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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 OSTI2024

The Chalkboard: An Introduction to Electrochemical Separations

Chemical separations are a cornerstone of industrial manufacturing processes that generate products and services that have improved the standard of living for humans across the globe. To give some context as to how ubiquitous separations are in the modern world, they are involved in the production of fuels, medicines, clean water, fertilizers, materials used in semiconductor chip manufacturing, and other goods. A 2019 report by the National Academies of Sciences, Engineering, and Medicine highlights that chemical separations account for about 10 to 15% of energy use in the United States. Of the four broad sectors (residential, transportation, industry, and commerce) that use energy in the United States, industry has the largest use at 32% and about half of the energy use in industry hails from separations. It is likely that the transportation and residential sectors will experience significant decarbonization in the next 25 years with the proliferation of wind and solar energy sources coupled with electrochemical energy storage and electrification of vehicles. Finally, industrial decarbonization, on the other hand, is far more complex and challenging and it is imperative that future engineers and scientists work hard to devise alternative processes that can be powered on renewable electrons while generating little waste to produce the goods and services that make up our modern lives.

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

Industrial Assessment Center

Established in 1990, San Diego State University’s (SDSU) Industrial Assessment Center (IAC) is proud of its years of service. During this period, it has served over 620 small and medium-sized manufacturing plants in Southern California. SDSU/IAC’s efforts to transfer state-of-the-art technologies to industry have increased revenues, cultivated creativity, improved energy efficiencies, and benefited the environment. The Center has contributed to the region's economic growth and stability by assisting small and medium size companies to better compete in the global market. It has helped mitigate climate change by reducing greenhouse gas emissions. IAC activities have fostered productive relationships between the University and local industry, assisted industrial sectors to improve their energy efficiency and enhance their manufacturing productivity, in turn impacting the material and working conditions of their employees. In addition to financial savings and environmental benefits, we have trained tens of students who became energy specialists in various companies. Thus, a substantial benefit of the IAC has been the ongoing training of engineering faculty and students. All IAC graduates were offered jobs before or within weeks of their graduation. The activities of the SDSU/IAC have expanded the institutional expertise of the College and improved the knowledge base of the faculties involved leading to several related publications, master’s theses, and senior student projects. Significant number of peer-reviewed publications of the IAC director at SDSU have greatly benefitted from the experience of the Center. As a result of this extensive exposure to manufacturing processes, the SDSU/IAC has grown to be an integral component of SDSU’s engineering research and training. We have successfully built upon these established achievements and academic excellence. IAC service to industry is particularly vital in Southern California, a region with one of the highest manufacturing concentrations in the country. SDSU/IAC has understood and implemented the overall objectives of DOE’s IAC program and guidelines except for the pandemic years when the country’s manufacturing sector was put in dire stress. In addition to student training and service to industry, IAC’s contribution to state and local governments as well as utility companies to assess energy policies and design rebate and incentive strategies cannot be undermined.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1998

Rapid Prototyping Roadmapping

Roadmapping has long been thought of as a process for getting from point A to point B within a single discipline. Roadmapping for Rapid Prototyping has multiple paths of which we will diagram in this meeting. When you consider the dynamic change that the computer has made in both developing as well as manufacturing products, we could only assume that further electronic medium matched with mechanical inventions will continue. This industry roadmap is intended to point and lead us to the promised manufacturing land. We hope to reduce the inherent risk associated with technology development by providing a clear goal of mapping to a manufacturing process. The work of DoE in 1994 was excellent and began a journey that would benefit the decision makers and allow for choices that would be good investment decisions. While this work included government agencies, this map is broader and includes industry and academia input.

