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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 811 records · Page 45
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Simulating combustion of a seven-component surrogate for a gasoline/ethanol blend including soot formation and comparison with experiments

Combustion of a seven-component surrogate for a research grade 87 octane gasoline mixed with 10% ethanol is investigated experimentally and numerically from the perspective of an isolated droplet burning under conditions that promote one-dimensional gas transport. The numerical analysis included a kinetic mechanism comprised of 398 species and 24,814 reactions and a soot model that accounted for nucleation, surface growth, coalescence/aggregation of soot particles, and luminous flame radiation. Measurements of droplet and flame diameters were made for an initial droplet diameter (D o ) of approximately 0.63 mm. The simulations agreed well with the measurements including the location of the soot shell. Preferential vaporization was revealed by simulations of the liquid concentrations in the droplet. Predicted peak soot volume fractions coincided with temperatures between 1300 K and 1400 K as a soot inception temperature. Simulations were also carried out for D o between 0.25 mm and 5 mm to explore the effect of radiation and D o on burning. Below 0.25 mm radiation was negligible and burning rates and flame temperatures converged to a single value. Increasing D o up to 1.8 mm lowered the burning rate with luminous radiation having a strong effect. When radiation was entirely removed from the model the burning rate was nearly constant. Above D o = 2 mm droplets extinguished almost immediately after ignition. The flame temperature decreased with increasing D o while it increased when radiation was omitted. As a result, the simulations show that soot precursors including polyaromatic hydrocarbons were concentrated around the soot shell.

42 ENGINEERING↗
DOE OSTI2022

Economic analysis of the benefits to petroleum refiners for low carbon boosted spark ignition biofuels

A refinery modeling framework is developed to estimate the benefits of blending high-quality biofuels directly with refinery gasoline components for attaining a premium grade fuel (also termed as Co-Optima Boosted SI gasoline here). Our results change the paradigm of bio-blendstocks (BBs) being competitors to fossil components, by identifying opportunities for refineries to add value to their product slate, from some favorable BB properties. This potential value can be characterized by calculating the breakeven value (BEV), as defined down below. The proposed modeling framework incorporates extensive data from (1) projected product over the next few decades, (2) crude oil and refinery products pricing, and (3) fuel specifications. The complete refinery models serve as a basis for assessing the value of biofuels, assuming profitability remains the same for representative petroleum refinery configurations. Our assessment showed wide range of variation of biofuels BEV from $\$$20-$\$$120/bbl, within the considered blending level and crude prices. Further, the BEV was correlated with the fuel octane ratings such as octane numbers (research, RON and motor octane numbers, MON) and both antiknock index (AKI, average of RON and MON) and sensitivity (S, difference between RON and MON), with a slightly higher correlation with the sensitivity. However, the expected decrease in gasoline demand for the upcoming years could negatively impact biofuels demand and value, in a business-as-usual scenario. Our analysis also showed a more valuable bio-blendstocks incorporation in smaller refineries since they can enhance the capabilities for producing specialty, high-value fuels/products, and introduce high octane-barrels into otherwise constrained blending operations. Additional implications towards refiners include opportunities to rebalance operations, access to high-value fuel markets, and synchronization with broader transportation industry trends. Furthermore, results indicate the value of Co-Optima boosted spark ignition (BSI) efficiency gains can extend to refiners to incentivize decarbonization and diversified feedstock production.

09 BIOMASS FUELS↗
DOE OSTI2022

Multi-stage heat release of multi-component fuels: Insights and implications for advanced engine operation

