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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 757 records · Page 42
All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Surrogate Final Technical Report for "Solar: A Photovoltaic Manufacturing Development Facility"

The project goal to create a first-of-a-kind crystalline Silicon (c-Si) photovoltaic (PV) Manufacturing & Technology Development Facility (MDF) that will support the growth and maturation of a strong domestic PV manufacturing industry, based on innovative and differentiated technology, by ensuring industry participants can, in a timely and cost-effective manner, access cutting-edge manufacturing equipment and production expertise needed to accelerate the transition of innovative technologies from R&D into manufacturing.

14 SOLAR ENERGY↗
DOE OSTI2017

Energy Innovation Clusters and their Influence on Manufacturing: A Case Study Perspective

Innovation clusters have been important for recent development of clean energy technologies and their emergence as mature, globally competitive industries. However, the factors that influence the co-location of manufacturing activities with innovation clusters are less clear. A central question for government agencies seeking to grow manufacturing as part of economic development in their location is how innovation clusters influence manufacturing. Thus, this paper examines case studies of innovation clusters for three different clean energy technologies that have developed in at least two locations: solar PV clusters in California and the province of Jiangsu in China, wind turbine clusters in Germany and the U.S. Great Lakes region, and ethanol clusters in the U.S. Midwest and the state of Sao Paulo in Brazil. These case studies provide initial insight into factors and conditions that contribute to technology manufacturing facility location decisions.

14 SOLAR ENERGY↗
DOE OSTI2017

Bio-Manufacturing to market pilot project

The Bio-Manufacturing to Market pilot project was a part of the AMJIAC, the Advanced Manufacturing Jobs and Innovation Accelerator Challenge grant. This internship program set out to further define and enhance the talent pipeline from the University and local Community Colleges to startup culture in East Bay Area, provide undergraduate STEM students with opportunities outside academia, and provide startup companies with much needed talent. Over the 4 year period of performance, the Bio-Manufacturing to Market internship program sponsored 75 undergraduate STEM students who were able to spend anywhere from one to six semesters working with local Bay Area startup companies and DOE sponsored facilities/programs in the biotech, bio-manufacturing, and biomedical device fields.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2021

Laser-based Adhesion Strength Measurements for Advanced Manufactured Sensor Adhesion Characterization

As part of the advanced manufacturing (AM) focus of the Nuclear Energy Enabling Technologies (NEET) Advanced Sensors and Instrumentation (ASI) Program, new in-house capabilities to fabricate and test novel active and passive in-pile sensors are being developed at the Idaho National Laboratory (INL). These advanced-manufactured sensors, such as peak temperature monitors and strain gauges, must be miniaturized and be able to provide real-time feedback, all while withstanding the coupled extremes of temperature and radiation typically observed in the environment of a nuclear test reactor. Fabricating durable and robust in-pile sensors with high fidelity requires a fundamental understanding of the optimal process parameters required in the AM technique, as well as the effect of deviations from optimal process parameters on the sensor-substrate adhesion and the ultimate robustness of the sensor. This report presents the use of a laser-based, non-contact approach for characterizing the adhesion of sensors manufactured using aerosol jet printing (AJP) that comprise of silver nanoparticle inks deposited and sintered on austenitic stainless steel (SS) 316L substrates. The effect of substrate surface roughness, surface energy, ink sintering time and sintering temperature on the printed sensor topography and the sensor-substrate adhesion has been systematically investigated. The sensor-substrate interfacial adhesion strength was determined from the critical laser pulse energy required to ablate/ detach the printed sensor from the substrate. Measurements of the sensor topography using optical profilometry revealed that post-deposition sintering at 400°C for 60 minutes resulted in a reduced sensor thickness, while plasma treating the substrate prior to printing yielded sensors with uniform thickness profiles transverse to the print direction. Sintering temperature and time were found to be the dominant parameters that affected sensor-substrate adhesion, followed by substrate surface roughness. The laser-based and locally-destructive approach for adhesion strength measurements shows promise in overcoming the challenges and limitations of current standardized peel tests and can be developed into a post-fabrication process control protocol for evaluating the durability of AM printed sensors in a high throughput fashion. Future studies will investigate the use of laser-induced spallation techniques as well as non-destructive laser ultrasonic methods for sensor-substrate adhesion characterization on sensors manufactured using AJP and other AM techniques such as plasma jet printing (PJP).

