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All sources NASA NTRS DOE OSTI

DOE OSTI2022

Integrated charging infrastructure planning and charging scheduling for battery electric bus systems

We report studies on the electric bus system planning problem have typically focused exclusively on either the deployment of charging infrastructure or the scheduling of charging events; few have examined the impact of charging facility deployment on charging activities. Considering the interdependence of system design and operational strategies, this study proposes a two-phase optimization framework for charging infrastructure planning and charging scheduling for battery electric bus systems. An integrated optimization model is first developed to simultaneously optimize charger deployment, on-board battery capacity, and charging schedules. A charging scheduling model is further proposed and a rolling horizon approach is utilized in the second phase to optimize the real-time charging scheduling of electric buses. Compared to existing electric bus system planning methods, the proposed integrated model can reduce the total system cost by 19.5%. In addition, compared to uncontrolled charging, the proposed rolling horizon-based charging strategy can reduce the total charging cost by 68.3%.

25 ENERGY STORAGE↗

NASA NTRS1993

Advanced transportation system study: Manned launch vehicle concepts for two way transportation system payloads to LEO

The purpose of the Advanced Transportation System Study (ATSS) task area 1 study effort is to examine manned launch vehicle booster concepts and two-way cargo transfer and return vehicle concepts to determine which of the many proposed concepts best meets NASA's needs for two-way transportation to low earth orbit. The study identified specific configurations of the normally unmanned, expendable launch vehicles (such as the National Launch System family) necessary to fly manned payloads. These launch vehicle configurations were then analyzed to determine the integrated booster/spacecraft performance, operations, reliability, and cost characteristics for the payload delivery and return mission. Design impacts to the expendable launch vehicles which would be required to perform the manned payload delivery mission were also identified. These impacts included the implications of applying NASA's man-rating requirements, as well as any mission or payload unique impacts. The booster concepts evaluated included the National Launch System (NLS) family of expendable vehicles and several variations of the NLS reference configurations to deliver larger manned payload concepts (such as the crew logistics vehicle (CLV) proposed by NASA JSC). Advanced, clean sheet concepts such as an F-1A engine derived liquid rocket booster (LRB), the single stage to orbit rocket, and a NASP-derived aerospace plane were also included in the study effort. Existing expendable launch vehicles such as the Titan 4, Ariane 5, Energia, and Proton were also examined. Although several manned payload concepts were considered in the analyses, the reference manned payload was the NASA Langley Research Center's HL-20 version of the personnel launch system (PLS). A scaled up version of the PLS for combined crew/cargo delivery capability, the HL-42 configuration, was also included in the analyses of cargo transfer and return vehicle (CTRV) booster concepts. In addition to strictly manned payloads, two-way cargo transportation systems (CTRV's) were also examined. The study provided detailed design and analysis of the performance, reliability, and operations of these concepts. The study analyzed these concepts as unique systems and also analyzed several combined CTRV/booster configurations as integrated launch systems (such as for launch abort analyses). Included in the set of CTRV concepts analyzed were the medium CTRV, the integral CTRV (in both a pressurized and unpressurized configuration), the winged CTRV, and an attached cargo carrier for the PLS system known as the PLS caboose.

Duffy, James B.↗

NASA NTRS1994

Program test objectives milestone 3

The following conclusions have been developed relative to propulsion system technology adequacy for efficient development and operation of recoverable and expendable launch vehicles (RLV and ELV) and the benefits which the integrated propulsion technology demonstrator will provide for enhancing technology: (1) Technology improvements relative to propulsion system design and operation can reduce program cost. Many features or improvement needs to enhance operability, reduce cost, and improve payload are identified. (2) The Integrated Propulsion Technology Demonstrator (IPTD) Program provides a means of resolving the majority of issues associated with improvement needs. (3) The IPTD will evaluate complex integration of vehicle and facility functions in fluid management and propulsion control systems, and provides an environment for validating improved mechanical and electrical components. (4) The IPTD provides a mechanism for investigating operational issues focusing on reducing manpower and time to perform various functions at the launch site. These efforts include model development, collection of data to validate subject models, and ultimate development of complex time line models. (5) The IPTD provides an engine test bed for tri/bi-propellant engine development firings which is representative of the actual vehicle environment. (6) The IPTD provides for only a limited multiengine configuration integration environment for RLV. Multiengine efforts may be simulated for a number of subsystems and a number of subsystems are relatively independent of the multiengine influences.