Multi-stage heat release (MSHR) is a unique phenomenon typically seen in lean/diluted and low- to intermediate-temperature combustion. Despite its relevance to advanced engine operation, the MSHR of multi-component fuels has barely been quantified. This study aims to characterize the MSHR of multi-component fuels in a rapid compression machine (RCM) at conditions representative of advanced combustion engines. New experimental data are first reported in the RCM at an equivalence ratio of 0.4, pressure of 60 bar and temperatures from 702 to 795 K for a research grade, multi-component gasoline surrogate, termed PACE-20. Here, experiments confirm the existence of MSHR for PACE-20 at all temperatures, and reveal the strong inhibiting effect of temperature on MSHR, where increasing temperature inhibits MSHR by suppressing first stage heat release and promoting second and third stage heat release. A detailed chemical kinetic model is also adopted to model the experiments, with good agreement observed. The response of MSHR characteristics to changes in different engine operating parameters (i.e., temperature, pressure, equivalence ratio and CO 2 dilution level) and fuel compositions (i.e., mole fraction of n-pentane, n-heptane, isooctane, cyclopentane, 1-hexene, ethanol and aromatics in PACE-20) is further evaluated via statistical analysis coupling quasi-random sampling, extensive computer experiments and high-dimensional model representation. The change in MSHR is characterized through 8 quantities of interest (QOIs), i.e., duration and extent of each heat release stage, and their standard deviations. The analysis highlights the dependence of the QOIs on the individual parameters as well as their interplays, with temperature exhibiting the strongest impact among all parameters. Furthermore, it is demonstrated that if MSHR is to be facilitated and combustion phasing is to be extended to enable engine operation at higher compression ratios, it is recommended to operate the engine at low intake temperatures, boosted intake pressures and high CO 2 dilutions (i.e., high EGR levels) with gasoline fuels containing more n-pentane and less aromatics.

42 ENGINEERING↗
DOE OSTI2022

GAMBL – A dual-cooled fusion blanket using SiC-based structures

We describe a novel fusion reactor blanket concept called GAMBL – GA Modular BLanket. This design concept exploits the advantages of SiC-based structures while minimizing their limitations. Material microstructures are tailored for different functions throughout the first wall and blanket, including the use of graded W/SiC composites to enhance heat transfer capabilities and resist erosion at the plasma-facing surface. The design contains a decoupled first wall and breeding blanket, which we show can provide adequate tritium breeding. By decoupling the breeding part of the blanket, we can operate at very low PbLi breeder pressure and support gravity loads in simple, radiatively-cooled structural beams that do not contain coolant. First wall performance capabilities are enhanced by eliminating constraints imposed by the deep blanket. We have performed initial fluid, thermal, mechanical and neutronics analysis of this concept to show its capabilities to meet the design requirements. R&D needs are mostly related to materials development. Except for unique manufacturing needs, no new facilities are required beyond existing or planned facilities for the US base program on steel-based DCLL blankets.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Review of allanite: Properties, occurrence and mineral processing technologies

Allanite is commonly encountered as an accessory rare-earth silicate mineral in association with minerals such as garnet, biotite, and feldspar. It is distributed globally and occurs in igneous formations such as granites, pegmatites, and syenites, as well as in various metamorphic rocks such as schist, gneiss, and amphibolite. Moreover, it can be found in mineral veins formed through hydrothermal activity. While allanite has not yet been extensively utilized for the production of rare-earth elements, recent discoveries of high-grade rare-earth-rich allanite deposits in Wyoming, USA, highlight its economic potential. However, despite ongoing research on the mineralogy and processing of rare-earth minerals, allanite has not received widespread attention in mineral processing. To achieve economical extraction of rare-earth elements from allanite in the future, systematic studies on processing techniques (e.g., density separation, magnetic separation, flotation, leaching) are imperative to fully unlock the potential of allanite as a rare-earth element source. To pave the way for future investigation of allanite and address the unique processing challenges, this review article aims to comprehensively summarize previous studies, encompassing properties, occurrences, and processing technologies of allanite.

42 ENGINEERING↗
DOE OSTI2024

Process parameter translation strategies for variable directed energy deposition spot size using 316L, copper, and Inconel 625

Directed energy deposition (DED) is a form of additive manufacturing available across a variety of laser spot diameter values, often referred to as spot sizes. However, there is no method to easily transfer process parameters across discrete spot sizes, leading to DED process parameters that are equipment specific and not widely applicable. In this study, a strategy is proposed and investigated for five spot sizes that keep the areal energy density constant while varying power, feed rate, and powder flow during the deposition of 316L stainless steel. An assessment of trends in hardness and microstructure is possible due to the novel production of components of a single material across several spot sizes using a single nozzle on a single DED system. The proposed strategy was used to nullify the hardness drop during functional grading of Inconel 625 and pure copper, enabling fabrication of multi-material sample that does not compromise desirable properties. This application shows the value in establishing more efficient process parameter development and understanding spot size influences on geometric and material property flexibility, to enable a more diverse powder-based DED design space and to increase the industry adoption of DED systems.

