A thermal-gradient approach to variable-temperature measurements resolved in space
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99 GENERAL AND MISCELLANEOUS↗
SEARCH · Engineering Papers
Results for “resistive heating”
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In situ chamber for studying battery failure using high-speed synchrotron radiography
The investigation of lithium-ion battery failures is a major challenge for personnel and equipment due to the associated hazards (thermal reaction, toxic gases and explosions). To perform such experiments safely, a battery abuse-test chamber has been developed and installed at the microtomography beamline ID19 of the European Synchrotron Radiation Facility (ESRF). The chamber provides the capability to robustly perform in situ abuse tests through the heat-resistant and gas-tight design for flexible battery geometries and configurations, including single-cell and multi-cell assemblies. High-speed X-ray imaging can be complemented by supplementary equipment, including additional probes (voltage, pressure and temperature) and thermal imaging. Together with the test chamber, a synchronization graphical user interface was developed, which allows an initial interpretation by time-synchronous visualization of the acquired data. Enabled by this setup, new meaningful insights can be gained into the internal processes of a thermal runaway of current and future energy-storage devices such as lithium-ion cells.
25 ENERGY STORAGE↗
A High-Ceramic-Loading LATP–PVDF–Al 2 O 3 Composite Film for Lithium-Ion Batteries With Favorable Porous Microstructure and Enhanced Thermal Stability
A separator plays a crucial role in a Li-ion battery to carry liquid electrolytes while preventing short-circuiting between electrodes. Nevertheless, conventional commercial separators often exhibit poor wettability and are prone to shrink at elevated temperatures due to their limited thermal stability. Herein, we report a heat-resistant LATP–PVDF–Al 2 O 3 composite film with outstanding wetting performance. The thin film was prepared using ball mill mixing and tape-casting processes. Two solvents, NMP and glycerol, were applied to prepare the slurry, and a favorable microstructure in the film was created after drying. Here, the ionic conductivity of the film was tested at 1.39 mS cm –1 when paired with liquid electrolyte, almost double that of the commercial counterpart. The high ceramic loading of 70% improved both the thermal shrinkage resistance and dendrite inhibition of the membrane. When assembled in an NMC half-cell, the cycling capacity retentions of 92.8% and 92.1% are achieved after 50 cycles at 0.5 C and 1 C, demonstrating its capability to be used in Li-ion batteries.
25 ENERGY STORAGE↗
Carbon Nanotube and Graphene Oxide Reinforced Composites for Lightning Strike Protection of Composite Structures
Carbon fiber reinforced plastics (CFRP) composites have become the primary materials in the aerospace industry. Future transportation means, such as urban air mobility (UAM), will be employing CFRP structures. However, lightning strike damage on composite structures is a serious concern. CFRP composites possess low through-thickness electrical conductivity (≈ 1 S/m), which can cause extreme resistive heat in the event of lightning strikes. Research on polymeric lightning strike protection has gained momentum in the past few years. Researchers have studied various conductive fillers to improve the CFRP performance against lightning strikes. Carbon nanotubes (CNTs) and graphene oxide (GO) have been studied as future lightning Strike Protection (LSP) materials the most. The use of CNT and GO-based composites has shown improved mechanical properties and improved electrical conductivity of the composites. Researchers investigated CNTs and GO as the fillers to the matrix system, sizing the carbon fibers and the surface coating on top of the CFRP surface. This chapter highlights the remarkable improvement in the lightning damage suppression of CNT and GO-based composites and their structural applications. Special attention is given to their potential use as LSP material in future aircraft.
