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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Development of Reduced Glass Furnace Model to Optimize Process Operation (Final Report)

This was a collaborative effort between Lawrence Livermore National Security, LLC as manager and operator of Lawrence Livermore National Laboratory (LLNL) and PPG Industries to develop a reduced-order glass furnace model that enables plant operators to make informed, real time process adjustments. This CRADA project is sponsored under the High-Performance Computing for Manufacturing (HPC4Mfg) Program of the Department of Energy's Advanced Manufacturing Office (AMO) within the Energy Efficiency and Renewable Energy (EERE) Office. This program ran from June 2016 to July 2017 with no extensions.

42 ENGINEERING↗
DOE OSTI2019

Final Report for Industrial Base Cybersecurity Initiative (IBCI) Project (FY2019)

Information security issues impact all manufacturing sectors and are particularly troublesome when designs for advanced weapons systems are lost via attacks that propagate through the relatively unprotected lower tiers of the nation's supply chains. The US Manufacturing Industrial Base (MIB) consists of suppliers and distributors that range in size from large prime contractors with extensive cybersecurity resources to small shops with little or no in-house information technology capabilities. The acquisition and maintenance of the technologies, systems, and financial resources needed to assure secure collaborations can be an overwhelming challenge for many manufacturers yet the cost of poor cybersecurity practices can lead to the compromise of national security information worth hundreds of millions of dollars. The Department of Defense Manufacturing Industrial Base Policy organization and the Department of Energy, Energy Efficiency and Renewable Energy Advanced Manufacturing Office have chartered the Los Alamos National Laboratory (LANL) and the Oak Ridge Y-12 National Security Complex (Y-12) to design, develop, and demonstrate a Manufacturing Threat Evaluation Wargaming System (MTEWS). The MTEWS concept is based on the use of a virtual model of the computer networks and cybersecurity protocols used across the MIB that will be continuously updated to reflect the dynamic threat environment. The MTEWS cyber-physical test range will demonstrate a prototype wargaming system that analyzes the impact of new and existing cybersecurity threats while also providing the information needed to sustain the integrity of the MIB supply chains. A long-term goal is the establishment of an enduring national manufacturing operations center that proactively responds to the continuously changing attacks that threaten the MIB and US national security. LANL and Y-12 have formed an Industrial Base Cybersecurity Initiative Team (IBCI), consisting of partners from the public, private and academic sectors, that is developing the MTEWS. To date, most of the project tasks have been centered on the technologies required to create a representative model of the MIB because this is a foundational element for the entire project. Modeling activities at the University of North Carolina at Charlotte (UNC Charlotte) have demonstrated a VMware-based prototype system that can accommodate a network model with up to 350 nodes and includes features such as the option to incorporate network scanning information when building the model and the ability to down select the elements of duplicative networks to a statistically significant subset that avoids redundantly duplicating network configurations. Broad Ordering Agreements have been established with UNC Charlotte and the University of West Florida (UWF) that support a variety of cybersecurity for manufacturing tasks and wide-spread endorsement has been received from government, industry and academia sectors concerning the IBCI goals and technical direction.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2019

Multi-layer Printing of Complex Antennas Using Aerosol Jet Technology (CRADA NFE-18-07315 Final Report)

This project demonstrated the feasibility of producing multilayer radio-frequency (RF) and microwave-frequency components using aerosol jet additive manufacturing technology. Funded by the U.S. Department of energy, Advanced Manufacturing Office, this effort focused on novel stacked component designs for devices such as antennas, electronic filters, resistive/inductive/capacitive (RLC) components, and transmission lines. Our approach to RF/microwave component fabrication by aerosol jet printing has the potential to reduce component size, improve performance characteristics, and allow devices to be fabricated on non-planar surfaces. Specifically, folded micro-patch antenna designs were fabricated by stacking layers of conductors and dielectrics printed in sequence using Optomec’s aerosol jet technology. ORNL supported the effort by providing design input on printing parameters and characterizing the performance of printed structures. ORNL identified suitable stacked antenna designs, produced finite element models (FEM) in high-frequency simulation software (HFSS), and provided the designs to Optomec for printing. After printing, the devices were tested and characterized at ORNL to determine the frequency response and material characteristics of the printed components. These proof-of-principle devices will provide feedback on printing parameters, optimizations for the FEM models, and a path for more complex multilayer device designs.

