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All sources NASA NTRS DOE OSTI

DOE OSTI2023

Charge trapping at Al/Al 2 ⁢O 3 interface facilitates hydrogen-induced superabundant metal vacancy formation

Hydrogen is a ubiquitous impurity that deteriorates the metal/oxide interface, causing challenges such as current leakage and blistering. Here, in this work, we uncover the mechanisms behind hydrogen-induced damage at the prototypical Al/A⁢l 2 ⁢O 3 interface. The precursor that we identify is charge trapping at the interface, which facilitates hydrogen segregation to the interface plane as H – . Presence of hydrogen increases aluminum vacancy concentration at the interfacial metal and oxide planes. Each Al vacancy can trap multiple hydrogen atoms. As a result, the interfacial aluminum vacancy and hydrogen concentrations increase by orders of magnitude. Additionally, hydrogen behaves as an n-type dopant and increases electronic conductivity at the oxide layer adjacent to the interface by forming H + , and the [V Al –H] complex is the predominant defect at this layer. These findings provide the precursor mechanisms of hydrogen-induced damage at the metal-oxide interfaces and have implications for advancing Al/A⁢l 2 ⁢O 3 –based coatings and electronic devices.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Facilitating Staging-based Unstructured Mesh Processing to Support Hybrid In-Situ Workflows

In-situ and in-transit processing alleviate the gap between the computing and I/O capabilities by scheduling data analytics close to the data source. Hybrid in-situ processing splits data analytics into two stages: the data processing that runs in-situ aims to extract regions of interest, which are then transferred to staging services for further in-transit analytics. To facilitate this type of hybrid in-situ processing, the data staging service needs to support complex intermediate data representations generated/consumed by the in-situ tasks. Unstructured (or irregular) mesh is one such derived data representation that is typically used and bridges simulation data and analytics. However, how staging services efficiently support unstructured mesh transfer and processing remains to be explored. This paper investigates design options for transferring and processing unstructured mesh data using staging services. Using polygonal mesh data as an example, we show that hybrid in-situ workflows with staging-based unstructured mesh processing can effectively support hybrid in-situ workflows, and can significantly decrease data movement overheads.

data-driven↗

DOE OSTI2024

Data‐driven identification of environmental variables influencing phenotypic plasticity to facilitate breeding for future climates

Summary Phenotypic plasticity describes a genotype's ability to produce different phenotypes in response to different environments. Breeding crops that exhibit appropriate levels of plasticity for future climates will be crucial to meeting global demand, but knowledge of the critical environmental factors is limited to a handful of well‐studied major crops. Using 727 maize ( Zea mays L.) hybrids phenotyped for grain yield in 45 environments, we investigated the ability of a genetic algorithm and two other methods to identify environmental determinants of grain yield from a large set of candidate environmental variables constructed using minimal assumptions. The genetic algorithm identified pre‐ and postanthesis maximum temperature, mid‐season solar radiation, and whole season net evapotranspiration as the four most important variables from a candidate set of 9150. Importantly, these four variables are supported by previous literature. After calculating reaction norms for each environmental variable, candidate genes were identified and gene annotations investigated to demonstrate how this method can generate insights into phenotypic plasticity. The genetic algorithm successfully identified known environmental determinants of hybrid maize grain yield. This demonstrates that the methodology could be applied to other less well‐studied phenotypes and crops to improve understanding of phenotypic plasticity and facilitate breeding crops for future climates.

Kusmec, Aaron↗

DOE OSTI2023

Assisted migration in a warmer and drier climate: less climate buffering capacity, less facilitation and more fires at temperate latitudes?

Assisted tree migration has been proposed as a conceptual solution to mitigate lags in biotic responses to anthropogenic climate change. The rationale behind this concept is that tree species currently growing under warmer and drier climates will be more resistant and resilient to the new climatic conditions than tree species naturally growing in currently wetter and colder climates. However, we hypothesize that, by being more stress‐tolerant to warmer and drier conditions, translocated species should exhibit different functional attributes, which could induce important ecological and societal costs and overcome the desired benefits of maintaining wood production and other ecosystem services. We used principal component analysis (PCA) to analyze variation in seven traits of 106 tree and tall shrub species from contrasting latitudinal distributions in western North America and Europe to predict the potential functional changes of forest ecosystems due to the translocation of tree species from low to high latitudes. We show that species from both continents differed primarily by their position on the leaf economy spectrum (LES) and their size traits. Even though, in Europe, differences in LES were significantly correlated to species southern latitudinal positions, in both continents differences in size traits were significantly correlated to latitude. These results suggest that assisted migration by translocating more conservative species of shorter stature in currently cooler climates should decrease the buffering capacity of forest canopies, decrease facilitation for understory species, and increase wildfire risks, whose effects have the potential to accelerate climate warming through negative atmospheric feedback processes. As an alternative solution to assisted migration that may accelerate rather than mitigate climate change, we recommend that foresters gradually diversify the vertical structure and layering of the existing forest canopy to maintain a sustainable water cycle and energy balance between the soil, the tree and the atmosphere without increasing the wildfire risk.