Kumar, Vipin↗
Accurate temperature determination from XRD and EXAFS measurements (Full Technical Final Report)
Measuring temperature is of fundamental importance for High Energy Density science (HED), for studying melting, phase transitions and equations of state. However, temperature determination of high pressure and high temperature (0.1-1 eV) condensed matter remains one of the biggest challenges in such experiments. This project used a combination of advanced experimental techniques and state-of-the-art computational methods to construct a framework relating the observed attenuation of X-ray diffraction (XRD) and Extended X-ray Absorption Fine Structure (EXAFS) signals due to thermal fluctuations to the actual temperature achieved in the experiments. This approach was benchmarked against low temperature resistive heating diamond anvil cell (DAC) experiments and cross-validated at higher pressure and temperature by combining the two complementary and independent techniques, diffraction and EXAFS.
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
Wear in particle based CSP systems from particle abrasion and attrition at high temperature
High temperature particle-based receivers offer distinct advantages over conventional molten salt receivers due to their ability to achieve temperatures above 700 ºC, direct absorption of solar energy as they fall through a beam of concentrated sunlight, and the relative ease of storage (and retrieval using a secondary working fluid) in insulated storage tanks. The use of particles, however, also raises concerns with material degradation from the flow of hot or cold particles through discharge hoppers or along the inner receiver surfaces and other system components (e.g. tubes, valves etc.), depending on operating mode of the receiver. The flow of particles over surfaces may result in loss of material from abrasive wear, impact erosion from impingement under gravitational fall and particle attrition as particles fall and move on top of each other. In the present study, the performance of candidate materials and particles were evaluated through a series of abrasion erosion and particle attrition experiments at room temperature as well as at 800 °C. Candidate materials were subject to abrasive wear from particles at low particle to material velocities inside a resistance heated kiln, and analyzed for changes in mass and surface morphology using cross-sectional scanning electron microscopy (SEM) and energy dispersive x-ray spectroscopy (EDS) tests. The wear rate for different specimens was noted to be largely driven by the strength of chromia scales built on the specimens from exposure to high temperature. Particle attrition measurements explored the susceptibility of particles to breakdown from particle to particle interaction and the generation of fines from this process. At the low velocities expected in particle based CSP plants, the particles tested exhibited near negligible breakdown. However, changes in the particle hardness at 800 ºC resulted in a significantly higher particle breakdown to sizes <40 microns raising potential environmental concerns. In addition to particle breakdown, it was also noted that the sample had oxides from the stainless steel test setup mixed in with the particles. Similar oxides can be expected to turn up in the utility scale particle based CSP plants as well. The presence of oxide was also noted to affect the solar absorptivity of the mixture compared to a clean initial specimen, potentially resulting in a change in the overall efficiency of the CSP plant.
14 SOLAR ENERGY↗
X-Ray Spectroscopic Studies of X-Pinch Plasmas with 3-5 Picosecond Resolution: A Quest for Clear Experimental Evidence for Radiative Collapse in the X-ray Spectra (Final Report)
Dense Z-pinch plasmas produced from current-carrying exploding wires frequently produce very brief (less than 0.1 nanosecond), intense, bursts of soft X-rays from tiny (about 1 micrometer), very hot (10-30 million K) regions of the plasma. This project addresses the physical processes that lead to those tiny, high-energy density plasmas and develops means to measure the conditions just before and during the X-ray bursts. One possible relevant process is radiative collapse, which starts if the power radiated by a dense Z-pinch, proportional to the density-squared, exceeds the resistive heating rate from the current flow, thereby cooling the plasma and enabling the magnetic pinching force to exceed the outward plasma thermal pressure. As the resulting radius reduction further increases the radiation