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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 1,099 records · Page 61
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Synthesizing Highly Crystalline Graphite Powder for Lithium-Ion Battery Anodes from Bulk Polyethylene Waste

Upcycling plastic waste into graphite can potentially be used to manage existing waste materials and diversify graphite supply chains. However, synthesizing large quantities of crystalline graphite powder from plastic waste, particularly polyethylene (PE), remains a challenge because PE decomposes into light gases during thermal processing, and simple methods do not exist at any appreciable size scale to address this challenge. In this work, a method is developed for air processing bulk forms of PE waste to create a stable carbon char, then be converted into a highly crystalline bulk graphite powder using a Fe-based catalytic process. The PE-derived graphite demonstrates excellent electrochemical performance as an anode material for lithium-ion batteries.

Gao, Yuan↗
DOE OSTI2024

Synthesizing Highly Crystalline Graphite Powder from Bulk Polyethylene Waste for Lithium-Ion Battery Anodes

Upcycling plastic waste into graphite can potentially be used, in conjunction with other methods, to manage existing waste materials and diversify graphite supply chains. However, synthesizing large quantities of crystalline graphite powder from plastic waste, particularly polyethylene (PE), remains a challenge because PE decomposes into light gases during thermal processing, and simple methods do not exist at any appreciable size scale to address this challenge. In this work, a method is developed for air processing bulk forms of PE waste to create a stable carbon char that does not readily decompose during high-temperature processing. This method employs solid additives in the form of salts, which are combined with the PE melt during air processing to increase the effective surface area of the melt and improve the oxygen-driven chemistry that stabilizes the PE for high-temperature processing. After removing the solid salt additives from the PE-derived char, it is converted into a highly crystalline bulk graphite powder using a Fe-based low-temperature (<1500 °C) catalytic process. The PE-derived graphite powder showed excellent electrochemical performance as an anode material for lithium-ion batteries (LIBs) with a capacity of up to 302 mAh/g at 0.5 discharge/charge cycles per hour (0.5 C) and capacity retention of 100% after 415 cycles. This method illustrates there are opportunities for upcycling large quantities of PE waste to produce graphite powders.

Huynh, Ngoc Tien [NETL Site Support Contractor, Na↗
DOE OSTI2022

Low-Cost, High Performance Catalyst Coated Membranes for PEM Water Electrolyzers (Final Technical Report)

In this project, the objective was to develop reduced-cost manufacturing techniques capable of producing proton exchange membrane water electrolyzer (PEMWE) catalyst coated membranes (CCMs) with further improved performance relative to then-current 3M CCM technology. Processes to be developed would enable 1) production of 0.5 m wide CCMs (approximately 2x wider than produced by the current laboratory/pilot-scale processes) and 2) 3x higher net-effective linear rates (lineal-meters of CCM produced per cumulative process time) than the baseline CCM process. In combination, the wider width CCM and increased net-effective linear rates would result in a 6-fold decrease in CCM manufacturing cost (defined as cumulative machine and labor time) per m 2 of CCM produced. PEMWE CCMs produced with these optimized processes were targeted to produce 1) 0.25 A/cm 2 or greater at 1.5 V, 2) 2.0 A/cm 2 or greater at 1.75 V and 3) 4 A/cm 2 or greater at 1.95V, 4) with total catalyst platinum-group metal (PGM) loadings of ≤ 0.50 mg/cm 2 , measured in a cell with 50 cm 2 active area (or larger) at 80°C cell temperature and ambient outlet pressures.

08 HYDROGEN↗
DOE OSTI2021

Gaussian process regression constrained by boundary value problems

We develop a framework for Gaussian processes regression constrained by boundary value problems. The framework may be applied to infer the solution of a well-posed boundary value problem with a known second-order differential operator and boundary conditions, but for which only scattered observations of the source term are available. Scattered observations of the solution may also be used in the regression. The framework combines co-kriging with the linear transformation of a Gaussian process together with the use of kernels given by spectral expansions in eigenfunctions of the boundary value problem. Furthermore, it benefits from a reduced-rank property of covariance matrices. We demonstrate that the resulting framework yields more accurate and stable solution inference as compared to physics-informed Gaussian process regression without boundary condition constraints.

