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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 883 records · Page 49
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Uncertainty Quantification of Fatigue Behavior of Rough AM Surfaces and Microstructures to Enable Hydrogen Gas Turbine

Modifying fossil-fueled industrial gas turbines to utilize low or zero-carbon fuels, such as hydrogen or hydrogen-natural gas blends, is a complex endeavor. The successful implementation of this technology hinges on three key design criteria: (1) developing new fuel injectors capable of efficiently burning alternative fuels, (2) ensuring manufacturability to meet cost and time-to-market goals, and (3) achieving component durability in the demanding environment of an operating gas turbine. Additive manufacturing (AM) accelerates product development, yet concerns persist regarding the durability of parts with rough AM surfaces. A fully experimental approach to quantify the fatigue performance of rough AM microstructures is both costly and labor-intensive. To address this, ORNL and Solar Turbines Incorporated (Solar) employed a crystal plasticity finite element (CPFE) model to identify the factors influencing AM surface fatigue behavior. These CPFE findings, combined with targeted experimental data, were used to develop a computationally efficient surrogate model suitable for assessing the lifespan of gas turbine engine components.

08 HYDROGEN↗
DOE OSTI2020

Fallout Cloud Regimes

The U.S. Department of Defense (DOD), Department of Energy (DOE), and other organizations maintain operational nuclear explosion and atmospheric dispersion models to provide critical guidance on the expected effects of an accidental or deliberate explosion of a nuclear weapon (in this paper simply referred to as “device”). To be effective, these models must represent, as accurately as possible, the complex interactions of the blast, fire, and residual radiological hazards with the environment and population. One hundred atmospheric nuclear tests that form the basis for many models were conducted at the Nevada Test Site (NTS) (now referred to as the Nevada Nuclear Security Site, NNSS) in a dry desert environment. Other environments should be studied, but have less data available and are beyond the scope of the work presented in this paper. The debris clouds produced by the NTS tests, frequently called “mushroom clouds,” are familiar, with common structural elements such as a buoyant cap connected to a skirt of raised dust at the desert surface by a thin, dirt-filled stem. The film scanning project at LLNL has investigated historical film records of nuclear weapons tests. Here, we summarize findings showing that the mushroom cloud behavior for historic U.S. tests conducted in Nevada, has similar characteristics based on the distance of the device from the ground surface or Height of Burst (HOB), scaled by the energy release, or yield, of the device. This scaled height is referred to as the scaled-height-of-burst (SHOB). The findings discussed below show that mushroom clouds look and behave similarly when detonated at the same SHOB. The amount of residual radiation that is produced by a nuclear detonation is proportional to the yield. But, the amount of that residual radiation that actually becomes local fallout is strongly dependent on the SHOB and the type of surface over which the detonation occurs. In order to develop a more comprehensive model that predicts the fraction of the residual radiation that becomes local fallout, it is convenient to define a series of regimes based on SHOB values in which all detonations that occur within a given regime can be modeled using the same algorithms. The purpose of this paper is to provide a framework for defining different regimes, and, in a qualitative way, a basic understanding of the fundamental characteristics of each of these regimes.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2020

Transport of colloidal particles in microscopic porous medium analogs with surface charge heterogeneity: experiments and fundamental role of single-bead deposition

Understanding colloid transport in subsurface environments is challenging due to complex interactions between colloids, ground water, and porous media over several length scales. Here, we study the transport of colloidal particles through bead-assembled microfluidic porous media analogs (PMAs) with surface charge heterogeneity. The pore-scale dynamics of colloidal particle deposition were measured, as well as the breakthrough curves (BTC) and retention profiles (RP) of deposited colloidal particles at the scale of the entire PMA. From pore-scale experiments, the maximum surface coverage (?max = 0.51) was measured directly, from which the surface blocking function and deposition coefficient (kpore = 3.56 s-1) were obtained. Using these pore-scale parameters, the transport of colloidal particles was modeled using a one-dimensional advection-dispersion equation under the assumption of irreversible adsorption between oppositely charged beads and colloids, showing good agreement with experimental data. This work presents a new approach to fabricate chemically heterogeneous porous media in a microfluidic device that enables direct measurements of pore-scale colloidal deposition. The approach allows a quantitative prediction of colloidal breakthrough and retention via coupling of direct measurements and an advection-dispersion-deposition model.