42 ENGINEERING↗
DOE OSTI2021

Development of Reduced Glass Furnace Model to Optimize Process Operation

This was a collaborative effort between Lawrence Livermore National Security, LLC as manager and operator of Lawrence Livermore National Laboratory (LLNL) and PPG Industries to develop a reduced-order glass furnace model that enables plant operators to make informed, realtime process adjustments. This CRADA project is sponsored under the High-Performance Computing for Manufacturing (HPC4Mfg) Program of the Department of Energy's Advanced Manufacturing Office (AMO) within the Energy Efficiency and Renewable Energy (EERE) Office. This program ran from June 2016 to July 2017 with no extensions.

42 ENGINEERING↗
DOE OSTI2021

Future of Water Infrastructure and Innovation Summit

Energy and water systems are interdependent, and the U.S. Department of Energy (DOE) has invested in energy and water for several years, including the Energy-Water Desalination Hub (led by the National Alliance for Water Innovation, NAWI), and research and development (R&D) in resource recovery from wastewater, among other areas. The Advanced Manufacturing Office (AMO) at the U.S. Department of Energy (DOE) held The Future of Water Infrastructure and Innovation Summit to inform the understanding of future opportunities in the water space. The virtual summit was held on October 27 and 28, 2020. The organizers gathered information from a diverse group of relevant water and wastewater stakeholders representing academia, industry, government, nongovernmental organizations, and local/regional utilities. Topics from Day 1 discussions included: desalination, water and wastewater treatment/recovery, produced water, industrial management of water, and hydropower, conveyance, and water systems.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Sustainability of the U.S. Manufacturing Sector: Use of the United Nations Sustainable Development Goals

The United Nations' 17 Sustainable Development Goals (SDGs) aim to improve health and education, reduce inequality, and encourage economic growth, while also preserving or improving the conditions of our oceans and forests. Pursuing these SDGs would mean $12 trillion in economic opportunities for companies, while also improving the lives of all people and bettering the planet. Some manufacturing companies are already focusing on sustainability, but not all. In 2019, almost 30% of National Association of Manufacturers members did not have a sustainable policy, goals, or program in place. Business drivers for sustainability and the SDGs are similar, with focuses on economic growth and consumer demands. Despite the shortcomings of the SDGs, they represent an opportunity for manufacturing companies to further improve energy, material efficiency, and productivity. This report evaluates the SDGs and the manufacturing sector. The manufacturing sector was analyzed using the technology assessments (TAs) introduced in the 2015 Quadrennial Technology Review (QTR) review, which focused on concepts, challenges, and solutions to meet the United States' energy needs. Annual or sustainability reporting of companies performing work in one of those TAs were analyzed for mentions of the SDGs. The call-out boxes throughout this report provide examples of companies making progress toward the SDGs. The possible overlap between the SDGs and the Advanced Manufacturing Office (AMO) was also evaluated. The TAs in the 2015 QTR Review were furthered with detailed targets in the draft Multi-Year Program Plan (MYPP) for Fiscal Years 2017-2021. Direct and likely relationships between the SDGs and the TAs were established. Positives, challenges, SDG-related literature, and future steps are also discussed in this report.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Theory-guided Design of Refractory MPEAs for High-Temperature, Harsh-Service Conditions

Focusing on novel materials for harsh-service environments (oxidation, corrosion, and load), durability, higher operational temperature, and direct impact on power-generation technology, the goal was, using a quantitative theory-guided design approach integrated with high-throughput synthesis and characterization for validation, to accelerate by 50% the development of high temperature, refractory-based multi-principal element alloys (MPEAs) materials platforms (with co-designed oxidation-resistant, self-healing coatings) that demonstrate phase-stable operation with desired properties at 10-20% higher temperatures in oxidizing environments over state-ofthe- art systems (like Ni-stainless steels, i.e., Haynes 282 – used in critical gas turbine applications, and refractory TZM, i.e., molybdenum-rich Mo99.4-Ti0.5-Zr0.08-C0.02 in wt%). Notably, refractory MPEAs may achieve higher operational temperatures with superior creep strength and offer 50-100% larger thermal conductivity (140-170 W/m-K) than Ni-based systems, potentially eliminating active cooling, reducing system weight, complexity, and cost. Achieving this goal addresses DOE material challenges in energy generation and efficiency (higher-temperature operation), reduced lifecycle energy (waste-heat recovery), and accelerating materials development in support of AMO’s Strategic Plan and QTR goals. DOE’s Advanced Manufacturing Office (AMO) goal of reducing industrial energy intensity and GHG emissions is addressed by development of coated refractory MPEAs exhibiting 20%+ higher operational temperature (direct increase of Carnot efficiency), higher melting temperatures (better phase stability), superior creep strength (better lifetime with creep rate lower by factor of 10), larger (50-100%) thermal conductivity (improved cooling without active cooling), reduced complexity (single-phase alloys), self-healing coating (reliable oxidation-resistance) and cost.