42 ENGINEERING↗
DOE OSTI2025

Feature Based Qualification of 17-4PH Stainless Steel to Evaluate Location-Specific Variability in Wire Arc Additive Manufacturing

Qualifying large-scale metal additive manufacturing (M-AM) technologies such as wire arc additive manufacturing (WAAM) can be challenging. This is especially significant in precipitation hardened martensitic stainless steels like SS 17-4PH, where thermal histories induce location-specific microstructural variability and property anisotropy. The Department of Defense (DOD) and the United States Army Combat Capabilities Development Command Ground Vehicle Systems Center (GVSC) Ground Vehicle Materials Engineering (GVME) aim to build robust and qualified large-scale M-AM workflows that could reduce the time and cost through quick and informed evaluation, testing, and development of feedstock, processes, and parts. The report presents the findings from the collaborative efforts between Oak Ridge National Laboratory (ORNL) and the U.S. Army GVSC GVME. The aim of this project was to develop a geometric feature-based qualification framework for WAAM of SS 17-4PH components. This report outlines selection methodology of representative build geometries, optimization of WAAM process parameters, in-situ monitoring, microstructure-property evaluation, thermal simulations, as well as data visualization techniques incorporated in this project. The results from this project demonstrate a clear understanding of thermal history dependent phase evolution and consequent location-specific property variations in WAAM of SS 17-4PH. These results in conjunction with the data-driven methodologies used in this project are expected to reduce qualification timelines, improve predictability, and accelerate the development of reliable feature-based qualification strategies for part production via large-scale M-AM technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Feedback from International Decommissioning Planning Projects - 20269

Decommissioning of Nuclear Power Plants is an increasing reality in many countries with nuclear power. Already many years before final shutdown, planning of the decommissioning work is usually started in order to understand for example the costs, waste volume capacity and licensing work needed. In many countries it is required to have a final decommissioning plan before any decommissioning work is allowed to start. Westinghouse has been involved in international decommissioning planning for more than 30 years, where the first 20 years was mostly funding and preliminary plans due to that decommissioning was many years away. However, as many more plants are now moving into decommissioning, the focus has shifted to final decommissioning plans with budgets instead of funding plans, strategic decisions instead of choices, waste volume specifications instead of estimates and a defined approach instead of what ifs. Westinghouse has developed a methodology based on the planning and execution of many decommissioning projects in Europe, America and Asia. That international experience and understanding helps the customers to adopt a systematic planning process where strategy development is done with the end state in mind, where the goals are clearly outlined and the starting point described. The process and steps to reach the desired end state need to be clearly defined and all options/alternatives evaluated from a cost/benefit point of view. This is followed by a thorough and quantitative risk analysis in order to give solid recommendations and credible conclusions. One important feedback has been that real decommissioning experience from reference projects is invaluable for an efficient and timely progress in order not to spend unnecessary time and effort on understanding the barriers and links between different activities in decommissioning. Skilled project managers or engineers can drive the project forward, but without decommissioning experience previously gained, valuable lessons learned are not used and the same mistakes can be made again. Many utilities have invested in knowledge transfer from other decommissioning projects through site visits, exchange programs and supplier meetings, which is a valuable asset and way of implementing lessons learned from performed decommissioning projects into the planning process. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Fast Data Processing for Hyperspectral Sensors on Small Platforms

Hyperspectral imaging is a very promising technology for nuclear proliferation detection. However, due to size and weight restrictions, small hyperspectral platforms such as satellites and small drones lack the on-board computing resources for accurate, real-time analysis of the enormous flow of data that a continuously operating hyperspectral sensor generates. This severely limits satellite systems, which can collect far more data than what they can telemeter, and hinders the ability of all platforms to adapt their missions on the fly in response to observations. This program addresses the hyperspectral data processing challenge through development of new, fast and accurate algorithms that produce data products in real time. The algorithms circumvent the major computational bottlenecks in existing processing streams, and would be incorporated in lightweight, power-efficient single-board computer systems. The toolkit of fast algorithms will be immediately useful in current and future hyperspectral systems being built by the Government and by private industry, including drone-based systems and satellite constellations that acquire timely global imagery.

