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At least 865 records · Page 48

SURFACE FINISHING AND ELECTROLESS NICKEL PLATING OF ADDITIVELY MANUFACTURED (AM) METAL COMPONENTS

This study investigates the application of electroless nickel deposition on additively manufactured stainless steel samples. Current additive manufacturing (AM) technologies produce metal components with a rough surface. Rough surfaces generally exhibit fatigue characteristics, increasing the probability of initiating a crack or fracture to the printed part. For this reason, the direct use of as-produced parts in a finished product cannot be actualized, which presents a challenge. Post-processing of the AM parts is therefore required to smoothen the surface. This study analyzes chempolish (CP) and electropolish (EP) surface finishing techniques for post-processing AM stainless steel components CP has a great advantage in creating uniform, smooth surfaces regardless of size or part geometry EP creates an extremely smooth surface, which reduces the surface roughness to the sub-micrometer level. In this study, we also investigate nickel deposition on EP, CP, and as-built AM components using electroless nickel solutions. Electroless nickel plating is a method of alloy treatment designed to increase manufactured component's hardness and surface resistance to the unrelenting environment. The electroless nickel plating process is more straightforward than its counterpart electroplating.. We use low-phosphorus (2-5% P), medium-phosphorus (6-9% P), and high-phosphorus (10-13% P). These Ni deposition experiments were optimized using the L9 Taguchi design of experiments (TDOE), which compromises the prosperous content in the solution, surface finish, plane of the geometry, and bath temperature. The pre-and post-processed surface of the AM parts was characterized by KEYENCE Digital MicroscopeVHX-7000 and Phenom XL Desktop SEM. The experimental results show that electroless nickel deposition produces uniform Ni coating on the additively manufactured components up to 20 μm per hour. Mechanical properties of as-built and Ni coated AM samples were analyzed by applying a standard 10 N scratch test. Nickel coated AM samples were up to two times scratch resistant compared to the as-built samples. This study suggests electroless nickel plating is a robust viable option for surface hardening and finishing AM components for various applications and operating conditions.

Keywords: additive manufacturing, fatigue, chempol↗

Development of Approaches to Model Excited State Charge and Energy Transfer in Solution

The development of next generation energy conversion and catalytic systems requires fundamental understanding of the interplay between photo-excitation and the resulting proton and electron transfer processes that occur in solution. To address these challenges requires accurate and efficient methods to compute ground and excited states, as well as the ability to treat the dynamics of energy transfer in the presence of solvent fluctuations. Our team is developing accurate and efficient theoretical models for solution phase reactions. These developments provide an improved understanding of photo-initiated excitations, electron transfer, and proton coupled electron transfer processes. Our research team brings together expertise in electron and nuclear dynamics (classical and quantum), electronic structure, and analysis of solvation networks. We are developing and validating techniques for modeling condensed phase charge and energy transfer and to simulate the methods to monitor them using optical and vibrational spectroscopy.

74 ATOMIC AND MOLECULAR PHYSICS↗

Preface to Special Topic: New Physics and Materials for Neuromorphic Computation

Artificial Intelligence is a topic that is pervasive in many modern developments and not just confined to science anymore. Many practical applications are based on performing classification tasks inspired by how the natural brain processes information. This current Special Topic on New Physics and Materials for Neuromorphic Computation looks toward solutions for such computational processes that go beyond the currently well-established semiconducting digital computation paradigm.

36 MATERIALS SCIENCE↗

Cesium Removal from Tank Waste Simulants Using Crystalline Silicotitanate at 12% and 100% TSCR Bed Heights

