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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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To summarize the optimized electrochemical performances of the polymer matrix, ceramic nanofibers, and composite electrolytes, including ionic conductivity, electrochemical window, and fuel-cell performance
Leveraging an open-subsystem formulation of Density Functional Theory (DFT) we aim at describing periodic and molecular systems alike, including their electronic and nuclear dynamics. Subsystem DFT enables first principles simulations to approach realistic time- and length-scales, and most importantly sheds light on the dynamical behavior of complex systems. Taking subsystem DFT to the time domain allows us to inspect the electron dynamics of condensed-phase systems in real time. In liquids and interfaces, we observe all the relevant regimes proper of non-Markovian open quantum system dynamics, such as electronic energy transfer, and screening. In addition, the ab-initio modeling of system-bath interactions brought us to observe and justify the holographic time-dependent electron density theorem. Contrary to interactions between molecular (finite) systems, when molecules interact with metal or semiconductor surfaces the electron dynamics is strongly non-Markovian with dramatic repercussions to the molecule’s response to external perturbations. Metals and semiconductors typically have large polarizabilities, and even in a regime of low coupling their effect on impinging molecular species is significant–line broadening, peak shift, and intensity borrowing are observed, characterized, and explained in terms of inter-subsystem dynamical interactions and a many-body decomposition of the system’s density-density response function in a way that transcends the canons of Fermi Golden Rule.
The objective of this project was to develop and demonstrate an extreme fast charging (XFC) station with three 350 kW charging ports that operate at a combined power exceeding 1 MW and mitigate the grid impact by employing smart charging algorithms, using an energy storage system, and connecting directly to a medium-voltage (15 kV-class three-phase) distribution feeder. This final report describes the team's achievements in all aspects of the technology development.
The project advances the manufacture of RMA for ultrahigh-temperature service with three main innovations: a thermodynamically derived high-throughput AM synthesis and characterization using reactive synthesis of elemental powders, a new dimensional number to predict processing parameters, and a novel processing scheme for the fabrication of components with functional grading microstructures. With these advances, the project demonstrates in Phase I the manufacture of RMAs exhibiting room temperature compression ductility above 20%, room temperature fracture toughness above 10 MPam 0.5 , and the fabrication of tensile test samples that have a transformative impact on the manufacturing of RMAs by enabling cost-efficient and large-scale fabrication of components.
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The Fuels Development Team's goal is to try to learn drilling speeds and electrode dimensions to achieve desired diameters on a ZrC disk. We desire to send both the drawing and material to Sodick for drilling.
Thermal barrier coatings (TBC) applied to pistons have been a recently renewed research topic in the field of internal combustion engines. Single cylinder testing of a conventional C15™ Tier 4 final pro-duction steel piston and a TBC coated piston showed that the Yttrium stabilized Zirconia (YSZ) TBC did not significantly alter engine performance, with the TBC piston having slower combustion rates and higher criteria emissions. For deeper understanding, research continued by studying 3D-piston sections optically in a constant pressure vessel using photodiodes, four high-speed cameras (natural luminosity, CH*, and OH*), and visualization of the flame from two orthogonal directions. Particle Im-aging Velocimetry (PIV) algorithms were adapted to perform Combustion Imaging Velocimetry (CIV) to aid in quantification of the observed visual combustion flow field differences. The optical work showed that the TBC piston flame development is slower, spatially different, with lower mixing energy for the TBC variant. Geometric profiles of engine pistons and optical vessel 3D-piston sections were measured using a Coordinate Measurement Machine (CMM), and surface roughness was measured with a stylus surface profilometer. CMM results showed that the TBC piston bowl had reasonable macroscopic accuracy, but the rim had a larger radius with less reentrancy. A discussion of the results and analyses in relation to future TBC effort and direction concludes the work.
