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NASA NTRS1979

Composites for Advanced Space Transportation Systems - (CASTS)

The CASTS Project initiated to develop graphite fiber/polyimide matrix (GR/PI) composite structures with 589K operational capability for aerospace vehicles is described. Near term tasks include screening composites and adhesives for 589K service, developing fabrication procedures and specifications, developing design allowables test methods and data, design and test of structural elements, and construction of a full scale aft body flap for the space shuttle orbiter vehicle for ground testing. Far term tasks include research efforts directed at new materials, manufacturing procedures and design/analysis methodology. Specific results discussed include: (1) identification of four GR/PI composites and three PI adhesives with 589K service potential for periods ranging from 125 to 500 hours; (2) development of an adhesive formulation suitable for bonding reusable surface insulation (RSI) titles to 589K (GR/PI) substructure; (3) the capability to fabricate and nondestructively inspect laminates, hat section shaped stiffeners, honeycomb sandwich panels, and chopped fiber moldings; and (4) test methods for measuring design allowables at 117K.

Davis, J. G., Jr.↗

NASA NTRS1987

Robust eigenstructure assignment by a projection method: Application using multiple optimization criteria

New ideas which lead to feedback control laws for large flexible structures which are insensitive to model uncertainty are presented. A pole placement method is presented which leads to near-unitary closed loop eigenvectors, and a new method is introduced to design the control while simultaneously considering three competing measures of optimality. Robustness versus Integral algorithms are applicable to at least moderately high-dimensioned systems. In the present discussion, controls for two coupled flexible bodies are considered. A 6x24 gain matrix is designed to control a 12 modes system using 6 actuators. Researchers also developed control laws for the R2P2 simulator at Martin Marietta; in this case 3 actuators are used to control a 12th order system. Simulation studies indicate that researchers indeed achieved robust designs without significant difficulties associated with spillover into the uncontrolled modes. Here, several key ideas and numerical results are given. In the references, details of the formulation, discussions of salient features, and connection to the availiable literature are given.

Junkins, J. L.↗

DOE OSTI2023

Coal-based Bricks & Blocks (CBBs): Process Development to Prototype Fabrication Coupled with Techno-Economic Analysis and Market Survey

The decline of coal use for energy production provides an abundance of local feedstock for new innovative uses and value-added products. Expanding the U.S. coal-value chain to manufacture high-value carbon products can strengthen the nation’s energy and mineral security, enhance the U.S. national defense security, increase the United States’ economic prosperity, while achieving U.S. environmental objectives. The primary project goal is a relatively light-weight composite product with superior (or comparable) compressive strength. Both virgin and, where available, post-consumer recycled thermoplastic versions are tested for each thermoplastic species. A useful attribute of thermoplastics as binders is that they can be heated to their melting point, cooled, and reheated again without significant degradation. A key advantage of thermoset CBBs is that they require only mixing and molding. CBB advantages include low cost, availability, binding ability and processability. Coal-based bricks and blocks (CBBs) weigh about 50% less than clay bricks and can be manufactured with an interlocking design to promote ease of use for the novice builder. CBB formulation is evaluated according to a design-of-experiments (DoE) approach. DoE variables are a) relative weight fractions of binder, b) relative proportions of large versus small (milled) anthracite size fractions, and c) additive percentage. Fabrication methods include hot-press molding and extrusion, the later being the most commercially viable. CBBs are tested for compressive strength, modulus of rupture (by flexure test) and water absorption per ASTM C67, with density determined by the Archimedes drainage method. Fractured interfaces are examined by SEM (Scanning Electron Microscopy) to resolve fracture dynamics and interior microstructure uniformity. Differential scanning calorimetry (DSC) is used to compare plastic transition temperatures i.e., glass and melting temperatures to contrast virgin with post-consumer recycled thermoplastics and optimize their usage. These results are used in the DoE analysis to identify the binder and relative weight percentages for optimum strength, density, and porosity. Overall, CBBs possess strength comparable to clay-based bricks but are non-permeable and hydrophobic, and hence resistant to degradation by freeze-fracturing, corrosion, and efflorescence. The strongest composites have been made with the following thermoplastic binders (in order of strength): thermoset, high-density polyethylene crosslink resin, high-density polyethylene, nylon 6/6, and polypropylene. Results from a techno-economic analysis TEA show economy of scale for CBBs by modularization and reveal the binder as the cost driver for material costs. Ideally, the incorporation of post-consumer recycled thermoplastic will decrease material acquisition costs and increase product sustainability. Notably, CBBs do not require the high temperature calcination needed to produce cement, nor do they require firing in the 1600-2400 °F range for three days using natural gas, as do clay brick equivalents. Instead, CBBs are heated to a modest <600 °F according to the melt flow index of the thermoplastic binder. Existing anthracite mines can be expanded to produce CBBs to reduce aggregate transportation costs and emissions that exist for clay bricks. TEA reflects this reduced energy cost while a comparative CO2 emission analysis quantifies the reduced environmental footprint. The market survey identifies several commercialization opportunities, dependent upon the brick classification.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS2013