42 ENGINEERING↗
DOE OSTI2021

Additively Manufactured Solid-State Luminaire

This project addresses several key barriers to wide-spread adoption of additive manufacturing (AM) technology as applied to solid state lighting luminaires. The solution will utilize cutting edge AM approaches for integrating structure with thermal management solutions, electronic functionality, and optics. The research team (Eaton, Lighting Research Center (LRC) at Rensselaer Polytechnic Institute, Xerox Research Centre of Canada (XRCC)) utilize their AM and lighting expertise to investigate breakthrough manufacturing approaches that will significantly reduce cost, eliminate manufacturing process waste, and improve luminaire efficacy. The team has identified critical areas of research and proposed novel technical approaches to achieve these goals. Key areas of focus in Budget Period 1 (BP1) of the project quantified the impact of applying AM methodologies to the main, discrete subsystem components (Heat Sink, Housing, Optics, Electronics). Budget Period 2 (BP2) research explored similar impact on a fully integrated, AM modular luminaire concept. Final Achievement of the Target Metrics for the project are as follows: Material Reduction: achieved > 57.45% (target is 50%) Manufacturing Process: achieved > 51% reduction (target is 50%) Application Efficacy: achieved 126 lm/W (target is 130 lm/W) First Cost vs Baseline: demonstrated 49% improvement in project timing, 59% improvement in man hour savings and 89% worse BOM costs (due to deficiencies in current “state of the art” equipment). The BOM costs improve to 53% savings if state of the art processes and equipment could have been used.

3D Printing↗
DOE OSTI2022

Surface Roughness Calculations of Additively Manufactured Cylinders via X-Ray Computed Tomography

X-ray Computed Tomography (X-ray CT) is an analytical technique used in materials science to non–destructively characterize features in variety of materials like polymers, metals, composites, and explosives. It also has the capability of imaging additively manufactured, machined and assembled parts and processes. The non-destructive imaging allows for the analysis of features (voids and cracks), which give a fundamental understanding of material characteristics. Additionally, X-ray CT can obtain accurate measurements of dimensional and topographic variations as a result of different stimuli, and assess accuracy of material production. This study will focus on parts manufactured via metal additive manufacturing (AM). Although, AM produces parts faster and easier, the printing process can produce defects (pores and surface roughness) that undermine the part’s mechanical properties. The analysis of 3D printed objects has a strength in analysis in that the material has an STL file from which the item was printed, which is not available in many manufactured materials (i.e. foams) due to stochastic structures. For this study, the print accuracy of several 3D printed cylinders will be assessed via X-ray CT to determine optimal printing parameters for parts with less defects and stronger mechanical properties. This will be accomplished by having the original STL file serve as the baseline surface to compute difference in the CT rendering to calculate surface roughness for each cylinders.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Public – Private Partnership to Promote Efficient Manufacturing and Workforce Development (IAC Final Technical Report)

Through delivering ninety (90) energy assessments to small- and medium-sized manufacturing facilities in and around Tennessee, significant understandings were gained through providing detailed energy assessment reports to manufacturers and training seventy-seven (77) engineering students in which thirty-five (35) certified IAC students were recognized by DOE. The robust involvement of Tennessee Valley Authority (TVA), local utility and Tennessee Tech’s Cybersecurity Education, Research, and Outreach Center (CEROC) in majority of assessments made the technical operation very effective where leaded to 40.5% implementation rate of energy recommendations. Other benefits of the award to the public are a dynamic modeling tool capable of analyzing existing cooling towers for energy use optimization was developed and presented to DOE IAC, providing technical assistance to non-participating manufacturers in the form of workshop and training, publishing fifteen (15) peer-reviewed conference and journal papers as well as a book chapter in the area of industrial energy efficiency field, assisting the TVA Magnolia Combined Cycle Power Plant to become the First 50001 Ready Certified Power Plant in the U.S. through briefing them on ISO 50001 and 50001 Ready as well as providing an energy assessment to the plant, assisted the new IAC center at Clemson University with on-site and remote support, and provided assessment and training in unique areas of water, waste water, cyber security and smart manufacturing to our clients, students and community.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Manufacturing Supply Chain Development for Modular Solar-Thermochemical Conversion Platform - CRADA 387 (Final Report)