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Ceramic-metallic (cermet) materials show promise for use in nuclear thermal propulsion applications due to attractive thermophysical properties including high temperature stability and high thermal conductivity. In this work, molybdenum-uranium dioxide (Mo-UO 2 ) cermet fuel elements were fabricated by means of spark plasma sintering (SPS) and were subsequently exposed to hydrogen at high temperatures (2500 K). Mo-UO 2 samples pre- and post-exposure were characterized by means of optical microscopy, scanning electron microscopy, and X-ray diffraction (XRD). Microscopy analyses of the as-produced material displayed microscopic cracking on the interior of the spherical UO 2 fuel particles but confirmed that the fuel particles were fully encapsulated in the Mo matrix. The results further showed mass loss, macroscopic swelling, and cracking in the cermet samples which occurred during high temperature hydrogen testing. Nanoscale swelling was evidenced by XRD in the Mo matrix and UO 2 fuel structure due to the incorporation of defects and accompanied microstrain.
The heavy-duty off-road industry continues to expand efforts to reduce fuel consumption and CO 2 e (carbon dioxide equivalent) emissions. Many manufacturers are pursuing electrification to decrease fuel consumption and emissions. Future policies will likely require electrification for CO2e savings, as seen in light-duty on-road vehicles. Electrified architectures vary widely in the heavy-duty off-road space, with parallel hybrids in some applications and series hybrids in others. The diverse applications for different types of equipment mean different electrified configurations are required. Companies must also determine the value in pursuing electrified architectures; this work analyzes a range of electrified architectures, from micro hybrids to parallel hybrids to series hybrids to a BEV, looking at the total cost, total CO 2 e, and cost per CO 2 e (cost of carbon abatement, or cost of carbon reduction) using data for the year 2021. This study is focused on a heavy-duty off-road material handler, the Pettibone Cary-Lift 204i. This machine’s specialty application, including events like unloading large oil pipes from a railcar, requires a unique electrified architecture that suits its specific needs. However, the results from this study may be extrapolated to similar machinery to inform fuel savings options across the heavy-duty off-road industry. In this study, a unique electrified architecture is determined for the Cary-Lift. This architecture is informed by multiple rounds of a Pugh matrix decision analysis to select a shortened list of desirable electrified architectures. The shortened list is modeled and simulated to determine CO 2 e, cost, and cost per CO 2 e. A final architecture is determined as a plug-in series hybrid that reduces fuel consumption by 65%, targeting the large fuel and CO 2 e savings that are likely to be required for the future of the heavy-duty off-road industry.
Nuclear Thermal Propulsion (NTP) systems hold promise in reducing transit times for exploration of the solar system by both crewed and uncrewed missions. NTP systems currently under investigation include a once-through high temperature gas-cooled fission reactor to provide thermal energy to heat the coolant which also serves as the propellant. The fuel systems of angular UN fuel particles dispersed in a matrix of W/Re, creating a ceramic and metallic composite or cermet, has been irradiated in Idaho National Laboratory’s (INL) Transient Reactor Test Facility (TREAT) enabling evaluation of these materials under representative nuclear heating rates (~95 K/s) and peak temperatures (~2527 K). These tests named Sirius-1 (UN-W/Re), have been irradiated and this paper will present post-irradiation examination results. The Sirius-1 test produced cracks in the fuel specimen and spalling of surface material. Uranium soot was found on the inner wall of the irradiation capsule indicating loss of some fissile material from the fuel specimen. Spalling from the surfaces was also noted upon visual inspection. Uranium diffusion from the fuel particles resulted in the formation of U/Re phases and edge features producing a laminar microstructure.
The thermal conductivity of a ceramic-metal composite consisting of 60 vol % uranium nitride incorporated into a molybdenum-tungsten matrix has been measured up to a temperature of 1200°C. Compositing nuclear fuel with refractory materials is considered a viable way to improve the thermal and mechanical properties of fuels, and more recently, has been investigated as a way to improve hydrogen compatibility in a nuclear thermal propulsion rocket reactor. Here, we demonstrate that high-density composites can be produced from direct current sintering and that the resulting thermal conductivity is improved compared to the pure.