ISSM: Ice Sheet System Model

In order to have the capability to use satellite data from its own missions to inform future sea-level rise projections, JPL needed a full-fledged ice-sheet/iceshelf flow model, capable of modeling the mass balance of Antarctica and Greenland into the near future. ISSM was developed with such a goal in mind, as a massively parallelized, multi-purpose finite-element framework dedicated to ice-sheet modeling. ISSM features unstructured meshes (Tria in 2D, and Penta in 3D) along with corresponding finite elements for both types of meshes. Each finite element can carry out diagnostic, prognostic, transient, thermal 3D, surface, and bed slope simulations. Anisotropic meshing enables adaptation of meshes to a certain metric, and the 2D Shelfy-Stream, 3D Blatter/Pattyn, and 3D Full-Stokes formulations capture the bulk of the ice-flow physics. These elements can be coupled together, based on the Arlequin method, so that on a large scale model such as Antarctica, each type of finite element is used in the most efficient manner. For each finite element referenced above, ISSM implements an adjoint. This adjoint can be used to carry out model inversions of unknown model parameters, typically ice rheology and basal drag at the ice/bedrock interface, using a metric such as the observed InSAR surface velocity. This data assimilation capability is crucial to allow spinning up of ice flow models using available satellite data. ISSM relies on the PETSc library for its vectors, matrices, and solvers. This allows ISSM to run efficiently on any parallel platform, whether shared or distrib- ISSM: Ice Sheet System Model NASA's Jet Propulsion Laboratory, Pasadena, California uted. It can run on the largest clusters, and is fully scalable. This allows ISSM to tackle models the size of continents. ISSM is embedded into MATLAB and Python, both open scientific platforms. This improves its outreach within the science community. It is entirely written in C/C++, which gives it flexibility in its design, and the power/speed that C/C++ allows. ISSM is svn (subversion) hosted, on a JPL repository, to facilitate its development and maintenance. ISSM can also model propagation of rifts using contact mechanics and mesh splitting, and can interface to the Dakota software. To carry out sensitivity analysis, mesh partitioning algorithms are available, based on the Scotch, Chaco, and Metis partitioners that ensure equal area mesh partitions can be done, which are then usable for sampling and local reliability methods.

