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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 955 records · Page 53

XploreNAS : Explore Adversarially Robust and Hardware-efficient Neural Architectures for Non-ideal Xbars

Compute In-Memory platforms such as memristive crossbars are gaining focus as they facilitate acceleration of Deep Neural Networks (DNNs) with high area and compute efficiencies. However, the intrinsic non-idealities associated with the analog nature of computing in crossbars limits the performance of the deployed DNNs. Furthermore, DNNs are shown to be vulnerable to adversarial attacks leading to severe security threats in their large-scale deployment. Thus, finding adversarially robust DNN architectures for non-ideal crossbars is critical to the safe and secure deployment of DNNs on the edge. This work proposes a two-phase algorithm-hardware co-optimization approach called XploreNAS that searches for hardware efficient and adversarially robust neural architectures for non-ideal crossbar platforms. We use the one-shot Neural Architecture Search approach to train a large Supernet with crossbar-awareness and sample adversarially robust Subnets therefrom, maintaining competitive hardware efficiency. Our experiments on crossbars with benchmark datasets (SVHN, CIFAR10, CIFAR100) show up to ~8–16% improvement in the adversarial robustness of the searched Subnets against a baseline ResNet-18 model subjected to crossbar-aware adversarial training. We benchmark our robust Subnets for Energy-Delay-Area-Products (EDAPs) using the Neurosim tool and find that with additional hardware efficiency–driven optimizations, the Subnets attain ~1.5–1.6× lower EDAPs than ResNet-18 baseline.

97 MATHEMATICS AND COMPUTING↗

Contaminant Cation Effect on Oxygen Transport through the Ionomers of Polymer Electrolyte Membrane Fuel Cells

We characterized the effects of cobalt (Co 2+ ) and other cation contaminants on the oxygen (O 2 ) transport properties of the PFSA ionomer used in polymer electrolyte membrane fuel cells (PEMFCs) and gained insight into the mechanisms by which contaminant cations inhibit O 2 transport. Such cations can be released by alloy catalysts and environmental conditions and pose a significant challenge to maintaining high current density performance with low platinum (Pt) loadings. We used a test cell capable of isolating the ionomer from the membrane electrode assembly (MEA), allowing for O 2 transport resistance (R O2 ) measurements using a limiting current technique. We contaminated ionomer membranes with Li + , Na + , Ni 2+ , Co 2+ , and Ce 3+ and found a general increase in R O2 for increased contamination levels and decreased water activity. In addition, our Co 2+ results indicated distinct concentration-dependent regimes. The other cation-form ionomers allowed us to separate the impacts of ion pair strength, multivalency, and reduced water uptake. We believe that these factors cause a more compressed hydrophilic domain and tortuous O 2 diffusion path, and a commensurate increase in R O2 . Lastly, we studied the impact of Co 2+ on an operating PEMFC and found an increase in R O2 consistent with the results of our isolated membrane tests.

25 ENERGY STORAGE↗

NEONiso R Package, versions greater than 0.5.2

Carbon fluxes in terrestrial ecosystems and their response to environmental change are a major source of uncertainty in the modern carbon cycle. The National Ecological Observatory Network (NEON) presents the opportunity to merge eddy covariance (EC)-derived fluxes with CO2 isotope ratio measurements to gain insights into carbon cycle processes. Collected continuously and consistently across >40 sites, NEON EC and isotope data facilitate novel integrative analyses. However, currently provisioned atmospheric isotope data are uncalibrated, greatly limiting ability to perform cross-site analyses. Here, we present two approaches to calibrating NEON CO2 isotope ratios, along with an R package to calibrate NEON data. We find that calibrating CO2 isotopologues independently yields a lower d13C bias (<0.05‰) and higher precision (<0.40‰) than directly correcting d13C with linear regression (bias: <0.11‰, precision: 0.42‰), but with slightly higher error and lower precision in calibrated CO2 mole fraction. The magnitude of the corrections to d13C and CO2 mole fractions vary substantially by site, underscoring the need for users to apply a consistent calibration framework to data in the NEON archive. Post-calibration data sets show that site mean annual d13C correlates negatively with precipitation, temperature, and aridity, but positively with elevation. Forested and agricultural ecosystems exhibit larger gradients in CO2 and d13C than other sites, particularly during the summer and at night. The overview and analysis tools developed here will facilitate cross-site analysis using NEON data, provide a model for other continental-scale observational networks, and enable new advances leveraging the isotope ratios of specific carbon fluxes.