Fission power systems have demonstrated higher thermal energy density per unit mass than chemical systems. High mass specific energy density offers advantages in space thermal propulsion applications. In the 1960s, nuclear thermal propulsion (NTP) development included the ROVER/NERVA program, in which full-scale prototype reactors were tested on the ground using hydrogen as the reactor coolant and propellant. NTP systems are being revisited, with expectations of improved performance resulting from improved fuel materials, allowing propellant temperatures near 2,800 K and over 20 thermal propulsion cycles. An apparatus has been developed to test NTP fuel materials in a research reactor at temperature and in a radiation environment typical of the NTP application. Here, this paper presents the design constraints, preliminary scoping thermal analysis, and basic thermal qualification testing for the out-of-pile experiment set apparatus, or OUTSET.
The diffusion of hydrogen in metals and alloys induces embrittlement that can adversely affect the structural properties. We examine the adsorption and diffusion of hydrogen in Inconel-718 (IN-718), and scrutinize the ensuing effects on the dislocation behavior in the alloy to elucidate the fundamental mechanisms of hydrogen-microstructure interactions from classical molecular simulations. Hydrogen adsorption increases with time until the surface saturates, while hydrogen diffusion exhibits strong temperature dependence, with diffusion coefficients converging above 1300 K regardless of the initial hydrogen concentration in the alloy. The diffusion in IN-718 is significantly sluggish than in pure Ni, Fe, or Cr, and is strongly impacted by hydrogen concentrations, resulting in an order of magnitude higher diffusion coefficient for hydrogen (10-14 m2/s relative to 10-15 m2/s) at high concentrations, especially below 600 K. Hydrogen diffusion coefficient varies from 10-12 to 10-15 m2/s in IN-718 depending on temperature (500–1400 K). More critically, our results reveal that increasing hydrogen concentration induces microstructural changes in the alloy, transforming perfect dislocations into stair-rods and Shockley partials, with higher temperatures favoring the latter. The results are significant for hydrogen fuel applications to gain insights into the materials chemistry for designing safer and more efficient propulsion systems, particularly in high-performance environments related to controlled hydrogen combustion applications.
This is an overview of EVALS (Enhanced VALidation of advanced battery Supply chains), funded by the U.S. Department of Energy Vehicle Technologies Office (VTO) and some initial data from a transformational laboratory directed research and development (LDRD) program project funded at NREL. EVALS aims to accelerate the process to bring domestic and allied primary sources of battery materials online, from production to deployment.
This project conducts research to develop new power electronics thermal management technologies to increase power density, enable high WBG temperature operation, and decrease cost. One of the main challenges to achieving high power densities is associated with packaging of high-temperature (up to 250 degrees C) WBG devices near lower-temperature-rated components (e.g., electrical boards and capacitors). Additionally, the high junction temperatures of the WBG devices will result in large temperature gradients through the power module layers, which will present reliability challenges and require higher-temperature substrates and bonding materials.
Carbide-based fuel assembly includes outer structural member of ceramic matrix composite material (e.g., SiC—SiC composite), insulation layer of porous refractory ceramic material (e.g., zirconium carbide with open-cell foam structure or fibrous zirconium carbide), and interior structural member of refractory ceramic-graphite composite material (e.g., zirconium carbide-graphite or niobium carbide-graphite). Spacer structures between various layers provide a defined and controlled spacing relationship. A fuel element bundle positioned between support meshes includes a plurality of distributively arranged fuel elements or a solid, unitary fuel element with coolant channels, each having a fuel composition including high assay, low enriched uranium (HALEU). Fuel assemblies are distributively arranged in a moderator block and the upper end of the outer structural member is attached to a metallic inlet tube for hydrogen propellant and the lower end of the outer structural member is interfaced with a support plate, forming a nuclear thermal propulsion reactor.