Gaynor, T. L.↗

NASA NTRSDate not supplied

Towards Erecting Straighter Lightweight Towers on the Moon Using Deployable Guy Wires

This paper reports our static stability test findings for a simple guy wire system to correct the natural lateral deflections of an 8.5m tall, compact deployable composite tower intended to support exploration of lunar permanently shadowed regions by nearby robotic assets. Deployable composite booms with microgravity flight heritage are currently being investigated at NASA Langley Research Center (LaRC) and Massachusetts Institute of Technology(MIT)’s Space Resources Workshop for their potential to be vertically deployed in the lunar gravity field, in support of NASA’s Artemis campaign. These applications include vertical solar arrays and the provision of elevated lines-of-sight to science or engineering payloads on landers and rovers, in support of nearby or distant crewed or robotic assets exploring scientifically interesting and hard to reach areas. Useful elevated payloads include radio repeaters, remote sensing and imaging, navigation and power beaming systems. However, while these lightweight booms have an excellent height to mass ratio, they typically exhibit slight axial curvature upon deployment resulting in appreciable lateral dead-load deflection of the tip mass relative to the tower base. This static deflection increases with tower height and tip mass, not only constraining the value delivered by the tower but also endangering its integrity. To develop a competitive, lightweight deployable composite boom tower, a capability to correct static deflections during and after deployment may be required. This paper presents a pathfinder deployable guy wire stability system for the MIT / LaRC self-erecting composite boom lunar tower that provides real time measurements, maintains tension passively, and can serve as a reconfigurable platform to test new guy wire components, configurations and control algorithms. Using a validated, calibrated photogrammetry system, the natural lateral deflection of the boom tip relative to the boom base at different deployed heights in Earth’s gravity field was recorded. With real-time tension measurements it was found that guy wires can significantly reduce the tip deflection of a deployable composite boom under dead load. Specifically, we found that (1) control capability is greatest where it is needed most, i.e. for the lever arm closest to being opposite the direction of deflection, and (2) for a tower height of at least 8.5 m and arm length of at least 60 cm, a solution of differential tension in all three arms exists and, in principle, provides sufficient control capability to correct or significantly reduce boom deflections. We also found that natural deflections occur almost entirely out-of-plane of the seams of the boom cross-section, which was expected, and that the natural boom tip lateral deflection under dead load upon deployment was ~5% of boom deployed length, unexpectedly exceeding the manufacturing acceptance specification of 1%.Ongoing and future collaborative work between LaRC and MIT includes the further investigation of the unexpected lateral deflection, testing of alternative guy wire system designs at higher tensions and higher deployed heights, as well as trade studies of costs and benefits of an optimized integrated guywire system compared to other types of static stability solutions.