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

Platform for efficient large-scale storage and analysis of multi-omics data in plant and microbial systems (Final Technical Report)

Genomic variation at the sequence level fundamentally affects the phenotypic state of all organisms at all stages of development, while dynamic processes such as changes in the epigenome (e.g. DNA methylation state) and transcriptome regulate the specific phenotype expressed at any given state of development based upon that genomic variation. In plants, DNA methylation is a particularly important mechanism for both regulating transcriptomic expression and for management of genomic variations that could be deleterious to the organism due to the presence of active retrotransposons in plant genomes. While DNA methylation is heritable, it is also dynamic through a given plant’s development and life cycle, particularly during the development from seed to mature specimen suggesting variations in DNA methylation could be critical regulators of biologically and commercially important phenotypes such as time to flowering; in addition, plant DNA methylation is more complex than that of animals, with methylation of CHG and CHH trinucleotides evident in addition to the better-known CG methylation. The complexity of plant DNA methylation and its interplay with genomic sequence variation, transcriptomics and other epigenomic factors demand a storage and analysis framework that can cope with the complexity both within a single specimen and with analyses that span many individuals and even many species, such as attempts to extend models from model organisms to commercially relevant species. In addition to complexity, the rapid development and proliferation of sequencing technology has led to an explosion of data volume that conventional storage and analysis solutions will likely be unable to cope with in the long run. We proposed to study these with suitable distributed storage and computation and therefore for the application of cloud computing to biological analyses; integrate with existing data sources and compatible with virtually any interface use case, from fully automated shell scripts to notebooks and do all these at scale in this STTR grant.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

MSR Salt Spill Accident Testing Using Eutectic NaCl-UCl 3

Assessing the potential consequences of identified accident scenarios is an essential part of the licensing process for a new nuclear reactor and is achieved by using accident progression models. A likely accident scenario that will be evaluated by developers of molten salt reactors (MSRs) is a spill of radionuclide-bearing fuel salt onto the reactor containment floor (i.e., a salt spill accident). Models to determine the consequences of a molten salt spill accident need to be parameterized and validated using experimental data, but little experimental effort has been dedicated to fill these data gaps to date. Specifically, data is needed to enable model development for individual processes (e.g., spreading, heat transfer, corrosion, radionuclide vaporization, and aerosol generation) that quantifies the sensitivities towards the initial conditions of the spill, the ambient environment, and the features of the containment. In addition, integrated experiments that simulate salt spill accidents will need to be conducted to provide insight into coupled processes and data for model validation, but these experiments will require the use of proven methods to quantify the processes under evaluation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Ideas and perspectives: Enhancing research and monitoring of carbon pools and land-to-atmosphere greenhouse gases exchange in developing countries

Carbon (C) and greenhouse gas (GHG) research has traditionally required data collection and analysis using advanced and often expensive instruments, complex and proprietary software, and highly specialized research technicians. Partly as a result, relatively little C and GHG research has been conducted in resource-constrained developing countries. At the same time, these are often the same countries and regions in which climate change impacts will likely be strongest and in which major science uncertainties are centered, given the importance of dryland and tropical systems to the global C cycle. Increasingly, scientific communities have adopted appropriate technology and approach (AT&A) for C and GHG research, which focuses on low-cost and low-technology instruments, open-source software and data, and participatory and networking-based research approaches. Adopting AT&A can mean acquiring data with fewer technical constraints and lower economic burden and is thus a strategy for enhancing C and GHG research in developing countries. However, AT&A can have higher uncertainties; these can often be mitigated by carefully designing experiments, providing clear protocols for data collection, and monitoring and validating the quality of obtained data. For implementing this approach in developing countries, it is first necessary to recognize the scientific and moral importance of AT&A. At the same time, new AT&A techniques should be identified and further developed. All these processes should be promoted in collaboration with local researchers and through training local staff and encouraged for wide use and further innovation in developing countries.