Environmental Sciences & Ecology↗

DOE OSTI2026

TRIZ-Based Design Improvement for Facilitating Transmission Control Unit Remanufacturing

Design for Remanufacturing (DfRem) centers on enhancing product design and operations to facilitate remanufacturing while increasing both economic and environmental sustainability. DfRem requires a comprehensive understanding of product characteristics, production conditions, and operational constraints. Thus, DfRem requires a systematic methodology to identify and implement alternative designs. Among many critical steps in remanufacturing, disassembly is essential because it directly supports remanufacturing by separation of product components for cleaning, inspection, and other subsequent process steps. This study proposes a TRIZ-based framework to improve product design for disassembly in support of remanufacturing. The framework is applied to a transmission control unit (TCU) case study. The current TCU design prevents remanufacturing due to the sealant-based component joinery, which complicates disassembly and risks damaging the printed circuit board (PCB). After defining technical contradictions for the TCU product design and reviewing the suggested TRIZ principles to solve the conflicts, a cantilever snap-fit design alternative is developed. The economic feasibility of the snap-fit design is assessed by comparing the current and snap-fit design costs for three life cycles. The cost analysis demonstrates that the cost of the snap-fit design remains the same as the current design. Additionally, the snap-fit design offers substantial cost savings for three life cycles compared to the current design. We demonstrate how snap-fit design supports both environmental and economic sustainability.

42 ENGINEERING↗

DOE OSTI2023

Adsorptive exchange of coccolith biominerals facilitates viral infection

Marine coccolithophores are globally distributed, unicellular phytoplankton that produce nanopatterned, calcite biominerals (coccoliths). These biominerals are synthesized internally, deposited into an extracellular coccosphere, and routinely released into the external medium, where they profoundly affect the global carbon cycle. The cellular costs and benefits of calcification remain unresolved. Here, we show observational and experimental evidence, supported by biophysical modeling, that free coccoliths are highly adsorptive biominerals that readily interact with cells to form chimeric coccospheres and with viruses to form “viroliths,” which facilitate infection. Adsorption to cells is mediated by organic matter associated with the coccolith base plate and varies with biomineral morphology. Biomineral hitchhiking increases host-virus encounters by nearly an order of magnitude and can be the dominant mode of infection under stormy conditions, fundamentally altering how we view biomineral-cell-virus interactions in the environment.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

Redox conduction facilitates direct interspecies electron transport in anaerobic methanotrophic consortia

Anaerobic methanotrophic archaea (ANME) and sulfate-reducing bacteria (SRB) form syntrophic partnerships in marine sediments to consume greenhouse gas methane. While direct interspecies electron transport is proposed to enable ANME/SRB symbiosis, its electrochemical properties remain uncharacterized. Here, using sediment-free enrichment cultures, we measured the electron transport capabilities of marine consortia under physiological conditions. Diverse ANME/SRB consortia exhibited high dry conductance close to electrogenic biofilms. This conductance diminished upon exposure to heat or oxygen but was preserved following paraformaldehyde fixation, indicating a biomolecular origin for this electric charge transfer. Cyclic voltammetry revealed redox activity centered at 28 ± 11, 94 ± 6, and 24 ± 7 millivolts for ANME-1/Desulfofervidus, ANME-2a/Seep-SRB1, and ANME-2a+2c/Seep-SRB1+2 consortia, respectively. Generator-collector measurements further demonstrated that these redox components facilitate electron transport over micrometer-scale distances, sufficient to link archaeal and bacterial partners. Collectively, our results establish that marine ANME/SRB symbiosis uses redox conduction, consistent with multiheme cytochromec, for direct interspecies electron transport.