Guo, Yang↗
DOE OSTI2024

Subsurface Redox Interactions Regulate Ebullitive Methane Flux in Heterogeneous Mississippi River Deltaic Wetland

Abstract As interfaces connecting terrestrial and ocean ecosystems, coastal wetlands develop temporally and spatially complex redox conditions, which drive uncertainties in greenhouse gas emission as well as the total carbon budget of the coastal ecosystem. To evaluate the role of complex redox reactions in methane emission from coastal wetlands, a coupled reactive‐transport model was configured to represent subsurface biogeochemical cycles of carbon, nitrogen, and sulfur, along with production and transport of multiple gas species through diffusion and ebullition. This model study was conducted at multiple sites along a salinity gradient in the Barataria Basin at the Mississippi River Deltaic Plain. Over a freshwater to saline gradient, simulated total flux of methane was primarily controlled by its subsurface production and consumption, which were determined by redox reactions directly (e.g., methanogenesis, methanotrophy) and indirectly (e.g., competition with sulfate reduction) under aerobic and/or anaerobic conditions. At fine spatiotemporal scales, surface methane fluxes were also strongly dependent on transport processes, with episodic ebullitive fluxes leading to higher spatial and temporal variability compared to the gradient‐driven diffusion flux. Ebullitive methane fluxes were determined by methane fraction in total ebullitive gas and the frequency of ebullitive events, both of which varied with subsurface methane concentrations and other gas species. Although ebullition thresholds are constrained by local physical factors, this study indicates that redox interactions not only determine gas composition in ebullitive fluxes but can also regulate ebullition frequency through gas production.

03 NATURAL GAS↗
DOE OSTI2026

Energy-conserving contact dynamics of nonspherical rigid-body particles

Understanding the contact dynamics of nonspherical particles is crucial for accurately modeling colloidal and granular systems where shape anisotropy dictates structural organization and transport properties. We here introduce an energy-conserving contact dynamics framework for arbitrary convex rigid-body particles by implementing vertex–boundary interactions in 2D and vertex–surface and edge–edge detection in 3D. The established formulation enables continuous force evaluation and prevents particle overlap while conserving total energy during translational and rotational motion. We demonstrate the framework’s stability and its utility to capture packing behavior, anisotropic diffusion, and equations of state of polygonal and polyhedral particles as examples. The framework establishes a robust and extensible foundation for investigating nonequilibrium dynamics of complex nonspherical particulate systems, enabling enhanced understanding of phenomena across spatiotemporal scales in self- and directed-assembly, granular flows, and hydrodynamics, potentially coupled with interactions that represent underlying physical mechanisms.

Discrete element method↗
DOE OSTI2023

Plasma surface ionization wave interactions with single channels

Abstract The study of plasma surface ionization waves (SIWs) in recent years has primarily focused on planar surfaces and periodic two dimensional structures. In application, substrates are likely to have non-planar morphology such as cracks, pores, and steps. Additionally, targets for the applications of medicine or catalysis may have targets with heterogeneous composition. This classification of targets are brought under the umbrella of complex interfaces. In this work, plasma SIWs were incident on a complex target consisting of a single channel cut into glass slides. The SIW velocities for the in-channel portion of the wave and radially propagating portion of the wave were tracked. It was found that surface wave velocities are not significantly affected by channel geometry, but primarily increase with pulse energy. A third propagation direction for the SIW is characterized in the azimuthal direction relative to the radial portion of the wave. Channel geometry is found to greatly effect the area treated by the plasma but not the propagation velocity of the surface wave. Surface wave morphology and the impact on application is also discussed. A simple model was introduced to understand the mechanisms behind SIW escape from a channel. It was found that the ratio of pulse energy to a geometry dependent minimum energy can predict the escape angle of a SIW from single channels.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Band Heater Heat Flux Characterization Using Inverse Heat Conduction Problem Models

Abstract An experimental apparatus was constructed to correlate water flowrate and temperature rise under an external band heater. Due to the physical characteristics of the band heater, its transient heating behavior is unknown. This paper investigates the application of inverse heat conduction problem (IHCP) methods to characterize the heat flux from the band heater. Three experiments with different heating times (5, 10, and 20 s) and no flowrate were conducted to measure the transient temperature under the 400 W band heater. Type-T thermocouples measure surface temperature at the centerline of the band heater. The experimental results are computed with five different heat conduction models. The models are chosen to identify how the heat flux response varies from a simplified to a realistic model. Additionally, the results of the experimental heat flux are compared to the manufacturer band heater data (58.9 kW/m2) for each model. The minimum time needed for the heater to fully energize the system is from 10 to 12 s. The residuals for each model are analyzed and used to evaluate the appropriateness of the five different models. The results show that the use of simpler models can achieve results similar to those of complex models, with less time and computational cost.