Larour, Eric↗

NASA NTRSDate not supplied

Capability Gaps Assessment and Identification of Critical Technology Elements for Mars Transit Habitat

The Habitation Systems Development Office (HP40) at NASA Marshall Space Flight Center supports systems engineering, integration, and project management for next generation space habitats. For in space operations and eventual transport of humans to Mars, NASA will rely on a Mars Transit Habitat (TH). The TH will be designed for an up to 1,200-day Mars mission and will carry all food and supplies needed to support four crew for this duration. In the current concept of operations, Mars TH transfers to near rectilinear halo orbit (NRHO) following launch and docks at Gateway as a visiting vehicle. While there, the TH will complete system shakedown testing and a series of analog missions which will grow from 3 to 6+ months in duration TH also augments Gateway’s habitation capabilities beyond 60-days. Proposed Gateway-TH missions will far exceed the longest duration cislunar human missions to date. These shakedown missions will also be the first operational readiness tests of Mars TH’s long-duration deep space systems, and of the split crew (two crew on the surface, two crew in space) operations that are vital to the approach for the first human Mars mission. Once shakedown missions are complete, Mars TH departs Gateway to aggregate with the Mars propulsion system in NRHO before onboarding the crew and final supplies in Earth orbit via a co-manifested Orion-logistics module. Orion and the LM return to Earth prior to the now aggregated Deep Space Transport vehicle’s journey to Mars. Development of the Mars TH requires significant technology development and maturation. Each year the agency performs a capability gaps assessment, where gaps developed by subject matter experts (SMEs) in various engineering/science disciplines are linked to architectural elements in formulation and prioritized. A gap captures the difference between the current state-of-the-art and the maturity of the capability that is needed to enable or enhance a mission as it is currently envisioned in the government reference architecture. HP40 conducted a gap analysis for Mars TH which will be summarized in this poster. Gaps classified as enabling (which means the mission cannot achieve success without gap closure) were subsequently used to identify critical technology elements (CTEs) for Mars TH. This identification of CTEs was also informed by an examination of the product breakdown structure for Mars TH and focused conversations with SMEs in specific technology areas. CTEs identified for Mars TH to date include the following (note this is not a comprehensive list – CTEs listed represent those in MSFC’s capability areas): inflatable softgoods for habitation; enhanced CO2 recovery; life support systems with greater levels of reliability and maintainability; autonomous guidance, navigation, command and control; and radiators for the Mars TH application. The habitation systems development team is currently delving deeper into each CTE to assess technology approaches being pursued, their maturity, and the degree of difficulty in maturation to meet projected Mars TH timelines. This poster will summarize work to date on the identification of enabling capability gaps linked to Mars TH and provide insight into the associated CTEs and technology maturation efforts.

technology development↗

NASA NTRS1998

Use of a Passive Reaction Wheel Jitter Isolation System to Meet the Advanced X-Ray Astrophysics Facility Imaging Performance Requirements

Third in the series of NASA great observatories, the Advanced X-Ray Astrophysics Facility (AXAF) is scheduled for launch from the Space Shuttle in November of 1998. Following in the path of the Hubble Space Telescope and the Compton Gamma Ray Observatory, this observatory will image light at X-ray wavelengths, facilitating the detailed study of such phenomena as supernovae and quasars. The AXAF project is sponsored by the Marshall Space Flight Center in Huntsville, Alabama. Because of exacting requirements on the performance of the AXAF optical system, it was necessary to reduce the transmission of reaction wheel jitter disturbances to the observatory. This reduction was accomplished via use of a passive mechanical isolation system to interface the reaction wheels with the spacecraft central structure. In addition to presenting a description of the spacecraft, the isolation system, and the key image quality requirement flowdown, this paper details the analyses performed in support of system-level imaging performance requirement verification. These analyses include the identification of system-level requirement suballocations, quantification of imaging and pointing performance, and formulation of unit-level isolation system transmissibility requirements. Given in comparison to the non-isolated system imaging performance, the results of these analyses clearly illustrate the effectiveness of an innovative reaction wheel passive isolation system.