lunar towers↗

DOE OSTI2020

Functional Photoresists for Energy Applications. Final Report

Monolithic ultralow-density porous bulk materials have recently attracted much interest due to many emerging applications in the areas of catalysis, energy storage and conversion, and thermal insulation. They are also important components of high energy density (HED) and inertial confinement fusion (ICF) targets. However, despite tremendous progress that has been made in the synthesis of porous materials, deterministic and independent control over microscopic architecture, density and composition remain key issues, and their integration in high precision devices requires cost and time-intensive mechanical machining that not only reduces reproducibility by generating debris but also limits the complexity of the 3D shapes that can be realized. In this project, we overcame these limitations by developing a universal templating capability that provides deterministic and independent control over density, composition, architecture, and macroscopic sample shape. This was achieved by developing the technology to 1) 3D print ultrahigh resolution, ultra-high precision polymeric micro-lattice templates, 2) coat these templates with the desired materials, and 3) removing the template (Fig. 1a). Atomic layer deposition (ALD) provides the atomic scale coating thickness accuracy required for precisely controlling density. While this templating approach had been demonstrated in prior work, limitations in suitable photoresists, 3D print technologies, print design, and template removal techniques did not allow the fabrication of millimeter-sized high-precision parts with sub-micron resolution. To enable this technology, we developed 1) two-photon polymerization (TPP) print designs that enable the fabrication of millimeter-sized, mechanically robust polymeric templates with sub-micron resolution and 2) a continuum level TPP printing simulation capability for additional print design guidance; 3) atomistic models to study photoresist polymerization kinetics and network topography, 4) refractive index matched polymeric and preceramic TPP photoresists, and 5) functional TPP photoresists including porous voxel structures and self-immolative polymer photoresist chemistries; and 6) damage free template removal techniques that enable the fabrication of defect-free high-precision low-density foam components. We also developed a templating approach for pure carbon microlattices with a unique tube-in-tube ligament morphology. As a test platform, we pursued the fabrication of foam liners that promise to further increase the neutron yield in indirect drive ICF experiments by improving implosion symmetry control and coupling between the laser and the deuterium-tritium fuel. This application requires fabrication and integration of a ultra-high precision, millimeter-sized, thin-walled (200-400 micrometer thick), low-density (10-30 mg/cc), high atomic number (high Z) cylindrical foam tube into the gold hohlraum of an indirect drive ICF target (Fig. 1b). While our hohlraum liner test case will mainly find application in HED and ICF experiments, the underlying science will also directly apply to previously developed nanoparticle and additive manufacturing technologies and will advance those techniques as well.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Comparison of Commercial, State-of-the-Art, Fossil-Based Ammonia Production

This NETL report provides a comprehensive techno-economic analysis of current, state-of-the-art, fossil-based ammonia production processes, explicitly utilizing natural gas as the feedstock. The study thoroughly investigates three distinct configurations: conventional Steam Methane Reforming (SMR) without carbon capture, SMR integrated with carbon capture and storage (CCS), and Autothermal Reforming (ATR) also with CCS. The analysis incorporates detailed equipment cost accounting as part of its methodology. The primary objective is to meticulously evaluate the cost and performance of these established and emerging technological pathways, considering factors such as capital expenditures, operational costs, and energy consumption. While the report acknowledges and quantifies environmental impacts, its central focus remains on the economic and technical feasibility of each process design employing these current technologies. The analysis provides a direct comparison of the Levelized Cost of Ammonia (LCOA) for each pathway, revealing how the integration of CCS within these state-of-the-art systems impacts the overall production cost. The ATR+CCS configuration, representing an advanced approach, emerged with a slightly more favorable LCOA compared to SMR+CCS. This benefit was attributed to its inherent process efficiencies, high carbon capture rates, and economy of scale advantages. The report details the energy consumption profiles for each case, including metrics like net energy consumption and thermal efficiency, which are critical for assessing the performance of these contemporary industrial processes. Sensitivity analyses further explore how variables such as natural gas price, capital costs, and capacity factors influence the LCOA across all scenarios, offering critical insights into the economic robustness and scalability of these current ammonia production technologies.

03 NATURAL GAS↗

NASA NTRS1976

Cost estimation: An expert-opinion approach

A methodology is outlined which can be used to estimate the costs of research and development projects. The approach uses the Delphi technique a method developed by the Rand Corporation for systematically eliciting and evaluating group judgments in an objective manner. The use of the Delphi allows for the integration of expert opinion into the cost-estimating process in a consistent and rigorous fashion. This approach can also signal potential cost-problem areas. This result can be a useful tool in planning additional cost analysis or in estimating contingency funds. A Monte Carlo approach is also examined.