Engineering↗
DOE OSTI2023

Formal Experimentation and Analysis of Handheld RFID Readers as a Tool for Nuclear Material Accounting

Commercial, off-the-shelf Radio Frequency Identification (RFID) systems have been successfully deployed for inventory tracking in numerous industries, but their viability in the tracking of complex environments containing nuclear material is less understood. Of primary interest in this setting is a RFID tracking system for nuclear material accounting which can reliably identify as many tags as possible with high accuracy, while also reducing an operator’s exposure to radiation. In this work, we develop a formal statistical approach to identify relevant handheld RFID reader settings which optimize tagging performance. To achieve this goal, we design a full factorial split-plot experiment for a static shelf configuration scene with 50 randomly placed nuclear material containers affixed with RFID tags. We use Bayesian inference to fit a second-order response surface model which expresses the probability of a successful match for each container as a function of the experimental factors. Such effects are allowed to vary across individual containers and the containers’ population in its entirety to estimate overall effects. Uncertainties of estimates and predictions are quantified via their corresponding posterior distributions. Following extensive model checking and validation, the fitted model is used to identify experimental factors which maximize matching probabilities at both the container-level and for the full shelf configuration scene. We also analyze sensitivity of performance to relevant factors.

25 ENERGY STORAGE↗
DOE OSTI2025

Data Integration and Visualization for Enhanced Resilience and Sustainability in Hydropower (DIVERS-H)

U.S. hydropower plants face potential threats from shrinking water supply, rising demands, and warmer stream temperatures from various causes. Power plant owners, operators, and regulators require new tools to take advantage of and interpret the diverse range of scientific data being produced by both observational methods (for example, satellite, radar, stream gauges) and computer modeling methods that evaluate and predict how earth's dynamic systems (atmosphere, oceans, land surface, and sea ice) are changing and interacting. Combining datasets such as these with AI-based analyses introduces a novel decision support system to help users anticipate and address potential impacts on power generation stations. This new technology has been named DIVERS-H for "Data Integration and Visualization for Enhanced Resilience and Sustainability in Hydropower." In Phase I, technical feasibility was established with the development and demonstration of all the new technologies that are required. Most notably, DIVERS-H will use new artificial intelligence (AI) methods to capture the complex dynamics of water availability, demand, and environmental changes. In addition, new data management software was developed, and a prototype user interface was implemented as the precursor to a full scale decision support system. With technical research complete, the project focus now shifts to development of a commercial software product to provide users with actionable insight into water availability and the risk/resilience of critical systems at their locations of interest. Although DIVER-H was originally conceived as a tool for hydroelectric power applications, the same underlying technology can be readily applied to other water-consuming systems including coal, natural gas, oil, and nuclear power plants.

Chaudhary, Aashish [Kitware, Inc., Clifton Park, N↗
DOE OSTI2025

CoCoMET v1.0: a unified open-source toolkit for atmospheric object tracking and analysis

Advances in performance and analysis capabilities have accelerated the development of object tracking algorithms for atmospheric research. This has resulted in a growing number of studies using Lagrangian tracking techniques to analyze the evolution of atmospheric phenomena and the underlying processes. However, the increasing complexity and variety of tracking algorithms present a steep learning curve for new users and make it difficult for existing users to compare algorithm performance. We introduce CoCoMET (Community Cloud Model Evaluation Toolkit), an open-source toolkit that addresses these issues. CoCoMET simplifies the process of running multiple tracking algorithms simultaneously and analyzing objects in both model and observational datasets by specifying parameters in a single configuration file. It standardizes input data from different sources into a consistent format and unifies the tracking output across algorithms. CoCoMET enhances the functionality of existing tracking methods by calculating additional properties such as cell growth and dissipation rates, perimeter, surface area, convexity, and irregularity. In addition, CoCoMET includes a novel method for identifying mergers and splits in 2D and 3D tracks and supports the integration of Eulerian/stationary datasets external to the tracking data for process studies. Its potential utility is demonstrated through examples of model intercomparison, model evaluation against observations, and comparisons between tracking algorithms. Designed for open-source environments, CoCoMET will continue to expand with future releases, incorporating more input data types and tracking algorithms.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Process Capability Study on the Volume Manufacturing of a Complex Rotating Automotive Component in Laser Powder Bed Fusion Additive Manufacturing