Kim, Dong-Gill↗
DOE OSTI2023

Investigating microstructural evolution in SolidStir™ extruded oxide dispersion strengthened 14YWT alloy fuel cladding tube

Structural components for extreme environments require advanced materials and manufacturing processes. One such advanced material is oxide dispersion strengthened (ODS) Fe–14 wt.%Cr–3W–0.4Ti–0.3Y 2 O 3 (14YWT), which is developed for components to be used in Gen IV and fusion nuclear reactors. However, the conventional manufacturing processes to produce components, such as fuel cladding tubes, either do not retain the desired microstructural attributes or are costly and less efficient. As a result, a more attractive option is a novel manufacturing process developed on the principle of friction stir welding or processing (FSW/P) and commercially referred to as SolidStir™ Extrusion (SSE). Here this study used the SSE technique to study the manufacturing and microstructural evolution of a fuel cladding tube made of ODS 14YWT alloy. The cladding extrusion by the SSE technique involved the use of ball-milled 14YWT powders with Y, Ti, and O in the solid solution and the use of a specially designed W-25Re-Hf tool for consolidation and extrusion of the powders. A scanning electron microscope (SEM), electron backscattered diffraction (EBSD), and transmission electron microscope (TEM) were utilized for microstructural characterization. A Keyence microscope captured macrostructural photographs of the extruded tube. EBSD examination of the extruded tube on both transverse and longitudinal cross-sections showed the presence of dynamically recrystallized grains and revealed that the average grain size of the transverse cross-section was smaller than that of the longitudinal cross-section. The texture was weak and consisted of some amount of shear texture. The presence of nano-oxide clusters or precipitates of Y, Ti, and O (pyrochlores) in the extruded tube was determined by TEM. Aging heat treatment caused the average precipitate size to decrease and the density to increase compared to the as-processed condition. The results indicated that SSE is a viable tool for manufacturing fuel cladding tubes with the desired microstructural attributes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Accelerating Laboratory-Based, All-Solid-State Battery Research and Development: Industrially Relevant Small-Batch Dry-Processing, Small and Low-Cost Test Fixtures, and Short-Tolerant Separators

This work presents improvements to mixing (for dry-processed electrodes), separator robustness, and cell testing jigs for all-solid-state batteries (ASSBs). These developments combine synergistically to enable rapid research and development of ASSB catholytes. A mechanical "kneader" is designed and built which emulates the mixing and fibrillation of poly-tetrafluoroethylene binder that occurs in industrially relevant twin-screw extruders. A modest improvement in the mixing and dispersion catholyte materials is observed using micro-resolution X-ray computed tomography (X-ray CT). Catholytes are paired with an In-metal anode and separated by a novel, dual-layer, polyaramid-fiber-supported, sulfide-solid electrolyte (Li6 PS5 Cl) separator. This separator achieves high short tolerance which enabled a 95% success rate across 20 attempted cells and to date over 100 successful cells have been built. ASSBs were tested in a 2032 coin-cell format. Simultaneous cycling of a large number of cells is further enabled by a compact and low cost (~ 38 USD per jig) pressure application jig of which 100 have been constructed to date. The utility of these advances is demonstrated through a brief study on the effect cathode-side conductive carbon and current collector type has on capacity and rate performance.