Buffalano, C.↗

DOE OSTI2021

Economic and Environmental Sustainability of an Integrated Direct Air Capture System with Advanced Algal Biofuel Production

The presentation titled Economic and Environmental Sustainability of an Integrated Direct Air Capture System with Advanced Algal Biofuel Production. The background and motivation of the presentation will encompass promotion of decarbonization of the atmosphere, decouple algae production facilities from anthropogenic CO2 sources, identify key economic drivers, minimize cost and greenhouse gas emissions through process integration and optimization.

algal biofuel production↗

DOE OSTI2022

Cross-scale sensing of field-level crop residue cover: Integrating field photos, airborne hyperspectral imaging, and satellite data

Conservation tillage practices can bring benefits to agricultural sustainability. Accurate spatial and temporal resolved information of field-scale crop residue cover, which reflects tillage intensity, is highly valuable for evaluating the outcomes of government conservation programs and voluntary ecosystem service markets, as well as facilitating agroecosystem modeling to quantify cropland biogeochemical processes. Remote sensing has the potential to cost-effectively detect crop residue cover, however, existing regional-scale studies were limited by insufficient ground truth data, scale mismatch between coarse satellite pixels and ground data, and the lack of key spectral data for detecting crop residues. Therefore, this study developed an innovative cross-sensing framework to integrate proximal sensing, airborne hyperspectral imaging, and satellite Earth Observation through deep learning to quantify field-level crop residue cover fractions at the regional scale. Specifically, we have collected intensive ground orthographic photos and conducted airborne hyperspectral surveys at corn and soybean fields of Champaign and nearby counties in Illinois, the heartland of the U.S. Corn Belt. Through semi-automatic labeling aided by ResNet-50 and superpixel image segmentation, we obtained 6719 records of ground residue fractions. With these ground data, we developed the 1-dimensional convolution neural network (CNN) model using airborne hyperspectral reflectance, which has 0.5m spatial resolution and 3–5 nm spectral resolution from 400 to 2400 nm, to predict residue fractions. By applying the CNN model to airborne pixels, we augmented “ground truth” data of crop residues and further combined them with Harmonized Landsat and Sentinel-2 (HLS) satellite data to quantify regional residue fractions at 30 m resolution. Results show that airborne hyperspectral imagery with CNN can accurately detect residue fractions (R 2 = 0.82, relative RMSE = 11.73%) to effectively generate quasi “ground truth” data to support satellite upscaling to all fields. With independent ground data for testing, we found that the ground-airborne-satellite integrative framework achieved better predictions in estimating crop residue cover (R 2 = 0.67, relative RMSE = 17.53%) than the conventional ground-satellite upscaling (R 2 = 0.22, relative RMSE = 32.09%). Here we also found that the shortwave infrared wavelengths, particularly 2100–2300 nm, are vital for predicting crop residue cover. Sentinel-2 and Landsat-8 data have a comparable capability to track residue fractions due to similar shortwave infrared wavelengths. This study highlights the high accuracy of hyperspectral imaging to detect agroecosystem tillage management practices and the advantages of cross-scale sensing to cost-effectively integrate multi-source data to quantify field-level agroecosystem variables across scales.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2025

A Novel Manufacturing Process of Lightweight Automotive Seats: Integration of Additive Manufacturing and Reinforced Polymer Composite

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

A Novel Manufacturing Process of Lightweight Automotive Seats (Integration of Additive Manufacturing and Reinforced Polymer Composite)

