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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 1,225 records · Page 68
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Advances in high-pressure and high-temperature heat exchangers: Innovations via additive manufacturing and their applications

This paper provides a comprehensive overview of technological developments and applications for high-pressure and high-temperature (HPHT) heat exchangers produced through additive manufacturing (AM) techniques. As the demand for high-efficiency energy systems has been rising, the role of heat exchangers for thermal management and transport is becoming increasingly crucial. In this context, AM has emerged as a promising manufacturing solution to address the challenges posed by higher operating temperatures and/or pressures. This paper delves into three primary areas: the exploration of HPHT regimes supported by conventional heat exchangers, the impact of AM processes on thermal transport devices, and the discussion focused on HPHT heat exchangers produced via AM. The study examines the traditional manufacturing processes, materials, structures and geometries, and limitations of the commonly used heat exchangers for HPHT applications. Furthermore, it highlights the potential of AM in optimizing HPHT heat exchanger design, by reviewing studies that enable uniform flow distribution, minimization of fouling, and thermo-hydraulic performance augmentation without compromising structural stability. While addressing the limitations of cost, size, and other constraints, this study offers insights into the possibilities of AM in revolutionizing HPHT heat exchanger technology. The goal has been to fill the gap in literature by summarizing key studies, findings, and limitations, presenting a detailed examination, and proposing new areas for research. In conclusion, this review contributes to a deeper understanding of AM’s role in advancing HPHT heat exchangers for future energy systems.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Sub-Sampled Imaging for STEM: Maximising Image Speed, Resolution and Precision Through Reconstruction Parameter Refinement

Sub-sampling during image acquisition in scanning transmission electron microscopy (STEM) has been shown to provide a means to increase the overall speed of acquisition while at the same time providing an efficient means to control the dose, dose rate and dose overlap delivered to the sample. In this paper, we discuss specifically the parameters used to reconstruct sub-sampled images and highlight their effect on inpainting using the beta-process factor analysis (BPFA) methodology. The selection of the main control parameters can have a significant effect on the resolution, precision and sensitivity of the final inpainted images, and here we demonstrate a method by which these parameters can be optimised for any image in STEM. As part of this paper, we also provide a link to open source code and a tutorial on its use, whereby these parameters can be tested for any datasets. When coupled with the hardware necessary to rapidly sub-sample images in STEM, this approach can have significant implications for imaging beam sensitive materials and dynamic processes.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Machine learning for ultrasonic nondestructive examination of welding defects: A systematic review

Recent years have seen a substantial increase in the application of machine learning (ML) for automated analysis of nondestructive examination (NDE) data. One of the applications of interest is the use of ML for the analysis of data from in-service inspection of welds in nuclear power and other industries. These types of inspections are performed in accordance with criteria described in the ASME Boiler and Pressure Vessel Code and require the use of reliable NDE techniques. The rapid growth in ML methods and the diversity of possible approaches indicate a need to assess the current capabilities of ML and automated data analysis for NDE and identify any gaps or shortcomings in current ML technologies as applied to the automated analysis of NDE data. In particular, there is a need to determine the impact of ML on the NDE reliability. This paper discusses the findings from a literature survey on the current state of ML for the automated analysis of data from ultrasonic NDE of weld flaws. It discusses an overview of ultrasonic NDE as used for weld inspections in nuclear power and other industries. Herein, data sets and ML models used in the literature are summarized, along with a generally applicable workflow for ML. Findings on the capabilities, limitations and potential gaps in feature selection, data selection, and ML model optimization are discussed. The paper identified several needs for quantifying and validating the performance of ML methods for ultrasonic NDE, including the need for common data sets.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Production of high-quality polyethylene (PE) films from post-consumer shrink wrap with solvent targeted recovery and precipitation (STRAP)

