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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 1,243 records · Page 69
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Process–Property–Performance Mapping of Additively Manufactured 316H Stainless Steel Components

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development of advanced materials and components fabricated via additive manufacturing, and is using laser powder bed fusion (LPBF) of 316H stainless steel as an initial case study. In the previous fiscal year, miniature high-throughput specimens were printed on multiple LPBF systems to provide initial processing windows to minimize porosity and limit epitaxial grain growth during prints. This fiscal year, scaled builds were completed on three different LPBF systems at ORNL: a GE Concept Laser M2, a Renishaw AM400, and an EOS M290. Builds on the Concept Laser were conducted on multiple powder lots and processing parameter ranges to provide microstructure effects on time-independent and time-dependent mechanical properties. Builds on the Renishaw were produced using Oak Ridge National Laboratory (ORNL)-optimized printing parameters and Argonne National Laboratory (ANL)-optimized printing parameters to compare outcomes of parallel process optimization efforts at different national laboratories on the same LPBF system. Similarly, the build completed on the EOS M290 replicated the processing parameters of builds completed at Los Alamos National Laboratory (LANL). Optical microscopy and electron backscatter diffraction characterization was completed on all builds. In addition to the general round robin characterization, this work-package generated time-independent data, including tensile and fracture toughness test data on scaled Concept Laser builds as a function of processing parameters and post-build heat treatment. This analysis is complimentary to work in parallel work packages aiming to establish heat treatment and processing effects on time-dependent properties. It was found that although the stress-relief heat treatment provides the highest strength at lower-temperatures, tensile strength begins to converge at higher temperatures regardless of heat treatment condition. In addition, the more rigorous solution annealing and hot-isostatic pressing post-build heat treatments result in higher fracture toughness than the stress-relieved condition. The root-causes of the lower fracture toughness of the stress-relieved LPBF 316H material was informed via a stress-relief optimization study on a scaled concept laser print, where it was found that although dislocation recovery was largely complete after only a couple hours at 650°C, the extended hold of the current 24h heat treatment employed on scaled builds likely caused increased carbide volume fractions along the LPBF 316H grain boundaries, thereby deteriorating crack propagation resistance. This trend was seen to become more deleterious with additional increases of stress-relief temperature to 750°C or 850°C. These results have helped inform a new optimal stress-relief annealing condition for LPBF 316H for future campaign testing (650°C for 2h).

36 MATERIALS SCIENCE↗
DOE OSTI2024

Process–Property–Performance Mapping of Additively Manufactured 316H Stainless Steel Components

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development of advanced materials and components fabricated via additive manufacturing, and is using laser powder bed fusion (LPBF) of 316H stainless steel as an initial case study. In the previous fiscal year, miniature high-throughput specimens were printed on multiple LPBF systems to provide initial processing windows to minimize porosity and limit epitaxial grain growth during prints. This fiscal year, scaled builds were completed on three different LPBF systems at ORNL: a GE Concept Laser M2, a Renishaw AM400, and an EOS M290. Builds on the Concept Laser were conducted on multiple powder lots and processing parameter ranges to provide microstructure effects on time-independent and time-dependent mechanical properties. Builds on the Renishaw were produced using Oak Ridge National Laboratory (ORNL)-optimized printing parameters and Argonne National Laboratory (ANL)-optimized printing parameters to compare outcomes of parallel process optimization efforts at different national laboratories on the same LPBF system. Similarly, the build completed on the EOS M290 replicated the processing parameters of builds completed at Los Alamos National Laboratory (LANL). Optical microscopy and electron backscatter diffraction characterization was completed on all builds. In addition to the general round robin characterization, this work-package generated time-independent data, including tensile and fracture toughness test data on scaled Concept Laser builds as a function of processing parameters and post-build heat treatment. This analysis is complimentary to work in parallel work packages aiming to establish heat treatment and processing effects on time-dependent properties. It was found that although the stress-relief heat treatment provides the highest strength at lower-temperatures, tensile strength begins to converge at higher temperatures regardless of heat treatment condition. In addition, the more rigorous solution annealing and hot-isostatic pressing post-build heat treatments result in higher fracture toughness than the stress-relieved condition. The root-causes of the lower fracture toughness of the stress-relieved LPBF 316H material was informed via a stress-relief optimization study on a scaled concept laser print, where it was found that although dislocation recovery was largely complete after only a couple hours at 650°C, the extended hold of the current 24h heat treatment employed on scaled builds likely caused increased carbide volume fractions along the LPBF 316H grain boundaries, thereby deteriorating crack propagation resistance. This trend was seen to become more deleterious with additional increases of stress-relief temperature to 750°C or 850°C. These results have helped inform a new optimal stress-relief annealing condition for LPBF 316H for future campaign testing (650°C for 2h).

