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DOE OSTI2020

Molten Chloride Thermophysical Properties, Chemical Optimization, and Purification

Next-generation concentrating solar power (CSP) technology requires high-temperature heat-transfer fluids and thermal energy storage that can operate in the temperature range of 500°–720°C. This high temperature demands a new chemistry for the heat-transfer fluids that must have high-temperature thermal and chemical stabilities, high energy density, and low corrosion rate on metallic materials used in the heat exchangers, piping, and thermal energy storage tanks. A ternary MgCl 2 -KCl-NaCl chloride-salt system has been proposed to achieve such goals, given its high-temperature thermal stability. The chloride-salt-based systems have been used by the metallurgy industry as the electrolyte to electrolytically extract metallic magnesium. They have also attracted attentions from the nuclear industry for developing the molten salt fast reactors that can operate at close to atmospheric pressure and at higher temperature than traditional light-water reactors. However, the corrosion properties of the ternary salt are not well known. The corrosion mechanism is believed to be correlated to the presence of MgOHCl impurity at the operation temperature. MgOHCl is fundamentally caused by the hygroscopic nature of the MgCl 2 component. Therefore, the first key objective of this project is to understand the nature of the corrosiveness of the ternary chloride-salt system and its prevention by designing new lab-scale purification processes. Because of its importance, a working group called the Chloride Salt Collective across multiple U.S. Department of Energy national laboratories is established to gain experimental agreement on the corrosion behaviors. In addition, water generation during salt dehydration could lead to highly corrosive HCl/water mixture via a hydrolysis process between water and anhydrous MgCl 2 or MgCl 2 hydrates. MgOHCl will eventually be converted to MgO particulates regardless of the chemical path chosen (i.e., by thermal decomposition, chemical purification with an active metal, or electrochemical purification utilizing the reduction power of electron flows). Large MgO particles with high hardness can wear out bearing and bushing and even clog the delicate channels in the primary heat exchanger. Because of this, a second objective is to understand the chemistry behind salt purification and transfer the scientific understanding to a set of engineering know-how for large-scale salt melter design. Because there is limited information on the thermophysical properties and the sensitivity of these properties around the targeted salt composition, a third objective is to measure thermophysical properties relevant to system and component design and support Topic 1 Liquid Pathway development. For example, composition shift due to salt reaction with water can be a potential issue because it can lead to changes of thermophysical properties, such as (1) melting point (or freeze point), which can jeopardize safe operation of the supercritical CO 2 power cycle proposed for next-generation CSP, and (2) heat capacity and density, which can decrease the overall power-generation capability of the plants. The value of the thermal conductivity of the selected salt composition is also a critical criterion for the solar receiver design.

14 SOLAR ENERGY↗

DOE OSTI2021

Characteristics of Ultralow Aspect Ratio Toroidal Plasmas and Non-Solenoidal Startup and Edge Stability Studies at Near-Unity Aspect Ratio (Final Report)