The solvent-targeted recovery and precipitation (STRAP™) process separates polymers from contaminants present in the feedstock. In this work, we demonstrate the recyclability of a post-consumer waste (PCW) shrink wrap that contains inks, adhesives, and paper using STRAP. We produced a clear rPE cast film from the PCR shrink wrap with no visual contamination from paper or inks. STRAP decreased the ash content from 0.96 wt% to 0.24 wt%. A techno-economic analysis (TEA) shows that a STRAP plant processing 50,000 metric tons annually of shrink wrap waste (purchased at $\$0.25$/kg) containing 85 wt% PE can achieve an IRR of 16.2% when selling rPE at $\$1.30$/kg, an IRR of 10.7% with an rPE price of $\$1.00$/kg, or an IRR of 3.79% with an rPE price of $\$0.70$/kg. Furthermore, the life cycle assessment (LCA) shows a 64% reduction in global warming potential (kg CO 2 equivalent) when compared to the production of virgin LDPE. As a result, this work shows how feedstocks with insoluble impurities can be recycled using STRAP on a large scale.

Radkevich, Elizaveta [University of Wisconsin-Madi↗
DOE OSTI2021

Observations of modal coupling due to bolted joints in an experimental benchmark structure

The goal of this paper is to present a set of measurements from a benchmark structure containing two bolted joints to support future efforts to predict the damping due to the joints and to model nonlinear coupling between the first two elastic modes. Bolted joints introduce nonlinearities in structures, typically causing a softening in the natural frequency and an increase in damping because of frictional slip between the contact interfaces within the joint. These nonlinearities pose significant challenges when characterizing the response of the structure under a large range of load amplitudes, especially when the modal responses become coupled, causing the effective damping and natural frequency to not only depend on the excitation amplitude of the targeted mode, but also the relative amplitudes of other modes. In this work, two nominally identical benchmark structures, known in some prior works as the S4 beam, are tested to characterize their nonlinear properties for the first two elastic modes. Detailed surface measurements are presented and validated through finite element analysis and reveal distinct contact interactions between the two sets of beams. The free-free test structures are excited with an impact hammer and the transient response is analyzed to extract the damping and frequency backbone curves. A range of impact amplitudes and drive points are used to isolate a single mode or to excite both modes simultaneously. Differences in the nonlinear response correlate with the relative strength of the modes that are excited, allowing one to characterize mode coupling. Each of the beams shows different nonlinear properties for each mode, which is attributed to the different contact pressure distributions between the parts, although the mode coupling relationship is found to be consistent between the two. Lastly, the test data key finding are presented in this paper and the supporting data is available on a public repository for interested researchers.

42 ENGINEERING↗
DOE OSTI2022

Developing a heterogeneous ensemble learning framework to evaluate Alkali-silica reaction damage in concrete using acoustic emission signals

The monitoring and evaluation of Alkali-silica reaction (ASR) damage in concrete structures are required to ensure the serviceability and integrity of concrete infrastructures such as bridges and dams. The innovation of this paper lies in the development of an automatic ASR monitoring and evaluation approach by leveraging acoustic emission (AE) and a heterogeneous ensemble learning framework. Here, in this paper, ASR was monitored by AE sensors attached to a concrete specimen, which was placed in a chamber with high humidity and temperature. The recorded AE signals were filtered and divided by four ASR phases according to signal strength, crack width and expansion strain. A heterogeneous ensemble network including convolutional neural networks (CNN) and random forest models was employed to learn different features from AE signals and classify the AE signals into their corresponding phases. The results suggest that the proposed model has a high performance and classifies the signals into the assigned phases with high accuracy.

42 ENGINEERING↗
DOE OSTI2022

Experiments of water-moderated plutonium metal arrays: part I — description

In the mid-1970s and early 1980s, almost one hundred critical and approach-to-critical experiments using water-moderated plutonium metal arrays were performed at the Rocky Flats Critical Mass Laboratory. The experiments were performed in two programs: 2x2xN arrays conducted in the 1970s and 3x3x3 arrays conducted in the 1980s. Both sets of experiments used the same double-canned plutonium parts and were water moderated. The major differences between the two programs were the support structure and tank and the administrative limits on criticality. This paper summarizes the critical data and results of both sets of experiments. In conclusion, these experiments are then analyzed in a companion paper.