rate, this process produces a runaway magnetic implosion. A competing mechanism is a sausage-like instability that can develop in a Z-pinch plasma at a lower current than is needed to induce radiative collapse. This mechanism can also produce tiny hot spots in the neck regions of the sausage-shaped plasma column. It is also possible that these two mechanisms work together to produce the X-ray emitting hot spots. If radiative collapse does contribute to hot spot formation, it would be terminated when the plasma becomes so dense that the radiation cannot escape, enabling the plasma kinetic pressure to build up and stop the current-driven implosion. This project aims to study the development of the hot spots by means of high temporal and spatial resolution X-ray spectroscopy to determine if there is evidence for the presence of the radiative collapse mechanism. Progress toward this goal is presented. To summarize, during the four-year period 09/15/2017 - 9/14/2021, we have collected necessary spectroscopic data to determine the plasma conditions and continue to do so. We are also now in the process of calibrating diagnostic systems (especially the x-ray streak camera system) and analyzing data to determine plasma conditions as a function of time before, during and after the X-ray burst.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Multiscale Modeling of Corrosion and Oxidation Performance and Their Impact on High-temperature Fatigue of Automotive Exhaust Manifold Components
The persistent need to reducing automobile emissions has led to the wide adoption of turbocharger technology and engine downsizing, which results in a substantial raise in exhaust temperature, reaching as high as 950°C. Therefore, the material selection for exhaust manifolds and turbocharger housings becomes significantly challenging. The successful development of the multiscale models on oxidation and corrosion performance, and their impact on high-temperature fatigue will enable the acceleration of new, high-performance, heat-resistant alloy solutions and the reduction of time and cost in achieving a durable design. In this project, we developed and validated multiscale models that can accurately predict the corrosion and oxidation performance and their impact on high-temperature fatigue of high-temperature automotive exhaust manifold components. The capability of accurately predicting the corrosion/oxidation-fatigue damage can significantly reduce the time and cost of achieving a durable design. The models were used to guide the development of new high thermomechanical fatigue (TMF) performance alloys.
Li, Mei↗
Current-Activated Reactive Ultrafast Joining (CARUJ)
We have demonstrated Current Activated Reactive Ultrafast Joining (CARUJ) as a novel approach for rapid fabrication of similar and dissimilar materials, such as ceramic-ceramic and ceramic-metal joint assemblies. The CARUJ technology utilizes resistive heating of carbon-based materials to apply localized heat at, (through or around) joint zones at rates of 10 1 -10 2 ˚C/min, enabling joining at time scales considerably shorter (several minutes as opposed to hours) than conventional approaches for similar systems. Herein, we present our findings while evaluating the CARUJ concept. Three methods of heat application were evaluated: (i) using carbon joule heating elements to apply heat directly through the joint interface; (ii) using flexible joule heating elements to locally apply heat around the assembly interface; and (iii) non-contact heating of the joint assembly using inductive power. Schemes (ii) and (iii) proved to be the most effective in producing mechanically sound reliable joints. We demonstrated single-step fabrication of dense SiC-SiC joints with a Si- SiC interface using minimal pressure (1–2 MPa) in under 30 minutes. Measured average joint strengths of about 15 MPa are initially achieved for joined bodies when tested in single lap offset (SLO) compressive shear, while tuning of the interfacial composition along with a reduction in interlayer thickness, results in improved joint strengths of approximately 43 MPa. We further demonstrated SiC-SiC joining using Active Brazing Alloys (ABAs) proof of concept joining of tubular geometries. The versatility of CARUJ is demonstrated by utilizing non-contact heating via induction, to join dissimilar materials systems of SiC, SS316 and MAX phase ceramics with ABA interlayers. The localized and rapid heat application realizes a versatile material joining technique that can be extended for joining components at the plant site.
