems for such processes is more complex than providing the same thermal input in the form of a heat transfer medium (HTM) entering the reactor, kiln, or furnace. Moreover, in case convective heat transfer using SHIP is envisioned, for example using supercritical CO2 as the HTM from a particle receiver, the thermal integration might be more challenging than initially envisioned: lower heat transfer coefficients and limited approach temperature might require large flow rates, causing a mismatch between the process thermal requirements and the thermal capacity of the SHIP system. In addition, even if the heat exchange between SHIP and reactor is effective, there is still a cold leg HTM at the reaction temperature or slightly below it. Chemical plants usually include a set of heat exchangers, heat recovery steam generators, and even power generation units - in a tightly integrated design - to recover the flue gases which are eventually vented. With SHIP systems mostly operating on a closed HTM loop, bottoming the cold leg is crucial. In this talk, we will present different modeling results for a variety of syngas production reactions, using catalytic and chemical looping processes, and discuss some of the challenges and design considerations for off-sun chemical reactors using SHIP systems.

14 SOLAR ENERGY↗