42 ENGINEERING↗
DOE OSTI2021

Analytical solution for the cumulative wake of wind turbines in wind farms

This paper solves an approximate form of conservation of mass and momentum for a turbine in a wind farm array. The solution is a fairly simple explicit relationship that predicts the streamwise velocity distribution within a wind farm with an arbitrary layout. As this model is obtained by solving flow-governing equations directly for a turbine that is subject to upwind turbine wakes, no ad hoc superposition technique is needed to predict wind farm flows. A suite of large-eddy simulations (LES) of wind farm arrays is used to examine self-similarity as well as validity of the so-called conservation of momentum deficit for turbine wakes in wind farms. The simulations are performed with and without the presence of some specific turbines in the wind farm. This allows us to systematically study some of the assumptions made to develop the analytical model. A modified version of the conservation of momentum deficit is also proposed to provide slightly better results at short downwind distances, as well as in the far wake of turbines deep inside a wind farm. Model predictions are validated against the LES data for turbines in both full-wake and partial-wake conditions. While our results highlight the limitation in capturing the flow speed-up between adjacent turbine columns, the model is overall able to acceptably predict flow distributions for a moderately sized wind farm. Finally, the paper employs the new model to provide insights on the accuracy of common wake superposition methods.

17 WIND ENERGY↗
DOE OSTI2023

Activity-induced migration of viscous droplets on a solid substrate

Active matter exploits motion to induce changes in shape and conformation via external input. Here, in this paper, we establish theoretically that viscous liquid droplets containing magnetic nanoparticles with frozen-in magnetic moments, sitting on a solid substrate and surrounded by an ambient gas phase, can deform and migrate under the influence of a magnetic torque. The effect arises because the collective rotation of the magnetic nanoparticles at the liquid–gas interface tilts the droplet away from a symmetric configuration, breaks the reflection symmetry with respect to the centre axis, and leads to a left–right asymmetry of the contact angles. A sufficiently strong magnetic torque leads the contact angles to overcome hysteresis effects leading the droplet to migrate. We develop a general framework to explain how symmetry-breaking affects droplet migration. Thus previous results of droplet spreading and migration can be recovered as special cases. Such droplets can be employed as agents in active surfaces and can move against gravity, chemical and thermal gradients, providing a mechanism that could be utilized by both industry and medicine.

Aggarwal, A.↗
DOE OSTI2023

OPERATOR 4.0 FOR HYBRID MANUFACTURING

Hybrid manufacturing, a combination of additive and subtractive manufacturing capabilities in one system, has recently become a more viable production option across several industries. Although current hybrid manufacturing research covers a broad range of topics, there is a lack of focus on how this new technology impacts both the designer and the operator of hybrid systems. This paper identifies areas of literature across design theory and Industry/Operator 4.0 research efforts and presents a path for applying this research to hybrid manufacturing users. The unique relationship between operator and designer is highlighted as they learn new strategies and develop new intuitive judgements over time to become the first experienced/expert users of hybrid manufacturing. The potential impact of excessive cognitive workload due to the novel combination of processes is discussed. This paper begins a critical discussion about proper knowledge transfer to other hybrid designers and operators, as well as towards efforts of monitoring, inspecting, and automating hybrid manufacturing processes.

Fillingim, Blane↗
DOE OSTI2023

The DESC stellarator code suite Part 3: Quasi-symmetry optimization

The DESC stellarator optimization code takes advantage of advanced numerical methods to search the full parameter space much faster than conventional tools. Only a single equilibrium solution is needed at each optimization step thanks to automatic differentiation, which efficiently provides exact derivative information. A Gauss–Newton trust-region optimization method uses second-order derivative information to take large steps in parameter space and converges rapidly. With just-in-time compilation and GPU portability, high-dimensional stellarator optimization runs take orders of magnitude less computation time with DESC compared to other approaches. This paper presents the theory of the DESC fixed-boundary local optimization algorithm along with demonstrations of how to easily implement it in the code. Example quasi-symmetry optimizations are shown and compared to results from conventional tools. Three different forms of quasi-symmetry objectives are available in DESC, and their relative advantages are discussed in detail. In the examples presented, the triple product formulation yields the best optimization results in terms of minimized computation time and particle transport. This paper concludes with an explanation of how the modular code suite can be extended to accommodate other types of optimization problems.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