Fiorella, Richard↗

Quantification of Energy Savings and Demand Reduction for a Heat Pump Integrated with Thermal Energy Storage (Final Report)

To mitigate the variation in demand on the electric grid, thermal energy storage (TES) is an alternative to electric batteries or installing new peaking power plants. Stakeholders and policy makers across the United States have expressed interests in promoting TES, as demonstrated by the US Department of Energy’s Grid-Interactive Efficient Buildings program and the efforts of various state legislatures. However, the cost value provided by TES are unclear. If reliable cost benefits were determined, stakeholders would have a clearer picture of the financial returns that can be gained from their investment in TES. The study in this report is conducted by ORNL with collaboration with Emerson the Helix Innovation Center. In the first part of this report, EnergyPlus was used to perform whole-building simulations for two residential buildings in Indianapolis and Atlanta. The HVAC system in both buildings were equipped with phase change material TES. The TES tank was charged in off-peak hours and discharged in peak hours to perform load shifting. First, the economic value implied by existing time-of-use (TOU) rates offered by utility companies was analyzed via whole-building simulation. Second, existing demand reduction (DR) incentives sourced from 3 different electrical grid administrators (i.e., California, Texas, and New England region) were surveyed to determine their implied value. The study suggests that the traditional value analysis that focuses on ROI for the building owner significantly undervalues TES technology making economic viability difficult. A more comprehensive value analysis that includes peak demand management and deferred capital for peaking power plants shows that TES should be economically viable but here the value is greater for the utility and requires large market penetration and aggregation to fully realize the benefits. Therefore, to facilitate commercialization, new business models are needed that include a broader range of stakeholders and distribute the value of TES proportionally. In the 2 nd part of this project, the benefits of a novel phase change material (PCM) integrated heat pump configuration were evaluated via detailed component based simulation. A one-dimensional PCM heat exchanger model which discretizes the PCM tank and refrigerant tubes into small control volumes is developed. Each control volume can have different PCM temperatures, PCM properties, and heat transfer coefficients. The PCM tank is charged by a wrapped tank condenser and discharged by an internal refrigerant coil. The PCM heat exchanger model is integrated into DOE/ORNL Heat Pump Design Model for heat pump system simulation. To demonstrate the performance of the PCM integrated heat pump, a case study in Chicago was performed. A Time-of-Use utility structure-based control strategy is implemented to schedule the PCM tank charging and discharging mode switching. Compared with a conventional electric heat pump, the PCM integrated heat pump shows superior performance on load shifting and utility cost reduction. As a result, the proposed system demonstrates 24.6% utility saving for cooling application and 25.8% utility saving for heating application.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

The Tianlai Cylinder Pathfinder Array: System Functions and Basic Performance Analysis

The Tianlai Cylinder Pathfinder is a radio interferometer array designed to test techniques for 21 cm intensity mapping in the post-reionization Universe, with the ultimate aim of mapping the large scale structure of the Universe and measuring cosmological parameters such as the dark energy equation of state. Each of its three parallel cylinder reflectors are oriented in the north-south direction, and the array has a large field of view. As the Earth rotates, the northern sky is observed by drift scanning. The array is located in Hongliuxia, a radio quiet site in Xinjiang, and saw its first light in September 2016. In this first paper on the data analysis of the Tianlai cylinder array, we describe the system functions of the array, the commissioning observations during 2016- 2018, and present its basic performance characteristics. We show examples of the interferometric visibility data, then using the observational data, we derive the actual beam profile in the east-west direction, the bandpass response, and calibrate the complex gains for the array elements either with a strong astronomical point source, or with an artificial calibrator source. Based on the preliminary analysis of the data, we derive the system temperature and sensitivity of the array.

79 ASTRONOMY AND ASTROPHYSICS↗

Open Source Intelligence for Cybersecurity Events via Twitter Data

Open-Source Intelligence (OSINT) is largely regarded as a necessary component for cybersecurity intelligence gathering to secure network systems. With the advancement of artificial intelligence (AI) and increasing usage of social media, like Twitter, we have a unique opportunity to obtain and aggregate information from social media. In this study, we propose an AI-based scheme capable of automatically pulling information from Twitter, filtering out security-irrelevant tweets, performing natural language analysis to correlate the tweets about each cybersecurity event (e.g., a malware campaign), and validating the information. This scheme has many applications, such as providing a means for security operators to gain insight into ongoing events and helping them prioritize vulnerabilities to deal with. To give examples of the possible uses, we present three case studies demonstrating the event discovery and investigation processes. We also examine the potential of OSINT for identifying the network protocols associated with specific events, which can aid in the mitigation procedures by informing operators if the vulnerability is exploitable given their system’s network configurations.