36 MATERIALS SCIENCE↗
DOE OSTI2025

Crossing the Finish Line: Integration of Data-Driven Process Control for Maximization of Energy and Resource Efficiency in Advanced Water Resource Recovery Facilities

Improvements in process monitoring and control at water resource recovery facilities (WRRFs) could result in reductions in electricity consumption, chemical inputs, and greenhouse gas emissions, as well as improved energy recovery. Many current WRRF data collection, monitoring, and control approaches use 20th century process monitoring and control systems, which require large design safety factors to ensure reliability in the absence of more advanced, precise controls. Implementation of more modern data-driven control tools could lead to more efficient operations that provide intrinsic reliability with better overall process performance at full-scale. This project (1) developed and demonstrated data-driven process controls at full-scale facilities for five promising WRRF process technologies that provide whole-plant approaches and offer substantial energy and resource recovery benefits, and (2) created a Machine Learning (ML) Toolkit and an implementation guide of new process control approaches that walks users through each step of the ML workflow and illustrates the steps through case study examples.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2019

Optimization of enhanced law correlation glasses for processing

Primary objectives of this work are given below. Review past test data to identify potential causes for poor processing characteristics of some glass compositions generated by the Enhanced LAW Glass Correlation and conduct tests to investigate these effects. Evaluate strategies to ameliorate processing characteristics of poorly performing Enhanced LAW Glass Correlation compositions through manipulation of glass compositions and GFC additives. Characterize new glass compositions to be processed on the DM100 with respect to properties affecting processability and product quality for melt viscosity, melt electrical conductivity, VHT, PCT, crystallization, refractory corrosion, and sulfate incorporation. Conduct Inconel 690 corrosion tests for various compositions designed by the Enhanced LAW Glass Correlation. Characterize melter feeds to be processed on the DM100 to verify that they have physical and rheological properties that are acceptable for melter feed processing at the WTP. Further refine the Enhanced LAW Glass Correlation based on the results from the rheology, feed VGF, Inconel 690 corrosion, crucible and melter tests.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Characterization of Precipitate Reactor Feed Tank (PRFT) Batches 44 and 49 from the Defense Waste Processing Facility (DWPF)

The Savannah River Site (SRS) Defense Waste Processing Facility (DWPF) processes a Monosodium Titanate/Sludge Solids (MST/SS) waste stream received from the Salt Waste Processing Facility (SWPF) via the Precipitate Reactor Feed Tank (PRFT). During processing, DWPF is required to provide evidence of compliance with the Waste Acceptance Product Specifications (WAPS). Savannah River Mission Completion (SRMC) has requested Savannah River National Laboratory (SRNL) to analyze PRFT samples representing each SWPF salt batch for thirty-two radionuclides. Additionally, elemental analysis of PRFT slurry and MST/SS solids was performed to aid SRMC in further refinement of the inputs and assumptions used in future frit development and Material Tracking Program calculations. The analyses of PRFT Batches 44 and 49, which correspond to material from the processing of Salt Batches (StB) 12 and 11, respectively, are reported herein. The unwashed dried solids of the PRFT Batches 44 and 49 are predominately MST, ~63-59% MST. The two batches have a much higher amount of Fe, Mn, and Ni compared to all previous batches. For Batch 44 this appears to be due to the use of a sludge simulant filter aid during processing of StB 12 and for Batch 49, it is possibly due to the larger amount of insoluble solids for StB 11 in comparison to all previous salt batches. Like previous PRFT batches, a significant amount of the unwashed dried solids are alkaline earth metals. The total sulfate, in mg/kg of slurry, for PRFT Batches 44 and 49 is 119 and 139, respectively, which is well below the current sulfate concentration used in Material Tracking Program calculations and is in agreement with DWPF laboratory sulfate measurements.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

ON PROCESS STABILITY IN WAAM-CMT OF ALUMINUM ALLOYS

Wire-arc additive manufacturing (WAAM) has become a cost-efficient metal additive manufacturing process. However, depositing aluminum with WAAM is challenging due to its sensitivity to heat input (linear energy density), which can cause undesirable surface topology waviness if not controlled. Thus, a process window is needed that can produce stable geometry and deposition conditions while minimizing production times. In this study, 5183 aluminum alloy wire is used to deposit 10-layer walls with varying wire feed speeds (WFS) and traverse speeds (TS) (at a constant WFS/TS ratio) and varying interpass temperature (IPT). In-situ process data consisting of optical contact-tip-workpiece-distance (CTWD) and current/voltage measurements are collected to determine process condition stability throughout the build. Part geometry is measured using a 3D scanner and build porosity is characterized via digital X-ray. A process window is identified that produces stable surface topology and process conditions at a minimal production time.