Cooper, Kenneth G.↗
NASA NTRS2008

Electron Beam Freeform Fabrication: A Fabrication Process that Revolutionizes Aircraft Structural Designs and Spacecraft Supportability

The technological inception and challenges, as well as current applications of the electron beam freeform fabrication (EBF3) process are outlined. The process was motivated by the need for a new metals technology that would be cost-effective, enable the production of new alloys and that would could be used for efficient, lightweight structures. EBF3 is a rapid metal fabrication, layer-additive process that uses no molds or tools and which yields properties equivalent to wrought. The benefits of EBF3 include it near-net shape which minimizes scrap and reduces part count; efficiency in design which allows for lighter weight and enhanced performance; and, its "green" manufacturing process which yields minimal waste products. EBF3 also has a high tensile strength, while a structural test comparison found that EBF3 panels performed 5% lower than machined panels. Technical challenges in the EBF3 process include a need for process control monitoring and an improvement in localized heat response. Currently, the EBF3 process can be used to add details onto forgings and to construct and form complex shapes. However, it has potential uses in a variety of industries including aerospace, automotive, sporting goods and medical implant devices. The novel structural design capabilities of EBF3 have the ability to yield curved stiffeners which may be optimized for performance, low weight, low noise and damage tolerance applications. EBF3 has also demonstrated its usefulness in 0-gravity environments for supportability in space applications.

Taminger, Karen M.↗
NASA NTRS2012

Face-Sheet Quality Analysis and Thermo-Physical Property Characterization of OOA and Autoclave Panels

Increased application of polymer matrix composite (PMC) materials in large vehicle structures requires consideration of non-autoclave manufacturing technology. The NASA Composites for Exploration project, and its predecessor, Lightweight Spacecraft Structures and Materials project, were tasked with the development of materials and manufacturing processes for structures that will perform in a heavy-lift-launch vehicle environment. Both autoclave and out of autoclave processable materials were considered. Large PMC structures envisioned for such a vehicle included the payload shroud and the interstage connector. In this study, composite sandwich panels representing 1/16th segments of the barrel section of the Ares V rocket fairing were prepared as 1.8 m x 2.4 m sections of the 10 m diameter arc segment. IM7/977-3 was used as the face-sheet prepreg of the autoclave processed panels and T40-800B/5320-1 for the out of autoclave panels. The core was 49.7 kg/sq m (3.1 lb/cu ft (pcf)) aluminum honeycomb. Face-sheets were fabricated by automated tape laying 153 mm wide unidirectional tape. This work details analysis of the manufactured panels where face-sheet quality was characterized by optical microscopy, cured ply thickness measurements, acid digestion, and thermal analysis.

Miller, Sandi G.↗
NASA NTRS2024

Electron Beam Welding of Additively Manufactured Niobium Alloy Heat Pipes

Additively manufactured refractory alloy-liquid metal heat pipes are being developed and tested for thermal management systems within nuclear propulsion and power applications. This study investigated electron beam (EB) welded joints on a laser powder bed fusion printed niobium alloy (C-103) and the impact of multiple joined heat pipe sections on working fluid flow and container leak-tightness. Results showed that EB welded joints connecting multiple heat pipe sections do not impact working fluid wicking behavior and the printed C-103 material and the EB welds joining the tubular sections created a leak-tight container. Interestingly, CT data showed an order of magnitude greater number and volume of porosity indications in the ground mating surface weld compared to the as-printed mating surface weld. The work concluded that AM is a viable manufacturing process for niobium alloy heat pipes and provided valuable insights for future AM heat pipe research and development.

Electron beam welding↗
NASA NTRS2018

Automated Fiber Placement Defect Identity Cards: Cause, Anticipation, Existence, Significance, and Progression

Automated Fiber Placement (AFP), a major composite manufacturing process, can result in many defects during the layup process that often require manual corrective action to produce a part with acceptable quality. These defects are the main limitation of the technology and can be hard to categorize or define in many situations. This paper provides a thorough definition and classification of all AFP defects. This effort constitutes a comprehensive and extensive library relevant to AFP defects. The defects selected and defined in this work are based on understanding and experience from the manufacture and research of advanced composite structure. Proper classification of these defects required an in-depth literature review and consideration of various viewpoints ranging from designers, manufacturers, analysts, and inspection professionals. Collectively, these sources were utilized to develop the most accurate view of each of the individual defect types. The results are presented as identity cards for each defect type, intended to provide researchers and the manufacturing industry a clear understanding of the (1) cause, (2) anticipation, (3) existence, (4) significance, and (5) progression of the defined AFP defects. The link between AFP defects and process planning, layup strategies, and machining was also investigated. Categorization of all important automated fiber placement defects is presented.