Dale, Dakota↗

Working with Trusted Local Organizations to Address Impediments to Cost-Effective and Holistic Building Performance Improvements

Commercial buildings are at the heart of any community. Investments towards the health and performance of community buildings can support a wide range of critical community and individual benefits; however, many buildings have been left behind in these investments due to a spectrum of barriers, especially those located in underserved communities. This portfolio of work stands with the intent that if we can create solutions to support the hardest-to-reach commercial buildings in gaining equitable access to energy efficiency, zero energy, and zero carbon solutions, we can support all commercial buildings with these goals. To understand success and barriers, and identify new, innovative, and impactful solutions, NREL is taking a four-part approach to: 1. Develop a methodology for defining affordability in commercial buildings and understand its impact on underserved communities, 2. Work with trusted, local organizations to address barriers that impede access to cost-effective, holistic, building performance improvements, 3. Support minority-focused developer incubator programs for, and within, underserved communities, and 4. Identify overlapping value streams that support underserved community and utility needs.

barriers↗

A Methodology for Defining Affordability in Commercial Buildings and its Impact on Underserved Communities

Commercial buildings are at the heart of any community. Investments towards the health and performance of community buildings can support a wide range of critical community and individual benefits; however, many buildings have been left behind in these investments due to a spectrum of barriers, especially those located in underserved communities. This portfolio of work stands with the intent that if we can create solutions to support the hardest-to-reach commercial buildings in gaining equitable access to energy efficiency, zero energy, and zero carbon solutions, we can support all commercial buildings with these goals. To understand success and barriers, and identify new, innovative, and impactful solutions, NREL is taking a four-part approach to: 1. Develop a methodology for defining affordability in commercial buildings and understand its impact on underserved communities, 2. Work with trusted, local organizations to address barriers that impede access to cost-effective, holistic, building performance improvements, 3. Support minority-focused developer incubator programs for, and within, underserved communities, and 4. Identify overlapping value streams that support underserved community and utility needs.

building electrification↗

Mechanism for Acetone and Crotonaldehyde Production during Steam Reforming of Ethanol over La 0.7 Sr 0.3 MnO 3–x Perovskite: Evidence for a Shared C4 Aldol Addition Intermediate

Here a mechanistic study was conducted on the catalytic conversion of ethanol over La 0.7 Sr 0.3 MnO 3–x perovskite catalysts in the presence and absence of water. The study sought insights into the path of C–C coupling toward acetone and crotonaldehyde and also into clarifying whether the lack of previous reports of C–C coupling over La 0.7 Sr 0.3 MnO 3–x (100) could be due to a “pressure gap”. Several types of experiments were performed at 400–800 K: flow experiments with a torr range reactant gas flown over La 0.7 Sr 0.3 MnO 3–x powders; ultra-high vacuum experiments with continuous gas exposures to a La 0.7 Sr 0.3 MnO 3–x (100) single-crystal sample; and torr range continuous gas exposures to a La 0.7 Sr 0.3 MnO 3–x (100) single-crystal sample. When ethanol and water were flown over La 0.7 Sr 0.3 MnO 3–x powders at 400–800 K, the products detected were ethene, acetaldehyde, acetone, crotonaldehyde, CO, CO 2 , and H 2 . Acetone was catalytically produced over both the La 0.7 Sr 0.3 MnO 3–x powder and the La 0.7 Sr 0.3 MnO 3–x (100) single-crystal sample at temperatures of 700–800 K when reaction conditions were on the order of 1 Torr of reactant gas and with an excess of water relative to ethanol (1 ethanol/9 water). Isotopic labeling with deuterium was used to gain insights into the C–C coupling reaction mechanism and paths in species with three and four carbons (C 3 and C 4 species). Additionally, steady-state isotopic transient kinetic analysis (SSITKA) experiments + simulations using carbon labeling of the ethanol feed were performed. Three mechanistic paths were considered for the C–C coupling step: the first two paths, A and B, involve coupling between two intermediates which are both in oxygen vacancies; and the third path, C, involves coupling between one intermediate in an oxygen vacancy and one intermediate outside of an oxygen vacancy. The results suggest that the dominant path to the C 3 product, acetone, depends on the conditions. The less active path (attributed to path A or B) occurs at 600–700 K and involves coupling between two irreversibly bound species. The more active path (attributed to path C) requires an excess of water, becomes dominant at 600–800 K, and involves coupling between one irreversibly bound species and one reversibly bound species. Based on these various observations from experiments and simulations, an elementary step is proposed for acetone formation involving a previously unreported C 4 transition state that is formed after aldol addition. Density functional theory calculations were performed based on this hypothesis, and it confirmed that this specific and previously unreported aldol addition path to acetone does exist and that this path consistent with the experimental data. In this path, C–C formation occurs to create a C 4 intermediate that is bound to an oxygen vacancy, then a hydrogen transfer with C–C bond breaking occurs that results in the production of the acetone molecule. The proposed mechanism is also consistent with the experimental observation that acetone formation has a greater than first-order dependence on the water vapor pressure.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Thermal power plant upgrade via a rotating detonation combustor and retrofitted turbine with optimized endwalls