aluminum alloy↗
DOE OSTI2021

Differential Gene Expression in Host Ubiquitination Processes in Childhood Malarial Anemia

Background: Malaria remains one of the leading global causes of childhood morbidity and mortality. In holoendemic Plasmodium falciparum transmission regions, such as western Kenya, severe malarial anemia [SMA, hemoglobin (Hb) < 6.0 g/dl] is the primary form of severe disease. Ubiquitination is essential for regulating intracellular processes involved in innate and adaptive immunity. Although dysregulation in ubiquitin molecular processes is central to the pathogenesis of multiple human diseases, the expression patterns of ubiquitination genes in SMA remain unexplored. Methods: To examine the role of the ubiquitination processes in pathogenesis of SMA, differential gene expression profiles were determined in Kenyan children ( n = 44, aged <48 mos) with either mild malarial anemia (M l MA; Hb ≥9.0 g/dl; n = 23) or SMA (Hb <6.0 g/dl; n = 21) using the Qiagen Human Ubiquitination Pathway RT 2 Profiler PCR Array containing a set of 84 human ubiquitination genes. Results: In children with SMA, 10 genes were down-regulated ( BRCC3 , FBXO3 , MARCH5 , RFWD2 , SMURF2 , UBA6 , UBE2A , UBE2D1 , UBE2L3 , UBR1 ), and five genes were up-regulated ( MDM2 , PARK2 , STUB1 , UBE2E3 , UBE2M ). Enrichment analyses revealed Ubiquitin-Proteasomal Proteolysis as the top disrupted process, along with altered sub-networks involved in proteasomal, protein, and ubiquitin-dependent catabolic processes. Conclusion: Collectively, these novel results show that protein coding genes of the ubiquitination processes are involved in the pathogenesis of SMA.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2024

Inverse prediction of PuO2 processing conditions using Bayesian seemingly unrelated regression with functional data

Over the past decade, a variety of innovative methodologies have been developed to better characterize the relationships between processing conditions and the physical, morphological, and chemical features of special nuclear material (SNM). Different processing conditions generate SNM products with different features, which are known as “signatures” because they are indicative of the processing conditions used to produce the material. These signatures can potentially allow a forensic analyst to determine which processes were used to produce the SNM and make inferences about where the material originated. This article investigates a statistical technique for relating processing conditions to the morphological features of PuO 2 particles. We develop a Bayesian implementation of seemingly unrelated regression (SUR) to inverse-predict unknown PuO 2 processing conditions from known PuO 2 features. Model results from simulated data demonstrate the usefulness of the technique. Applied to empirical data from a bench-scale experiment specifically designed with inverse prediction in mind, our model successfully predicts nitric acid concentration, while results for Pu concentration and precipitation temperature were equivalent to a simple mean model. Our technique compliments other recent methodologies developed for forensic analysis of nuclear material and can be generalized across the field of chemometrics for application to other materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

The Origin of r-process Elements in the Milky Way

Some of the heavy elements, such as gold and europium (Eu), are almost exclusively formed by the rapid neutron capture process (r-process). However, it is still unclear which astrophysical site between core-collapse supernovae and neutron star–neutron star (NS–NS) mergers produced most of the r-process elements in the universe. Galactic chemical evolution (GCE) models can test these scenarios by quantifying the frequency and yields required to reproduce the amount of europium (Eu) observed in galaxies. Although NS–NS mergers have become popular candidates, their required frequency (or rate) needs to be consistent with that obtained from gravitational wave measurements. We address the first NS–NS merger detected by LIGO/Virgo (GW170817) and its associated gamma-ray burst and analyze their implication for the origin of r-process elements. The range of NS–NS merger rate densities of 320–4740 Gpc -3 yr -1 provided by LIGO/Virgo is remarkably consistent with the range required by GCE to explain the Eu abundances in the Milky Way with NS–NS mergers, assuming the solar r-process abundance pattern for the ejecta. Under the same assumption, this event has produced about 1–5 Earth masses of Eu, and 3–13 Earth masses of gold. When using theoretical calculations to derive Eu yields, constraining the role of NS–NS mergers becomes more challenging because of nuclear astrophysics uncertainties. This is the first study that directly combines nuclear physics uncertainties with GCE calculations. Finally, if GW170817 is a representative event, NS–NS mergers can produce Eu in sufficient amounts and are likely to be the main r-process site.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