36 MATERIALS SCIENCE↗
Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology
Refrigerator technology has advanced significantly over the last couple of decades. Today’s refrigerators use only about 25% of the energy that was required to power models built in 1975. Even as they continually improve efficiency to meet standards, refrigerators have increased in size by almost 20%, added energy-consuming features such as through-the-door ice, and provide more benefits than ever before. However, a few challenges and technology gaps are preventing further improvement of the demand responsiveness and efficiency of the refrigerators. One of the major technology gaps in existing refrigerators is their outdated de-icing process. When the evaporator generates frost, an old-fashioned resistive heating element melts the ice. Most refrigerators have a timed defrost cycle, rather than an active system that could monitor the state of the frost. In these systems, not only is the precious electricity used at its least efficient form of conversion (direct conversion of electricity to heat), but also all the latent heat associated with the ice is wasted during the melting process. On top of that, the refrigerator needs to work harder to pull the temperature down after defrosting, and, last but not least, the food quality is severely impacted by the temperature swings during the defrost cycle. According to a study, the EU alone wastes 89 million tons of food in the supply chain every year. Any temperature swing during defrosting (about 6F according to Emerson for low-temperature cases) can negatively impact the shelf life of meat and other products for multiple days. All these issues can happen during the peak demand time of the electric grid. Unlike the conventional systems, the proposed novel advanced micro-vibrational deicing process uses no heat for defrosting. Instead, it uses the micro vibrations generated by a piezoelectric or vibration-generating module to mechanically break ice from the heat exchanger almost instantaneously. The project titled “Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology, performed by Ultrasonic Technology Solutions, LLC (UTS) of Knoxville, TN, in collaboration with Emerson (now Copeland), represents the final phase of a multi-year effort funded under the U.S. Department of Energy’s Building Technologies Office (BTO) BENEFIT FOA 2020. Initiated on October 1, 2021, and completed after a nine-month no-cost extension ending September 30, 2025, this project aimed to develop and validate a novel micro-vibrational mechanical defrosting system, achieving more than 25% improvement in defrosting energy efficiency over conventional baseline defrosting technologies. Over sixteen quarters, the project advanced from fundamental ice-mechanical characterization and prototype development to full-scale system integration and validation. Initial efforts established project management infrastructure and characterized ice adhesion properties, followed by the design and fabrication of early aluminum-based prototypes for resonance frequency testing. Subsequent quarters saw rapid technical progression, including the identification of optimal piezoelectric and motor-based vibration mechanisms, the demonstration of effective de-icing over 6x6-inch aluminum surfaces. The team achieved its Go/No-Go milestone by exceeding the 25% energy-efficiency improvement target—reaching up to 3,340% under optimized conditions—and later confirmed that motor-driven systems offered superior performance and energy efficiency compared to piezoelectric alternatives. Continued refinement led to the development of amplifier systems on printed circuit boards, improved control and instrumentation hardware, and integration into full-scale heat exchanger (HX) prototypes at both UTS and Copeland facilities. Multiple vibration-mounting studies and frost-growth experiments guided mechanical optimization and noise-mitigation strategies, achieving a 17.5 dB reduction in sound pressure level and verifying robust mechanical performance. Advanced analyses, including modal and harmonic simulations, established a quantitative understanding of vibrational behavior and de-icing efficiency across >1000 cm² systems. The final project phase successfully demonstrated scalable integration within reach-in and chest freezer prototypes, confirmed >25% efficiency improvements in large-area systems, and completed a comprehensive business model and scale-up strategy identifying electric defrost systems as the primary beachhead market. The culmination of this DOE-supported effort establishes micro-vibrational defrosting as a viable, high-efficiency, low-noise, and demand-flexible de-icing technology, paving the way for commercial deployment and broader application in next-generation refrigeration systems.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Ambient and Initial Temperature Effects on Energy Consumption Rate Modeled in FASTSim
Ambient and initial temperatures significantly impact the energy consumption rate (ECR) of battery electric vehicles (BEVs) due to auxiliary loads and the temperature dependence of battery efficiency. This study introduces a streamlined, physics-based thermal modeling approach within the FASTSim tool that bridges the gap between oversimplified constant-load models and computationally expensive high-fidelity simulations. By employing a lumped thermal mass framework, the model captures fundamental energy balances and critical non-linear energy penalties while maintaining the computational efficiency required for expansive sensitivity studies. The simulations evaluated a compact BEV hatchback with a resistive heater over city (UDDS) and highway (HWFET) test cycles. Compared to a 22 degrees Celsius initial and ambient temperature baseline, a -7 degrees Celsius initial/ambient temperature resulted in a 221% increase in the ECR for the city cycle and a 100% increase for the highway cycle. Conversely, a 45 degrees Celsius initial / 40 degrees Celsius ambient temperature resulted in a 40% increase for UDDS and an 18% increase for HWFET. These results demonstrate that while cold conditions impose the most severe energy penalties due to resistive heating, the impact is consistently more pronounced in city driving where auxiliary loads represent a larger proportion of total energy. This lightweight yet robust framework enables researchers to rapidly quantify BEV thermal sensitivity across diverse climates without the need for high-overhead simulation environments.