Over the past decade, pressure gain combustion research has promised over 10 percentage-points of increase in power plant thermal efficiency. Alas, to realize such potential gain, one must effectively couple the turbine with the detonation combustor, whose exhaust conditions differ substantially from current state of the art gas turbines. This paper presents a modeling approach that enables a superior thermodynamic cycle with a rotating detonation combustor and a retrofitted gas turbine by including a diffuser downstream of the combustor and by contouring the turbine endwall, while preserving the airfoil geometry. We propose a multi-step optimization strategy, parametrizing the endwall geometry with a few control points, without altering the airfoil geometry, and with the stage turbine efficiency as objective function. In a first step the turbine performance is assessed with steady inlet conditions by solving the steady three-dimensional Reynolds-Averaged Navier-Stokes equations. In a second step, the inlet conditions are unsteady, as predicted from a detonation combustor and a diffuser, and three-dimensional full unsteady simulations are performed with an unsteady Reynolds-Averaged Navier-Stokes solver. By altering the vane endwall, the steady optimization yielded an efficiency increase of 12% relative to the baseline, while the unsteady optimization resulted in 21% increase compared to the datum turbine. Finally, a full engine analysis demonstrated the superiority of pressure gain combustion which included a realistic thermodynamic cycle of the combustor, the diffuser and the optimized turbine components.

42 ENGINEERING↗

Comparing Control Performance Between Simulation and Experiment using the Microreactor Automated Control System Testbed

In the advanced reactor domain, a flexible and scalable software/hardware infrastructure is crucial for integrating and validating various control technologies. This study used the Microreactor Automated Control System (MACS) hardware platform as a testbed. MACS was originally designed to mirror Idaho National Laboratory (INL)'s Microreactor Applications Research Validation and Evaluation (MARVEL), a 85-kW thermal fission microreactor. It features control drums for simulated reactivity control; lights that function as a surrogate reactor core, with the brightness being proportional to the reactor power; and light sensors that emulate neutron detectors. To transform MACS into a physical twin of MARVEL for evaluating control methods, the Control and Optimization Modular Modeling Application for Nuclear Deployment (COMMAND) software was employed. This software integrated the hardware with two models of the MARVEL core, based on Reactor Excursion and Leak Analysis Program (RELAP5-3D) and Monte Carlo N-Particle (MCNP) models. The study aimed to demonstrate the gap between control theory and actual practice—a gap that often necessitates empirical adjustments such as control gain retuning, filters, time discretization, and integrator anti-windup measures. Controllers were developed based on increasingly complex simulations without hardware, starting from the base MARVEL model and then introducing actuator saturation constraints and sensor noise. The final control strategy was then tested using MACS, and a comparative performance analysis was conducted.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

Understanding and mitigating degradation in amine-based sorbents for CO 2 direct air capture

