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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 1,261 records · Page 70
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Manufacturing Improvement Program for the Oil and Gas Industry Supply Chain and Marketing Cluster

This project supported upgrades for manufacturing companies in the oil and natural gas supply chain in Oklahoma. The goal is to provide assistance that will lead to the improved efficiency advancement of the manufacturing processes currently used by the existing manufacturing clients. The basis for the work is to improve the economic environment for the clients and the communities they serve.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2016

Roll-to-Roll Advanced Materials Manufacturing DOE Lab Consortium - FY16 Annual Report

A DOE laboratory consortium comprised of ORNL, ANL, NREL and LBNL, coordinating with Kodak’s Eastman Business Park (Kodak) and other selected industry partners, was formed to address enhancing battery electrode performance and R2R manufacturing challenges. The objective of the FY 2016 seed project was to develop a materials genome synthesis process amenable to R2R manufacturing and to provide modeling, simulation, processing, and manufacturing techniques that demonstrate the feasibility of process controls and scale-up potential for improved battery electrodes. The research efforts were to predict and measure changes and results in electrode morphology and performance based on process condition changes; to evaluate mixed, active, particle size deposition and drying for novel electrode materials; and to model various process condition changes and the resulting morphology and electrode performance.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Tribal Colleges and Universities/American Indian Research and Education Initiatives Advanced Manufacturing Technical Assistance Project

The overall goal of this project is to establish a network of TCUs with essential advanced manufacturing (AM) facilities, associated training and education programs, and private sector and federal agency partnerships to both prepare an American Indian AM workforce and create economic and employment opportunities within Tribal communities through design, manufacturing, and marketing of high quality products. Some examples of high quality products involve next generation grid components such as mechanical energy storage, cabling for distribution of energy, and electrochemical energy storage enclosures. Sandia National Laboratories (Sandia) is tasked to provide technical advising, planning, and academic program development support for the TCU/American Indian Higher Education Consortium (AIHEC) Advanced Manufacturing Project. The TCUs include Bay Mills Community College (BMCC), Cankdeska Cikana Community College (CCCC), Navajo Technical University (NTU), Southwestern Indian Polytechnic Institute (SIPI), and Salish Kooteani College. AIHEC and Sandia, with collaboration from SIPI, will be establishing an 8-week summer institute on the SIPI campus during the summer of 2017. Up to 20 students from TCUs are anticipated to take part in the summer program. The goal of the program is to bring AM science, technology, engineering, and mathematics (STEM) awareness and opportunities for the American Indian students. Prior to the summer institute, Sandia will be providing reviews on curriculum plans at the each of the TCUs to ensure the content is consistent with current AM design and engineering practice. In addition, Sandia will provide technical assistance to each of the TCUs in regards to their current AM activities.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2017

Manufacturing Process for OLED Integrated Substrate

The main objective of this project was to develop a low-cost integrated substrate for rigid OLED solid-state lighting produced at a manufacturing scale. The integrated substrates could include combinations of soda lime glass substrate, light extraction layer, and an anode layer (i.e., Transparent Conductive Oxide, TCO). Over the 3 + year course of the project, the scope of work was revised to focus on the development of a glass substrates with an internal light extraction (IEL) layer. A manufacturing-scale float glass on-line particle embedding process capable of producing an IEL glass substrate having a thickness of less than 1.7mm and an area larger than 500mm x 400mm was demonstrated. Substrates measuring 470mm x 370mm were used in the OLED manufacturing process for fabricating OLED lighting panels in single pixel devices as large as 120.5mm x 120.5mm. The measured light extraction efficiency (calculated as external quantum efficiency, EQE) for on-line produced IEL samples (>50%) met the project’s initial goal.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Additive Manufacturing of Dense Hexagonal Boron Nitride Objects