R-process-rich Stellar Streams in the Milky Way*

We present high-resolution Magellan/MIKE spectra of 22 bright (9 < V < 13.5) metal-poor stars (-3.18 < [Fe/H] < -1.37) in three different stellar streams, the Helmi debris stream, the Helmi trail stream, and the ω Centauri progenitor stream. We augment our Helmi debris sample with results for 10 stars by Roederer et al. for a total of 32 stars. Detailed chemical abundances of light elements as well as heavy neutron-capture elements have been determined for our 22 stars. All three streams contain carbon-enhanced stars. For 13 stars, neutron-capture element lines were detectable, and they all show signatures in agreement with the scaled solar r -process pattern, albeit with a large spread of -0.5 < [Eu/Fe] < +1.3. Eight of these stars show an additional small s -process contribution superposed onto their r -process pattern. This could be discerned because of the relatively high signal-to-noise ratio of the spectra given that the stars are close by in the halo. Our results suggest that the progenitors of these streams experienced one or more r -process events early on, such as a neutron star merger or another prolific r -process source. This widely enriched these host systems before their accretion by the Milky Way. The small s -process contribution suggests the presence of asymptotic giant branch stars and associated local (inhomogeneous) enrichment as part of the ongoing chemical evolution by low-mass stars. Stars in stellar streams may thus be a promising avenue for studying the detailed history of large dwarf galaxies and their role in halo assembly with easily accessible targets for high-quality spectra of many stars.

Astronomy & Astrophysics↗
DOE OSTI2022

Impact of Hypernova νp-process Nucleosynthesis on the Galactic Chemical Evolution of Mo and Ru

We calculate the Galactic Chemical Evolution of Mo and Ru by taking into account the contribution from νp-process nucleosynthesis. We estimate yields of p-nuclei such as 92,94 Mo and 96,98 Ru through the νp-process in various supernova progenitors based upon recent models. In particular, the νp-process in energetic hypernovae produces a large amount of p-nuclei compared to the yield in ordinary core-collapse SNe. Because of this, the abundances of 92,94 Mo and 96,98 Ru in the Galaxy are significantly enhanced at [Fe/H] = 0 by the νp-process. We find that the νp-process in hypernovae is the main contributor to the elemental abundance of 92 Mo at low metallicity [Fe/H] < −2. Our theoretical prediction of the elemental abundances in metal-poor stars becomes more consistent with observational data when the νp-process in hypernovae is taken into account.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Novel estimation of aerosol processes with particle size distribution measurements: a case study with the TOMAS algorithm v1.0.0

Atmospheric aerosol microphysical processes are a significant source of uncertainty in predicting climate change. Specifically, aerosol nucleation, emissions, and growth rates, which are simulated in chemical transport models to predict the particle size distribution, are not understood well. However, long-term size distribution measurements made at several ground-based sites across Europe implicitly contain information about the processes that created those size distributions. This work aims to extract that information by developing and applying an inverse technique to constrain aerosol emissions as well as nucleation and growth rates based on hourly size distribution measurements. We developed an inverse method based upon process control theory into an online estimation technique to scale aerosol nucleation, emissions, and growth so that the model–measurement bias in three measured aerosol properties exponentially decays. The properties, which are calculated from the measured and predicted size distributions, used to constrain aerosol nucleation, emission, and growth rates are the number of particles with a diameter between 3 and 6 nm, the number with a diameter greater than 10 nm, and the total dry volume of aerosol ( N 3–6 , N 10 , V dry ), respectively. In this paper, we focus on developing and applying the estimation methodology in a zero-dimensional “box” model as a proof of concept before applying it to a three-dimensional simulation in subsequent work. The methodology is first tested on a dataset of synthetic and perfect measurements that span diverse environments in which the true particle emissions, growth, and nucleation rates are known. The inverse technique accurately estimates the aerosol microphysical process rates with an average and maximum error of 2 % and 13 %, respectively. Next, we investigate the effect that measurement noise has on the estimated rates. The method is robust to typical instrument noise in the aerosol properties as there is a negligible increase in the bias of the estimated process rates. Finally, the methodology is applied to long-term datasets of in situ size distribution measurements in western Europe from May 2006 through June 2007. At Melpitz, Germany, and Hyytiälä, Finland, the average diurnal profiles of estimated 3 nm particle formation rates are reasonable, having peaks near noon local time with average peak values of 1 and 0.15 cm –3 s –1 , respectively. The normalized absolute error in estimated N 3–6 , N 10 , and V dry at three European measurement sites is less than 15 %, showing that the estimation framework developed here has potential to decrease model–measurement bias while constraining uncertain aerosol microphysical processes.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1974