316L↗
DOE OSTI2023

Experimental results of embedded phase change material capsules for increasing the performance of a wrapped heat pump water heater

Herein, to enhance the capacity of heat pump water heaters (HPWHs), high energy density phase change material (PCM) was used in two experimentally tested HPWH prototypes. Preliminary findings showed that in the PCM, stored thermal potential energy could be effectively converted into sensible heat in the water over a slight temperature difference, with the goal of increasing the capacity of hot water above a desired cut-off temperature. This exchange of energy results in an increased amount of hot water necessary for mixing at the location utilized by the consumer. It was also found that for a wrapped HPWH, there was an average increase of 27.7% in the capacity when 7.6 L of novel PCM filled spherical capsules were added to a 22.7 L tank downstream of the HPWH. In the second design (Beta), PCM capsules were immersed into the tank with a cylindrical geometry, and the UEF was increased by 5.5% over the baseline HPWH test result. As for the Beta design, heat loss was reduced significantly compared to a typical HPWH and the Alpha design. Food-grade PCMs were selected as appropriate. The novel encapsulation design increased the effective conductivity inside the capsule by adding metal fins.

42 ENGINEERING↗
DOE OSTI2022

Experimental driving performance evaluation of battery-powered medium and heavy duty all-electric vehicles

As the push to reduce air pollutants and carbon dioxide for global warming continues, there is increasing interest in the development and deployment of battery electric vehicles for heavy-duty applications as one of the critical and challenging steps of a broader effort to fully electrify the transportation sector. This study evaluated and quantified the energy consumption rates and energy regeneration rates for three heavy-duty battery electric vehicles (a step van, a yard tractor, and a class 8 truck) using driving cycle tests with a heavy-duty vehicle chassis dynamometer. Information in this area is currently very limited, and yet it is critical to understanding how effective heavy-duty battery electric vehicles will be for a wide range of applications as the electrification of the heavy-duty vehicle market continues to expand. Energy consumption rates ranged from 0.37 and 2.71 kWh/km for most vehicle/cycle combinations. On a diesel liter energy-equivalent basis, the heavy-duty vehicles had approximately 3 to 6 times better energy consumption rates compared to comparable diesel vehicles, with weight normalized energy consumption rates also comparing favorably to the current and future greenhouse gas/fuel economy standards for equivalent diesel vehicles. Based on battery capacities ranging from 80 to 215 kWh, the vehicle ranges varied from 38.18 km to 171.2 km, with ranges of 115.9 km to 171.2 km for most types of driving and lower ranges of 38.18 to 42.20 km for sustained grade cycles. Overall, the advantage of improved energy consumption rates coupled with improvements that can be expected for battery technology and vehicle range, provide promise for expanded use of heavy-duty vehicles going into the future.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Beta-Amino Carboxylate (BAC) non-aqueous physical solvents for enhanced CO2 separations in pre-combustion carbon capture, industrial CO 2 capture, and biogas upgrading processes

Novel beta-amino carboxylate (BAC) solvents have been synthesized and tested to efficiently capture carbon dioxide (CO 2 ) from process gas streams with CO 2 partial pressure intermediate between pre-combustion and post-combustion capture. The BAC solvents have molecular structures characterized by alkyl-substituted amides or esters containing a secondary amine functional group on the second carbon from the carbonyl carbon (referred to as the beta “β” carbon). The ester or amide functional group combined with optimal steric crowding around the amine nitrogen by proximate alkyl groups are tailored to modify the strength of CO 2 binding in the solvent. The solvents possess high CO 2 solubilities and high gas selectivity including good CO 2 /H 2 O selectivity and can be utilized for CO 2 absorption over a range of partial pressures. Due to low volatility, many of the solvents can be operated at or above ambient temperature which eliminates solvent chilling and allows regeneration using low grade waste heat. These novel solvents offer an opportunity for efficient carbon capture for a range of applications including biogas upgrading, hydrogen production, and pre-combustion carbon capture.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Cost-efficient copper-nickel alloy for active cooling applications