The success of direct air capture (DAC) of CO 2 depends on sorbents that combine high capacity, low energy requirements, and long-term durability. Amine-based sorbents-including solid-supported aminopolymers, grafted amines, and amine-functionalized resins-remain the leading candidates, but their limited lifetimes drive up costs and constrain deployment. In this review, we outline the current understanding of amine-based sorbent degradation with an emphasis on clearly identifying what is known about structure-property-performance relationships, as well as important knowledge gaps. More specifically, we discuss how polymer chemistry, sorbent design variables, and environmental and process conditions contribute to performance loss. In parallel, we outline how advances in spectroscopy, modeling, and accelerated testing are beginning to illuminate chemical and physical degradation mechanisms. Looking forward, we identify future research directions that will be critical for gaining a deeper understanding of degradation, as well as opportunities for developing innovative mitigation strategies for improving the lifetime of amine-based sorbents.

organic↗

Pressure effects on reactivity and extinction of n -dodecane diffusion cool flame

Low-temperature combustion at high pressure has gained increasing interest owing to the growing demand for clean and efficient propulsion and energy systems. In particular, cool flame structure, extinction limits, and fuel reactivities at high pressure are critical in affecting the engine performance at near-limit conditions. Here, this paper investigates the effects of pressure on the cool flame extinction limit, structure, radical index, reactivity, and oxygen concentration dependence by experiments, analysis, and modeling. A large n-alkane, namely n-dodecane (n C 12 H 26 ), is selected to study its diffusion cool flame dynamics and reactivity in a high-pressure counterflow burner up to 10 atm. The experimental results show that higher pressure increases the cool flame extinction strain rates, and that the pressure-weighted extinction strain rate (aP) is proportional to the square of pressure, P 2 . A scaling analysis explains the relationship between the dependence of flame structure, heat release rate, and pressure-weighted cool flame strain rate on pressure. Furthermore, radical indexes at different pressures are measured by isolating the thermal and transport effects from the chemical contribution to diffusion cool flame extinction. The radical index clearly shows that the low-temperature reactivity increases with pressure. In addition, due to the critical role of multiple oxygen addition reactions in low-temperature chemistry, the relationship between the cool flame extinction limit and the oxygen concentration is explored. It is found that the cool flame extinction limits are proportional to the n th power of the oxygen concentration, [O 2 ] n , and increasing pressure leads to stronger extinction limit dependence (larger n) on the oxygen concentration. The present experiment and detailed kinetic analysis show clearly that increasing pressure promotes the low-temperature chemistry including the oxygen addition reactions, while the scaling analysis explains well the experimental results.

33 ADVANCED PROPULSION SYSTEMS↗

Coalescing Cation Selectivity Approaches in Ionomers

Inconsistent selectivity measures used in the literature to quantify an ionomer’s preference for one ion over another make it challenging to compare uptake of different ions across studies. Preferential ion-partitioning, which leads to partially exchanged membranes, needs to be studied to gain a fundamental understanding of the nature of ion/membrane interactions as well as to begin to unravel how varying ion fractions, whether or not intentional, may affect the membrane’s properties and thus durability and performance. In this focus review, we use Nafion as a prototypical example to explore partial exchange studies and codify the various literature experiments and theory into a comprehensive whole, enabling formation of ionomer databases. Here, a few representative approaches to selectivity are dissected to identify the points of divergence between them as well as to re-examine the embedded assumptions therein. Lastly, modeling strategies for ion selectivity of the membrane are reviewed to arrive at and correlate fundamental ion properties to ionomer selectivity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Measured gain suppression in FBK LGADs with different active thicknesses

In recent years, the gain suppression mechanism has been studied for large localized charge deposits in Low-Gain Avalanche Detectors (LGADs). LGADs are a thin silicon detector with a highly doped gain layer that provides moderate internal signal amplification. Using the CENPA Tandem accelerator at the University of Washington, the response of LGADs with different thicknesses to MeV-range energy deposits from a proton beam were studied. Three LGAD prototypes of 50 μm, 100 μm, and 150 μm were characterized. The devices' gain was determined as a function of bias voltage, incidence beam angle, and proton energy. This study was conducted in the scope of the PIONEER experiment, an experiment proposed at the Paul Scherrer Institute to perform high-precision measurements of rare pion decays. LGADs are considered for the active target (ATAR), and energy linearity is an important property for particle ID capabilities.