Oak Ridge National Lab (ORNL) and Ford Motor Company used an AddUp FormUp 350 to print a turbo wheel geometry to show feasibility of laser powder bed fusion (L-PBF) additive manufacturing (AM) in producing cost-effective components for automotive industries. L-PBF AM has potential to disrupt traditional manufacturing techniques by introducing novel materials and geometries that cannot otherwise be produced. Fundamental challenges associated with L-PBF include limitations on printing overhang geometries and resulting surface finish. In this collaboration, ORNL and Ford partnered with AddUp to show the viability of using L-PBF for an AM design turbine wheel while reducing as-fabricated surface roughness. A cost model associated with mass production was produced to analyze benefits of pursing LPBF AM compared to investment casting.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Flowability of Crumbler Rotary Shear Size-Reduced Granular Biomass: An Experiment-Informed Modeling Study on the Angle of Repose

Biomass has potential as a carbon-neutral alternative to petroleum for chemical and energy products. However, complete replacement of fossil fuel is contingent upon efficient processes to eliminate undesirable characteristics of biomass, e.g., low bulk density, variability, and storage-induced quality problems. Mechanical size reduction via comminution is a processing operation to engineer favorable biomass flowability in handling. Crumbler rotary shear mill has been empirically demonstrated to produce more uniformly shaped particles with higher flowability than hammermilled biomass. This study combines modeling and experimentation to unveil fundamental understandings of the relation between granular particle characteristics and biomass flow behavior, which elucidate underlying mechanisms and guide selection of critical processing parameters. For this purpose, the impact of critical material attributes, including particle size (2–6 mm), particle shape (briquette, chip, clumped-sphere, cube, etc.), and surface roughness, on the angle of repose (AOR) of milled pine chips were investigated using discrete element method (DEM) simulations. Forest Concepts Crumbler rotary shear system is used to produce milled pine particles within the same size range considered in DEM simulations. AOR of different sets of these particles were measured experimentally to benchmark DEM results against experimental data. Specific energy consumption for the comminution of biomass with different particle size and moisture content are measured for technoeconomic analysis. Our results show that the smaller size (2 mm) of pine particle achieves better followability (i.e., smaller AOR) while the energy cost of comminution is significantly higher and bulk density is almost the same as the 6-mm pine particles. For the 2-mm particle size, Crumbles from veneer have better flow properties than Crumbles from chips. Contrarily, no significant difference was observed between the AOR of the two materials for the 6-mm particle size. Furthermore, from DEM simulations, mechanical interlocking between particles was found as a dominant factor in determining AOR of complex-shaped particles such as milled pine, which cannot be accurately captured by using simple particle shapes (e.g., mono-sphere) with a rolling resistance model. Conversely, clumped-sphere model alleviates this limitation without increasing computational cost significantly and can be used for accurate representation of biomass granular particles when simulating free-flow behavior.

09 BIOMASS FUELS↗
DOE OSTI2021

Reaction kinetics during early hydration of calcined phyllosilicates in clinker-free model systems

Investigations of nearly pure, calcined phyllosilicates (“meta-phyllosilicates”) in clinker-free model systems were performed in presence and absence of sulfate. Calorimetric investigations show a pronounced reaction during the early reaction period only for metakaolin. Quantitative in situ X-ray diffraction reveals calcium silicate hydrate formation in the systems with metakaolin and metaillite, but not in those with metamuscovite. Ettringite crystallizes in all systems containing sulfate, where only the metakaolin system reaches the maximum ettringite content possible. The amount of aluminum ions released from 2:1 meta-phyllosilicates seems to be insufficient to reach the maximum content. Differences in portlandite dissolution and bound water indicate adsorption effects of calcium or calcium – sulfate ion pair complexes on surfaces of the calcined clay particles. Thus, the chemical as well as the physical influence of the meta-phyllosilicates must be considered to predict the reaction kinetics of calcined clays during early hydration.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Practical Considerations for Understanding Surface Reaction Mechanisms Involved in Heterogeneous Catalysis

Acquiring useful knowledge about the active site(s) of a catalyst, nature of reactant–catalyst interactions, nature of reactive intermediates, rate-determining step, reaction rate orders that affect various process parameters, and reaction mechanism as a whole is exceedingly challenging. This is especially true in the case of heterogeneous catalysts due to the complexity of the nature of surface active sites and their nonstatic behavior. Here, we present our perspective on differentiating between various surface reaction mechanisms in light of pioneering studies by leaders in the field, with the aim of clarifying some of the confusion associated with these complex mechanisms, especially the Eley–Rideal mechanism. Using bibliometric analysis, we identify and discuss the following four reactions that most commonly invoke the Eley– Rideal mechanism: H 2 activation, CO oxidation, esterification of alcohols by acids, and selective catalytic reduction (SCR) of NO x with NH 3 . Our analysis of studies utilizing well-suited experimental and computational methodologies for differentiating surface reaction mechanisms suggests that the above-mentioned four reactions do not occur via the Eley–Rideal mechanism. Instead, each reaction occurs via the Langmuir–Hinshelwood mechanism with nonidealities present. Lastly, we highlight practical considerations regarding select experimental (characterization methods and differential kinetics) and computational modeling that we believe can provide useful insights to accurately discern between the various possible reaction mechanisms in heterogeneous catalysis.