An ontology-based fault generation and fault propagation analysis approach for safety-critical computer systems at the design stage

Abstract Fault propagation analysis is a process used to determine the consequences of faults residing in a computer system. A typical computer system consists of diverse components (e.g., electronic and software components), thus, the faults contained in these components tend to possess diverse characteristics. How to describe and model such diverse faults, and further determine fault propagation through different components are challenging problems to be addressed in the fault propagation analysis. This paper proposes an ontology-based approach, which is an integrated method allowing for the generation, injection, and propagation through inference of diverse faults at an early stage of the design of a computer system. The results generated by the proposed framework can verify system robustness and identify safety and reliability risks with limited design level information. In this paper, we propose an ontological framework and its application to analyze an example safety-critical computer system. The analysis result shows that the proposed framework is capable of inferring fault propagation paths through software and hardware components and is effective in predicting the impact of faults.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Graph interpolating activation improves both natural and robust accuracies in data-efficient deep learning

Improving the accuracy and robustness of deep neural nets (DNNs) and adapting them to small training data are primary tasks in deep learning (DL) research. In this paper, we replace the output activation function of DNNs, typically the data-agnostic softmax function, with a graph Laplacian-based high-dimensional interpolating function which, in the continuum limit, converges to the solution of a Laplace–Beltrami equation on a high-dimensional manifold. Furthermore, we propose end-to-end training and testing algorithms for this new architecture. The proposed DNN with graph interpolating activation integrates the advantages of both deep learning and manifold learning. Compared to the conventional DNNs with the softmax function as output activation, the new framework demonstrates the following major advantages: First, it is better applicable to data-efficient learning in which we train high capacity DNNs without using a large number of training data. Second, it remarkably improves both natural accuracy on the clean images and robust accuracy on the adversarial images crafted by both white-box and black-box adversarial attacks. Third, it is a natural choice for semi-supervised learning. This paper is a significant extension of our earlier work published in NeurIPS, 2018. For reproducibility, the code is available at https://github.com/BaoWangMath/DNN-DataDependentActivation .

Mathematics↗
DOE OSTI2021

Recent Advances in Nonclassical Crystallization: Fundamentals, Applications, and Challenges

We report crystals are ubiquitous and play an important role in our daily life. Recent studies on properties and formation of crystals have proven the attachment of particle ranging from ion pairs to well-crystallized nanocrystal is one of the most important ways for crystallization. Compared with the monomer-by-monomer (i.e., atoms, ions, or molecules) addition described in longstanding classical theories, so-called nonclassical crystallization pathways are more complex as the non-specific interaction of variation in system free energy and reaction kinetics. In view of the detailed insights into nonclassical crystallization pathways has broadened the scope of research across various disciplines such as geological events, biomineralization mechanisms, environmental remediation, and the development of functional materials, this paper reviews the current state of the art in nonclassical nucleation (the prenucleation clusters pathway, aggregation pathway, etc.) and growth pathways (oriented attachment and random attachment) based on several spotlights. In addition, the observed specific phenomena on crystallization in the last 10 years as well as recent advancements and achievements made on the synthesis of mesocrystals are also elucidated. With implications and perspectives of nonclassical crystallization researches proposed in this paper, this review aims to summarize research advancement regarding crystallizing systems. Emphasis will be placed on novel insights into nonclassical crystallization of materials, which are expected to provide completely new perspectives on the underlying crystallization mechanisms.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Community Data Mining Approach for Surface Complexation Database Development