This grant supported a long-term research and development program to explore the physics and technology of spherical tokamak (ST) plasma behavior at near-unity aspect ratio ( A ). The PEGASUS Toroidal Experiment is a university-scale ( R ) ~ 0.40 m, α ~ .35 m, I p ≤ 0.3 MA, B T ≤ 0.15 T) experiment that accesses A → 1, to provide large values of the normalized plasma current, I N = I p /α B T , or equivalently the toroidal field utilization factor I p / I TF . The research activities focused on: 1) developing the technique of Local Helicity Injection (LHI) as a viable means of initiating and growing an ST plasma without the use of a central solenoid; 2) exploring the equilibrium and stability properties of spherical tokamak plasmas at extremely low aspect ratio; and 3) obtaining new insights in the properties of the enhanced confinement H-mode regime at A ~ 1. The initial (Phase I) facility employed a unique high-stress central solenoid Ohmic for current drive and heating with simple magnet current waveforms. A subsequent major upgrade (Phase II) offered more flexible control of the plasma evolution along with a powerful LHI system for plasma initiation, heating and sustainment. The LHI technique consists of injection of high-density current streams into vacuum toroidal and vertical magnetic fields. These streams become unstable and support magnetic reconnection to allow the system to relax into a tokamak-like magnetic configuration. This program focused on: 1) development of electron current sources that provide sufficiently high injection currents in the challenging edge plasma region; 2) validation of theoretical limits to achievable I p arising from magnetic helicity and energy conservation plus absolute limits arising from relaxation to a minimal energy states; 3) tests of a power balance model to describe the evolution of the plasma current I p (t); and 4) study of magnetic fluctuations and their role in the I p evolution. This culminated in the production of toroidal currents of I p ≥ 0.2 MA with only ~8 kA of injected current. Operation with Ohmic induction alone in Phase I created plasmas with soft limits on the achievable I p and field utilization ( I p / I TF ~ 1) due to the onset of large low-order (2/1 or 3/2) internal resonant tearing modes. With the expanded capabilities in Phase II operation, methods employed to mitigate those modes and achieve I p / I TF > 1 were: 1) I TF ramp-downs; 2) non-solenoidal startup via LHI; and 3) extremely low I TF Ohmic operations assisted by LHI current injector pre-ionization. Extensive use of LHI-driven startup and drive for non-solenoidal operation produced favorable current profiles to stably operate tokamak plasmas with unprecedentedly high I N = I p / aB T ~ 15 and I p / I TF > 2. With strong reconnection-driven anomalous ion heating, this in turn provided access to tokamak plasmas with B t up to 100%, a world record 2 times higher than that previously achieved in advanced or spherical tokamaks. This high B t regime had a large fraction (~50%) of the plasma volume in a region of an absolute minimum- B configuration. The MHD stability limit in this regime was the ideal external kink mode without a stabilizing wall. These results provided the first demonstration of access to tokamak plasmas with very high B t , high i N , high elongation κ, and low internal inductance ℓ i , and as such served as a proof-ofprinciple for access to this long-sought ST regime. The naturally low B T needed for stability at A ≤ 1.2 reduces the L-H mode power threshold, P LH , so that H-mode plasmas were achieved with Ohmic heating alone. The power threshold for the transition to the H-mode regime was found to be 10× the accepted values from the ITER international scaling, confirming initial trends indicated by experiments on MAST and NSTX, and suggesting that the physics behind this transition is not yet fully understood. The density dependence of the transition and the observed insensitivity to whether the plasma is bounded by a limiter or magnetic divertor are consistent with the recent FM 3 model. Multiple unstable toroidal magnetic modes were measured during ELM (Edge Localized Mode) crashes, with generally lower toroidal mode numbers than seen at higher A , which was attributed to the larger peeling mode instability drive at low A . First-ever edge current profile measurements through an ELM crash showed current-carrying filaments were generated, as seen in ELM simulations and in electromagnetic blob transport theory.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1993

Attitude control of the LACE satellite: A gravity gradient stabilized spacecraft

The Low-power Atmospheric Compensation Experiment (LACE) satellite was launched in February 1990 by the Naval Research Laboratory. The spacecraft's pitch and roll are maintained with a gravity gradient boom and a magnetic damper. There are two other booms with much smaller tip masses, one in the velocity direction (lead boom) of variable length and the other in the opposite direction (balance boom) also of variable length. In addition, the system uses a momentum wheel with its axis perpendicular to the plane of the orbit to control yaw and keep these booms in the orbital plane. The primary LACE experiment requires that the lead boom be moved to lengths varying from 4.6 m to 45.7 m. This and other onboard experiments require that the spacecraft attitude remain within tight constraints while operating. The problem confronting the satellite operators was to move the lead boom without inducing a net spacecraft attitude disturbance. A description of a method used to change the length of the lead boom while minimizing the disturbance to the attitude of the spacecraft is given. Deadbeating to dampen pitch oscillations has also been accomplished by maneuvering either the lead or balance boom and is discussed.