The Direct Feed Low-Activity Waste flowsheet provides for the early production of immobilized low-activity waste (LAW) by feeding waste directly from Hanford tank farms to the Hanford Tank Waste Treatment and Immobilization Plant (WTP) for vitrification. Prior to the transfer of feed to the WTP LAW Vitrification Facility, tank waste supernatant will be pretreated by the Tank Side Cesium Removal (TSCR) system to meet the WTP LAW waste acceptance criteria (<3.18E-5 Ci 137 Cs/mole of Na). This pretreatment will remove cesium from the waste stream using ion exchange (IX). The selected media for IX is crystalline silicotitanate (CST), product number UOP-IONSIV-R9140-B, manufactured by Honeywell UOP LLC (Des Plaines, IL). Testing was requested by Washington River Protection Solutions to better define IX processing using Low-Activity Waste Pretreatment System (LAWPS) prototypic IX unit operation process steps at full height and medium height. The information is intended to significantly contribute towards establishing accurate process flowsheets for the individual feed campaigns planned for the LAWPS. Column testing at both the medium (12% of the full bed height) and full height scales was conducted to evaluate process variables and scale up performance of Cs exchange onto the CST, Lot 8056202-999. Nominal process conditions used 5.6 M Na simulant processed at 1.8 bed volumes per hour (BV/h) at 20 °C. Process variables included 1) increased process temperature to 35 °C, 2) increased Na concentration to 6.0 M, 3) added organics to the 5.6 M Na simulant, and 4) flowrate changes. The medium scale tests used single columns containing 44 mL of <25 mesh CST in a 1.44 cm diameter column, 27 cm tall CST bed. The full height columns used lead/lag columns containing 1.15 L unsieved (as-received) CST in 2.54-cm-diameter columns, 226 cm tall CST beds. Two process flowrates were tested at the full height: 1.30 and 1.82 BV/h. IX testing with simulant solutions was conducted using TSCR prototypic IX unit operations: feed processing, feed displacement with 0.1 M NaOH, water rinse, and solution expulsion with compressed air.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

A Role for 2-Methyl Pyrrole in the Browning of 4-Oxopentanal and Limonene Secondary Organic Aerosol

“Brown Carbon” (BrC) is a type of organic particulate matter that absorbs visible and near ultraviolet radiation. Reactions of carbonyls in secondary organic aerosol (SOA) produced from limonene with ammonia (NH3) or ammonium sulfate (AS) are known to produce BrC with a distinctive absorption band at 500 nm. Although the general mechanism for this process has been proposed in previous studies, the specific molecular structures of the light-absorbing species remain unclear. This study examined the browning processes occurring in aqueous solutions of AS and 4-oxopentanal (4-OPA), which has a 1,4-dicarbonyl structural motif present in many limonene SOA compounds. The reaction of 4-OPA with AS in a bulk aqueous solution produces a 2-methyl pyrrole (2-MP) intermediate, which is not a strong light absorber by itself, but can react further with carbonyl compounds leading to the eventual formation of BrC chromophores. The direct involvement of 2-MP in the browning process was demonstrated by reacting 2-MP with 4-OPA and with limonene SOA, both of which produced BrC chromophores with distinctive absorption bands at visible wavelengths. The formation of BrC in reaction of 4-OPA with AS and ammonium nitrate (AN) was found to be accelerated by evaporation of the solution suggesting an important role of the dehydration processes in BrC formation from 1,4- dicarbonyls. 4-OPA was also found to produce BrC in aqueous reactions with a broad spectrum of amino acids and amines. The results suggest that 4-OPA may be the smallest atmospherically relevant compound capable of browning by the same mechanism as limonene SOA.

Environmental Molecular Sciences Laboratory↗

Synthesis and Photonic Sintering of Proton Conducting Lanthanide Nickelates

Lanthanide nickelate perovskites are known proton conductors at intermediate temperatures (350-600°C). They are attractive targets for proton conducting fuel cells and electrolyzers due to their operational temperature range and their stability in the presence of CO 2 . These materials have the formula LNiO 3 , with the lanthanide L = La, Ce, Pr, Nd, or Sm. Sintering is challenging due to phase transformations that occur at lower temperatures than those required for sintering. In this project, a series of lanthanide nickelate perovskites was synthesized via both a precursor solid solution method and the glycine nitrate process. Powders derived from the precursor solid solution method for LaNiO 3 and NdNiO 3 were sintered at Utility Global Inc. at various temperatures utilizing fast photonic sintering. LaNiO 3 was successfully sintered while maintaining the perovskite phase. NdNiO 3 underwent a phase transformation at all the conditions tested. The stability of the perovskite phase decreases moving right across the lanthanides in the periodic table, while the expected proton conductivity increases. These results will inform further investigations into lanthanide nickelate perovskites toward the goal of producing a free-standing, sintered, proton-conducting membrane.