This paper presents a comprehensive data-to-model workflow, including a findable, accessible, interoperable, reusable (FAIR) community sorption database (newly developed LLNL Surface Complexation/Ion Exchange (L-SCIE) database) along with a data fitting workflow to efficiently optimize surface complexation reaction constants with multiple surface complexation model (SCM) constructs. This workflow serves as a universal framework to mine, compile, and analyze large numbers of published sorption data as well as to estimate reaction constants for parameterizing reactive transport models. Here the framework includes (1) data digitization from published papers, (2) data unification including unit conversions, and (3) data-model integration and reaction constant estimation using geochemical software PHREEQC coupled with the universal parameter estimation code PEST. We demonstrate our approach using an analysis of U(VI) sorption to quartz based on a first L-SCIE implementation, concluding that a multisite SCM construct with carbonate surface species yielded the best fit to community data. Surface complexation reaction constants extracted from this approach captured all available sorption data available in the literature and provided insight into previously published reaction constants and surface complexation model constructs. The L-SCIE sorption database presented herein allows for automating this approach across a wide range of metals and minerals and implementing novel machine learning approaches to reactive transport in the future.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2021

Static and Dynamic Intensification of Water–Ethylene Glycol Separation Using a Dividing Wall Column

This paper makes several first-of-a-kind contributions toward “double intensification” (static/dynamic) of distillation systems, focusing in particular on the energy-intensive separation of a mixture of water and ethylene glycols. First, we demonstrate that a dividing wall column (DWC) can be an appropriate choice for separating wide-boiling zeotropic mixtures. Additionally, we show that the conventional DWC configuration where the wall is in the “middle” should be discarded in favor of a less frequently encountered “common-bottom” setup. For the mixture considered, choosing a DWC in lieu of a conventional two-column sequence can lead to over 6% energy cost savings and a 5% reduction in the number of stages compared to the conventional direct sequence two-column counterpart. The second part of this paper focuses on applying the previously introduced concept of dynamic process intensification to the DWC, the first time that such an effort is reported in the literature, to our knowledge. Here, we show that an additional 1.4% energy savings can be unlocked in this way, and confirm the stable operation of the column via dynamic simulation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

A Novel Multiagent Resource Sharing Algorithm for Control of Advanced Energy Systems

This paper implements a novel resource sharing control strategy on a fuel cell–gas turbine hybrid power system at the National Energy Technology Laboratory’s Hybrid Performance Facility (Hyper). In a fuel cell–gas turbine hybrid power system, the simultaneous interaction of the gas turbine and the fuel cell creates a tightly coupled environment characterized by conflicting dynamics. In this paper, a model-free control approach is applied to solve the tightly coupled control problem posed by this challenging environment. Specifically, this control problem is presented as a resource sharing problem that can be solved using a resource sharing algorithm that is defined based on the distribution construction concept. This algorithm creates computational agents and solves the problem through the distribution and redistribution of shared resources defined as blocks. Furthermore, two agents were created; the first agent (agent 1) controls the gas turbine speed by adjusting the electric load, and the second agent (agent 2) controls the cathode mass flow through the fuel cell using the cold-air bypass valve. A parametric study was performed over the course of 15 experimental tests for both agents 1 and 2 through an evaluation of the responses based on setpoint changes. The algorithm was shown to have behavior comparable to a previously implemented multi-input multioutput state-space controller, which was designed through a model-based control approach. The resource sharing algorithm was able to find stable performance during run-time operations without any prior system knowledge identification on the power plant and without creating models used in traditional control strategies.

25 ENERGY STORAGE↗
DOE OSTI2024

Ceramic–Metal (Cermet) Composites: A Review of Key Properties and Synthesis Methods Focused on Nuclear Waste Immobilization

Here this paper reviews key properties, applications, and examples of ceramic-metal composites (cermets), and metal matrix composites (MMC) with emphasis on their applicability as waste forms for immobilizing nuclear waste. While the literature is mature for vitrified and cementitious radioactive waste forms, cermet materials have not received adequate attention as potential candidates for immobilizing nuclear waste. To promulgate this effort, this review connects cermet and MMC design, such as hardened tools, with the chemistry of radioactive waste streams. A discussion on certification and qualification standards for cermet waste forms, literature gaps, and “how-to” sections on cermet processing techniques. Key parameters discussed include thermal conductivity, chemical durability, and waste loading, as well as examples for metal-containing waste forms. As cermet waste forms gain momentum within the community, this review paper aims ensure the end-of-life nuclear fuel cycle is addressed from a materials and waste disposition perspective.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