Modular chemical process intensification (MCPI) is an emerging field where chemical processing is performed using small-scale modular equipment instead of conventional large centralized chemical plants. Conventional chemical plants benefit from economies of scale that encourage scale-up to ever larger plants. A goal of MCPI is to develop technology that intensifies processing so that equipment can be dramatically smaller and integrated into modular systems. Scale-up occurs by adding more modules in parallel rather than making the equipment larger. A key concept is that equipment and modules can ultimately be cheaper by leveraging economies of mass production, analogous to the automotive industry, in manufacturing the equipment. This project made significant progress toward this outcome by meeting the RAPID institute metric to reduce equipment cost by 20% for each doubling in manufacturing volume. The MCPI application was thermochemical technology that is being commercialized by STARS Technology Corporation, one of the CRADA partners. The technology converts solar and renewable power to chemical energy to produce renewable hydrogen, fuels, and chemicals. The benefit to the public is reduction in greenhouse gases that are contributing to climate change. The project transitioned the steam methane reforming (SMR) reactor from conventional fabrication methods to additive manufacturing (AM) direct metal laser sintering (DMLS) process. This is projected to reduce the cost of making a reactor by 58% when producing 100 reactors per year. Innovations in the DMLS process produced a patented design that reduces reactor weight by 60%. Reductions in material costs and processing time extend the DMLS advantage to higher production volumes. The new design promises to be 38% cheaper than the conventional processes at 1000 units per year. The resulting 87% reduction in the steam methane reforming (SMR) module cost in scaling from current costs meets the RAPID metric. The project was successful in producing and testing the first ever additively manufactured SMR reactors. A reactor achieved over 82% efficiency in converting electric power to chemical energy, which is a world record for an inductively heated SMR. The project has contributed to the design and assembly of a first demonstration plant that is headed to a hydrogen bus filling station in Thousand Palms, CA.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

AOI [1] Advanced Manufacturing of Ceramic Anchors with Embedded Sensors for Process and Health Monitoring of Coal Boilers

Researchers at West Virginia University (WVU) developed methods to fabricate and test ceramic anchors with an embedded sensor technology for monitoring the health and processing conditions within pulverized coal (PC) and fluidized-bed combustion (FBC) boiler systems. The technology included the development of advanced manufacturing processes for 2D/3D printing electroceramic (conductive ceramic) sensor designs within the ceramic anchor microstructure during the manufacturing process. This advanced manufacturing process would allow for the precise control of local microstructure and composition in order to engineer layer-by-layer any protective and electrically active materials within the refractory anchor. This 3D printing technology would permit the rapid and controlled design of the refractory microstructure and embedded sensor design throughout the volume of the ceramic anchor. The work also included a method to interconnect the sensors to boiler shell through the anchor clamp, where the sensor signals will be processed by low-power electronics and transmitted wirelessly to a central processing hub. The end-goal of the program was to produce a ceramic anchor sensor system which would be ready for implementation within a coal boiler, and/or other similar refractory liner systems (such as that in the glass and metal manufacturing areas). The project objectives were to: 1) Define the chemical and microstructural stability, in addition to the electrical properties, of oxide and non-oxide ceramic composites to be embedded within the ceramic anchor compositions that may operate up to 1400ºC; 2) Develop and implement the 2D/3D printing technology to pattern and control the microstructure of the ceramic anchor and embedded sensor circuits; 3) Develop an interconnect technology which will permit easy installation of the ceramic anchors and signal collection at the boiler shell; 4) Develop low power analog electronics and wireless communication hardware to efficiently collect the sensor signal at each processing unit and transmit data to a central hub for data analysis; 5) Demonstrate the smart ceramic anchor system for temperature and liner fracture within a high-temperature processing unit, such as a boiler furnace or glass melting furnace floor/wall liner.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Novel Hot Gas Components for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