It is recently proposed that active (Peltier) and passive (conductive) cooling could be combined to design highly-efficient thermal conductors as active heat sinks. Here we study the potential of low-cost copper-nickel alloys for active cooling applications. We show that for this application, copper-nickel alloys prepared using industrial-grade powders to lower the manufacturing cost, are as good as copper-nickel alloys made out of high purity metals. Furthermore, directed energy deposition, a type of additive manufacturing, can produce copper-nickel alloys which have about 10 percent lower thermoelectric power factor compared to mechanical-alloying methods but have larger thermal conductivity values, hence, possessing similar effective thermal conductivity values, reaching 403 W m -1 K -1 at 390K. Much larger values are expected at higher temperatures. The usage of additive manufacturing enables complex geometries and large-scale production.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Hydrogen-assisted fracture resistance of pipeline welds in gaseous hydrogen

Fracture resistance of pipeline welds from a range of strength grades and welding techniques was measured in air and 21 MPa hydrogen gas, including electric resistance weld of X52, friction stir weld of X100 and gas metal arc welds (GMAW) of X52, X65 and X100. Welds exhibited a decrease in fracture resistance in hydrogen compared to complementary tests in air. A general trend was observed that fracture resistance in 21 MPa hydrogen gas decreased with increasing yield strength. To accommodate material constraints, two different fracture coupon geometries were used in this study, which were shown to yield similar fracture resistance values in air and 21 MPa hydrogen gas; values using different coupons resulted in less than 15% difference. In addition, fracture coupons were removed from controlled locations in select welds to examine the potential influence of orientation and residual stress. The two orientations examined in the X100 GMAW exhibited negligible differences in fracture resistance in air and, similarly, negligible differences in hydrogen. Residual stress exhibited a modest influence on fracture resistance; however, a consistent trend was not observed between tests in air and hydrogen, suggesting further studies are necessary to better understand the influence of residual stress. A comparison of welds and base metals tested in hydrogen gas showed similar susceptibility to hydrogen-assisted fracture. The overall dominant factor in determining the susceptibility to fracture resistance in hydrogen is the yield strength.

08 HYDROGEN↗
DOE OSTI2024

Effects of hydrogen partial pressure on crack initiation and growth rate in vintage X52 steel

There is an increasing interest in ensuring compatibility of existing natural gas infrastructure with conveyance of hydrogen, especially for vintage (pre-1970s) pipeline steels. While hydrogen is known to affect the fatigue and fracture resistance of these materials, there is a lack of data on its effects on crack initiation at low hydrogen partial pressure. To address this gap, the current work presents a series of fatigue tests on vintage API Grade X52 steel in pure nitrogen, air and gaseous hydrogen at partial pressures of 1 and 207 bar. Circumferential notch tension (CNT) specimens with direct current potential difference (DCPD) measurements are used to get S–N curves for crack initiation and failure, and compact tension (CT) tests to assess crack growth rates. Results indicate that air accelerates crack initiation, low hydrogen partial pressure affects the crack growth rate, and higher pressures have the largest impact on both. Surprisingly, crack initiation is faster in air than at 1 bar hydrogen partial pressure. The CNT tests also reveal that the orientation of the banded microstructure has no effect on the crack initiation site, but it influences its growth behavior. Moreover, fractography shows that hydrogen also promotes instances of quasi-cleavage and intergranular fracture, linked to embrittlement of the material. Here, these results demonstrate that, while hydrogen may impact the entirety of the fatigue process, its effects on the early stages of damage accumulation become relevant only at larger pressures. More comprehensive studies of crack initiation in hydrogen atmospheres will be critical to future codes and standards for hydrogen infrastructure.