Ivory, J. E.↗

NASA NTRS1973

Simulator evaluation of the low-speed flying qualities of an experimental STOL configuration with an externally blown flap wing or an augmentor wing

The low-speed flying qualities of an experimental STOL configuration were evaluated by using a fixed-base six-degree-of-freedom simulation. The configuration had either an externally blown flap (EBF) wing or an augmentor wing (AW). The AW configuration was investigated with two tails, one sized for the AW configuration and a larger one sized for the EBF configuration. The emphasis of the study was on the 70-knot approach task. The stability and control characteristics were compared with existing criteria. Several control systems were investigated for the normal four-engine condition and for the engine-out transient condition. Minimum control and stall speeds were determined for both the three- and four-engine operation.

Powers, B. G.↗

NASA NTRS1976

DSN research and technology support

The activities of the Venus Station (DSS 13) and the Microwave Test Facility (MTF) during the period April 19 through June 13, 1976, are discussed and progress noted. Continuing reliability testing and computer program refinement of the remote controlled, unattended automated pulsar observing station is noted, along with routine observations of 17 pulsars. Radar observations of a geostationary satellite are reported, along with the routine automatic testing of the stability of the DSS 13 maser-receiving system. Additional testing of thermal characteristics of semiflexible coaxial cables is reported, along with phase stabilization measurements thereon. Routine support of the planetary radio astronomy experiment, with 43.25 hours of observations of Jupiter and various radio calibration sources, is reported, along with 18.75 hours of differential VLBI observations in conjunction with Australia, DSS 43. Modifications of the clock synchronization winterization system are reported, along with a discussion of the activities of the DSN High-Power Transmitter Maintenance Facility.

Jackson, E. B.↗

NASA NTRS1991

Computing Linear Mathematical Models Of Aircraft

Derivation and Definition of Linear Aircraft Model (LINEAR) computer program provides user with powerful, and flexible, standard, documented, and verified software tool for linearization of mathematical models of aerodynamics of aircraft. Intended for use in software tool to drive linear analysis of stability and design of control laws for aircraft. Capable of both extracting such linearized engine effects as net thrust, torque, and gyroscopic effects, and including these effects in linear model of system. Designed to provide easy selection of state, control, and observation variables used in particular model. Also provides flexibility of allowing alternate formulations of both state and observation equations. Written in FORTRAN.

Duke, Eugene L.↗

NASA NTRS2007

Correlation between Mechanical Behavior and Actuator-type Performance of Ni-Ti-Pd High-temperature Shape Memory Alloys

High-temperature shape memory alloys in the NiTiPd system are being investigated as lower cost alternatives to NiTiPt alloys for use in compact solid-state actuators for the aerospace, automotive, and power generation industries. A range of ternary NiTiPd alloys containing 15 to 46 at.% Pd has been processed and actuator mimicking tests (thermal cycling under load) were used to measure transformation temperatures, work behavior, and dimensional stability. With increasing Pd content, the work output of the material decreased, while the amount of permanent strain resulting from each load-biased thermal cycle increased. Monotonic isothermal tension testing of the high-temperature austenite and low temperature martensite phases was used to partially explain these behaviors, where a mismatch in yield strength between the austenite and martensite phases was observed at high Pd levels. Moreover, to further understand the source of the permanent strain at lower Pd levels, strain recovery tests were conducted to determine the onset of plastic deformation in the martensite phase. Consequently, the work behavior and dimensional stability during thermal cycling under load of the various NiTiPd alloys is discussed in relation to the deformation behavior of the materials as revealed by the strain recovery and monotonic tension tests.