Pendergast, Karl J.↗

NASA NTRS2000

Numerical Simulation of Receptivity for a Transition Experiment

The cost of fuel to overcome turbulence induced viscous drag on a commercial airplane constitutes a significant fraction of the operating cost of an airline. Achieving laminar flow and maintaining it over a large portion of the wing can significantly reduce the viscous drag, and hence the cost. Design of such laminar-flow-control wings and their practical operation requires the ability to accurately and reliably predict the transition from laminar to turbulent flow. The transition process begins with the conversion of environmental and surface disturbances into the instability waves of the flow by a process called receptivity. The goal of the current research project has been to improve the prediction of transition through a better understanding of the physics of receptivity. The initial objective of this work was to investigate the specific stability and receptivity characteristics of a particular experimental investigation of boundary layer receptivity at NASA Langley. Some simulation results using direct solutions of the linearized Navier-Stokes equations which modeled this experiment where presented in the 1999 APS DFD meeting. However, based on these initial investigations, it became clear that to cover the vast receptivity parameter space required for a practical transition prediction tool, more efficient methods would be required. Thus, the focus of this research was shifted from modeling this particular experiment to formulating and developing new techniques that could efficiently yet accurately predict receptivity for a wide range of disturbance conditions.

Collis, S. Scott↗

NASA NTRSDate not supplied

Evaluation of Spectral Band Adjustment Factors for Cross-Calibration of Visible Imagers

The NASA CERES EBAF dataset provides TOA SW and LW fluxes for long-term monitoring of the Earth’s energy balance and to validate climate models. The EBAF products, based on the Terra, Aqua, and NOAA20 CERES instrument observed radiances, rely on coincident measurements from the onboard MODIS or VIIRS imagers to determine cloud properties used for angular distribution model scene selection, which is required to convert the CERES observed radiances into flux values. Furthermore, CERES utilizes geostationary imager (GEO) hourly fluxes and clouds to infer the regional averaged daily flux in the SYN1deg product. A seamless transition of fluxes and clouds can only occur if the analogous MODIS, VIIRS, and GEO channels are properly inter-calibrated. The analogous band SRFs differ noticeably and require scene dependent spectral band adjustment factors (SBAF) for proper radiometric scaling between them. Given their disparate but overlapping SRFs, the coincident VIIRS I1 and M5 band TOA reflectance measurements provide the optimal opportunity to validate SBAFs over many surface and cloud conditions. The CERES project maintains SCIAMACHY, GOME-2, and Hyperion scene-stratified hyper-spectral reflectance measurements that can be convolved with sensor pair SRFs to compute the corresponding SBAF. This study highlights the SCIAMACHY, GOME-2, and Hyperion based SBAFs for different MODIS, VIIRS, and GEO inter-calibration targets, including all-sky tropical ocean (ATO), Libya-4, Dome-C, and deep convective clouds. To mitigate the observed sensor radiance fluctuations due to atmospheric absorption and aerosol variations, the Earth target observed radiances are correlated with multiple atmospheric parameters, such as precipitable water and ozone. The remaining M5 and I1 mean spectral band radiance difference should be resolved by the SBAF correction. The formulation of hyper-spectral sensor based SBAFs and validation methods can be verified in future utilizing high-accuracy, SI-traceable hyper-spectral measurements from CLARREO Pathfinder.

David R Doelling↗

DOE OSTI2024

Applications of Lifted Nonlinear Cuts to Convex Relaxations of the AC Power Flow Equations

Here, we demonstrate that valid inequalities, or lifted nonlinear cuts (LNC), can be projected to tighten the Second Order Cone (SOC), Convex DistFlow (CDF), and Network Flow (NF) relaxations of the AC Optimal Power Flow (AC-OPF) problem. We conduct experiments on 38 cases from the PGLib-OPF library, showing that the LNC strengthen the SOC and CDF relaxations in 100% of the test cases, with average and maximum differences in the optimality gaps of 6.2% and 17.5% respectively. The NF relaxation is strengthened in 46.2% of test cases, with average and maximum differences in the optimality gaps of 1.3% and 17.3% respectively. We also study the trade-off between relaxation quality and solve time, demonstrating that the strengthened CDF relaxation outperforms the strengthened SOC formulation in terms of runtime and number of iterations needed, while the strengthened NF formulation is the most scalable with the lowest relaxation quality improvement due to these LNC.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1990