25 ENERGY STORAGE↗
DOE OSTI2023

Auxiliary sequential deposition enables 19%-efficiency organic solar cells processed from halogen-free solvents

High-efficiency organic solar cells are often achieved using toxic halogenated solvents and additives that are constrained in organic solar cells industry. Therefore, it is important to develop materials or processing methods that enabled highly efficient organic solar cells processed by halogen free solvents. In this paper, we report an innovative processing method named auxiliary sequential deposition that enables 19%-efficiency organic solar cells processed by halogen free solvents. Our auxiliary sequential deposition method is different from the conventional blend casting or sequential deposition methods in that it involves an additional casting of dithieno[3,2-b:2’,3’-d]thiophene between the sequential depositions of the donor (D18-Cl) and acceptor (L8-BO) layers. The auxiliary sequential deposition method enables dramatic performance enhancement from 15% to over 18% compared to the blend casting and sequential deposition methods. Furthermore, by incorporating a branched-chain-engineered acceptor called L8-BO-X, device performance can be boosted to over 19% due to increased intermolecular packing, representing top-tier values for green-solvent processed organic solar cells. Comprehensive morphological and time-resolved characterizations reveal that the superior blend morphology achieved through the auxiliary sequential deposition method promotes charge generation while simultaneously suppressing charge recombination. This research underscores the potential of the auxiliary sequential deposition method for fabricating highly efficient organic solar cells using environmentally friendly solvents.

14 SOLAR ENERGY↗
DOE OSTI2023

Pre-ceramic polymer-assisted nucleation and growth of copper sulfide nanoplates

Abstract Polymer-derived ceramics derived from pre-ceramic polymers (PCPs), have access to several form factors and are highly tunable systems. Tunability can be further expanded with the incorporation of functional nanoparticle fillers throughout the matrix for advanced nanocomposite polymer-derived ceramic development. However, capping ligands used in nanoparticle syntheses mix unfavorably with PCPs, giving aggregated filler material and diminished properties. To control dispersion, secondary nanoparticle processing is performed by adhering PCP-miscible caps to the surface after synthesis. This often sacrifices size control established for small nanoparticles (<10 nm). Herein, we successfully eliminate the need for extra nanoparticle processing through the development of a one-pot, copper sulfide synthesis in which a PCP assists the stable formation of nanoparticles and serves as the final graft molecule. We monitor the success of this methodology and the PCP’s role in the reaction through several characterization methods probing both the nanoparticle core and polymer graft.

Loughney, Patricia A. (ORCID:0000000199472267)↗
DOE OSTI2021

Springtime Drought Shifts Carbon Partitioning of Recent Photosynthates in 10-Year Old Picea mariana Trees, Causing Restricted Canopy Development

Springtime bud-break and shoot development induces substantial carbon (C) costs in trees. Drought stress during shoot development can impede C uptake and translocation. This is therefore a channel through which water shortage can lead to restricted shoot expansion and physiological capacity, which in turn may impact annual canopy C uptake. We studied effects of drought and re-hydration on early season shoot development, C uptake and partitioning in five individual 10-year old Picea mariana [black spruce] trees to identify and quantify dynamics of key morphological/physiological processes. Trees were subjected to one of two treatments: (i) well-watered control or (ii) drought and rehydration. We monitored changes in morphological [shoot volume, leaf mass area (LMA)], biochemical [osmolality, non-structural carbohydrates (NSC)] and physiological [rates of respiration (R d ) and light-saturated photosynthesis ( A sat )] processes during shoot development. Further, to study functional compartmentalization and use of new assimilates, we 13 C-pulse labeled shoots at multiple development stages, and measured isotopic signatures of leaf respiration, NSC pools and structural biomass. Shoot water potential dropped to a minimum of −2.5 MPa in shoots on the droughted trees. Development of the photosynthetic apparatus was delayed, as shoots on well-watered trees broke-even 14 days prior to shoots from trees exposed to water deficit. R d decreased with shoot maturation as growth respiration declined, and was lower in shoots exposed to drought. We found that shoot development was delayed by drought, and while rehydration resulted in recovery of A sat to similar levels as shoots on the well-watered trees, shoot volume remained lower. Water deficit during shoot expansion resulted in longer, yet more compact (i.e., with greater LMA) shoots with greater needle osmolality. The 12 C: 13 C isotopic patterns indicated that internal C partitioning and use was dependent on foliar developmental and hydration status. Shoots on drought-stressed trees prioritized allocating newly fixed C to respiration over structural components. In conclusion, temporary water deficit delayed new shoot development and resulted in greater LMA in black spruce. Since evergreen species such as black spruce retain active foliage for multiple years, impacts of early season drought on net primary productivity could be carried forward into subsequent years.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Competitiveness Improvement Project Informational Workshop

