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At least 883 records · Page 49

Wire Arc Additive Manufacturing of Lightweight High Pressure Die Casting Tooling

Oak Ridge National Laboratory (ORNL) and Mercury Marine partnered to develop and test methods for additively manufactured tooling for aluminum die casting applications under CRADA agreement NFE-20-08193. Tooling is the largest capital expense for high production casting projects. The lead time for tooling is often measured in months with a typical project taking 9-12 months to realize Production Part Approval Process (PPAP) ready die cast samples. This project demonstrated the technical viability of rapidly produced steel components for high pressure die casting tooling via Wire Arc Additive Manufacturing (WAAM). A 410 stainless steel tool was redesigned and optimized with conformal cooling channels and additively manufactured. The finished tool was tested and used to produce over 4000 parts, which well surpassed expectations. A secondary objective was to evaluate the durability of multi-material additively manufactured (AM) components with conformal cooling. A large multi-material tool (H13 and 410SSNiMo) was manufactured using the same methods showing potential reductions in used material and cost. However, the H13 section sustained material cracking. Further analysis showed that the potential cause was the CTE mismatch of the two materials at higher temperatures. It is also suggested that the material mix can be used if the steel processing temperature does not exceed 600 ̊C.This project has shown high potential for using the WAAM technology for creating AM parts for aluminum dies casting. However, the multi-material approach requires extended study and tests.

99 GENERAL AND MISCELLANEOUS↗

Wire Arc Additive Manufacturing of Lightweight High Pressure Die Casting Tooling

Oak Ridge National Laboratory (ORNL) and Mercury Marine partnered to develop and test methods for additively manufactured tooling for aluminum die casting applications under CRADA agreement NFE- 20-08193. Tooling is the largest capital expense for high production casting projects. The lead time for tooling is often measured in months with a typical project taking 9-12 months to realize Production Part Approval Process (PPAP) ready die cast samples. This project demonstrated the technical viability of rapidly produced steel components for high pressure die casting tooling via Wire Arc Additive Manufacturing (WAAM). A 410 stainless steel tool was redesigned and optimized with conformal cooling channels and additively manufactured. The finished tool was tested and used to produce over 4000 parts, which well surpassed expectations. A secondary objective was to evaluate the durability of multi-material additively manufactured (AM) components with conformal cooling. A large multi-material tool (H13 and 410SSNiMo) was manufactured using the same methods showing potential reductions in used material and cost. However, the H13 section sustained material cracking. Further analysis showed that the potential cause was the CTE mismatch of the two materials at higher temperatures. It is also suggested that the material mix can be used if the steel processing temperature does not exceed 600 ˚C. This project has shown high potential for using the WAAM technology for creating AM parts for aluminum dies casting. However, the multi-material approach requires extended study and tests.

36 MATERIALS SCIENCE↗

Advancing Building Performance: Field Results of Thin-Glass Triple-Pane Window Demonstrations

To meet California and the nation's ambitious energy targets, energy use in the building sector must drop dramatically. Windows continue to be the lowest thermally performing envelope system in the nation's buildings, resulting in poor overall envelope performance and potential impacts to human health and comfort. Current best practice new window performance is typically met by double-pane low-solar-gain glazing. Thin-glass triple-pane windows are a highly promising next step forward in performance and have been deployed in two California multi-family sites to quantify field performance and building energy savings. The technology assessed offers the performance benefits of traditional triple-pane but with little increase in weight or cost, enabling incremental costs competitive with alternative energy reduction solutions for the building envelope. This paper covers a detailed investigation into the demonstration project and measured performance benefits of the windows after a full year of data collection.