Circumferential notch tension↗
DOE OSTI2025

Ultra-high efficiency hydrogen production using a large-scale solid oxide electrolysis cell system

Efficient and cost-effective production of clean hydrogen is key to decarbonizing the production of hard-to-abate industries, such as chemicals, fuels, steel, cement and many other commodities that form the basis of modern societies. High-temperature steam electrolysis (HTSE) has recently become commercially available and offers opportunities for producing hydrogen at higher efficiency and lower cost than competing low temperature technologies. In this work, we report world record setting hydrogen production efficiency from large-scale prototype HTSE systems based on solid oxide electrolysis cell (SOEC) technology. Independent tests performed at Idaho National Laboratory (INL) employed a Bloom Energy 100 kW SOEC system to achieve a hydrogen production direct current specific electric energy consumption as low as 36.7 kWh per kilogram of hydrogen. Remarkably, similar high efficiencies in the range of 36–39 kW/kg-H2 were obtained over a wide range of hydrogen production rates and even during dynamic ramping as the hydrogen production and electric power consumption of the system were varied between 20 % and 100 % of nominal conditions. Furthermore, these test results validate previous projections that commercial SOEC systems can produce clean hydrogen at efficiencies approaching 100 % for less than 2 U S. dollars per kilogram when located near sources of inexpensive, low-grade heat and clean electricity.

08 HYDROGEN↗
DOE OSTI2021

In situ X-ray imaging of pore formation mechanisms and dynamics in laser powder-blown directed energy deposition additive manufacturing

Directed energy deposition (DED) additive manufacturing (AM) is receiving growing attention in many applications, such as repair, remanufacturing, and fabrication of functionally graded structures. However, the laser-matter interactions and melt pool dynamics in laser DED with powder flow are still unclear, particularly in how pores form and flow inside the melt pool during the process. Understanding the porosity formation mechanisms is critical in the qualification, certification, and overall properties of a DED AM part. Porosity is a common phenomenon and can significantly hinder the quality of DED fabricated parts, as the pores can act as sites of crack nucleation and propagation. Here in this paper, we reveal four types of pore formation mechanisms through in-situ and operando high-speed high-resolution X-ray imaging in the DED AM process. Our results confirm that porosity within the feedstock powder induces pores in the process. We also observed pore formation mechanisms unique to the laser-based, powder-blown DED process as a result of powder delivery, keyhole dynamics, melt pool dynamics, and shield gas. High-speed X-ray images provide direct evidence for pore formation mechanisms and show that the pores related to the interaction between the delivered powder and melt pool are the largest in size in laser-based powder-blown DED AM. These results will guide porosity mitigation, elimination, and control in DED AM.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Analytical Determination of Radioactive Strontium and Cesium by Thermal Ionization Mass Spectrometry

Thermal ionization mass spectrometry (TIMS) has been evaluated for the detection of the radioactive isotopes of strontium and cesium. The instrument was investigated for the analysis of isotopic ratios of 89Sr to 90Sr and 135Cs to 137Cs in the presence of atomic isobars (Y and Zr for Sr analysis and Ba for Cs analysis). Signicant discrimination using TIMS was found for both Sr and Cs through evaluation using stable isotopes. Fusion procedures with different flux were evaluated for preparation of sample matrices. Chemical separations were developed and used after fusion to isolate the Sr and Cs from a prepared background matrix (i.e., Montana Soil). A graded approach, increasing in stable background isotopes, was performed to monitor the chemistry and instrument response. A thermal neutron irradiation was performed to produce a sample that contained the radioisotopes of Sr and Cs. Even though the irradiated sample was not a certified standard it does provide accurate expectation values via published, well understood cumulative fission yield data. The results presented in this work correlate extremely well with the published data. Furthermore, a significant decrease in uncertainty (by a factor of 5 { 10) was found for the isotopic ratios measured with TIMS compared to the published values.