36 MATERIALS SCIENCE↗

Experimental evaluation of a semi-open membrane-based absorption heat pump system utilizing ionic liquids

While the use of energy efficient absorption heat pumps has been typically limited to the high capacity commercial and industrial applications, the use of a semi-open absorption heat pump for water heating has been demonstrated to be an energy efficient alternative for residential scale applications. A semi-open absorption system uses ambient water vapor as the refrigerant in the absorber where its heat of phase change is transferred to the process water, cooling the solution in the absorber. The solution is pumped to the desorber, where by adding heat, the water vapor is released from the solution and condensed in the condenser. The heat of phase change of water vapor is transferred to process water again in the condenser. This cycle when implemented with a membrane-based absorber in a plate and frame form of heat exchanger using ionic liquids can overcome the challenges related to the system architecture of conventional absorption heat pumps like the lower efficiency at small scale, crystallization/corrosion issues with the desiccants and the high cost of hermetically sealed components. The cycle COP for such a system was previously demonstrated by Chugh et al. for high humidity conditions. In this experimental study, design improvements were made that expand the system’s applicability to more practical and standardized test conditions. With these improvements, the performance of the system was evaluated. The results presented in this study demonstrate the improved system’s viability as a heat pump water heater conforming to standard water heater test conditions. Performance was measured at a cycle thermal COP of 1.2 with a hot water delivery water temperature of 56 °C and ambient air at 19 °C and 49% RH.

42 ENGINEERING↗

Prediction of Power Measurements Using Adaptive Filters

With the advent of smart grid concept, Internet of Things (IoT) and the deployment of smart meters, the cyberattack threats on power networks have increased due to the use of communication systems that can be accessed by adversaries. Attackers will have the ability to manipulate the outcomes of smart meters which in turn influence the core application of Energy Management System 9EMS): State Estimation (SE). Bad data analytic tools may fail to detect some attacks into measurements. Meanwhile, Machine Learning (ML) solutions have been proposed for detecting False Data Injection (FDI) attacks. However, there is a lack of ML time-series solutions presented in the state-of-the-art that is yet to be complex. In signal processing, time-series solutions do not only consider the signal, but also the statistics of the signal over time. Therefore, in this paper, a machine learning for time-series solutions is presented as an application to model the measurements of the power grid that are used in SE. The presented model takes into account adaptive linear and non-linear filters: Finite Impulse Response (FIR), and Infinite Impulse Response (IIR). The presented models are implemented and performed on the IEEE-118 bus system. The results indicate the advantage of applying those filters over the state-of-the-art machine learning solutions.

Hamad, Khaled↗

Novel High Temperature Carbide and Boride Ceramics for Direct Power Extraction Electrode Applications. Final report

The current project aims to develop new carbide and boride ceramic materials that incorporate different metal elements (e.g., (Hf 1-x Zr x )B 2 , also called ceramic solid solutions) and understand the fundamental composition-processing-structure-property relationships for such materials. Specifically, nano powders and related nano-composites for selected mixed metal carbide and boride materials are synthesized from nano-scale mixed precursors obtained from solution-based processing via heat treatment in inert atmosphere. The obtained fine powders were then consolidated into dense ceramics via a novel flash sintering process. The mechanical properties and thermal oxidation resistance for the obtained materials were evaluated for these materials. It was found that different synthesis routes produced powders with somewhat different characteristics in terms of composition and microstructure, which then led to different properties for the final ceramics. The synthesis and processing methods demonstrated in this study might be adopted for developing other similar high temperature ceramics, while the mixed metal or solid solution ceramic materials obtained from this study might be used as hot electrodes for direction power extraction and other energy-related applications.