Science & Technology - Other Topics↗

DOE OSTI2025

CpoS-Inc interactions facilitate host cell modulation during Chlamydia trachomatis infection

ABSTRACT Chlamydia trachomatis ( C.t .), the leading bacterial cause of sexually transmitted infections, replicates within a unique intracellular compartment called the inclusion, which is modified by secreted proteins known as inclusion membrane (Inc) proteins. Here, we further characterize CpoS, an Inc protein previously shown to be critical for bacterial replication and inclusion development. We demonstrate that CpoS directly binds multiple coiled-coil region-containing Incs and engages Rab GTPases at a separate site. Notably, CpoS-InaC interactions facilitate the recruitment of select Arf GTPases to the inclusion membrane, while Rab recruitment occurs independently of these interactions. Biochemical and biophysical analyses revealed that Incs self-oligomerize to form higher-ordered structures, with CpoS adopting a tetrameric conformation resembling that of eukaryotic SNARE proteins. We propose that these assemblies serve as scaffolds to orchestrate vesicle docking, tethering, and fusion. Our findings highlight the intricate interplay between bacterial and host factors, revealing how C.t . leverages both Inc-Inc interactions and host protein engagement to manipulate vesicular trafficking and sustain infection.

Tijerina, Xavier [Department of Microbiology and I↗

DOE OSTI2022

Host-region parameters for an adjustable model for crustal earthquakes to facilitate the implementation of the backbone approach to building ground-motion logic trees in probabilistic seismic hazard analysis

The backbone approach to constructing a ground-motion logic tree for probabilistic seismic hazard analysis (PSHA) can address shortcomings in the traditional approach of populating the branches with multiple existing, or potentially modified, ground-motion models (GMMs) by rendering more transparent the relationship between branch weights and the resulting distribution of predicted accelerations. To capture epistemic uncertainty in a tractable manner, there are benefits in building the logic tree through the application of successive adjustments for differences in source, path, and site characteristics between the host region of the selected backbone GMM and the target region for which the PSHA is being conducted. The implementation of this approach is facilitated by selecting a backbone GMM that is amenable to such host-to-target adjustments for individual source, path, and site characteristics. The NGA-West2 GMM of Chiou and Youngs (CY14) has been identified as a highly adaptable model for crustal seismicity that is well suited to such adjustments. Rather than using generic source, path, and site characteristics assumed appropriate for the host region, the final suite of adjusted GMMs for the target region will be better constrained if the host-region parameters are defined specifically on the basis of their compatibility with the CY14 backbone GMM. To this end, making use of a recently developed crustal shear-wave velocity profile consistent with CY14, we present an inversion of the model to estimate the key source and path parameters, namely the stress parameter and the anelastic attenuation. With these outputs, the effort in constructing a ground-motion logic tree for any PSHA dealing with crustal seismicity can be focused primarily on the estimation of the target-region characteristics and their associated uncertainties. The inversion procedure can also be adapted for any application in which different constraints might be relevant.

Stafford, Peter J.↗

DOE OSTI2022

Intra-canopy leaf trait variation facilitates high LAI and compensatory growth in a clonal woody encroaching shrub in the tallgrass prairie

This data package contains the data for Tooley et al. (2022) Intra-canopy leaf trait variation facilitates high leaf area index and compensatory growth in a clonal woody encroaching shrub. The purpose of this project was to evaluate the leaf ecophysiological traits of Cornus drummondii C.A. Mey to better understand how C. drummondii maximizes photosynthetic rates across large gradients of light availability in its short, dense canopies. We also evaluate how C. drummondii modifies its allocation of leaf traits in response to grassland disturbance. High LAI canopies and a compensatory growth response to disturbance are two key factors contributing to the success of C. drummondii and other woody species responsible for the encroachment of grasslands.The data package contains ecophysiological measurements, including leaf morphological, physiological, and chemical traits; photosynthetic measurements, leaf carbon and nitrogen stable isotopes, leaf area index, and photosynthetically active radiation. All measurements were taken vertically across canopies of the clonal woody-encroaching shrub Cornus drummondii under browsed, grazed, and control (unbrowsed and ungrazed) conditions.Files:SeasonalMeasurements_Archive.csv - Data for all seasonal measurements used in the study.LeafPhotoSeasonalRaw_Archive.zip - zip file containing raw data from an li-6400 for each sampling period in the study.LAI_Archive.xlsx - Data for LAI Measurements.ACiandLightCurveResults_Archive.xlsx - Contains parameters extracted from A-ci and Light Response curves along with the morphological and chemical traits for each leaf.ACiRaw Archive.xlsx - Raw data from Li-6400 for A-ci response curvesLightCurves_Raw.zip - zip file containing raw data for Li-6400 light response curves. Excel file format: "IslandID"-"Depth"-lc.xlsx (or .csv)DataCollectionMethods.docx - file containing the methods of data collection, processing, and QA/QC for all data files. File also contains a list of excel file headers, abbreviations, and their units.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Highly functional microspheres facilitating Diels–Alder network formation