The National Renewable Energy Laboratory (NREL) is hosted an in-person workshop and webinar for the distributed wind Competitiveness Improvement Project (CIP) on Tuesday, December 17, 2019, at NREL's Flatirons Campus. The CIP is a periodic solicitation issued by NREL on behalf of the U.S. Department of Energy's Wind Energy Technologies Office. Through a competitive process, component suppliers and manufacturers of small- to medium-sized wind turbine technology are awarded cost-shared subcontracts to optimize their designs, develop advanced manufacturing processes, and perform turbine testing. The CIP aims to make wind energy cost competitive with other distributed generation technologies and increase the number of wind turbine designs certified to national performance and safety standards.

17 WIND ENERGY↗
DOE OSTI2026

Stochastic fracture generation and thermo-hydro-mechanical modeling in an equivalent continuum framework for enhanced geothermal systems

Enhanced geothermal systems (EGS) involve fracturing low permeability material to establish well connectivity and then injecting and circulating fluid into the fractured subsurface for geothermal power production. Changes in fracture aperture from contraction of the cooling matrix rock may alter network connectivity and risk thermal short-circuiting. Thermo-hydro-mechanical (THM) models are a useful tool to study these processes. However, as fracture networks are complex, and data may be limited, fracture networks in THM models are often stochastically generated. Given reliance on stochastic fracture networks and THM modeling to represent the subsurface and assess productivity of EGS, increased understanding of the influence of such statistically derived fracture networks on flow and heat transport in THM models is needed. Here, a new fracture process model is developed in the reactive transport code PFLOTRAN to stochastically generate fracture families and simulate changes in fracture aperture over time due to temperature changes of the rock matrix. Sixty-four different fracture networks ranging from well to poorly-connected, are modeled in PFLOTRAN with and without mechanical processes (THM vs TH). Results indicate that for well-connected fracture networks, thermal short-circuiting is less of a concern due to the abundance of available alternative flowpaths. For poorly-connected fracture networks, inclusion of mechanical processes showed steep thermal drawdown coincident with increase in fracture aperture along developing colder flowpaths, demonstrating the risk of thermal short-circuiting. Simulations with additional, larger fractures engineered to establish connectivity in a poorly-fractured subsurface, indicate that while stochastic variation of fracture orientation of the background network had limited influence, such variation in the engineered fractures significantly affected flow and heat transport.

Discrete fracture networks (DFN)↗
DOE OSTI2026

Extremized nonlinear and linearized responses in soft metamaterials enabled by gradient-based design and grayscale digital light processing

In this study, we develop a gradient-based design approach that exploits grayscale digital light processing (DLP) 3D printing for extremizing the nonlinear and linearized response of soft metamaterials — materials that harness engineered geometric instabilities to undergo large and programmable changes in configuration. Grayscale DLP approaches modulate local mechanical properties at the pixel scale by tuning the light intensity within a single grayscale image, unlocking an exceptionally large design space. To effectively navigate this space, we develop smooth mappings between local light intensity values and global quantities of interest that characterize the behavior of soft metamaterials. Enabling these smooth mappings are robust and differentiable nonlinear finite element simulations powered by a trust region solver. A PDE-constrained optimization problem is then solved to invert these mappings and produce light intensity distributions that endow the printed part with varying stiffness and flexibility in distinctive regions. It is shown that optimizing the distribution of soft and stiff phases throughout a metamaterial structure results in markedly different buckling and self-contact configurations to drive extremized nonlinear compression and linearized vibration responses. Optimized light intensity distributions are translated to grayscale images and directly used to print soft metamaterial samples, showing remarkable agreement between the buckling and self-contact response in simulated and measured deformed configurations.

Additive manufacturing↗