Acoustic design criteria in a general system for structural optimization

Passenger comfort is of great importance in most transport vehicles. For instance, in the new generation of regional turboprop aircraft, a low noise level is vital to be competitive on the market. The possibilities to predict noise levels analytically has improved rapidly in recent years. This will make it possible to take acoustic design criteria into account in early project stages. The development of the ASKA FE-system to include also acoustic analysis has been carried out at Saab Aircraft Division and the Aeronautical Research Institute of Sweden in a joint project. New finite elements have been developed to model the free fluid, porous damping materials, and the interaction between the fluid and structural degrees of freedom. The FE approach to the acoustic analysis is best suited for lower frequencies up to a few hundred Hz. For accurate analysis of interior cabin noise, large 3-D FE-models are built, but 2-D models are also considered to be useful for parametric studies and optimization. The interest is here focused on the introduction of an acoustic design criteria in the general structural optimization system OPTSYS available at the Saab Aircraft Division. The first implementation addresses a somewhat limited class of problems. The problems solved are formulated: Minimize the structural weight by modifying the dimensions of the structure while keeping the noise level in the cavity and other structural design criteria within specified limits.

Brama, Torsten↗

NASA NTRS1997

External Boundary Conditions for Three-Dimensional Problems of Computational Aerodynamics

We consider an unbounded steady-state flow of viscous fluid over a three-dimensional finite body or configuration of bodies. For the purpose of solving this flow problem numerically, we discretize the governing equations (Navier-Stokes) on a finite-difference grid. The grid obviously cannot stretch from the body up to infinity, because the number of the discrete variables in that case would not be finite. Therefore, prior to the discretization we truncate the original unbounded flow domain by introducing some artificial computational boundary at a finite distance of the body. Typically, the artificial boundary is introduced in a natural way as the external boundary of the domain covered by the grid. The flow problem formulated only on the finite computational domain rather than on the original infinite domain is clearly subdefinite unless some artificial boundary conditions (ABC's) are specified at the external computational boundary. Similarly, the discretized flow problem is subdefinite (i.e., lacks equations with respect to unknowns) unless a special closing procedure is implemented at this artificial boundary. The closing procedure in the discrete case is called the ABC's as well. In this paper, we present an innovative approach to constructing highly accurate ABC's for three-dimensional flow computations. The approach extends our previous technique developed for the two-dimensional case; it employs the finite-difference counterparts to Calderon's pseudodifferential boundary projections calculated in the framework of the difference potentials method (DPM) by Ryaben'kii. The resulting ABC's appear spatially nonlocal but particularly easy to implement along with the existing solvers. The new boundary conditions have been successfully combined with the NASA-developed production code TLNS3D and used for the analysis of wing-shaped configurations in subsonic (including incompressible limit) and transonic flow regimes. As demonstrated by the computational experiments and comparisons with the standard (local) methods, the DPM-based ABC's allow one to greatly reduce the size of the computational domain while still maintaining high accuracy of the numerical solution. Moreover, they may provide for a noticeable increase of the convergence rate of multigrid iterations.

Tsynkov, Semyon V.↗

DOE OSTI2023

Small Angle X-Ray Scattering and Polymers

Polymers are some of the most versatile and useful materials on this planet. Properties of polymers are a result of their processing history, chemical makeup, and physical structure. Therefore, characterization is necessary to develop new polymer formulations and processes. Many established techniques for polymer characterization are destructive, and alternative methods that don’t destroy samples are in high demand. Thermal analysis techniques such as differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) yield important characteristic information for polymer samples while destroying the sample. Non-destructive strategies such as X ray diffraction (XRD) or small angle X-ray scattering (SAXS) can also find polymer characteristics while preserving a sample’s attributes. Sample preservation is desirable when investigating novel formulation and processing methods. SAXS analysis will be done on two different polymers: polyethylene, and a triblock copolymer. Using these two polymers allows for confidence between tests as polyethylene is very common, and well understood. Polyethylene analysis will be done first, and when methods have been refined so that the SAXS data matches accepted thermal analysis values for HDPE, there will be confidence to use the same analysis on block copolymers. Block copolymers remain relatively unexplored, so SAXS data will yield valuable information on their characteristics. Understanding the mechanical properties of these polymers is paramount to their application in upcycling, a process by which waste plastic can be converted into a higher value commodity. For this project, the upcycling process will be done via 3-dimensional (3d) printing.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Control Oriented Model of Cabin-HVAC System in a Long-Haul Trucks for Energy Management Applications