Bigelow, Glen S.↗

NASA NTRS2014

Intensity-Modulated Continuous-Wave Laser Absorption Spectrometer at 1.57 Micrometer for Atmospheric CO2 Measurements

Understanding the earth's carbon cycle is essential for diagnosing current and predicting future climates, which requires precise global measurements of atmospheric CO2 through space missions. The Active Sensing of CO2 Emissions over Nights, Days, and Seasons (ASCENDS) space mission will provide accurate global atmospheric CO2 measurements to meet carbon science requirements. The joint team of NASA Langley Research Center and ITT Exelis, Inc. proposes to use the intensity-modulated, continuous-wave (IM-CW) laser absorption spectrometer (LAS) approach for the ASCENDS mission. Prototype LAS instruments have been developed and used to demonstrate the power, signal-to-noise ratio, precision and accuracy, spectral purity, and stability of the measurement and the instrument needed for atmospheric CO2 observations from space. The ranging capability from laser platform to ground surfaces or intermediate backscatter layers is achieved by transmitted range-encoded IM laser signals. Based on the prototype instruments and current lidar technologies, space LAS systems and their CO2 column measurements are analyzed. These studies exhibit a great potential of using IM-CW LAS system for the active space CO2 mission ASCENDS.

Lin, Bing↗

NASA NTRS2014

Intensity-Modulated Continuous-Wave Lidar at 1.57 Micrometer for Atmospheric CO2 Measurements

Understanding the earth's carbon cycle is essential for diagnosing current and predicting future climates, which requires precise global measurements of atmospheric CO2 through space missions. The Active Sensing of CO2 Emissions over Nights, Days, and Seasons (ASCENDS) space mission will provide accurate global atmospheric CO2 measurements to meet carbon science requirements. The joint team of NASA Langley Research Center and ITT Exelis, Inc proposes to use the intensity-modulated, continuous-wave (IM-CW) lidar approach for the ASCENDS mission. Prototype instruments have been developed and used to demonstrate the power, signal-to-noise ratio, precision and accuracy, spectral purity, and stability of the measurement and the instrument needed for atmospheric CO2 observations from space. The ranging capability from laser platform to ground surfaces or intermediate backscatter layers is achieved by transmitted range-encoded IM laser signals. Based on the prototype instruments and current lidar technologies, space lidar systems and their CO2 column measurements are analyzed. These studies exhibit a great potential of using IM-CW lidar system for the active space CO2 mission ASCENDS.

Lin, Bing↗

NASA NTRSDate not supplied

Moderator Considerations for Space Nuclear Power and Propulsion Systems

Nuclear reactors have the potential to provide high energy density to enable sustainable surface power and advanced propulsion methods needed for human exploration activities at the moon and mars. Current mission planning is surveying different reactor types for space power and propulsion application. Of these reactor types, the use of a moderator within the reactor can enable reduced enrichment, reduce overall fuel loadings, and minimize the critical size of the reactor compared to unmoderated reference systems. This proceeding summarizes some moderator materials identified for space reactor applications: zirconium hydride, yttrium hydride, beryllium, and beryllium oxide, and the unique design considerations inherent to surface power and nuclear thermal propulsion reactor designs. It was found that there are four key considerations during the moderator selection and design process: nuclear properties, thermophysical & mechanical properties, manufacture & readiness, and environmental compatibility. Surface power reactors can benefit from moderators which minimize overall system mass and are capable of surviving high temperature irradiation environments for years with little degradation. Nuclear thermal propulsion reactors can benefit from moderators which are capable of retaining structural integrity under multiple burns while being exposed to a wide temperature range (40 < T < 500+ K). Moderator materials which exhibit good stability under irradiation and high temperature operation, minimize fuel pitch, and are high readiness are desirable for near term implementation.