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components. However, fabricating these metal polymer composite structures through traditional manufacturing processes limits their mechanical properties due to limited design freedom, lack of control over fiber orientation in composite parts, and poor interfacial bonding between the constituent materials. It is essential to develop a novel manufacturing process to enable high throughput production of lightweight automotive seats using metal and polymer composites. As such it is important to design the automotive seat suitable for manufacturing via this process and perform mechanical characterization on various subcomponents of the seat to ensure that the design and performance requirements provided by the auto manufacturer are met. The aim of this project is to develop a novel manufacturing technique to produce lightweight automotive seat by combining AM with conventional manufacturing processes. The car seat back panel will be designed via topology optimization and numerical simulations to minimize the overall weight while ensuring it meets all the performance requirements. The optimization of the seat back structure will be based on computational stress analysis to maximize the stiffness and minimize the weight. Materials currently used by Ford Motor Company will be adopted for a few subcomponents while the in-house composite materials will be used for the rest of the seat back. The composite and metallic materials will be tested to determine their mechanical properties as these are necessary for simulations. A novel manufacturing process will be developed to integrate AM metal inserts with discontinuous reinforced composite through large scale additive manufacturing and compression overmolding processes. The developed manufacturing technique will be used to fabricated various subcomponents suitable for the seat back design and mechanically tested to determine their properties. The manufacturing of the lightweight seat back design through this process involves integrated AM metal inserts with the composite structure for recliner connection. The manufacturing of the entire seat back which is lightweight through the novel manufacturing process will be discussed. The performance of the designed seat back will be investigated through numerical simulations and shown to meet all the requirements provided by the auto manufacturer. The final goal of developing a novel manufacturing process for lightweight automotive seats is met through design optimization of seat back, manufacturing of subcomponents, mechanical characterization, and validation through numerical simulations. The routes to achieve the final goal of the project and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. The project resulted in the development of a novel manufacturing process to integrate metal inserts with tailored polymer composite preforms through overmolding. Leveraging this proven manufacturing process, a lightweight seat back was designed through topology optimization and numerical simulations. The designed seat back uses AM metal inserts and compression overmolding of tailored polymer composite preforms obtained via large scale additive manufacturing. The metal polymer composite structures fabricated through this process exhibited enhancement in stiffness and improved ductility upon testing. Overall, the project provided an alternative design and manufacturing technique for automotive seat back that enables weight saving while meeting the safety and performance requirements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2003

Process-Based Cost Estimation for Ramjet/Scramjet Engines

Process-based cost estimation plays a key role in effecting cultural change that integrates distributed science, technology and engineering teams to rapidly create innovative and affordable products. Working together, NASA Glenn Research Center and Boeing Canoga Park have developed a methodology of process-based cost estimation bridging the methodologies of high-level parametric models and detailed bottoms-up estimation. The NASA GRC/Boeing CP process-based cost model provides a probabilistic structure of layered cost drivers. High-level inputs characterize mission requirements, system performance, and relevant economic factors. Design alternatives are extracted from a standard, product-specific work breakdown structure to pre-load lower-level cost driver inputs and generate the cost-risk analysis. As product design progresses and matures the lower level more detailed cost drivers can be re-accessed and the projected variation of input values narrowed, thereby generating a progressively more accurate estimate of cost-risk. Incorporated into the process-based cost model are techniques for decision analysis, specifically, the analytic hierarchy process (AHP) and functional utility analysis. Design alternatives may then be evaluated not just on cost-risk, but also user defined performance and schedule criteria. This implementation of full-trade study support contributes significantly to the realization of the integrated development environment. The process-based cost estimation model generates development and manufacturing cost estimates. The development team plans to expand the manufacturing process base from approximately 80 manufacturing processes to over 250 processes. Operation and support cost modeling is also envisioned. Process-based estimation considers the materials, resources, and processes in establishing cost-risk and rather depending on weight as an input, actually estimates weight along with cost and schedule.