Hart, Robert↗

Making Data-Driven Policy Decisions for the Nation’s First Building Energy Performance Standards

Nearly every major U.S. city has committed itself to ambitious climate action goals – for Washington, DC this means a 50 percent reduction in greenhouse gases by 2032 and carbon neutrality by 2050. In support of these goals, Washington, DC has passed one of the most aggressive and practical climate action bills in the nation—with the Clean Energy DC Omnibus Act, DC became the first city in the U.S. to adopt energy performance standards for existing buildings. DC’s Building Energy Performance Standards (BEPS) require energy efficiency improvements for all commercial and multifamily buildings that do not meet a sector-specific minimum ENERGY STAR score or equivalent metric, with iterative compliance cycles every five years that will accelerate the pace of whole building retrofits. This paper explores this revolutionary policy framework and uses two data analysis projects that DC conducted to evaluate the potential impact of the BEPS and move towards carbon neutrality. First, we analyze the potential energy savings and greenhouse gas reductions, as well as potential cost impacts, from the implementation of a BEPS policy in DC We then examine the role of BEPS in a carbon neutrality strategy, how BEPS savings iterate over time, and what additional existing building improvements will be driven by the gravitational pull of new building codes on median performance. The paper highlights the benefits and limitations of such data-driven approaches to support policy decisions. Finally, we will review ongoing BEPS implementation, including expected policy directions, critical supportive programs, and lessons learned to date.

Bergfeld, Katie↗

Transforming Energy Through Computational Excellence: A Virtual Test-Drive of Energy Scenarios

Researchers at the National Renewable Energy Laboratory (NREL) are conducting groundbreaking research to decarbonize transportation systems and reduce emissions. As they plan for growing populations and related demands on aging infrastructure and energy systems, local transportation departments and city planners are facing significant, complex challenges. New approaches to planning and operations, as well as capitalizing on rapidly advancing technology, can address mobility and energy-centric challenges, including cost and energy efficiency, emissions reduction, decarbonization, and congestion.

33 ADVANCED PROPULSION SYSTEMS↗

Energy Credits—A New Way to Save in ASHRAE/IES Standard 90.1-2022

This article discusses a new Section 11 that has been added to Standard 90.1-2022 to increase energy savings by requiring additional energy credit measures beyond the base prescriptive requirements. This new requirement targets a 5% reduction in overall building energy cost using a broad range of additional measures. Allowing designers to choose measures that are particularly suited to a particular project provides flexibility in increasing energy savings. There are resources available to help designers implement this new requirement in Standard 90.1.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

PGM-Free Oxygen-Reduction Catalyst Development for Proton-Exchange Membrane Fuel Cells: Challenges, Solutions, and Promises

Proton-exchange membrane fuel cells (PEMFCs) are efficient and clean hydrogen energy technologies for transportation and stationary applications. Highly active and durable low-cost cathode catalysts for the oxygen-reduction reaction (ORR) under challenging acidic environments are desperately needed to address the cost and durability issues of PEMFCs. The most promising platinum group metal (PGM)-free catalysts for the ORR in acidic media are atomically dispersed and nitrogen-coordinated metal site catalysts denoted as M–N–C, M = Fe, Co, or Mn. Due to significant efforts in the past few decades, these catalysts have demonstrated much-improved ORR activity and promising initial fuel cell performance approaching traditional Pt/C catalysts. However, the insufficient long-term stability (up to 5000 h) under PEMFC operation represents a primary technical barrier to making current PGM-free catalysts less viable yet in PEMFCs. In this Account, we highlight recent advances in synthesizing efficient PGM-free catalysts for the ORR in PEMFCs, emphasizing effective strategies to improve mass and intrinsic activity and the possible degradation mechanisms. In particular, a chemical doping method based on the zeolitic imidazolate framework (ZIF)-8 represents the key to developing efficient M–N–C catalysts containing atomically dispersed and nitrogen-coordinated single metal active sites (i.e., MN 4 ). The newly acquired understanding of the formation mechanism of MN 4 active sites during the thermal activation and its correlation to catalytic properties guide the rational catalyst design rather than relying on current trial-and-error approaches. Considerable efforts have further been invested in increasing the active site density and enhancing intrinsic activity by regulating carbon-phase structures and the local coordination environment. Furthermore, these highly active catalysts usually suffer from significant activity loss during the ORR. Therefore, breaking the activity–stability trade-off is the key to simultaneously achieving activity and stability in one catalyst, which is discussed on the basis of our recent successes in regulating local carbon structures surrounding active single metal sites. Significant research efforts toward understanding the degradation mechanisms and improving the lifetime of PGM-free catalysts are still crucial for viable applications in the future. Novel electrode designing strategies are needed to translate the PGM-free catalysts’ ORR activity to solid-state electrolyte-based membrane electrode assemblies (MEAs) with robust three-phase (i.e., gas–liquid–solid) interfaces for efficient charge and mass transports for performance improvement. On the basis of our effort at the University at Buffalo supported by ElectroCat Consortium associated with U.S. DOE’s Hydrogen and Fuel Cell Technologies Office, we provide a perspective on PGM-free cathode catalysts concerning remaining bottlenecks and future opportunities, aiming to inspire the community in both mechanistic understanding and technological development.