Harik, Ramy↗
DOE OSTI2023

Optimizing hierarchical membrane/catalyst systems for oxidative coupling of methane using additive manufacturing

The advantage of a membrane/catalyst system in oxidative coupling of methane (OCM) compared to conventional reactive systems is that by introducing oxygen to the OCM catalytic sites through a membrane, parasitic gas phase reactions of O 2 (g), responsible for lowering product selectivity, can be avoided. The design and fabrication of membrane/catalyst systems has, however, been hampered by low volumetric chemical conversion rates, high capital cost, and difficulties in codesigning membrane and catalyst properties to optimize the performance. We solve these issues by developing a dual-layer additive manufacturing process, based on phase inversion, to design, fabricate and optimize a hollow fiber membrane/catalyst system for OCM. We demonstrate the approach though a case study using BaCe 0.8 Gd 0.2 O 3-δ (BCG) as the basis of both the catalyst and separation layers. We show that by using the manufacturing approach we can codesign the membrane thickness and catalyst surface area so that the flux of oxygen transport through the membrane and methane activation rates in the catalyst layer match each other. Here, we demonstrate that this “rate matching” is critical for maximizing the performance, with the membrane/catalyst system significantly overperforming conventional reactor designs under identical conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Numerical and experimental investigation of the geometry dependent layer-wise evolution of temperature during laser powder bed fusion of Ti–6Al–4V

Abstract Laser powder bed fusion (L-PBF) is currently the additive manufacturing process with the widest industrial use for metal parts. Yet some hurdles persist on the way to a widespread industrial serial production, with reproducibility of the process and the resulting part properties being a major concern. As the geometry changes, so do the local boundary conditions for heat dissipation. Consequently, the use of global, geometry-independent processing parameters, which are today’s state of the art, may result in varying part properties or even defects. This paper presents a numerical simulation as a method to predict the geometry-dependent temperature evolution during the build. For demonstration, an overhang structure with varying angles towards the build platform was manufactured using Ti–6Al–4V. A calibrated infrared camera was integrated into a commercial L-PBF system to measure the temperature evolution over time for a total build height of 10 mm, and the results are used for validation of the simulation. It is shown that the simulation is capable of predicting the temperature between layers. The deviations between simulation and measurement remain in single digit range for smaller overhang structures (90°, 60° and 45°). For large overhang structures (30°), the simulation tends to over-predict the temperatures up to 15 °C. Experiments with varying process parameters showed the feasibility of energy reduction as compensation of the heat accumulation produced by overhang structures.

Li, Gefei (ORCID:0000000174837952)↗
DOE OSTI2023

Image Processing Pipeline for Fluoroelastomer Crystallite Detection in Atomic Force Microscopy Images

Phase transformations in materials systems can be tracked using atomic force microscopy (AFM), enabling the examination of surface properties and macroscale morphologies. In situ measurements investigating phase transformations generate large datasets of time-lapse image sequences. The interpretation of the resulting image sequences, guided by domain-knowledge, requires manual image processing using handcrafted masks. Here this approach is time-consuming and restricts the number of images that can be processed. Her in this study, we developed an automated image processing pipeline which integrates image detection and segmentation methods. We examine five time-series AFM videos of various fluoroelastomer phase transformations. The number of image sequences per video ranges from a hundred to a thousand image sequences. The resulting image processing pipeline aims to automatically classify and analyze images to enable batch processing. Using this pipeline, the growth of each individual fluoroelastomer crystallite can be tracked through time. We incorporated statistical analysis into the pipeline to investigate trends in phase transformations between different fluoroelastomer batches. Understanding these phase transformations is crucial, as it can provide valuable insights into manufacturing processes, improve product quality, and possibly lead to the development of more advanced fluoroelastomer formulations.