Introducing particles to dynamic covalent networks is a common approach to improve their performance. However, network formation can be impacted by their size and functionality. The influence can be predicted by common theories for small molecular precursors, but it is unclear whether they are applicable to precursors bearing numerous reactive groups and micrometer-scale dimensions. In this work, an experimental study was undertaken using dynamic covalent networks formed by the Diels–Alder reaction between furan and maleimide groups. The gelation behavior of the Diels–Alder networks was studied using rheometry to track their network formation at 40 °C with varying maleimide-functionalized microsphere loading. The highly functional microspheres can interact with the furan precursor, aiding in the formation of the Diels–Alder networks. A 5 wt% microsphere sample can reduce the gelation time by 23% and facilitate network formation in an unbalanced stoichiometry near the critical composition to form a percolating network.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Influence of Nanoconfinement and Elevated Temperatures on Geocolloid-Facilitated Transport of Energy related Contaminants

Fossil fuels obtained using hydraulic fracturing and nuclear energy are deemed crucial for meeting the current and future energy demands of the United States. The utilization of these resources, especially fossil fuels from hydraulic fracturing, has increased rapidly within the last decade. However, with the increasing levels of hydraulic fracturing activities, the occurrence and fate of chemicals used in these processes in the geosystem, as well as the potential consequences of their interactions with environment and geosystems (e.g. mineral-based geocolloids and geosurfaces), have been increasingly recognized as issues warranting consideration owing to the toxic nature of these chemicals. Scientific results originated from this project has brought better understandings on how such contaminants can preferentially or adversely interact with geosystems and how geocolloids can facilitate their transport by realistically mimicking geological conditions and environments in the laboratory level for the first time. Based on such knowledge, it may eventually lead to the development of mitigation strategies for reducing and minimizing the transport and wide distribution of contaminants and pollutants. This aspect is important for the society to ensure that energy-related contaminants do not find their way to waterbodies that are used as drinking water or irrigation. The project is also anticipated to increase public awareness about potential adverse effects of energy systems on the geosphere and environment and may motivate society to consider better mitigation strategies to prevent such occurrences.

(Nano)Confinement↗

DOE OSTI2020

Applied Science Investigations to Facilitate Closure of the F-Area and H-Area Seepage Basins

This report provides a roadmap of applied science studies that will facilitate reaching long term monitoring end state corrective actions for groundwater contamination at the F-Area Seepage Basins and the H-Area Seepage Basins at the Savannah River Site in Aiken, SC. The F-Area and H-Area Seepage Basins are waste units on the Savannah River Site in Aiken, SC at which low-level radioactive solutions were disposed into unlined basins, resulting in groundwater contamination. The current contaminants of interest in the groundwater are tritium, iodine-129, strontium-90, uranium isotopes and nitrate. Remediation at both sites has continued since 1988, consisting of closure and capping of the basins, operation of a groundwater pump-and-treat system from 1997 to 2004, and replacement of this system with a comprehensive in situ attenuation-based remedy. This report was requested by the U.S. Department of Energy - Office of Environmental Management in consultation with the Savannah River National Laboratory and Savannah River Nuclear Solutions - Area Completions Projects to provide a scientific basis for proactively addressing groundwater issues that may need to be resolved prior to final corrective actions at the F-Area and H-Area Seepage Basins.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Dynamic Building Load Control to Facilitate High Penetration of Solar Photovoltaic Generation (Final Technical Report)