08 HYDROGEN↗

Optical properties enhancement of thermal energy media for consistently high solar absorptivity

This study aimed to evaluate the optical properties of particles intended for use as thermal energy absorbers in generation 3 concentrated solar power systems. Their characterization involved UV–Vis NIR measurements with an integrating sphere for solar absorptivity, while a reflectometer was employed to measure thermal emittance. By combining absorptivity and emittance data, the solar absorption efficiency was calculated. Laser flash analysis, differential scanning calorimetry, and thermogravimetric analysis were utilized to determine thermal conductivity and specific heat. The solar absorptivity of the particles was initially measured at 0.90. After exposure to air at 1000 °C, it decreased to 0.73. However, following a reduction process, the particle recovered absorptivity of 0.90. The thermal aging and recovery were repeated multiple times, consistently achieving an absorptivity of 0.90. The thermal conductivity of the particles ranged from 0.50 to 0.88 W/(m-K). Solar absorptivity was found to be influenced by the types of iron oxide present in the particles. Particles with a predominance of hematite exhibited decreased solar absorptivity, while those containing magnetite, wüstite, and iron showed increased absorptivity. The estimated cost of the developed particles was more than ten times lower than that of current products. Given that component costs significantly impact the levelized cost of electricity (LCOE), this price reduction corresponded to an 8 % decrease in LCOE compared to other products. The low-cost thermal energy media show great promise for contributing to a reduced LCOE in the third generation of concentrating solar power systems.

14 SOLAR ENERGY↗

Evaluating Emissions Reductions from DERs in REopt Lite

Creating a clear business justification for an energy & water project is essential for developing projects by transforming data and analysis into a compelling story to secure management buy-in. This presentation provides an overview of how distributed energy resources (DERs) can provide cost savings, resilience benefits, and emissions reduction. Many technical and economic factors affect which distributed energy technologies can best meet site goals, and should be considered concurrently. With increasingly integrated and complex systems, back-of-the envelope calculations are no longer sufficient to determine distributed energy project potential. REopt Lite can be used to model emissions and evaluate the impact of DERs on reducing emissions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Ingeniously enhanced ferromagnetism in chemically-reduced 2D Ti 3 C 2 T X MXene

Chemical reduction is a facile and cost-effective technique for the modulation of the physical and chemical properties of nanomaterials. In this work, we demonstrate an enhancement of the magnetic behavior of Ti 3 C 2 T x MXene after its chemical reduction via l-ascorbic acid treatment. Small ferromagnetic loops have been observed below 50 K for Ti 3 C 2 T x prepared by hydrofluoric acid (HF) etching of Al layers from Ti 3 AlC 2 . Such a ferromagnetic ordering of spins was significantly enhanced via a chemical reduction of Ti 3 C 2 T x with l-ascorbic acid. Ferromagnetic hysteresis loops were observed for reduced Ti 3 C 2 T x (r-Ti 3 C 2 T x ) up to 150 K indicating a significant upshift of the paramagnetic to the ferromagnetic transition temperature, pushing towards room temperature. The enhancement of ferromagnetism and upshift of the ferromagnetic transition temperature could be attributed to the localized unpaired electron in Ti-3d orbital of the r-Ti 3 C 2 T x crystal and increase in the number of unsaturated Ti atoms upon l-ascorbic acid treatment. Chemical reduction via l-ascorbic acid treatment shows a promising pathway towards the modulation and enhancement of magnetism in various MXene materials for the development of 2D metallic soft ferromagnets and spintronic devices.