The feasibility of manufacturing hexagonal boron nitride objects via additive manufacturing techniques was investigated. It was demonstrated that it is possible to hot-extrude thermoplastic filaments containing uniformly distributed boron nitride particles with a volume concentration as high as 60% and that these thermoplastic filaments can be used as feedstock for 3D-printing objects using a fused deposition system. Objects 3D-printed by fused deposition were subsequently sintered at high temperature to obtain dense ceramic products. In a parallel study the behavior of hexagonal boron nitride in aqueous solutions was investigated. It was shown that the addition of a cationic dispersant to an azeotrope enabled the formulation of slurries with a volume concentration of boron nitride as high as 33%. Although these slurries exhibited complex rheological behavior, the results from this study are encouraging and provide a pathway for manufacturing hexagonal boron nitride objects via robocasting.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Additive Manufacturing of Wind Turbine Molds

The objective of this project was to explore the utility of Big Area Additive Manufacturing (BAAM) for low cost manufacturing of wind turbine molds. Engineers at Oak Ridge National Laboratory (ORNL) and TPI Composites (TPI) collaborated to design and manufacture a printed mold that can be used for resin infusion of wind turbine components. Specific focus was on required material properties (operating temperatures and pressures, coefficient of thermal expansion (CTE), thermal conductivity), surface finish (accuracy and coatings) and system integration (integrated vacuum ports, and heating element). The project began with a simple proof of principle components, targeting surface coatings and material properties for printing a small section (approximately 4’ x 4’ x 2’) of a mold. Next, the second phase scaled up and integrated with the objective of capturing all of the necessary components (integrated heating to accelerate cure time, and vacuum, sealing) for resin infusion on a mold of significant size (8’ x 20’ x 6’).

17 WIND ENERGY↗
DOE OSTI2017

Evaluation of Advanced Polymers for Additive Manufacturing

The goal of this Manufacturing Demonstration Facility (MDF) technical collaboration project between Oak Ridge National Laboratory (ORNL) and PPG Industries, Inc. (PPG) was to evaluate the feasibility of using conventional coatings chemistry and technology to build up material layer-by-layer. The PPG-ORNL study successfully demonstrated that polymeric coatings formulations may overcome many limitations of common thermoplastics used in additive manufacturing (AM), allow lightweight nozzle design for material deposition, and increase build rate. The materials effort focused on layer-by-layer deposition of coatings with each layer fusing together. The combination of materials and deposition results in an additively manufactured build that has sufficient mechanical properties to bear the load of additional layers, yet is capable of bonding across the z-layers to improve build direction strength. The formulation properties were tuned to enable a novel, high-throughput deposition method that is highly scalable, compatible with high loading of reinforcing fillers, and inherently low-cost.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Additive Manufacturing of Molds for Fabrication of Insulated Concrete Block

Oak Ridge National Laboratory (ORNL) worked with concrete block manufacturer, NRG Insulated Block, to demonstrate additive manufacturing of a multi-component block mold for its line of insulated blocks. Solid models of the mold parts were constructed from existing two-dimensional drawings, and the parts were fabricated on a Stratasys Fortus 900 using ULTEM™ 9085. Block mold parts were delivered to NRG and installed on one of their fabrication lines. While form and fit were acceptable, the blocks made from the molds collapsed when extruded from the printed molds during NRG’s testing. However, the project demonstrated significant time and cost reductions and achieving proper functionality through the use of different additive manufacturing techniques.

42 ENGINEERING↗
DOE OSTI2017

Innovative High-Performance Deposition Technology for Low-Cost Manufacturing of OLED Lighting

In this project, OLEDWorks developed and demonstrated the innovative high-performance deposition technology required to deliver dramatic reductions in the cost of manufacturing OLED lighting in production equipment. The current high manufacturing cost of OLED lighting is the most urgent barrier to its market acceptance. The new deposition technology delivers solutions to the two largest parts of the manufacturing cost problem – the expense per area of good product for organic materials and for the capital cost and depreciation of the equipment. Organic materials cost is the largest expense item in the bill of materials and is predicted to remain so through 2020. The high-performance deposition technology developed in this project, also known as the next generation source (NGS), increases material usage efficiency from 25% found in current Gen2 deposition technology to 60%. This improvement alone results in a reduction of approximately 25 USD/m 2 of good product in organic materials costs, independent of production volumes. Additionally, this innovative deposition technology reduces the total depreciation cost from the estimated value of approximately 780 USD/m 2 of good product for state-of-the-art G2 lines (at capacity, 5-year straight line depreciation) to 170 USD/m 2 of good product from the OLEDWorks production line.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

BAAM Additive Manufacturing of Magnetically Levitated Wind Turbine

ORNL worked with Hover Energy LLC (Hover) on the design of Big Area Additive Manufacturing (BAAM) extrusion components. The objective of this technical collaboration was to identify and evaluate fabrication of components using alternative additive manufacturing techniques. Multiple candidate parts were identified. A design modification to fabricate diverters using additive manufacturing (AM) was performed and the part was analyzed based on anticipated wind loading. Scaled versions of two parts were printed using the BAAM for wind tunnel testing.