Particle tracking detectors↗

Dynamically controlled random lasing with colloidal titanium carbide MXene

Control of lasing properties through tailorable and dynamically tunable materials and reconfigurable compositions can augment the performance of random lasers for a wide range of applications. Here, a colloid of randomly dispersed weakly scattering single-layer titanium carbide (Ti 3 C 2 T x ) MXene flakes embedded within rhodamine 101 gain medium is experimentally shown to provide feedback for random lasing. Additionally, in contrast to previously reported random laser systems where the optical properties of scatterers are static, the relative permittivity of Ti 3 C 2 T x MXene flakes can be varied under optical pumping due to the saturable absorption properties. Numerical simulations indicate that the observed nonlinear response of Ti 3 C 2 T x MXene flakes enables dynamically tunable random lasing. Thus, pumping the Ti 3 C 2 T x MXene flakes with a second optical source decreases the gain threshold required to obtain random lasing. Also, using numerical simulations, it is shown that the control over the intensity of the second pump enables tuning the field distribution of the random lasing modes. Considering the diversity of the MXenes family, the proposed MXene colloidal metamaterial design opens up a new avenue to advanced control of lasing properties for photonic applications.

36 MATERIALS SCIENCE↗

Materials and Approaches for Mitigation of SOFC Cathode Degradation in SOFC Power Systems

Perovskites such as doped lanthanum manganite and cobaltite have been used successfully as a cathode material in SOFC power systems operating between 700-1000°C. The electrodes, however, remain prone to degradation in presence of Cr containing gas atmosphere under systems operating conditions. Cathode in SOFCs is considered as one of the largest contributors of electrochemical performance degradations, leading to significant increase in ohmic and non-ohmic losses as well as interfacial compound formation. These degradations are mostly irreversible due to permanent changes to chemical and morphological alterations in the electrodes, resulting in the blockage of triple phase boundary (TPB) sites and decrease in oxygen reduction reactions (ORR). Fundamental mechanistic understanding has been developed to elucidate the reaction pathways of electrode poisoning in electronically conducting electrodes (LSM) as well as mixed ionic and electronically conducting electrodes (LSCF). The overall goal of this program has been identification and development of cost effective solutions to mitigate electrode degradations under “real world” systems operating conditions. The overall technological innovations and impact from this work are: The research provides an understanding of the degradation mechanism and cost-effective approaches for implementation in SOFC systems; Develop mitigation processes utilizing low cost getters using conventional synthesis and fabrication route; Develop tailored high surface area powders and coatings for high Cr capture capacity under systems operating conditions; >Developed computational models to understand mechanistic behavior; Experimentally measure rate of Cr evaporation from chromia and alumina forming alloys under SOFC operating conditions; Developed conditions to minimize Cr evaporation from balance-of-plant alloys; This innovation will support the development of getter platform to capture both intrinsic and extrinsic impurities present in air; and, Applications under wide operating temperature range (500-900°C) as well for wide high-temperature electrochemical systems (SOFC, SOEC, and OTM). The work has been successfully developed, validated experimentally and implemented. Successful technology transfer of this knowledge with industrial partners has been accomplished and the getters have been independently tested and validated under their systems operating conditions. The innovation will also find application in related high temperature electrochemical systems such as OTM and SOEC for the prevention of Cr assisted performance degradation. The proposed approach for Cr capture can also be applied to oxy-combustion and other advanced combustion techniques for the reduction of Cr vapor in the exhaust gas stream. This fundamental knowledge gained also has led to the path forward for developing advanced getters for capturing more than one contaminant in air.

01 COAL, LIGNITE, AND PEAT↗

Development of Repair Techniques for Cast Iron Engine Blocks by Additive Manufacturing

ORNL partnered with Cummins Inc to demonstrate the feasibility of using additive manufacturing techniques to deposit large volume of new material on cast iron in the context of remanufacturing. Remanufacturing at Cummins Inc is carried out to repair any field damage and, in some cases, provide additional value by adding new features. Large volume deposition on difficult to weld materials is a challenging problem due to involved metallurgy. Phase-1 of this work evaluated the feasibility of using laser directed energy deposition technique to deposit new material layer by layer on cast iron engine blocks. During phase-1 deposits were made using Inconel-718, Nickel, Nr-Cr-B braze filler. Leveraging the knowledge gained during Phase-1, Phase-2 focused on developing a low- cost crack resistant ferrous alloy to repair cast iron via volume deposition techniques without preheating. Three different alloy chemistries were identified, and trials were performed on cast iron substrates to identify the optimal chemistry that provided adequate resistance to cracking in both, the deposits as well as the cast iron substrate.

42 ENGINEERING↗