36 MATERIALS SCIENCE↗
DOE OSTI2022

CABLE Big Idea RDD&D Workshop (Workshop Summary Report)

The U.S. Department of Energy’s (DOE’s) Advanced Manufacturing Office (AMO) held the CABLE Big Idea RDD&D Workshop April 7–9, 2021. The virtual workshop brought together approximately 250 leading scientific and technical experts to gather information on the state of the art in conductivity-enhanced materials and their applications. These stakeholders included scientists, engineers, manufacturers, materials experts, utility companies, and other entities within the conductor material and electrical product manufacturing supply chains. The two main goals of the workshop were to 1) start building and strengthening a research ecosystem around conductivity-enhanced materials and 2) inform AMO’s future portfolio of research, development, demonstration, and deployment (RDD&D) investments and other program activities in the area of conductivity-enhanced materials. CABLE—or Conductivity-enhanced materials for Affordable, Breakthrough Leapfrog Electric and thermal applications—was was established as an Office of Energy Efficiency and Renewable Energy initiative as a result of a competitive internal process to identify and prioritize potentially high-impact research topics. Since then, conductivity-enhanced materials have been identified as an important element of the shift to an electrified and decarbonized industry sector, and CABLE remains a Big Idea. The CABLE effort is led by AMO and supported by eight other offices within DOE. The first major effort under CABLE was the development of several subtopics for DOE’s Small Business Innovation Research/Small Business Technology Transfer (SBIR/STTR) programs in 2020. Another major activity was the launch of the CABLE Conductor Manufacturing Prize in March 2021.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Techno-Economic Analysis for Shear Assisted Processing and Extrusion (ShAPE) of High Strength Aluminum Alloys

Aluminum alloy 7075 (AA7075) is a high strength aluminum alloy (HSAL), attractive for applications such as automotive, aviation, aerospace, defense, and marine applications. However, AA7075 has not yet been widely adopted due slow extrusion speed, high energy use, narrow process window, and sensitivity to incipient melting common in conventional extrusion methods. Alternative extrusion methods may overcome these limitations. New research funded by the U.S. Department of Energy (DOE) Advanced Manufacturing Office (AMO) is exploring the use of a new SPP approach called Shear Assisted Processing and Extrusion (ShAPE) for the manufacture of AA7075 extrusions. Pacific Northwest National Laboratory (PNNL) are leading the development, testing and characterization of ShAPE, which is showing that high speed ShAPE extrusions (e.g., above 12 meters/min) which is significantly faster than the 1-2 meters/min possible with conventional AA7075 extrusions. Initial findings from the economic and energy analysis indicate that AA7075 tubes created with ShAPE use less energy than tubes that are conventionally heated and extruded. The reduction in energy use is primarily a result of using direct chill cast (non-homogenized) billets, eliminating the pre-heating step, and faster extrusion speeds. The TEA model translates CAPEX and O&M costs to a manufacturing cost, and then a minimum sustainable price (MSP) per ton of extruded product for multiple facility capacities. A sample output figure of the TEA model is presented below. It presents results of the preliminary version of the TEA model.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Workshop on Ultra-Precision Control for Ultra-Efficient Devices (Workshop Report)

On April 21–23, the U.S. Department of Energy’s (DOE’s) Advanced Manufacturing Office (AMO) within the office of Energy Efficiency and Renewable Energy (EERE) held the second in a series of workshops on different topics related to semiconductor research and development (R&D) to increase energy efficiency. This workshop focused on ultra-energy-efficient devices and the ultra-precision manufacturing (UPM) processes and next-generation control and metrology technologies needed to manufacture these devices. In addition to the industry needs and RDD&D opportunities, AMO’s new goal on greenhouse gas (GHG) reduction was addressed. The output of this workshop will inform AMO’s future R&D portfolio investments; provide perspectives on trends, drivers, and challenges for ultra-energy-efficient devices and enabling technologies; and help the stakeholder community understand the opportunities on the horizon.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Workshop on Integrated Sensor Systems for Manufacturing Applications (Workshop Report)

On January 25th and 26th, the Department of Energy’s Advanced Manufacturing Office (AMO) held the first in a series of workshops on different topics related to semiconductor research and development (R&D). This workshop focused on integrated sensor system R&D for manufacturing applications. As AMO is housed within the office of Energy Efficiency and Renewable Energy (EERE), the workshop addressed not only industry needs and R&D opportunities, but also the impacts that improvements in sensor systems can have on energy efficiency and greenhouse gas production. The output of this workshop will inform AMO’s future portfolio of R&D investments, provide perspectives on trends, drivers, and challenges for next generation semiconductor sensor systems, and help the stakeholder community understand the opportunities on the horizon.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Cooperative Research and Development Agreement among National Energy Technology Laboratory, The Board of Regents of the University System of Georgia by and on behalf of Georgia Institute of Technology, and University of Texas at El Paso [Abstract]