17 WIND ENERGY↗
DOE OSTI2018

Feasibility of Using Additive Manufacturing to Produce Automotive Tooling

Oak Ridge National Laboratory’s (ORNL) Manufacturing Demonstration Facility (MDF) worked with Diversified Tooling Group (DTG) in phase I of this technical collaboration to determine the feasibility of using additive manufacturing to produce automotive tooling using polymer Big Area Additive Manufacturing (BAAM) systems and will potentially work with DTG in phase II on metal BAAM systems. The following phase I goals in polymer BAAM were met: a polymer sheet metal check fixture and a polymer foundry casting pattern were completed and shipped to DTG.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Manufacturing Induced Residual Stress Development and Deformation in PMDI-10 Structural Foam

In this report, we investigate how manufacturing conditions result in the warpage of moderate density PMDI polyurethane foam (12-50 lb/ft 3 ) when they are released from a mold. We have developed a multiphysics modeling framework to simulate the manufacturing process including resin injection, foaming and mold filling, gelation of the matrix, elevated cure, vitrification, cool down, and demolding. We have implemented this framework within the Sierra Mechanics Finite Element Code Suite. We couple Aria for flow, energy conservation, and foaming/curing kinetics with Adagio for the nonlinear viscoelastic solid response in a multi-staged simulation process flow. We calibrate a model for the PMDI-10S (10 lb/ft 3 free rise foam) through a suite of characterization data presented here to calibrate the solid cure behavior of the foam. The model is then used and compared to a benchmark experiment, the manufacturing and warpage over 1 year of a 10 cm by 10 cm by 2.5 cm foam "staple". This component features both slender and thick regions that warp considerably differently over time. Qualitative agreement between the model and the experiment is achieved but quantitative accuracy is not.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Prototyping and Manufacturing of Magnetic Gearbox Components using Innovations in Castings

This project combines additive manufacturing with the broadly deployed practice of metal casting. Combining these methods will unlock new design possibilities while reducing the economic burden of early stage prototyping while leveraging well established high throughput sand casting. Two main approaches are evaluated: direct printing of single use sand molds and printing of reusable impression patterns used to create sand molds. Reusable impression molds typically can be used to produce hundreds to several thousands of casting thereby amplifying the function of the 3D printed replica mold. Emrgy’s newly developed and tested proprietary magnetic gearbox system for low head hydroelectricity generation was the subject part of this study. Leveraging ORNL’s additive manufacturing capability and expertise, a pattern impression was produced and used to create multiple sand molds of the gearbox during phase 1. Even before considering the cost savings possible once rigging and pattern mounting is optimized through repetition and improved design, final part costs using this combined method resulted in an 80% cost reduction over EMRGY’s previous method of subtractive manufacturing for gearbox production.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Additive Manufacturing of Sensors and Components for Non-Destructive Evaluation Applications

Additively manufactured machine components were designed for use in non-destructive evaluations. Additive manufacturing (3D printing) enables rapid production of simple or complex objects at a low cost for use in many fields of research and industry. 3D printed components were used to optimize an eddy current array probe to inspect various complex shaped objects, such as gears. Preliminary eddy current inspections were conducted to test the functionality and compatibility of the 3D printed components to the array probe and existing system. These were done by wrapping replica 3D printed gears with aluminum foil. The results were as expected, rough, uneven surface of the aluminum foil. Calibration scans were also executed to enable proper measurement of defect size in metal structures. For use in waveguide-based distributive sensing technologies, additively manufactured custom waveguides were designed for use in liquid environments to collect pressure and flow data. Waveguides were designed with membranes, thin sections of the walls, which would be pressed inward due to fluid pressure. Waveguide models continue to be developed and revised for most functional utility in liquid environments.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Design Considerations Which Can Simplify Manufacturing (U) [Slides]

The purpose of this paper is to recommend design considerations which can significantly reduce the time required to manufacture parts, reducing cost to manufacture parts while increasing the quality of manufactured parts and minimize the likelihood of nonconformance conditions. The product design is ultimately the responsibility of the project engineers and their design teams. This paper is not intended to supersede design requirements.