Solar photovoltaic (PV) resources are the most common form of distributed generation in residential and commercial customer premises within electric distribution networks. A higher penetration of PV generation in distribution circuits will impose challenges on maintaining service voltages within the range of industry standards, power quality, and power flow. Buildings consume 74% of the electricity produced in the United States, and a significant portion of the building load is dispatchable, making them responsive to electrical grid needs. Oak Ridge National Laboratory—in collaboration with Southern Company; the University of Tennessee, Knoxville; and the Georgia Institute of Technology—is examining the PV integration issues in distribution-level electrical grids and developing integrated demand-side control and communication systems to enable responsive loads. The proposed responsive loads mechanism performs renewable generation following to increase the penetration of solar PV within each feeder. The specific objectives of this project are to (1) examine distribution-level PV integration scenarios to understand requirements, (2) undertake an end-to-end simulation-based design of a distributed control strategy of loads geographically near the PV generation asset to minimize the effect on the distribution feeder, (3) deploy and demonstrate the control technology developed in partnership with utilities, and (4) perform a scalability analysis at the utility scale. This 3-year integrated project aims to develop, demonstrate, and validate demand-side control technology to enable increased the penetration of renewables while mitigating challenges that arise due to their intermittency. Activities in Budget Period (BP) 1 focused on a literature review and the formal design of a control system for integrating local distribution with generation and loads. The team used modeling and simulation to evaluate the impact of varying buildings loads, variable PV generation, and power flow dynamics on the distribution circuit. The dynamic models developed in BP 1 were used in BP 2 to develop a model-based control design and a test bed. The test bed has enabled the simulation-based testing and comparison of different control designs and formulations applied to different configurations of the distribution grid, PVs, and building loads. The control approaches developed in BP 2 were implemented in BP 3 in the form of hardware deployed at the Central Baptist Church (CBC) in Knoxville, Tennessee, for testing and evaluation. The outcome of this project was the development and demonstration of open-source, low-cost, low-touch sensing and control retrofits to distributed PV generation and building loads that, in a coordinated fashion, provide the load-shaping response needed to integrate high levels of renewable penetration. This research addresses the target metrics by dynamically controlling a load with solar generation variability to minimize the extent of two-way power flow, enhance reliability, facilitate high PV penetration (>100% of peak load in a line segment), and generate scalable software and hardware solutions adaptable to any penetration levels. The research and development activities are focused and designed to be impactful within the relevant 2020 targets time frame.An accurate open-source integration simulation framework for end-to-end control design was developed and deployed at the CBC facility for testing and evaluation. This final report provides a detailed review of the technical results achieved during this 3-year integrated project. A novel spectral analysis of PV data is demonstrated to derive the requirements of the control design. A detailed simulation-based analysis of PV integration at increasing penetration levels is presented using 1 year of PV data to demonstrate the impact on the distribution circuits. Two different control strategies were developed and demonstrated via simulation to track variable PV generation with adaptive load dispatch. The report concludes with a summary of accomplishments and recommendations for a path forward.

14 SOLAR ENERGY↗

DOE OSTI2022

Colloid-Facilitated Actinide Transport in a Cementitious-Impacted SRS Groundwater

The objective of this report is to provide a literature review relevant to the question of whether colloid facilitated transport of plutonium is enhanced in a cementitious groundwater system on the Savannah River Site (SRS). Contaminant transport is commonly described as taking place in a system with a mobile aqueous phase and an immobile solid phase. There has been an increasing awareness of a third phase, a mobile solid phase, also referred to as a mobile colloidal phase. Mobile colloids consist of organic and/or inorganic submicron-particles that move with groundwater flow. When radionuclides are associated with the mobile colloids, the net effect is that radionuclides can move faster through the subsurface system than would be predicted by transport models that do not include mobile colloids. It is important to distinguish between subsurface colloids and subsurface mobile colloids. The subsurface environment includes an enormous reservoir of colloids, but only a tiny fraction, if any, are mobile. Mobile colloid formation is commonly described as involving a three-step process: genesis, stabilization, and transport. It was concluded that there is a strong likelihood that submicron colloids of plutonium exist near the source term, (i.e., the genesis step is likely completed). While such particles have not been directly detected, it is highly likely that plutonium could either attach to submicron particles in the sediment or that submicron plutonium fragments exist at the source. However, the tendency for these plutonium colloids to move in the SRS subsurface is extremely low, especially in engineered cementitious environments where the ionic strength of the solution and the elevated concentrations of divalent cations greatly curtails colloid suspension stability (i.e., the stabilization step is likely not completed). Together these data strongly indicate that plutonium-bearing colloids would likely exist in the near field of a tank closure facility, but the colloids would be unlikely to be mobile, thereby providing a vector for enhanced transport. Under cementitious leachate impacted groundwater conditions, it is reasonable to assume plutonium transport occurs primarily as a two-phase system, a mobile aqueous phase and an immobile solid phase.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

National Smart Manufacturing Strategic Plan: To Facilitate More Rapid Development, Deployment and Adoption of Smart Manufacturing Technologies