Georgia Institute of Technology (GIT), University of Texas at El Paso (UTEP), and the National Energy Technology Laboratory (NETL) will collaborate and develop cyber-physical systems for advanced power systems. GIT will test virtual models on hybrid power system hardware and cyber physical components. UTEP will test novel actuators on hybrid power system hardware. NETL will access GIT’s expertise in the engineering and real time simulation of power system processes for cyber-physical systems and simulations to control hardware. NETL will establish a relationship to promote UTEP’s capabilities in additive manufacturing and high-temperature piezo-electric devices with the potential for controlling high-temperature flows with a light and inexpensive device at high response rates. This project is the result of an EERE Advanced Manufacturing Office open Multi-Topic awarded proposal led by GIT titled, “Robust Combined Heat and Hybrid Power (CHHP) for High Electrical Efficiency Cogeneration”.

42 ENGINEERING↗
DOE OSTI2022

Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy

The US Department of Energy’s (DOE’s) Advanced Manufacturing Office held the virtual workshop entitled “Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy” in November and December 2020. The workshop brought together participants from universities/laboratories, industries, equipment manufacturers, technology vendors, nongovernmental organizations, and subject-matter experts to discuss transformative technologies and strategies to substantially improve the performance (e.g., energy productivity, thermal efficiency, reduced greenhouse gas [GHG] emissions, reduced number of process steps) of thermal processing systems in the industrial sector.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

DOE EERE AMO Electrochemistry for Manufacturing (Workshop Report)

The Advanced Manufacturing Office (AMO) aims to improve the efficiency, productivity, environmental impact, and competitiveness of the manufacturing sector. The use of electrochemistry in manufacturing could help AMO achieve these goals with its potential to have significant impact on sustainability, energy and carbon efficiency, and U.S. manufacturing competitiveness. The “Electrochemistry for Manufacturing” workshop series was designed to help AMO understand (1) how electrochemistry can be used within the manufacturing sector to achieve AMO’s goals and (2) the support for technology and workforce development that is needed from AMO to leverage crosscutting efforts that can enable successful outcomes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

NC State University Industrial Assessment Center. Final Report

This report documents work from the Industrial Assessment Center program at NC State University. The program is funded by the US Department of Energy Advanced Manufacturing Office. The IAC provides energy conservation assessments for small and medium sized manufacturers in NC, SC, and VA. Students are involved in all aspects of the assessment including the on-site visit, interacting with plant personnel, collecting data, performing engineering analyses on potential energy efficiency measures, and producing a technical report for the client.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

2022 Combined Heat and Power/District Energy System Portfolio Meeting (Summary Report)

The U.S. Department of Energy’s (DOE’s) Advanced Manufacturing Office held the 2022 Combined Heat and Power & District Energy System Portfolio Meeting on June 7–9, 2022. The meeting brought together approximately 50 researchers from industry, national laboratories, and research institutes. The purpose of the meeting was for DOE to understand the performance of the projects being sponsored through the CHP program and the status of the technology development, which informs future program planning. This report summarizes the presentations that took place at this event.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Microstructural Characterization of Enhanced Conductivity Aluminum Alloys (Abstract)

In this project, Pacific Northwest National Laboratory (PNNL) will perform multimodal imaging to determine the microstructural features of enhanced conductivity aluminum alloys manufactured by NanoAL LLC. In particular, we will perform imaging to identify the basis of the strengthening mechanisms in the custom AA6X alloys provided by NanoAL LLC. These activities will be performed as part of a voucher service provided by the PNNL for the CABLE Manufacturing Prize stewarded by DOE Advanced Manufacturing Office. This 6-month effort will be executed predominantly at PNNL with a budget of $50,000.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Rapid CFD Using Machine Learning Algorithms (CRADA Final Report)

This is a collaborative effort between Lawrence Livermore National Security, LLC as manager and operator of Lawrence Livermore National Laboratory (“LLNL”) and Guardian Glass, LLC ("Guardian Glass") to develop a fast-running emulator of the reactive Computational Fluid Dynamics (“CFD”) simulations needed to understand the complex reactions and flows in the glass melting, fining, and forming subprocesses. This CRADA project is sponsored under the High-Performance Computing for Manufacturing (“HPC4Mfg”) Program of the Department of Energy’s Advanced Manufacturing Office (“AMO”) within the Energy Efficiency and Renewable Energy (“EERE”) Office.

36 MATERIALS SCIENCE↗