nuclear thermal propulsion↗

DOE OSTI2020

Design and Fabrication of the Mu2e Cryogenic Distribution System

The muon-to-electron conversion (Mu2e) experiment at Fermilab will be used to search for the charged lepton flavor-violating conversion of muons to electrons in the field of an atomic nucleus. The Mu2e experiment is currently in the design and construction stage and is expected to begin operations in 2022. The Mu2e experiment uses four large superconducting solenoid magnets including a Production Solenoid (PS), an Upstream and Downstream Transport Solenoid (TSu and TSd) and a Detector Solenoid (DS). This paper will focus on the cryogenic distribution system for these four solenoid magnets. Liquid helium will be supplied from two re-purposed Tevatron satellite refrigerators. A large cryogenic distribution box (DB) is located in the Mu2e building to distribute the required cryogens to each of the four solenoid magnets. Each solenoid magnet will have a dedicated transfer line and cryogenic feed box (FB). The solenoid magnets each require two liquid helium circuits and two liquid nitrogen circuits. The most unique feature about this cryogenic system is that the assemblies for the start of the superconducting portion of the power leads are mounted in feed boxes that are in the range of 23 m to 31 m away from the solenoid magnets. The cryogenic feed boxes are located remotely to provide protection from radiation damage and high magnetic fields. The power leads are NbTi superconducting cable stabilized with high conductivity aluminum. The 6061-T6 aluminum grade was selected for the transfer line piping so that the piping would thermally contract at the same rate as the power lead. A major concern for this transfer line is that a small helium leak could create an electric discharge arc due to the Paschen effect. This paper includes a description of the design features and testing done to ensure that the power leads are protected from the Paschen effect while still being adequately cooled to liquid helium temperatures.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

Operationalizing Synchrophasors for Enhanced Grid Reliability and Asset Utilization

The report discusses the development of production-grade synchrophasor software applications. The objective is to improve system reliability and asset utilization for offline as well as real-time considerations, as per the Department of Energy (DOE) guidelines specified by Funding Opportunity Announcement (FOA) DE-FOA-0001492. On the one hand, we have developed grid management applications on how to transform synchrophasor-based monitoring into operator guidance, and commercial grade tools addressing industry needs such as NERC Reliability Standards (MOD 26, MOD 27 and MOD 33). On the other hand, with the wide industrial adoption in mind, the developed applications have been fully discussed with utility partners and installed in the utility partners site including 6 field tests. The Model Validation and Calibration software module has been integrated into GE’s PhasorAnalyticsTM. The first commercial contract has been signed even before the close date of this project. The Angle-based Grid Management (AGM), Fast Voltage Security Assessment (FastVSA), Enhanced Islanding Monitoring(EIM) and Enhanced Disturbance Management (EDM) have been integrated into GE’s Grid Stability Assessment line of applications in e-terra Suite of EMS product.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

A Novel Power-Hardware-in-the-Loop Interface Method for Grid-forming Inverter Systems: Preprint

Power Hardware-in-the-Loop (PHIL) simulation of grid-forming (GFM) inverter systems facilitates the testing of drastic scenarios like on-grid to off-grid transition, islanded microgrid operation without stiff grid etc. To the authors best knowledge, most of studies in literature are focused on PHIL simulation for grid-following inverter systems and only few studies are focused on GFM inverters and those are challenging and problematic especially for high-power applications. In this article, a novel PHIL simulation platform is proposed that enables interfacing of high-power GFM inverter systems. It proposes the concept of a virtual GFM inverter as a part of the proposed PHIL interface for GFM inverter. This addition of virtual GFM inverter in the PHIL interface expands the conventional Ideal Transformer Model (ITM) method and enables it to overcome the issues of instability of existing ITM methods. In the validation stage, a PHIL experiment is conducted on a 3-phase 480 V, 125 kVA GFM inverter system with proposed interfacing method. The results corroborates the fact that the proposed PHIL simulation method performs well and stable for GFM inverter system.