Super Truck II is a 48V mild hybrid class 8 truck with an all auxiliary loads powered purely by the battery pack. Electric Heating Ventilation and Air Conditioning (HVAC) load is the most prominent battery load during the hotel period, when the truck driver is resting inside the sleeper. For the PACCAR Super Truck II (ST-II) project a 48 V battery system provides the required power during the hotel period. A cabin-HVAC model estimates the electric load on the 48V battery system, allowing the control system to implement an efficient energy management strategy that avoids engine idling during the hotel period. The thermal model accounts for the sun load due to the time of day and the geographic location of the truck during the hotel period. The cabin-HVAC model has two parts. First, a grey box model with two heat exchangers (Condenser and Evaporator) working in unison with refrigerant mass flow rate as an input and HVAC load as an output. Second, a two-node cabin model formulated to estimate the cabin temperature as a function of the Global Horizontal Irradiance (GHI), HVAC load and ambient temperature. The models are calibrated using experimental cabin-HVAC system data as for long-haul class 8 truck (e.g. ST-II). Here, the model simulations show that the overall Root Mean Square Error (RMSE) value of 0.4°C between the experimental and simulated cabin temperature.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

IM3 Projected U.S. Western Interconnection Grid Stress Dataset

This dataset provides projected grid stress and reliability results (including all model inputs and outputs from GO WEST and TEP) for Integrated Multisector, Multiscale Modeling (IM3) Phase 2 simulations across eight different scenarios for the U.S. Western Interconnection through 2055. The scenarios include combinations of two Shared Socioeconomic Pathways (SSP3 and SSP5) with four high-resolution climate projections specific to the United States from a set of Thermodynamic Global Warming (TGW) simulations. These climate projections include "hotter" and "cooler" variants for two Representative Concentration Pathways (RCP4.5 and RCP8.5). The resulting eight simulations are: rcp45cooler_ssp3 rcp45cooler_ssp5 rcp45hotter_ssp3 rcp45hotter_ssp5 rcp85cooler_ssp3 rcp85cooler_ssp5 rcp85hotter_ssp3 rcp85hotter_ssp5 GO WEST is an open-source power grid modeling framework for the U.S. Western Interconnection, which allows users to tailor the model depending on their research study and science questions. It covers 28 balancing authorities (BAs) and 12 states in U.S. Western Interconnection. GO WEST allows users to select different number of nodes and come up with a simplified network by utilizing 10,000 nodal topology of the U.S. Western Interconnection (ACTIVSg10k). Users can select different number of nodes, mathematical formulations (linear programming vs. mixed-integer linear programming), transmission line limit scaling factors, and hurdle rate scaling factors. GO WEST offers a unit commitment and economic dispatch (UC/ED) module to simulate grid operations on an hourly scale. In this sense, users can calibrate and validate their model versions by comparing model outputs to historical datasets. TEP is an open-source transmission capacity expansion model, built on the GO WEST framework. It utilizes linear programming to optimize transmission capacity addition investment on existing lines within the GO WEST framework. The TEP model only increases the thermal capacity of existing transmission lines and does not add new lines to the system, which leaves the topology preserved. In order to use TEP model, users need to create scenarios with the GO WEST framework. Please refer to README file for a detailed description of the dataset including individual files and references.