Process development of beam-lead silicon-gate COS/MOS integrated circuits

Two processes for the fabrication of beam-leaded COS/MOS integrated circuits are described. The first process utilizes a composite gate dielectric of 800 A of silicon dioxide and 450 A of pyrolytically deposited A12O3 as an impurity barrier. The second process utilizes polysilicon gate metallization over which a sealing layer of 1000 A of pyrolytic Si3N4 is deposited. Three beam-lead integrated circuits have been implemented with the first process: (1) CD4000BL - three-input NOR gate; (2) CD4007BL - triple inverter; and (3) CD4013BL - dual D flip flop. An arithmetic and logic unit (ALU) integrated circuit was designed and implemented with the second process. The ALU chip allows addition with four bit accuracy. Processing details, device design and device characterization, circuit performance and life data are presented.

Baptiste, B.↗
NASA NTRS1974

Thermochemical water decomposition processes

Thermochemical processes which lead to the production of hydrogen and oxygen from water without the consumption of any other material have a number of advantages when compared to other processes such as water electrolysis. It is possible to operate a sequence of chemical steps with net work requirements equal to zero at temperatures well below the temperature required for water dissociation in a single step. Various types of procedures are discussed, giving attention to halide processes, reverse Deacon processes, iron oxide and carbon oxide processes, and metal and alkali metal processes. Economical questions are also considered.

Chao, R. E.↗
NASA NTRS1976

Apollo Experiment Report: Lunar-Sample Processing in the Lunar Receiving Laboratory High-Vacuum Complex

A high-vacuum complex composed of an atmospheric decontamination system, sample-processing chambers, storage chambers, and a transfer system was built to process and examine lunar material while maintaining quarantine status. Problems identified, equipment modifications, and procedure changes made for Apollo 11 and 12 sample processing are presented. The sample processing experiences indicate that only a few operating personnel are required to process the sample efficiently, safely, and rapidly in the high-vacuum complex. The high-vacuum complex was designed to handle the many contingencies, both quarantine and scientific, associated with handling an unknown entity such as the lunar sample. Lunar sample handling necessitated a complex system that could not respond rapidly to changing scientific requirements as the characteristics of the lunar sample were better defined. Although the complex successfully handled the processing of Apollo 11 and 12 lunar samples, the scientific requirement for vacuum samples was deleted after the Apollo 12 mission just as the vacuum system was reaching its full potential.

White, D. R.↗
NASA NTRS1977

Effect of processing parameters on autoclaved PMR polyimide composites

A study was conducted to determine the effect of processing parameters on the processability and properties of autoclaved fiber reinforced PMR polyimide composites. Composites were fabricated from commercially available graphite fabric and glass fabric PMR polyimide prepreg materials. Process parameters investigated included degree of resin advancement, heating rate, and cure pressure. Composites were inspected for porosity by ultrasonic C scan and photomicrographic examination. Processing characteristics for each set of process parameters and the effect of process parameters on composite mechanical properties at room temperature and 600 F are described.

Vannucci, R. D.↗
NASA NTRS1978

Process feasibility study in support of silicon material task 1

Initial results for gas thermal conductivity of silicon tetrafluoride and trichlorosilane are reported in respective temperature ranges of 25 to 400 C and 50 to 400 C. For chemical engineering analyses, the preliminary process design for the original silane process of Union Carbide was completed for Cases A and B, Regular and Minimum Process Storage. Included are raw material usage, utility requirements, major process equipment lists, and production labor requirements. Because of the large differences in surge tankage between major unit operations the fixed capital investment varied from $19,094,000 to $11,138,000 for Cases A and B, respectively. For the silane process the original flowsheet was revised for a more optimum arrangement of major equipment, raw materials and operating conditions. The initial issue of the revised flowsheet (Case C) for the silane process indicated favorable cost benefits over the original scheme.

Fang, C. S.↗
NASA NTRS1977

Photographic image enhancement and processing

Scientists using aerial imagery frequently desire image processing or enhancement of that imagery to aid them in data analysis. Sophisticated digital image processing techniques are currently employed in many applications where the data is recorded in digital format, where processing hardware and programs are available. Aerial photographic imagery poses a problem in the magnitude of the digitization processing. Photographic image processing analogous to many available digital techniques is being employed by scientific investigators. Those techniques which may be applied in a cost effective manner to processing of aerial photographic imagery are described here.

Lockwood, H. E.↗