20 FOSSIL-FUELED POWER PLANTS↗

Energy-Storing Cryogenic Carbon Capture™ for Utility and Industrial-scale Processes (Final Report)

This project leverages work completed under funding from previous U.S. Department of Energy (DOE) projects and other sources of funding around the Cryogenic Carbon Capture Process™ (CCC). The purpose of this project is to further develop a perturbation of the CCC process that stores energy called the Cryogenic Carbon Capture™ Energy Storing (CCC-ES) process. The successful completion of the tasks in this project has prepared the CCC-ES process for scaling and developed initial plans and a feasibility analysis for an engineering-scale or small-commercial scale system that can store at least 10 MWh of energy. The specific areas of work in this project are: (1) Develop a conceptual, site-specific integrated process flow diagram: Sustainable Energy Solutions (SES) developed a conceptual, site-specific plan including a process flow diagram for integrating CCC-ES at a specific location. The proposed system was based on a typical engineering-scale CCC system designed to capture 30-50 metric tonnes of CO 2 per day (TPD), with modifications and additional changes and equipment put in place to add the energy storage element to the system. The 30-50 TPD scale corresponds to the required 10 MWh of stored energy. This task includes updating simulation software for transient analysis. SES also coordinated with the Jim Bridger Power Plant in Point of Rocks, Wyoming to get site-specific data. Using these data, SES completed site-specific preliminary process flow diagrams, estimated capital and operating costs for the CCC-ES system, and used the upgraded software package to estimate the primary figures of merit. (2) Complete a technoeconomic analysis (TEA): SES completed a full-scale TEA of the CCC-ES system to meet specific success criteria. This TEA used process information from the host site selected above. (3) Technology and data gap assessment for the CCC-ES process: As part of the technology gap assessment, SES performed an assessment of the best alternative energy storage solutions including figures of merit and operational strengths and weaknesses. SES then compared the proposed system with a discussion of how it addresses the weaknesses of alternative systems, showing for example a cost of stored energy at less than $50/MWh and with a roundtrip efficiency of greater than 95%. This assessment includes technical and other risk analyses and technology gaps with research and development needs to commercialize the process by 2030. Finally, work includes a commercialization roadmap/development pathway outlining the major milestones to move to a commercially operating CCC-ES system. (4) Phase II pre-FEED project plan: SES completed a project plan for the Phase II pre-FEED analysis using the same host site as in the Phase I conceptual study.

03 NATURAL GAS↗

Layer-by-Layer-Processed Organic Solar Cells with 18.02% Efficiency Enabled by Regulating the Aggregation of Bottom Polymers

The fabrication of organic solar cells (OSCs) by a layer-by-layer (LBL) method has attracted growing attention in recent years. As already known, the pre-aggregates of conjugated polymers in solution have a profound impact on their microstructure morphology in films. Herein, by simply controlling the solution temperature and annealing processes, the pre-aggregation behavior of D18 polymer in solution can be fine-tuned and the microstructure of D18 bottom layer is well manipulated. The optimized D18 bottom layer can effectively regulate L8-BO upper-layer-forming suitable networks for efficient charge transportation. In addition, a vertical phase separation with a special D/D:A/A structure (P-i-N-type component distribution) is also formed. As a result, compared to the 16.43% power conversion efficiency (PCE) of the bulk heterojunction devices, such control enables bilayer OSC devices based on the polymer D18 and L8-BO to deliver an enhanced PCE of 18.02% with simultaneously improved short-circuit current density, open-circuit voltage, and fill factor. Importantly, it is also demonstrated in these results that the LBL deposition process utilizing the pre-aggregation of polymer and its fiber-network-forming ability is a very promising approach to improve charge dynamics, suppress carrier recombination, and fabricate highly efficient OSCs.

14 SOLAR ENERGY↗

Transmission Interconnection Roadmap: Transforming Bulk Transmission Interconnection by 2035

The U.S. electricity system is amid a rapidly occurring and widespread energy transition. Regional, Tribal, state, and customer demand for new energy resources, combined with favorable policies, is driving a rapid rise of interconnection requests. Interconnection processes will need to evolve to handle this larger number of requests today and into the future, as policy and economic drivers continue to motivate significant resource development. This roadmap identifies and organizes nearer- and longer-term solutions to enable transmission interconnection processes to meet this expected demand, and it is intended for a diverse audience of stakeholders participating within transmission interconnection processes. The roadmap is a result of the Interconnection Innovation e-Xchange (i2X) program launched by the U.S. Department of Energy (DOE) in June 2022 to convene stakeholders and address interconnection challenges. The roadmap is organized into four primary goal areas, each important to the overall i2X mission to enable a simpler, faster, and fairer interconnection of clean energy resources while enhancing the reliability, resiliency, and security of our electric grid. The first goal aims to improve interconnection data transparency, to aid interconnection customers’ ability to screen and site potential projects, better enable third-party modeling, facilitate more process automation, enhance competition while ensuring equitable outcomes, and enable benchmarking, tracking, and auditing of interconnection processes and reforms. The second goal covers solutions to improve queue management practices, affected system studies, fair processes, and workforce development. The third goal incorporates solutions that aim to improve cost allocation, reduce costs to electricity consumers, enhance the coordination between transmission planning and the interconnection process, and optimize the rightsizing of transmission investment through improvements in interconnection studies. The fourth and final goal aims to reduce the performance issues not identified during interconnection studies by updating technical requirements within interconnection studies, models, and tools while also improving industry interconnection standards.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Design of an Additively Manufactured Recuperator With 800 °C Inlet Temperature for sCO2 Power Cycle Application