Capacity Expansion Model↗

NASA NTRS1990

Laser Atmospheric Wind Sounder (LAWS) phase 1. Volume 2

This report summarizes and documents the results of the 12-month phase 1 work effort. The objective of phase 1 was to establish the conceptional definition of the laser atmospheric wind sounder (LAWS) sensor system, including accommodations analyses to ensure compatibility with the Space Station Freedom (SSF) and the Earth Observing System (EOS) Polar Orbiting Platform (POP). Various concepts were investigated with trade studies performed to select the configuration to be carried forward to the phase 2 Preliminary Design Definition. A summary of the LAWS system and subsystem trade studies that were performed leading to the baseline design configuration is presented in the appendix. The overall objective of the LAWS Project is to define, design, and implement an operational space based facility, LAWS, for accurate measurement of Earth wind profiles. Phase 1 addressed three major areas: (1) requirements definition; (2) instrument concepts and configurations; and (3) performance analysis. For the LAWS instrument concepts and configurations, the issues which press the technological state of the art are reliable detector lifetime and laser performance and lifetime. Lag angle compensation, pointing accuracy, satellite navigation, and telescope design are significant technical issues, but they are considered to be currently state of the art. The primary issues for performance analysis concern interaction with the atmosphere in terms of backscatter and attenuation, wind variance, and cloud blockage. The phase 1 tasks were formulated to address these significant technical issues and demonstrate the technical feasibility of the LAWS concept. Primary emphasis was placed on analysis/trade and identification of candidate concepts. Promising configurations were evaluated for performance, sensitivities, risks, and budgetary costs. Lockheed's baseline LAWS configuration is presented.

Source record↗

DOE OSTI2022

A System Level Analysis of Ethanol Upgrading to Middle Distillates

We systematically study the upgrading of ethanol toward middle distillates with desired properties. To survey the large design space, we introduce a novel superstructure-based optimization framework integrating process design and fuel formulation. We show that biorefineries that produce middle distillates by upgrading lignocellulosic ethanol can have an energy return on investment (EROI) greater than 1. Additionally, we show that technological improvements can lead to significant increases in EROI. Furthermore, trade-offs between fuel properties and biorefinery profitability are established, showing how process economics are strongly influenced by fuel properties. In the case of diesel, the feasibility of producing high cetane number biofuels is demonstrated, coupled with a discussion of the technological requirements and costs to produce these superior fuels. It is also shown that the minimum fuel selling price (MFSP) can be reduced by increasing the biorefinery complexity. Lastly, we discuss the possibility of satisfying current and projected middle distillates demand in the U.S. using biofuels produced by ethanol upgrading, and we estimate the potential CO2 mitigation of these technologies.

09 BIOMASS FUELS↗

DOE OSTI2019

Scientific and Historic Impacts from the Manhattan Project [Slides]

The Manhattan Project (MP) was the international project that led to production of the first nuclear weapons. It opened up a new chapter in human history that we now call the atomic age. The MP is an example of living history where multiple generations continue to learn and evaluate the full magnitude of its history, science, technology, and deterrence and security implications throughout time. The idea to have a student symposium about the MP grew out of conversations with colleagues and students. The prevailing opinion was indeed that there is a growing interest in history, science, politics, and security implications of the MP. We thought it would be useful to keep the direct dialog and discussion going to allow younger generations the chance to formulate their own opinion. The scope of the symposium is large, covers multiple topics, and is impossible to cover in detail in one day. We are trying to embrace a very wide spectrum of questions. The world around us is evolving and it is important to present, as completely as possible, an arc of facts about the MP and what followed. Hence, we have presentations covering the MP and broad issues of the nuclear age from the initial stages of the MP in 1942 to modern day. I believe it is important to have a forum that enables better appreciation and understanding of the MP among younger generations. Our hope is that this symposium will strengthen the ongoing dialog and create an open student forum to hear and learn about the MP.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2021

Roll-to-Roll Advanced Materials Manufacturing DOE Laboratory Collaboration (FY2020 Final Report)