36 MATERIALS SCIENCE↗
NASA NTRS1990

Design and development of a space station hazardous material system for assessing chemical compatibility

As the Space Station nears reality in funding support from Congress, NASA plans to perform over a hundred different missions in the coming decade. Incrementally deployed, the Space Station will evolve into modules linked to an integral structure. Each module will have characteristic functions, such as logistics, habitation, and materials processing. Because the Space Station is to be user friendly for experimenters, NASA is anticipating that a variety of different chemicals will be taken on-board. Accidental release of these potentially toxic chemicals and their chemical compatibility is the focus of this discourse. The Microgravity Manufacturing Processing Facility (MMPF) will contain the various facilities within the U.S. Laboratory (USL). Each facility will have a characteristic purpose, such as alloy solidification or vapor crystal growth. By examining the proposed experiments for each facility, identifying the chemical constituents, their physical state and/or changes, byproducts and effluents, those payloads can be identified which may contain toxic, explosive, or reactive compounds that require processing or containment in mission peculiar waste management systems. Synergistic reactions from mixed effluent streams is of major concern. Each experiment will have it own data file, complete with schematic, chemical listing, physical data, etc. Chemical compatibility information from various databases will provide assistance in the analysis of alternate disposal techniques (pretreatment, separate storage, etc.). Along with data from the Risk Analysis of the Proposed USL Waste Management System, accidental release of potentially toxic and catastrophic chemicals would be eliminated or reduced.

Congo, Richard T.↗
DOE OSTI2023

Fast and accurate reduced-order modeling of a MOOSE-based additive manufacturing model with operator learning

One predominant challenge in additive manufacturing (AM) is to achieve specific material properties by manipulating manufacturing process parameters during the runtime. Such manipulation tends to increase the computational load imposed on existing simulation tools employed in AM. The goal of the present work is to construct a fast and accurate reduced-order model (ROM) for an AM model developed within the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework, ultimately reducing the time/cost of AM control and optimization processes. Our adoption of the operator learning (OL) approach enabled us to learn a family of differential equations produced by altering process variables in the laser’s Gaussian point heat source. More specifically, we used the Fourier neural operator (FNO) and deep operator network (DeepONet) to develop ROMs for time-dependent responses. Furthermore, we benchmarked the performance of these OL methods against a conventional deep neural network (DNN)-based ROM. Ultimately, we found that OL methods offer comparable performance and, in terms of accuracy and generalizability, even outperform DNN at predicting scalar model responses. The DNN-based ROM afforded the fastest training time. Furthermore, all the ROMs were faster than the original MOOSE model yet still provided accurate predictions. FNO had a smaller mean prediction error than DeepONet, with a larger variance for time-dependent responses. Unlike DNN, both FNO and DeepONet were able to simulate time series data without the need for dimensionality reduction techniques. Finally, the present work can help facilitate the AM optimization process by enabling faster execution of simulation tools while still preserving evaluation accuracy.

36 MATERIALS SCIENCE↗
DOE OSTI2025

MOOSE ProbML: Parallelized probabilistic machine learning and uncertainty quantification for computational energy applications

Here, this paper presents the development and demonstration of massively parallel probabilistic machine learning (ML) and uncertainty quantification (UQ) capabilities within the Multiphysics Object-Oriented Simulation Environment (MOOSE), an open-source computational platform for parallel finite element and finite volume analyses. In addressing the computational expense and uncertainties inherent in complex multiphysics simulations, this paper integrates Gaussian process (GP) variants, active learning, Bayesian inverse UQ, adaptive forward UQ, Bayesian optimization, evolutionary optimization, and Markov chain Monte Carlo (MCMC) within MOOSE. It also elaborates on the interaction among key MOOSE systems — Sampler, MultiApp, Reporter, and Surrogate — in enabling these capabilities. The modularity offered by these systems enables development of a multitude of probabilistic ML and UQ algorithms in MOOSE. Example code demonstrations include parallel active learning and parallel Bayesian inference via active learning. The impact of these developments is illustrated through five applications relevant to computational energy applications: UQ of nuclear fuel fission product release, using parallel active learning Bayesian inference; very rare events analysis in nuclear microreactors using active learning; advanced manufacturing process modeling using multi-output GPs (MOGPs) and dimensionality reduction; fluid flow using deep GPs (DGPs); and tritium transport model parameter optimization for fusion energy, using batch Bayesian optimization. These capabilities are part of the MOOSE framework.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Novel PV Array System Design to Accelerate Solar Deployment, Reduce LCOE, Reduce Land Use Competition, and Increase Siting Flexibility

The increasing demand for solar energy faces significant barriers, including inefficient construction processes, high project costs limiting LCOE reductions, and diminishing availability of "good" sites with favorable interconnection. Conventional solar installations are often constrained by long construction timelines and the need for flat, large plots. Furthermore, the industry struggles with a shortage of skilled labor. Planted Solar aims to address these challenges by fundamentally transforming solar deployment from a construction project into a streamlined manufacturing process. Our novel approach combines high-density racking, integrated terrain-following design software, and installation automation. Unlike competing solutions that either assist with standard array assembly or offer dense packing without terrain adaptability or automation, Planted's technology uniquely brings together a new array product with in-place automated manufacturing to achieve the lowest possible cost, greater site flexibility, and accelerated deployment.