Abstract Recuperators with design temperatures at and above 800 °C can further increase the thermal efficiency of supercritical CO2 power cycles by enabling higher turbine exhaust temperatures. Mar-M247 is a well-suited nickel-based superalloy for high temperature service due to its high creep strength that prevents excessive material thickness being required for pressure containment. Additive manufacturing using a high-speed laser-directed energy deposition (L-DED) process presents a promising solution, with build trials demonstrating the ability to produce nonconventional flow channels for enhanced heat transfer. A design process is presented that includes aerothermal and mechanical evaluation to maximize performance within the constraints of the manufacturing process. A 2-D heat transfer network and pressure drop code allows prediction of flow distribution and its effect on overall thermal performance. Established literature correlations, along with CFD simulation, inform the prediction of heat transfer coefficients and friction factors for the flowpaths and enhancement features in the heat exchanger core. Mechanical evaluation using finite element analysis (FEA) modeling with the intent of the ASME Boiler & Pressure Vessel Code (BPVC) Section VIII, Div. 2 assesses the operational safety of the design. The detailed design features annular finned passages that take advantage of helical flow paths to distribute the flow from separated headers to shared heat transfer surfaces. Performance predictions for the recuperator at a 50 kW scale provide insights into the feasibility of the additively manufactured (AM) process to produce recuperators on a commercial scale that extend existing operating envelopes.

Engineering↗

Effect of Extensional Flow on the Evaporative Assembly of a Donor–Acceptor Semiconducting Polymer

The ability to deposit polymer semiconductors (PSCs) over a large area at near-ambient conditions makes them exciting candidates for low-cost, large-area electronic applications. Given the sensitivity of the charge carrier mobility in PSCs to the nature of their deposition from solution, a mechanistic understanding of deposition processes is essential for enhancing and controlling a PSC’s electrical performance. Polymer chain alignment has been largely posited as a strategy for improving the electrical performance of PSCs. Herein, the ability of a micropillar shearing blade to align polymer chains of poly(2,5-bis(2-octyldodecyl)-3,6-di(thiophen-2-yl)diketopyrrolo[3,4-c]pyrrole-1,4-dione-alt-thieno[3,2-b]thiophen) (DPP-TT) during solution shearing by increasing extensional flow is investigated. A sufficiently strong extensional flow field is found to be capable of aligning polymer chains and inducing crystallization. Such an alignment of crystallite domains is observed to be correlated to increased charge carrier mobility, but the effect of alignment on charge transport is dependent on deposition conditions. Furthermore, the ability of polymer chains to be aligned by using extensional flow, and the effect of alignment on subsequent charge transport, is highly dependent on polymer chain length due to changes in both solution state properties and charge transport mechanisms.

field-effect transistor↗

Options for the Removal of Cesium and Strontium from Acidic Uranyl Sulfate Solutions from Molybdenum-99 Production: Part II The Effect of Sodium Carbonate Adjustment to pH 9 on Strontium Removal