Smart manufacturing technologies provide real-time data and insight to improve the productivity, efficiency, and competitiveness of U.S. manufacturing, creating the potential for new jobs in the manufacturing sector. These technologies can support U.S. manufacturers’ ability to increase throughput and energy efficiency, and decrease waste, defects, and costs. A wide range of manufacturing and industrial subsectors, particularly energy-intensive and energy-dependent industries, have the potential to benefit from smart manufacturing technologies. There are technical improvements still needed to reduce the costs and barriers (trained workforce and upskilling, software-hardware integration, cost, and technical barriers to deployment of advanced sensors, computing, and communication technologies for existing manufacturing assets) to the adoption of smart manufacturing technologies, especially to small and medium-sized manufacturers, and subsequently, increase the overall adoption rate of smart manufacturing technologies. This report outlines the Department of Energy’s (DOE) strategic plan to accelerate the development and implementation of smart manufacturing technologies in the United States and the actions DOE has taken to use these technologies in smart manufacturing for the United States. DOE’s plan to facilitate more rapid development, deployment and widespread adoption of smart manufacturing technologies derive from the 2018 Strategy for American Leadership in Advanced Manufacturing. The strategy outlines a vision for America’s leadership in advanced manufacturing including the development of intelligent manufacturing systems to optimize manufacturing facilities and support the manufacturing of transformative materials. DOE’s Clean Energy Smart Manufacturing Innovation Institute (CESMII), a Manufacturing USA Institute, focuses on accelerating the development and adoption of advanced sensors, controls, platforms, and models needed for smart manufacturing. The objective is to enhance U.S. manufacturing productivity and global competitiveness through the research and development of these technologies. Smart manufacturing has the potential to improve the overall performance, energy productivity, and efficiency of manufacturing, fostering the economic competitiveness of the manufacturing sector.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Integrated CO 2 -facilitated Hydrometallurgical and Electrochemical Technology for Sustainable Mining and Recovery of Critical Elements from Wastes and Ashes

The availability of critical materials and other metals is very important for our national security and economic growth since they are widely used in defense and energy applications including batteries and wind turbines. Unfortunately, high grade ores have become scarce and their productions is dominated by limited countries. Thus, there is a strong need to obtain these materials from domestic sources. Municipal wastes are great candidates since they often contain high concentrations of metals. Since the metals in wastes and waste ashes are not in the form found in natural ores and contain a wide range of impurities, conventional extraction processes would not be effective. Thus, our project has developed an innovative MIDAS process based on the integrated CO2-facilitated hydrometallurgical and electrochemical technology that can effectively recover critical materials and metals from waste ashes while minimizing the environmental impacts. We have (i) characterized waste ashes to understand their physico-chemical properties, (ii) developed green solvent systems for hydrometallurgical extraction of critical elements and metals from waste ashes, (iii) explored electrochemical interfaces to refine the extracted metals.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Integrated Turbine Component Cooling Designs Facilitated by Additive Manufacturing and Optimization

This research program involved the development of improved gas turbine cooling by optimizing the combined internal and film cooling configurations used for turbine blades and vanes. Improved cooling of turbine airfoils allows the gas turbines to be operated at higher temperatures which improves efficiency for gas turbine-based power generation. This also facilitates operation with hydrogen-based fuels which inherently generate higher operating temperatures. Designs of the new cooling configurations were based on the added geometric flexibility that is available when using metal additive manufacturing techniques. When making these designs, adjustments were made to account for imperfections occurring in the metal additive manufacturing process. New designs for film cooling holes were developed using computational adjoint gradient optimization techniques which generated a unique film cooling hole with 70% greater film cooling effectiveness compared to conventional shaped film cooling holes. A major factor in improving the film cooling effectiveness were small external protrusions on either side of the new hole which generated vortices that pushed coolant towards the surface and increased the lateral spreading of the coolant. Our studies also included optimization of film cooling holes that can be built with conventional manufacturing techniques and optimizing the internal coolant channels that supply coolant to the film cooling holes. Various internal coolant channel shapes were investigated and designs that maximized the cooling of the airfoil while minimizing pressure losses in the channel flows were identified. Testing and verification of the performance of the final configurations was done with a transonic wind tunnel facility which allowed testing at engine realistic high velocities. Final testing of the combined internal and film cooling configurations was done by incorporating the configurations in Penn State’s National Experimental Turbine (NExT) vane. These tests confirmed the enhanced overall cooling effectiveness provided by the new cooling configuration designs.

03 NATURAL GAS↗