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

Characterization of micro-sandwich structures via direct ink writing epoxy based cores

Sandwich structured (SS) composites demonstrate considerable flexural stiffness and high strength-to-weight ratios and can be tailored as functional materials. Historically they have been constrained to specific material types and geometry due to limitations in manufacturing methods. However, employing additive manufacturing (AM), specifically direct ink writing (DIW), can provide an alternative method for making SS composites with complex and controllable micro and mesostructures with multifunctionality targeted at desired mechanical, thermal, and electrical properties. DIW, an extrusion-based AM technique, uses a viscous and thixotropic ink with desired components that, once printed, is cured to obtain the final complex net shape parts. In this paper, a novel hybrid AM technique is employed to manufacture SS composite materials containing bisphenol A-based epoxy core and carbon fiber reinforced polymer (CFRP) face sheets that are fabricated via DIW and vacuum infusion process (VIP), respectfully. We demonstrate that the fabrication of these SS composites can be tailored from a thermosetting material, from which additives and/or various lattice structures can be manufactured to achieve enhanced and desirable mechanical integrity with functional properties. Surface topology and mechanical testing techniques are used to characterize the fabricated hybrid SS composites to study and assess mechanical stability. A rheo-kinetic cure model was developed for the core material to allow for additive manufacturing process requirements while ensuring complete cross-linking for the thermoset-based core material. Because of the ability to obtain relatively small core-thickness and controlled architecture, this method now allows for fabricating layered micro-sandwich structures for realizing further light-weighting in relevant applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Fitness for Service Assessment of a Corroded Heat Exchanger

Fermilab s Main Injector Accelerator has used shell & tube heat exchangers to cool various beamline components since its construction in the late 1990s. Many of the heat exchangers still around today are original to the machine. Untreated pond water has been used to exchange heat with the Low Conductivity Water. Throughout the lifetime of Fermilab s heat exchangers, they have undergone significant material degradation in the carbon steel end channels due to corrosion. Wall thickness measurements (per API 510) of each heat exchanger were used to generate a 3D model of the corroded surfaces. In order to continue their safe and reliable operation, ASME FFS-1/API 579 (Fitness-For-Service) was implemented to address their integrity. The assessments consisted of finite element analysis techniques outlined in ASME Section VIII Div. 2 (design by analysis methods for pressure vessels), in accordance with the requirements of ASME FFS-1 Part 4: General Metal Loss, Part 5: Local Metal Loss, and Part 9: Crack Like Flaws. The assessments concluded that each heat exchanger is coined Fit For Service . The Fitness-For-Service standard offers a unique opportunity to facilities and institutions within the DOE National Lab complex to properly and safely assess the integrity of aging equipment necessary to conduct science and research. This poster demonstrates the assessment process and techniques used to determine the heat exchangers are fit for service.

Humenik, Alex [Fermilab]↗
DOE OSTI2022

Magnetic-Core/Gold-Shell Nanoparticles for the Detection of Hydrophobic Chemical Contaminants

Magnetic-core/gold-shell nanoparticles (MAuNPs) are of interest for enabling rapid and portable detection of trace adulterants in complex media. Gold coating provides biocompatibility and facile functionalization, and a magnetic core affords analyte concentration and controlled deposition onto substrates for surface-enhanced Raman spectroscopy. Iron oxide cores were synthesized and coated with gold by reduction of HAuCl4 by NH2OH. MAuNPs were grafted with polyethylene glycol (PEG) and/or functionalized with 4-mercaptobenzoic acid (4-MBA) and examined using a variety of microscopic, spectroscopic, magnetometric, and scattering techniques. For MAuNPs grafted with both PEG and 4-MBA, the order in which they were grafted impacted not only the graft density of the individual ligands, but also the overall graft density. Significant Raman signal enhancement of the model analyte, 4-MBA, was observed. This enhancement demonstrates the functionality of MAuNPs in direct detection of trace contaminants. The magnetic deposition rate of MAuNPs in chloroform and water was explored. The presence of 4-MBA slowed the mass deposition rate, and it was postulated that the rate disparity originated from differing NP-substrate surface interactions. These findings emphasize the importance of ligand choice in reference to the medium, target analyte, and substrate material, as well as functionalization procedure in the design of similar sensing platforms.

36 MATERIALS SCIENCE↗