A small laboratory-scale column process aimed at removing fission products from prototypical acidic sulfate solution wastes from a prototypical Mo-99 recovery process has been operated in a radioactive materials hood at Savannah River National Laboratory. This equipment has been operated with realistic concentrations of uranium (0.4 wt % 235 U), plutonium ( 239 Pu), neptunium ( 237 Np), non-radioactive surrogates of common fission products (including Cs and Sr) and two promising absorbents – AMP-PAN and CST R9120-B. The goal of this work was to demonstrate the removal and concentration of high specific activity isotopes which are expected to dominate the classification of the low-level waste from the production of 99 Mo. Both AMP-PAN and CST R9120-B are attractive absorbents for the removal of 137 Cs from an acidic sulfate waste stream. They do not provide a solution for the removal of 90 Sr from the acidic solutions. CST was shown to be useful at removing both Cs and Sr after adjustment of the acidic sulfate solution with sodium carbonate to pH 9. Limited removal of transuranic species and almost no removal of uranium was observed for CST R9120B absorbent. This could be important due to the relatively large amount of uranium expected to be present in such waste streams. The capacity of these absorbents for 137 Cs will likely be dependent on the Cs concentration in the solutions processed but loading in excess of 0.7 mg Cs per gram of CST absorbent while loading 0.14 mg Sr per gram of CST absorbent appears to be achievable from pH 9 carbonate solution.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Computationally efficient and error aware surrogate construction for numerical solutions of subsurface flow through porous media

Limiting the injection rate to restrict the pressure below a threshold at a critical location can be an important goal of simulations that model the subsurface pressure between injection and extraction wells. The pressure is approximated by the solution of Darcy’s partial differential equation for a given permeability field. The subsurface permeability is modeled as a random field since it is known only up to statistical properties. This induces uncertainty in the computed pressure. Solving the partial differential equation for an ensemble of random permeability simulations enables estimating a probability distribution for the pressure at the critical location. These simulations are computationally expensive, and practitioners often need rapid online guidance for real-time pressure management. An ensemble of numerical partial differential equation solutions is used to construct a Gaussian process regression model that can quickly predict the pressure at the critical location as a function of the extraction rate and permeability realization. The Gaussian process surrogate analyzes the ensemble of numerical pressure solutions at the critical location as noisy observations of the true pressure solution, enabling robust inference using the conditional Gaussian process distribution. Our first novel contribution is to identify a sampling methodology for the random environment and matching kernel technology for which fitting the Gaussian process regression model scales as O ( n log n ) instead of the typical O ( n 3 ) rate in the number of samples n used to fit the surrogate. The surrogate model allows almost instantaneous predictions for the pressure at the critical location as a function of the extraction rate and permeability realization. Our second contribution is a novel algorithm to calibrate the uncertainty in the surrogate model to the discrepancy between the true pressure solution of Darcy’s equation and the numerical solution. Finally, although our method is derived for building a surrogate for the solution of Darcy’s equation with a random permeability field, the framework broadly applies to solutions of other partial differential equations with random coefficients.

54 ENVIRONMENTAL SCIENCES↗

FY 23 Filtration of Hanford Tank 241-SY-101 Supernatant at 16 °C

Approximately 9 liters of supernatant from Hanford waste tank 241-SY-101 was delivered by Washington River Protection Solutions to the Radiochemical Processing Laboratory (RPL) at Pacific Northwest National Laboratory. The thirty-six SY-101 sample bottles were comprised of six sets of six samples, with each set pulled from a unique tank sampling level. Prior to testing, samples from each level were composited to provide nominally level-independent feed for dead end filtration and ion exchange testing. The composited 241-SY-101 supernatant was chilled to 16 °C for 1 week prior to testing. Filtration testing was then conducted using a backpulse dead-end filter (BDEF) system equipped with a feed vessel and a Mott inline filter Model 6610 (Media Grade 5) in the hot cells of the RPL. This was done to provide waste processing benchmarks for 200 West Area wastes in the West Area Risk Management project. The feed was filtered through the BDEF system at a targeted flux of 0.065 gpm/ft 2 . During filtration of the differential pressure required to effect filtration at 0.065 gpm/ft 2 increased little over the filtration campaign and never reached 2 psid (the Tank Side Cesium Removal system action limit). This indicates that the Media Grade 5 filter should perform well when processing SY-101 supernatant. After completing filtration of the SY-101 feed, the filter was cleaned. Solids concentrated from the backpulse solutions displayed calcium phosphate, aluminum oxides, aluminum-chromium nanoparticle agglomerates. Electron diffraction was used to determine the types of phases that were present in the solids. Most of the phases found were only weakly crystalline, possibly owing to their rapid precipitation during the process water treatment. The identifications of the phases therefore are tentative.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