33 ADVANCED PROPULSION SYSTEMS↗
Electrically tunable metasurfaces incorporating a phase change material
Electrically tunable metasurfaces including an array of subwavelength metasurface unit elements are presented. The unit elements include a stacked metal-insulator-metal structure within which an active phase change layer is included. A purely insulator, metal, or coexisting metal-insulator phase of the active layer can be electrically controlled to tune an amplitude and phase response of the metasurfaces. In combination with the subwavelengths dimensions of the unit elements, the phase and amplitude response can be controlled in a range from optical wavelengths to millimeter wavelength of incident light. Electrical control of the unit elements can be provided via resistive heating produced by flow of current though a top metal layer of the unit elements. Alternatively, electrical control of the unit elements can be provided via electrical field effect produced by applying a voltage differential between the top and bottom metal layers of the unit elements.
Kim, Yonghwi↗
Andrew Dieringer Poster for review
Silicon carbide has been identified as a useful material for nuclear application due to its heat resistance, low neutron absorbing cross-section, chemical inertness, and its rigidity as a structural material. These properties make it very favorable for high temperature environments such as in TRISO fuel and advanced reactor designs. Treatments such as n-doping, where carrier atoms are added to increase the number of free electrons, are expected to further improve properties such as thermal conductivity and electrical resistivity. Due to the high amount of neutron interactions in a nuclear reactor, it is expected that silicon carbide used in a reactor will be passively n-doped via transmutation. Studying the effects of n-doping in silicon carbide can help us better understand how the material will operate under real world conditions. We have found that n-doping the SiC increases both thermal and electrical conductivity, providing positive feedback under reactor usage. Previously it had been thought that under reactor conditions material properties of SiC could only degrade due to defects caused by neutron interactions. This study shows that transmutation doping can help to counteract and slow this process. This research shows that SiC can be used in nuclear reactor components contrasting with more costly and complicated alternative materials.
36 - MATERIALS SCIENCE↗
Genes for enhancing drought and heat tolerance in plants and methods of use
The present disclosure provides methods for increasing drought resistance and heat resistance of a plant. The methods encompass expression of at least one heat shock protein (HSP) from the group consisting of HSP40, HSP60 or HSP70 together with a phosphoenolpyruvate carboxylase (PEPC) comprising an aspartic acid (D) at a position that corresponds to the position 509 of SEQ ID NO: 4, in the plant. In comparison to a plant not manipulated in this manner, the disclosed, genetically-modified, plants display improved drought resistance and heat resistance. Also provided are plants that can be obtained by the method according to the invention, and nucleic acid vectors to be used in the described methods.
Yang, Xiaohan↗
Increase resistance for efficient heating
Conductors for use in heating systems are provided. The conductors are configured to have an extended current path for the current and increased resistance as seen by the current. The heating system may be an induction system. For example, the conductor may comprise a conductive material having a surface which faces an induction coil of an oscillating circuit. This surface may have a predetermined pattern of peaks and valleys. The peaks and valleys form a non-linear current path for the induced current when exposed to an electromagnetic field generated by the oscillating circuit. Other conductors such as a heat pipe may be used. The pipe may have walls with varying thicknesses over its length. The varying thicknesses may include a first thickness and a second thickness which alternate. The heat pipe may be used in an induction or direct contact heating system where AC is directly applied to the pipe.