Singh, Brijendra↗

NASA NTRS1992

Industry survey of space system cost benefits from New Ways Of Doing Business

The cost of designing, building and operating space system hardware has always been expensive. Small quantities of specialty parts escalate engineering design, production and operations cost. Funding cutbacks and shrinking revenues dictate aggressive cost saving programs. NASA's highest priority is providing economical transportation to and from space. Over the past three decades NASA has seen technological advances that provide grater efficiencies in designing, building, and operating of space system hardware. As future programs such as NLS, LUTE and SEI begin, these greater efficiencies and cost savings should be reflected in the cost models. There are several New Ways Of Doing Business (NWODB) which, when fully implemented will reduce space system costs. These philosophies and/or culture changes are integrated in five areas: (1) More Extensive Pre-Phase C/D & E, (2) Multi Year Funding Stability, (3) Improved Quality, Management and Procurement Processes, (4) Advanced Design Methods, and (5) Advanced Production Methods. Following is an overview of NWODB and the Cost Quantification Analysis results using an industry survey, one of the four quantification techniques used in the study. The NWODB Cost Quantification Analysis is a study performed at Marshall Space Flight Center by the Engineering Cost Group, Applied Research Incorporated and Pittsburg State University. This study took place over a period of four months in mid 1992. The purpose of the study was to identify potential NWODB which could lead to improved cost effectiveness within NASA and to quantify potential cost benefits that might accrue if these NWODB were implemented.

Rosmait, Russell L.↗

NASA NTRS1991

Low cost high efficiency GaAs monolithic RF module for SARSAT distress beacons

Low cost high performance (5 Watts output) 406 MHz beacons are urgently needed to realize the maximum utilization of the Search and Rescue Satellite-Aided Tracking (SARSAT) system spearheaded in the U.S. by NASA. Although current technology can produce beacons meeting the output power requirement, power consumption is high due to the low efficiency of available transmitters. Field performance is currently unsatisfactory due to the lack of safe and reliable high density batteries capable of operation at -40 C. Low cost production is also a crucial but elusive requirement for the ultimate wide scale utilization of this system. Microwave Monolithics Incorporated (MMInc.) has proposed to make both the technical and cost goals for the SARSAT beacon attainable by developing a monolithic GaAs chip set for the RF module. This chip set consists of a high efficiency power amplifier and a bi-phase modulator. In addition to implementing the RF module in Monolithic Microwave Integrated Circuit (MMIC) form to minimize ultimate production costs, the power amplifier has a power-added efficiency nearly twice that attained with current commercial technology. A distress beacon built using this RF module chip set will be significantly smaller in size and lighter in weight due to a smaller battery requirement, since the 406 MHz signal source and the digital controller have far lower power consumption compared to the 5 watt power amplifier. All the program tasks have been successfully completed. The GaAs MMIC RF module chip set has been designed to be compatible with the present 406 MHz signal source and digital controller. A complete high performance low cost SARSAT beacon can be realized with only additional minor iteration and systems integration.

Petersen, W. C.↗

DOE OSTI2023

Pathway for decarbonizing residential building operations in the US and China beyond the mid-century

With global carbon budget targets looming, residential buildings in top economies must become carbon neutral as soon as possible to reserve more emission space for emerging carbon-emitting economies. This study is the first to compare the operational decarbonization process of China’s and the United States (US) residential buildings from 2000 to 2060 by combining the end-use emission model with the decomposing structural decomposition (DSD) method and Monte Carlo simulation. The results show that from 2001 to 2020 China decarbonized 1544 mega-tons of carbon dioxide (MtCO 2 ) and the US decarbonized 1848 MtCO 2 . In the business-as-usual scenario, China will hit its emission peak in 2031 (±3) with 934 (±61) MtCO 2 , while the US will maintain a lock-in level of 736 (±133) MtCO 2 since the 2030s. In the decarbonization scenario, operational carbon neutrality for residential buildings in 2060 is promoted by an increase in clean power generation proportion, building-integrated power generation level, building electrification level, and a reduction in end-use energy intensity, which will contribute 34.4 %, 21.4 %, 14.3 %, and 29.9 % in China and 32.9 %, 33.1 %, 8.2 %, and 25.8 % in the US, respectively. Especially, building-integrated power generation in China only costs about 40 % of what it costs in the US. Besides, high-decarbonization strategies for residential building operations are proposed as references for governments to formulate targeted climate policies. Overall, this study offers data benchmarks for buildings’ carbon neutrality of top economies to further promote synergistic carbon neutrality with the buildings of emerging economies in the age of Post COP27.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