R2R processing is used to manufacture a wide range of products for various applications which span many industrial business sectors. The overall R2R methodology has been in use for decades and this continuous technique traditionally involves deposition of material(s) onto moving webs, carriers or other continuous belt-fed or conveyor-based processes that enable successive steps to build a final version which serves to support the deposited materials. Established methods that typify R2R processing include tape casting, silk-screen printing, reel-to-reel vacuum deposition/coating, and R2R lithography. Products supported by R2R manufacturing include micro-electronics, electro-chromic window films, PVs, fuel cells for energy conversion, battery electrodes for energy storage, and barrier and membrane materials. Due to innovation in materials and process equipment, high-quality yet very low-cost multilayer technologies have the potential to be manufactured on a very cost-competitive basis. To move energy-related products from high-cost niche applications to the commercial sector, the means must be available to enable manufacture of these products in a cost-competitive manner that is affordable. Fortunately, products such as fuel cells, thin- and mid-film PVs, batteries, electrochromic and piezoelectric films, water separation membranes, and other energy saving technologies readily lend themselves to manufacture using R2R approaches. However, more early-stage research is needed to solve the challenge of linking the materials (particles, polymers, solvents, additives) used in ink and slurry formulations and the coating and drying processes to the ultimate performance of the final R2R product, especially for a process that uses multiple layers of deposition to achieve the end product. To solve the problems associated with these challenges, the R2R Collaboration is executing a research program with outcomes that will ultimately link modeling, processing, metrology and defect detection tools, thereby directly relating the properties of constituent particles and processing conditions to the performance of final devices. This collaborative approach was designed to foster identification and development of materials and processes related to R2R for clean-energy materials development. Using computational and experimental capabilities by acknowledged subject matter experts within the supported National Laboratory system, this project leverages the capabilities and expertise at each of five National Laboratories to further the development of multilayer technologies that will enable high-volume, cost-competitive platforms. A typical R2R process has three steps: (1) mixing of particles and various constituents in a slurry, (2) coating of the ink/slurry mixture on a substrate, and (3) drying/curing and processing of the coating. Final performance of devices made via R2R processes is dependent on the active materials (e.g., electrochemical particles in battery or fuel cell electrodes) and the device structure that stems from the governing component interactions within the various steps. However, a fundamental understanding of the underlying mechanisms and phenomena is still lacking, which is why industrial-scale R2R process development and manufacturing is still largely empirical in nature. The FY 2019 through FY 2021 program addresses aspects of the following two targets from the AMO Multi-Year Program Plan: (1) Target 8.1 Develop technologies to reduce the cost per manufactured throughput of continuous R2R manufacturing processes. (A) Increasing throughput of R2R processes by 5 times for batteries (to 50 square feet per minute (50 ft 2 /min)) and capacitors and 10 times for printed electronics and the manufacture of other substrates and MEs used in support of these products. (B) Developing resolution capabilities to enable registration and alignment that will detect, align, and co-deposit multiple layers of coatings and print < 1-micron (1 µm) features using continuous process scalable for commercial production. (C) Developing scalable and reliable R2R processes for solution deposition of ultra-thin (<10 nm) films for active and passive materials. (D) Develop in-line multilayer coating technology on thin films with yields greater than 95%. (2) Target 8.2 Develop in-line instrumentation tools that will evaluate the quality of single and multilayer materials in-process. (A) Developing in-line QC technologies and methodologies for real-time identification of defects and expected product properties “in-use/application” during continuous processing at all size-scales with a focus on the “micro” and “nano” scale traces, lines, and devices, i.e., <1 μm at 300 ft./min for R2R processing in air and <10 nm at 20 ft./min for vacuum (B) Developing technologies to increase the measurement frequency of surface rheology without significant cost increases with a goal of a 10-nanometer in-line profilometry at a production rate of 100,000 square millimeters per minute (100,000 mm 2 /min).

42 ENGINEERING↗