Kisner, Roger A.↗
Thermal analysis of RHIC arc dipole magnet cold mass with EIC beam screen
The existing RHIC storage rings – including their superconducting magnet arcs – will be used for the hadron storage ring of the Electron-Ion Collider (EIC). The vacuum chamber of these magnets was not designed for the EIC hadron beams, with shorter bunches and of higher average current than the RHIC beams. With the current stainless steel beam pipe, the resistive-wall (RW) heating will exceed the dynamic heat load budget. Limiting the RW heating is important to prevent the superconducting magnets from quenching and to maintain a low screen temperature necessary to impede the rise of RW heating (higher resistance at higher temperature) as well as to achieve desired ultra-high vacuum. In addition, simulations predict the formation of electron cloud which would further contribute to the dynamic heat load and could compromise the quality and stability of the beam. To reduce the resistive-wall heating and suppress electron cloud, a beam screen will be installed in the vacuum chamber of the RHIC SC magnets. The screen will have a high RRR copper layer at its inner face – useful to reduce the resistive-wall impedance thanks to its high conductivity especially at cryogenic temperatures – and will be coated with a thin layer of amorphous carbon, a material with low secondary electron yield to suppress the formation of electron clouds. The baseline solution envisages a screen that will be cooled by thermal contact to the 4.55 K beam pipe. Detailed thermal analysis have been conducted in ANSYS 2020 for an arc dipole cold mass equipped with a beam screen in order to study the feasibility of a passively-cooled screen and guide its design. Temperature-dependent thermal conductivity properties of all materials in the operating (cryogenic) temperature range are considered. Suitable assumptions and simplifications are made to model the magnet coil and calculate its homogenized thermal conductivity. Sensitivity studies with respect to layer thicknesses and area of contact are carried out and results are presented.
43 PARTICLE ACCELERATORS↗
Anomalous resistivity and electron heating by lower hybrid drift waves inside reconnecting current sheets
Inside an electron diffusion region of laboratory reconnection experiments, the quasi-electrostatic lower hybrid drift wave (ES-LHDW) is observed when a significant guide field component is present. Through direct measurement of the anomalous drag term and quasilinear analysis, it is shown that ES-LHDW can account for approximately 20% of the mean reconnection electric field in a case with moderate guide field. This value exceeds the contribution from classical resistivity, which is around 10%. The effects of the Lorentz force term, often neglected for electrostatic waves, are crucial for the observed correlation between electric field and density fluctuations. Anomalous electron heating by the perturbed current and resistivity (2.6 MW/m 3 ) also surpasses the classical Ohmic heating, which is about 2.0 MW/m 3 . For the case with a high guide field, significantly higher local electron temperatures were observed during periods of strong ES-LHDW activity. A statistical analysis further supports electron heating by LHDW, showing a larger increase in electron temperature with a high guide field. Finally, data from the Magnetospheric Multiscale mission provide evidence of Landau damping of ES-LHDW, suggesting that ES-LHDW may contribute to the generation of nonthermal electrons along the direction parallel to the magnetic field.
Magnetic reconnection↗
Different Damp-Heat-Induced Series Resistance Degradation Behaviors in Fielded Crystalline Silicon Photovoltaic Modules Due to Difference in Bill of Materials
This case study investigates mono-crystalline silicon modules from underperforming portions of a utility-scale photovoltaic power plant. Field-collected I-V curves and electroluminescence imaging suggested that increased series resistance was a primary factor driving module degradation. Selected modules were removed from the field for further analysis, including incremental damp heat accelerated testing, which confirmed a progression in series resistance degradation. Two distinct cell degradation behaviors became apparent during the investigation. Cross-sectional scanning electron microscopy (with elemental analysis) and scanning spreading resistance microscopy identified key differences between the two degradation mechanisms, primarily grid finger width and contact resistance. Additionally, the study highlights the reliability implications of retest requirements in International Electrotechnical Commission 61215 for material changes and how they may have mitigated the degradation observed at this site.
14 SOLAR ENERGY↗