A finite difference informed random walker (FDiRW) solver for strongly inhomogeneous diffusion problems

In nature, many complex multi-physics coupling problems exhibit strong diffusivity inhomogeneity. For instance, in the context of radionuclide absorption by porous wasteform materials within a flowing waste stream, the difference of species’ diffusivity in solid and liquid phases spans by 3~8 orders of magnitude. To solve the diffusion equations with strongly inhomogeneous diffusivity, traditional discretization-based methods, such as the Finite Difference Method (FDM), require infinitesimally small time steps (<10 -10 ) as high spatial resolutions are employed in most microstructure evolution processes, leading to prohibitively high computational costs. Here, this work developed an integrated numerical approach (FDiRW: Finite Difference informed Random Walk) to tackle this challenge. The idea is that utilizing the Random Walk concept, the fast diffusion is modeled as a superposition of point source’s solution for a concentration distribution while FDM is used to obtain the point source’s solution at each node. A mesh-coarsening algorithm is developed to generate an exclusive coarse mesh for FDiRW approach to maximize its efficiency. The effectiveness of the coarse mesh-based FDiRW approach is validated by benchmarking Finite Difference solutions. Numerical results demonstrated that FDiRW achieves a remarkable 1000x computational efficiency improvement over FDM while preserving desired accuracy for a medium-sized model of 192 × 192 × 192 grids. Finally, as models scale up, a floating-point operations (PLOPs) analysis of the FDiRW algorithm reveals that its computational complexity grows quadratically in terms of the number of nodes employed in computation.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Anion exchange membranes: The effect of reinforcement in water and electrolyte

Alkaline anion-conducting polymer-based CO 2 electrolysis and water electrolysis are among two emerging renewable energy conversion technologies. Their system design and integration offer promise of lower capital cost due to utilization of low-cost catalysts, in contrast to platinum group metal catalysts required for cation-conducting polymer-based devices. However, a critical component, the polymer electrolyte membrane, remains an obstacle hampering system performance and durability. In this study, commercially-available Sustainion® membranes with and without PTFE-reinforcement were investigated to understand previously unreported origins of improved device performance when compared to alternative membrane chemistries. We report critical membrane properties, such as morphology, thermal stability, as well as temperature-, hydration-, and counter-ion dependent ion conductivity. Moveover, the changes in uptake and conductivity of membranes in supporting electrolytes of K 2 CO 3 and KOH investigated as a function of their concentration. Presence of reinforcement and supporting electrolyte type alter the membrane's transport functionality, which could help guide device design for improved performance. In conclusion, the obtained results not only show how Sustainion® properties change with operating environment for CO 2 and water electrolysis applications, but also provide understanding for internal and external factors controlling anion-exhcnage membrane functionality in electrochemical devices.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Harnessing biomass-derived reinforcements for sustainable flame-resistant composite

Bio-based composites containing natural fiber reinforcements have been integral to developing innovative, low-cost, and low-energy technologies for transportation applications in marine, automotive, and other industries. The low density of natural fibers gives these materials a high specific stiffness and strength, which can lead to significant weight savings in composites. This study focused on a specialty type of wood fiber treated with boric acid (≤ 7%) sourced from Northern White Pine in the USA, marketed as TimberFill. TimberFill is a high aspect ratio, fibrillated wood fiber that is produced commercially for wood fiber insulation; it is chemically treated to improve both its flame retardance and water resistance. In the present study, TimberFill was processed into non-woven mats using a process akin to papermaking and then infiltrated with epoxy resin. Biochar from wood waste was also incorporated into the epoxy resin as a low-cost filler and functional additive. The effects of biochar concentration on composites’ flame retardance (17% improvement in burn rate), thermal conductivity (improved by 9%), and mechanical performance (33% improvement in modulus) are herein presented. Additionally, it explores the plasticizing effect of the boric acid used in the treatment of TimberFill on the thermal and mechanical properties of the resulting composites, specifically on the thermal expansion coefficient.

Joshy, Joslin [ORNL]↗