TIMS, environmental contamination, radiostrontium,↗
DOE OSTI2026

Effects of gas purity on backgrounds of collision reaction cell-equipped MC-ICP-MS

The advent of multi-collector inductively coupled plasma mass spectrometry (MC-ICP-MS) instruments equipped with collision reaction cells (CRCs) facilitates interference removal/mitigation via online gas phase separations. This approach has proven effective for high intensity ion beams measured on Faraday collectors; however, it has been observed that introduction of gas in the CRC can result in significant background signals relative to the more sensitive ion counters. These backgrounds hinder use of these instruments for low level concentration and isotopic ratio measurements when employing a reaction gas. Here, this work directly evaluates the effect of gas purity on backgrounds of CRC-MC-ICP-MS instruments. Introducing high-purity research grade O 2 (99.999%) into the CRC produces complex background spectra with intensities >10 4 cps observed at most masses across the measured mass range (7-300 m / z ). Some features of the observed spectra (i.e., positive mass defects) can be attributed to molecular compounds comprised of significant hydrogen. Additionally, some specific molecular species can be identified (i.e., MoO x H y + ) and appear to be derived from molybdenum rods comprising the CRC. Further purifying the gas reduces the intensity of these backgrounds by several orders of magnitude, to <10 2 cps in many cases, and reduces complexity of the resulting spectra. This reduction in background appears to be in part driven by removal of impurities (i.e., H 2 O) from the gas. This work demonstrates that additional purification of reaction gases prior to introduction into the CRC significantly reduces backgrounds detected, potentially expanding the utility of CRC-MC-ICP-MS for making low level measurements using inline gas phase ion separations.

Schlieder, Tyler D. [Pacific Northwest National La↗
DOE OSTI2023

A physics-driven Σ-Y atomization model for heavy-duty engine simulations

The atomization of a liquid jet is a multi-scale and multi-physics problem of interest for many engineering applications. Particularly, it drives the fuel-oxidizer mixing and dictates the efficiency of combustion engines. High-fidelity multi-phase simulations remain challenging due to the excessive computational cost required to capture all the atomization scales. Thus, atomization models are necessary to represent sub-grid liquid structures. Here, in this work, a modified Σ-Y model in the context of Eulerian-Lagrangian Spray Atomization (ELSA) is used to transport the surface area density of the spray. The model's predictive performance is assessed under various operating conditions relevant to heavy-duty engines using the Engine Combustion Network (ECN) Spray C and Spray D research-grade injectors. The classic droplet collision formulation of the Σ-Y model alone does not replicate the response of the measured spray surface area to changes in injector, ambient pressure, and injection pressure, requiring individual tuning of the model's parameters. Instead, a transition between dense and dilute spray breakup mechanisms is proposed in terms of the average droplet spacing. The collision breakup mechanism represents the dilute spray, whereas the droplet size in the dense spray is driven by a competition between the integral scale of turbulence and the balance between the turbulent kinetic energy and the surface energy of the droplets. Such an approach minimizes the requirements for model tuning. Moreover, the role of the constants of a compressible standard k-ε RANS model is assessed in the injector's internal flow and external spray simulation framework, and an updated set is proposed. The results are validated against x-ray radiography and Ultra-Small Angle X-ray Scattering (USAXS) data and highlight the predictive capabilities of the proposed physics-driven Σ-Y model, which is compatible with engine simulation turnaround times.

42 ENGINEERING↗
DOE OSTI2020

Effect of nickel on the kinematic stability of retained austenite in carburized bearing steels – In-situ neutron diffraction and crystal plasticity modeling of uniaxial tension tests in AISI 8620, 4320 and 3310 steels

The presence of kinematically metastable retained austenite in the microstructure of bearing components can significantly affect the macro and micro-mechanical material response. In the present work, the influence of Ni on the stability of the retained austenite within three different grades of high carbon bearing steel using in-situ neutron diffraction is investigated. For the first time, the results show that presence of Ni increases the stability of the austenite in the elastic regime whereas the transformation rate remains unaffected. Crystal plasticity finite element (CPFE) modeling was used to study the deformation in these three steels and shows that the predominant factor causing the difference in mechanical behavior of these steels is the austenite stability. Finally, the elastic and plastic response of the matrix martensite was found to be identical among all specimens while the austenite demonstrates similar elastic behavior but remarkably different stabilities under monotonic loading.

36 MATERIALS SCIENCE↗