36 MATERIALS SCIENCE↗

Near-term transition and longer-term physical climate risks of greenhouse gas emissions pathways

Policy, business, finance and civil society stakeholders are increasingly looking to compare future emissions pathways across both their associated physical climate risks stemming from increasing temperatures and their transition climate risks stemming from the shift to a low-carbon economy. Herein, we present an integrated framework to explore near-term (to 2030) transition risks and longer-term (to 2050) physical risks, globally and in specific regions, for a range of plausible greenhouse gas emissions and associated temperature pathways, spanning 1.5–4 °C levels of long-term warming. By 2050, physical risks deriving from major heatwaves, agricultural drought, heat stress and crop duration reductions depend greatly on the temperature pathway. By 2030, transition risks most sensitive to temperature pathways stem from economy-wide mitigation costs, carbon price increases, fossil fuel demand reductions and coal plant capacity reductions. Considering several pathways with a 2 °C target demonstrates that transition risks also depend on technological, policy and socio-economic factors.

54 ENVIRONMENTAL SCIENCES↗

Decarbonizing all-electric communities via carbon-responsive control of behind-the-meter resources

The progression of electrification in the building and transportation sectors brings new opportunities for energy decarbonization. With higher dependence on the grid power supply, the variation of the grid carbon emission intensity can be utilized to reduce the carbon emissions from the two sectors. Existing coordinated control methods for buildings with distributed energy resources (DERs) either consider electricity price or renewable energy generation as the input signal, or adopt optimization in the decision-making, which is difficult to implement in the real-world environment. This paper aims to propose and validate an easy-to-deploy rule-based carbon responsive control framework that facilitates coordination between all-electric buildings and electric vehicles (EVs). The signals of the grid carbon emission intensity and the local photovoltaics (PV) generation are used for shifting the controllable loads. Extensive simulations were conducted using a model of an all-electric mixed-use community in a cold climate to validate the control performance with metrics such as emissions, energy consumption, peak demand, and EV end-of-day state-of-charge (SOC). Our study identifies that 4.5% to 27.1% of annual emission reduction can be achieved with limited impact on energy costs, peak demand, and thermal comfort. Additionally, up to 32.7% of EV emission reduction can be obtained if the EV owners reduce the target SOC by less than 21.2%.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Analytics-at-scale of Sensor Data for Digital Monitoring in Nuclear Plants: 2nd Annual Report

For economic reasons, the nuclear industry is witnessing premature closure of nuclear power plants, despite excellent safety records. Operations and Maintenance (O&M) activities are some of the largest costs in operating legacy light-water plants. By reducing O&M costs, nuclear energy can become more economically competitive with other energy sources. This can be achieved by leveraging machine-learning and artificial intelligence technologies to develop data-driven algorithms to better diagnose potential faults within the system. Improved accuracy of the models can lead to a reduction in unnecessary maintenance, thus reducing costs associated with parts, labor, and unnecessary planned, forced, or extended outages. To address these challenges, the goal of this project is to perform research and development in the area of digital monitoring, i.e., the application of advanced sensor technologies (particularly wireless sensor technologies) and data science based analytic capabilities, to advance online monitoring and predictive maintenance in nuclear plants and improve plant performance (efficiency gain and economic competitiveness). This report summarizes the fiscal year 2020 research progress encompassing (1) different wireless vibration sensor and data indicators used to assess the health of a plant asset; (2) development of diagnostic models for fault detection; and (3) development of prognostic models for estimating the health of the system up to 7 days ahead.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Simple and Scalable Process for Nanocellulose Production from Residues and Waste (CRADA Final Report)