14 SOLAR ENERGY↗
NASA NTRS1991

HYMOSS signal processing for pushbroom spectral imaging

The objective of the Pushbroom Spectral Imaging Program was to develop on-focal plane electronics which compensate for detector array non-uniformities. The approach taken was to implement a simple two point calibration algorithm on focal plane which allows for offset and linear gain correction. The key on focal plane features which made this technique feasible was the use of a high quality transimpedance amplifier (TIA) and an analog-to-digital converter for each detector channel. Gain compensation is accomplished by varying the feedback capacitance of the integrate and dump TIA. Offset correction is performed by storing offsets in a special on focal plane offset register and digitally subtracting the offsets from the readout data during the multiplexing operation. A custom integrated circuit was designed, fabricated, and tested on this program which proved that nonuniformity compensated, analog-to-digital converting circuits may be used to read out infrared detectors. Irvine Sensors Corporation (ISC) successfully demonstrated the following innovative on-focal-plane functions that allow for correction of detector non-uniformities. Most of the circuit functions demonstrated on this program are finding their way onto future IC's because of their impact on reduced downstream processing, increased focal plane performance, simplified focal plane control, reduced number of dewar connections, as well as the noise immunity of a digital interface dewar. The potential commercial applications for this integrated circuit are primarily in imaging systems. These imaging systems may be used for: security monitoring systems, manufacturing process monitoring, robotics, and for spectral imaging when used in analytical instrumentation.

Ludwig, David E.↗
NASA NTRS2011

Unintended Consequences: How Qualification Constrains Innovation

The development and implementation of new materials and manufacturing processes for aerospace application is often hindered by the high cost and long time span associated with current qualification procedures. The data requirements necessary for material and process qualification are extensive and often require millions of dollars and multiple years to complete. Furthermore, these qualification data can become obsolete for even minor changes to the processing route. This burden is a serious impediment to the pursuit of revolutionary new materials and more affordable processing methods for air vehicle structures. The application of integrated computational materials engineering methods to this problem can help to reduce the barriers to rapid insertion of new materials and processes. By establishing predictive capability for the development of microstructural features in relation to processing and relating this to critical property characteristics, a streamlined approach to qualification is possible. This paper critically examines the advantages and challenges to a modeling-assisted qualification approach for aerospace structural materials. An example of how this approach might apply towards the emerging field of additive manufacturing is discussed in detail.

Brice, Craig A.↗
NASA NTRS2012

Face-Sheet Quality Analysis and Thermo-Physical Property Characterization of OOA and Autoclave Panels

Increased application of polymer matrix composite (PMC) materials in large vehicle structures requires consideration of non-autoclave manufacturing technology. The NASA Composites for Exploration project, and its predecessor, Lightweight Spacecraft Structures and Materials project, were tasked with the development of materials and manufacturing processes for structures that will perform in a heavy-lift-launch vehicle environment. Both autoclave and out of autoclave processable materials were considered. Large PMC structures envisioned for such a vehicle included the payload shroud and the interstage connector. In this study, composite sandwich panels representing 1/16th segments of the barrel section of the Ares V rocket fairing were prepared as 1.8 m x 2.4 m sections of the 10 m diameter arc segment. IM7/977-3 was used as the face-sheet prepreg of the autoclave processed panels and T40-800B/5320-1 for the out of autoclave panels. The core was 49.7 kilograms per square meters (3.1 pounds per cubic feet (pcf)) aluminum honeycomb. Face-sheets were fabricated by automated tape laying 153 mm wide unidirectional tape. This work details analysis of the manufactured panels where face-sheet quality was characterized by optical microscopy, cured ply thickness measurements, acid digestion, and thermal analysis.

Miller, Sandi G.↗