Additive Manufacturing (AM), also known as 3D printing, has emerged as a manufacturing method that enables new design freedom for gas turbine engine manufacturers. However, the material selection for AM processable high-temperature super alloys is currently limited. Additionally, the heat transfer performance of AM enabled micro-cooling architectures is not yet well understood. Accordingly, in support of advanced manufacturing and engine performance development, Oak Ridge National Laboratory (ORNL)and Solar Turbines (Solar) conducted a multidisciplinary project to generate both AM super alloy material properties data and micro-channel performance data for two AM super alloys. The data supported the design and analysis of an internally cooled turbine hot section AM tip shoe component. This data was used to analytically predict the reduction in operating temperature of a gas turbine tip shoe. The work concluded that the cooling flow required to cool the tip shoe can be tuned to suit the efficiency improvements desired in an industrial gas turbine.

36 MATERIALS SCIENCE↗
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 OSTI2025

Membrane Electrode Assembly Manufacturing Automation Technology for the Electrochemical Compression of Hydrogen: Cooperative Research and Development (Final Report)

Electrochemical compression has the possibility to outcompete mechanical compression for hydrogen end- use applications. While HyET has a compressor that can output JO kilograms (kg)/day (fully scalable from home-to-industrial application) at up to 700 bar, the energy demand and reliability require top-quality electrochemical hydrogen compression (EHC) membrane electrode assemblies (MEAs), preferably prepared by cost-effective high-capacity manufacturing. High pressure requires a special MEA design, deviating from typical proton exchange membrane fuel cell (PEMFC) MEAs with adapted catalyst layer substrates, asking for a modified coating process. The National Renewable Energy Laboratory (NREL) will help HyET by developing an automated catalyst coating process fit for EHC MEA manufacturing. In addition, inline quality inspection methods will be developed/selected to improve the MBA quality as it is used for EHC stack assembly. In a joint effort, NREL and HyET will even design an automated manufacturing process for the EHC MEA and approach potential United States (US) suppliers of manufacturing equipment.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2018

The Hardness of Additively Manufactured Alloys

The rapidly evolving field of additive manufacturing requires a periodic assessment of the progress made in understanding the properties of metallic components. Although extensive research has been undertaken by many investigators, the data on properties such as hardness from individual publications are often fragmented. When these published data are critically reviewed, several important insights that cannot be obtained from individual papers become apparent. We examine the role of cooling rate, microstructure, alloy composition and post process heat treatment on the hardness of additively manufactured aluminum, nickel, titanium and iron base components. Hardness data for steels and aluminum alloys processed by additive manufacturing and welding are compared to understand the relative roles of manufacturing processes. Furthermore, the findings are useful to determine if a target hardness is easily attainable either by adjusting AM process variables or through appropriate alloy selection.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Additive Manufacturing of Isotropic NdFeB PPS Bonded Permanent Magnets

Extrusion based additive manufacturing of polymer composite magnets can increase the solid loading volume fraction with greater mechanical force through the printing nozzle as compared to traditional injection molding process. About 63 vol% of isotropic NdFeB magnet powders were compounded with 37 vol% of polyphenylene sulfide and bonded permanent magnets were fabricated while using Big Area Additive Manufacturing without any degradation in magnetic properties. The polyphenylene sulfide bonded magnets have a tensile stress of 20 MPa, almost double than that of nylon bonded permanent magnets. Additively manufactured and surface-protective-resin coated bonded magnets meet the industrial stability criterion of up to 175 °C with a flux-loss of 2.35% over 1000 h. They also exhibit better corrosion resistance behavior when exposed to acidic (pH = 1.35) solution for 24 h and also annealed at 80 °C over 100 h (at 95% relative humidity) over without coated magnets. Thus, polyphenylene sulfide bonded, additively manufactured, protective resin coated bonded permanent magnets provide better thermal, mechanical, and magnetic properties.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Mitigating Scatter in Mechanical Properties in AISI 410 Fabricated via Arc-Based Additive Manufacturing Process