This project successfully developed an innovative, cost-effective, and scalable method for converting low-cost agricultural waste feedstocks into nanocellulose—a sustainable material with wide-ranging industrial applications. It addressed the critical challenges of high production costs and limited global supply, which have hindered the widespread adoption of nanocellulose in industry. Through this work, significant advancements were made in optimizing resource use, improving process efficiency, and reducing costs. Notable achievements included a 50% reduction in water usage, 30% lower chemical consumption, and 20% energy savings, all while maintaining high-quality product standards. The technical feasibility of the process was further validated at a 10L scale in collaboration with the Advanced Biofuels and Bioproducts Development Unit (ABPDU), demonstrating scalability and replicability. Key challenges in reducing nanocellulose production costs were addressed by utilizing low-cost biomass feedstocks and implementing low-temperature conversion reactions, leading to lower capital and operating expenses. The project also mitigated financial risk by generating critical data on the feasibility, adaptability, and scalability of the conversion technology, paving the way for its commercial implementation. Public benefits include advancing the circular bioeconomy, reducing environmental impact, fostering job creation, and enabling a shift toward biobased materials as sustainable alternatives to fossil-based products. These outcomes align closely with national goals to reduce greenhouse gas emissions and promote sustainable technological innovation.

09 BIOMASS FUELS↗

Fabrication of superconducting Nb 3 Sn film by Co-sputtering

High-efficiency SRF cavities are the key technology to construct cost-effective CW SRF accelerators. Improvements in the efficiency of SRF cavities are realized by using novel materials, such as niobium-tin. Advances in niobium-tin coatings on the inner surface of SRF cavities showed the potential for this material to increase the operating temperature of the SRF cavity to above 4 K, leading to significant reduction of the capital and operating cost of SRF accelerators. Among the techniques used to apply the niobium-tin coating to the surface of the SRF cavity is sputtering. Old Dominion University, Jefferson Lab, and Fermilab are collaborating on developing an optimized niobium-tin coating of the inside surface of niobium SRF cavities using a recently-developed cylindrical sputtering system. This research will result in optimized sputtering coating techniques leading to high efficiency SRF structures.

42 ENGINEERING↗

CO2ROpt (Feedstock Allocation Optimization Model) [SWR-22-13]

Reducing greenhouse gas emissions remains a critical challenge for the transportation and chemical sectors. The electrochemical reduction of carbon dioxide is a potential pathway for production of fuels and chemicals that uses atmospheric carbon dioxide as a feedstock. Here we present an analysis of the potential for carbon dioxide captured from point sources and via direct air capture to be utilized in electrochemical reduction under different market scenarios. Using a numerical optimization framework and national data sets, scenarios for nationwide production of ethylene, formate, and carbon monoxide are evaluated at scales comparable to current production of these molecules in the United States. We show that developing a network for production of these products at scale requires capture and utilization of significant portions of the carbon dioxide that is currently emitted from large stationary point sources. Because carbon dioxide point sources are spatially and compositionally variable, their use for carbon dioxide reduction depends on electricity prices, capture cost, and location. If the power sector in the United States is decarbonized, carbon dioxide supply decreases significantly, increasing the importance of utilizing other carbon dioxide streams, and increasing the likelihood that direct air capture plays a role in supplying carbon dioxide feedstocks. These findings provide a first insight into the feedstock and energy constraints for carbon dioxide reduction.

Badgett, Alex↗

Investigation of Ammonia Carrier Materials for Next Generation Ammonia Dosing System - CRADA 334 (Abstract)