42 ENGINEERING↗
DOE OSTI2018

FY2017 annual report: Roll-to-Roll Advanced Materials Manufacturing DOE Laboratory Consortium Project

The following report provides a description of the program structure and technical accomplishments made during FY 2017 to overcome challenges for expanding use of R2R technologies and processing for clean energy applications. Technologies are under development that enable enhanced manufacturing of battery electrodes, fuel cells and water separation membranes that take advantage of advancements in new functional materials. Data mining, visualization, modeling and simulation for the materials, technologies and processes being developed allow for improvements in R2R manufacturing applications. This report documents the research conducted by four DOE national laboratories as a consortium in collaboration with industry partnerships. The research is directly applicable to AMM strategies that apply the National Science and Technology Council’s Materials Genome Initiative (NSTC 2011) approach to enhance the performance of battery, fuel cell and water membrane materials. This effort supports building the foundation of technologies, processes and a U.S. manufacturing base that will enable an order of magnitude in shorter process development cycles with the pathway for initial commercialization within months instead of years.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Coatings and Process Development for Reduced Energy Automotive OEM Manufacturing Final Technical Report

The project team successfully developed a new low-temperature coating system that achieves performance, durability, and appearance requirements for an Automotive Original Equipment Manufacturer paint system. This coating system is compatible with current OEM manufacturing paint lines, allowing application to existing manufacturing locations. The new coating system can also save capital expenses for new lines or renovations of existing lines. The new paint system enable energy savings and operational expense savings. DURR has designed a reference system that can serve as the starting point for new or retrofit paint line upgrades to this low temperature coating system. NDSU has developed and demonstrated the value of high-throughput screening for polymers and cure performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

PTT System Performance Evaluation in 3-D Imaging of Calibrated Defects: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Research activity in this project is aimed at developing pulsed thermal tomography (PTT) architecture and algorithms for in-service non-destructive examination (NDE) of additively manufactured (AM) reactor components and materials. Recent advances in AM technology could allow cost-efficient fabrication of parts for operating reactors. However, because of stringent safety requirements, long-term performance of AM reactor components needs to be investigated before AM is widely accepted. Because of the complex shapes and significant surface roughness of components due to layer-by-layer welding process in AM, conventional methods might not be useful for in-service NDE of AM components. PTT is ideally suited for in-service NDE of AM metallic components because the method is non-contact, and offers high resolution #-D imaging of material flaws. The objective of this report is to provide initial evaluate of PTT performance sin detecting calibrated flaws in reactor structural materials. Preliminary COMSOL models were developed to conduct super computing simulations of PTT. In the experimental studies, high strength Stainless Steel 316 and Inconel 718 alloys were considered, as well as lower grade Stainless Steel 304, Nickel 200, and Hastelloy C276. Specimens investigated in this report consisted of approximately 1/4in-thick plates made out of these alloys using conventional manufacturing methods. The calibrated defects were created in the form of flat bottom holes (FBH) drilled in metallic plates. The diameters of FBH's varied from 1mm to 8mm, and their depths below the plate flat surface varied between 1mm and 6mm. The size of the smallest FBH was limited to 1mm because conventional mechanic drills were used for creating the holes. PTT imaging results have shown that 1mm-diameter FBH located 1mm and 2mm below the surface were detectable. Larger size FBH were detectable at greater depth. For example, 6mm-diameter FBH could be detected at 8mm depth. Image contrast varied slightly between the specimens, with the best reconstructions obtained in SS316 and C276 plates. In addition, a 2/3in-thick Inconel 718 nozzle plate produced with additive manufacturing method was imaged with PTT. It was shown that PTT can scan through the plate in approximately 20s. Several modes of 3-D data visualization were explored, including using ImageJ and MATLAB software packages.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