Wire-based metal additive manufacturing utilizes the ability of additive manufacturing to fabricate complex geometries with high deposition rates (above 7 kg/h), thus finding applications in the fabrication of large-scale components, such as stamping dies. Traditionally, the workhorse materials for stamping dies have been martensitic steels. However, the complex thermal gyrations induced during additive manufacturing can cause the evolution of an inhomogeneous microstructure, which leads to a significant scatter in the mechanical properties, especially the toughness. Therefore, to understand these phenomena, arc-based additive AISI 410 samples were fabricated using robotic gas metal arc welding (GMAW) and were subjected to a detailed characterization campaign. The results show significant scatter in the tensile properties as well as Charpy V-notch impact toughness data, which was then correlated to the microstructural heterogeneity and delta (δ) ferrite formation. Post-processing (austenitizing and tempering) treatments were developed and an ~70% reduction in the scatter of tensile data and a four-times improvement in the toughness were obtained. The changes in mechanical properties were rationalized based on the microstructure evolution during additive manufacturing. Based on these, an outline to tailor the composition of “printable” steels for tooling with isotropic and uniform mechanical properties is presented and discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Preparation of Smart Materials by Additive Manufacturing Technologies: A Review

Over the last few decades, advanced manufacturing and additive printing technologies have made incredible inroads into the fields of engineering, transportation, and healthcare. Among additive manufacturing technologies, 3D printing is gradually emerging as a powerful technique owing to a combination of attractive features, such as fast prototyping, fabrication of complex designs/structures, minimization of waste generation, and easy mass customization. Of late, 4D printing has also been initiated, which is the sophisticated version of the 3D printing. It has an extra advantageous feature: retaining shape memory and being able to provide instructions to the printed parts on how to move or adapt under some environmental conditions, such as, water, wind, light, temperature, or other environmental stimuli. This advanced printing utilizes the response of smart manufactured materials, which offer the capability of changing shapes postproduction over application of any forms of energy. The potential application of 4D printing in the biomedical field is huge. Here, the technology could be applied to tissue engineering, medicine, and configuration of smart biomedical devices. Various characteristics of next generation additive printings, namely 3D and 4D printings, and their use in enhancing the manufacturing domain, their development, and some of the applications have been discussed. Special materials with piezoelectric properties and shape-changing characteristics have also been discussed in comparison with conventional material options for additive printing.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Investigation of Deformation Behavior of Additively Manufactured AISI 316L Stainless Steel with In Situ Micro-Compression Testing

Additive manufacturing techniques are being used more and more to perform the precise fabrication of engineering components with complex geometries. The heterogeneity of additively manufactured microstructures deteriorates the mechanical integrity of products. In this paper, we printed AISI 316L stainless steel using the additive manufacturing technique of laser metal deposition. Both single-phase and dual-phase substructures were formed in the grain interiors. Electron backscatter diffraction and energy-dispersive X-ray spectroscopy indicate that Si, Mo, S, Cr were enriched, while Fe was depleted along the substructure boundaries. In situ micro-compression testing was performed at room temperature along the [001] orientation. The dual-phase substructures exhibited lower yield strength and higher Young’s modulus compared with single-phase substructures. Our research provides a fundamental understanding of the relationship between the microstructure and mechanical properties of additively manufactured metallic materials. The results suggest that the uneven heat treatment in the printing process could have negative impacts on the mechanical properties due to elemental segregation.

36 MATERIALS SCIENCE↗
NASA NTRS2014

Nano-Magnets and Additive Manufacturing for Electric Motors

High power density is required for application of electric motors in hybrid electric propulsion. Potential path to achieve high power density in electric motors include advanced materials, lightweight thermal management, lightweight structural concepts, high power density power electronics, and advanced manufacturing. This presentation will focus on two key technologies for achieving high power density, advanced magnets and additive manufacturing. The maximum energy product in current magnets is reaching their theoretical limits as a result of material and process improvements. Future improvements in the maximum energy product for magnets can be achieved through development of nanocomposite magnets combining the hard magnetic phase and soft magnetic phase at the nanoscale level. The presentation will provide an overview of the current state of development for nanocomposite magnets and the future path for doubling the maximum energy product. The other part of the presentation will focus on the role of additive manufacturing in fabrication of high power density electric motors. The presentation will highlight the potential opportunities for applying additive manufacturing to fabricate electric motors.

materials↗