Lean-burn gasoline and diesel engines can offer substantially higher fuel efficiency, good driving performance, and reduced carbon dioxide emission compared to stoichiometric gasoline engines. Various catalyst technologies have been developed to remove the pollutants from these engines. For example, a three-way catalyst (TWC) is used to remove hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxides (NOx) from gasoline engines during the stoichiometric conditions. During the lean-burn conditions, a TWC or a diesel oxidation catalyst (DOC) is used to control HC and CO emissions. NOx is removed by either lean NOx trap catalyst (LNT) that can store NOx under lean conditions and reduce NOx under rich conditions, or selective catalytic reduction catalyst (SCR) that can selectively remove NOx with a reducing agent. Among the NOx reduction catalyst technologies, SCR offers a number of advantages, including excellent NOx reduction efficiency over a wide range of temperatures and overall lower system cost. In fact, the SCR technology using ammonia (NH3) as reductant has been proven effective and used commercially for the removal of NOx emissions from stationary sources since the 1970s. Currently, SCR is being used to meet the NOx emission standards for diesel engines in Europe and North America, and also being considered for meeting the future NOx emission standards for lean-burn gasoline engines. Because of the challenges associated with storage, handling and transportation of ammonia on a vehicle, aqueous urea solution (e.g., Diesel Exhaust Fluid, AdBlue) has been developed as ammonia storage compound for mobile applications. When the aqueous urea solution is sprayed into exhaust gas stream, urea is decomposed to release ammonia, which then reduces NOx over the downstream SCR catalyst. Although aqueous urea solution technology has enabled automakers and engine manufacturers to meet the current NOx emission standards, this process of releasing ammonia requires a hot exhaust gas and sufficient mixing, creating challenges for low temperature NOx emission control and aftertreatment system packaging. For these reasons, alternative technologies have been developed as ammonia sources (e.g., solid urea, ammonium carbamate, metal ammine chloride) during the past few years. These technologies promise more convenient handling and distribution of ammonia sources, and help maximize the low-temperature performance of SCR catalysts and reduce the overall system volume and weight. However, none of these alternative technologies can be successfully implemented without the industry consensus. Therefore, the USCAR SCR work group, which is comprised of representatives from GM, Ford, and Chrysler, has decided to investigate the potential alternative ammonia carriers, define common standard vehicle interfaces, and address personal and environmental safety concerns with part suppliers and chemical companies. Under this CRADA Project, USCAR and Battelle will investigate alternative ammonia carrier materials that are currently under development. Based on the data and information derived under the CRADA project, the USCAR SCR work group plans to build the consensus and make recommendations for the industry.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Investigation of Ammonia Carrier Materials for Next Generation Ammonia Dosing System - CRADA 334 (Abstract)

Lean-burn gasoline and diesel engines can offer substantially higher fuel efficiency, good driving performance, and reduced carbon dioxide emission compared to stoichiometric gasoline engines. Various catalyst technologies have been developed to remove the pollutants from these engines. For example, a three-way catalyst (TWC) is used to remove hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxides (NOx) from gasoline engines during the stoichiometric conditions. During the lean-burn conditions, a TWC or a diesel oxidation catalyst (DOC) is used to control HC and CO emissions. NOx is removed by either lean NOx trap catalyst (LNT) that can store NOx under lean conditions and reduce NOx under rich conditions, or selective catalytic reduction catalyst (SCR) that can selectively remove NOx with a reducing agent. Among the NOx reduction catalyst technologies, SCR offers a number of advantages, including excellent NOx reduction efficiency over a wide range of temperatures and overall lower system cost. In fact, the SCR technology using ammonia (NH3) as reductant has been proven effective and used commercially for the removal of NOx emissions from stationary sources since the 1970s. Currently, SCR is being used to meet the NOx emission standards for diesel engines in Europe and North America, and also being considered for meeting the future NOx emission standards for lean-burn gasoline engines. Because of the challenges associated with storage, handling and transportation of ammonia on a vehicle, aqueous urea solution (e.g., Diesel Exhaust Fluid, AdBlue) has been developed as ammonia storage compound for mobile applications. When the aqueous urea solution is sprayed into exhaust gas stream, urea is decomposed to release ammonia, which then reduces NOx over the downstream SCR catalyst. Although aqueous urea solution technology has enabled automakers and engine manufacturers to meet the current NOx emission standards, this process of releasing ammonia requires a hot exhaust gas and sufficient mixing, creating challenges for low temperature NOx emission control and aftertreatment system packaging. For these reasons, alternative technologies have been developed as ammonia sources (e.g., solid urea, ammonium carbamate, metal ammine chloride) during the past few years. These technologies promise more convenient handling and distribution of ammonia sources, and help maximize the low-temperature performance of SCR catalysts and reduce the overall system volume and weight. However, none of these alternative technologies can be successfully implemented without the industry consensus. Therefore, the USCAR SCR work group, which is comprised of representatives from GM, Ford, and Chrysler, has decided to investigate the potential alternative ammonia carriers, define common standard vehicle interfaces, and address personal and environmental safety concerns with part suppliers and chemical companies. Under this CRADA Project, USCAR and Battelle will investigate alternative ammonia carrier materials that are currently under development. Based on the data and information derived under the CRADA project, the USCAR SCR work group plans to build the consensus and make recommendations for the industry.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