grid-forming inverters↗

NASA NTRS2008

Integrated Formation Optical Communication and Estimation System

An architecture has been designed that integrates formation estimation methodologies, precision formation sensing, and high-bandwidth formation communication into a robust, strap-on system that meets knowledge and communication requirements for the majority of planned, precision formation missions. Specifically, the integrated system supports (a) sub-millimeter metrology, (b) multiple greater than 10 Mbps communication channels over a large, 10 deg field-of-view (FOV), and (c) generalized formation estimation methodologies. The sensing sub-system consists of several absolute, metrology gauges with up to 0.1 mm precision that use amplitude-modulated lasers and a LISA-heritage phase meter. Since amplitude modulation is used, inexpensive and robust diode lasers may be used instead of complex, frequency-stabilized lasers such as for nanometer-level metrology. The metrology subsystem laser transceivers consist of a laser diode, collecting optics, and an avalanche photo diode (APD) for detecting incoming laser signals. The APD is necessary since received power is small due to the large (for optical applications) FOV. The phase meter determines the phase of the incoming amplitude modulations as measured by the APD. This phase is equivalent to time-of-flight and, therefore, distance. By placing three laser transceivers on each spacecraft, 18 clock-offset-corrupted distances are calculated. These measurements are communicated and averaged to obtain nine correct distances between the transceivers. From these correct distances, the range and bearing between spacecraft and their relative attitude are determined. Next, communication is integrated on the laser carrier through spectral separation. Metrology amplitude modulations are limited to the 45-50 MHz band, leaving 0-45 MHz for communication. Through careful design of coding scheme, error correction, and filters, six independent 10 Mbps receive channels are possible. Hence, a spacecraft can simultaneously broadcast at 10 Mbps and listen to six other spacecraft. The integrated sensing and communication architecture has been developed, as have formation estimation methodologies that allow the sensing topology to reconfigure as spacecraft maneuver. A bench-top implementation of the integrated sensing and communication architecture is in progress. The final, multiple sensing/communication systems will be tied together via formation estimation algorithms that are also undergoing further development.

Scharf, Daniel↗

DOE OSTI2023

Development of an All-Aqueous Thermally Regenerative Redox Flow Battery to Support Fossil Fuel Assets

Low-temperature thermal energy, a largely untapped resource, holds significant promise for large-scale electrical power generation globally. Various stationary sources, including industrial entities and thermal power plants, emit considerable low-temperature heat that currently remains unutilized. This energy is often overlooked because its low temperature renders it unsuitable for efficient power generation using conventional methods. However, current research is exploring diverse technologies capable of converting low-temperature heat into grid-scale power, aiming to enhance grid efficiency, further decarbonization initiatives, and facilitate a shift toward more decentralized power systems. One such innovative technology is the thermally regenerative battery (TRB), noted for its high power and energy densities compared to similar technologies, positioning it as a potential game-changer in power generation. TRBs integrate two scalable and well-established unit operations: a redox flow battery and a distillation column. This integration suggests that once an effective TRB chemistry is established, the pathway to commercialization could be expedited. The copper-based thermally regenerative ammonia battery (Cu aq -TRAB) stands out as the first TRB that circumvents electrodeposition/dissolution reactions, stabilizing Cu(I) and Cu(II) within the electrolyte and maintaining stability of all electroactive species in an aqueous phase. This stabilization has led to improvements in coulombic efficiency, open circuit potential, and copper solubility, thereby enhancing power density, energy density, and overall energy efficiency. Preliminary tests were conducted to determine the effects of various electrolyte species on the performance metrics of the battery, both theoretically and experimentally. These tests revealed that the solubility of copper in the Cu aq -TRAB electrolyte was constrained by the Cu(I)-NH 3 complex. Adjusting the background electrolyte to 5 M NH4Br and the ligand concentration to 4 M NH 3 enabled the copper concentration to reach a maximum of 0.6 M. This modification led to an estimated theoretical maximum energy density of 9.5 Wh L -1 for the Cu aq -TRAB. Additionally, full cell testing indicated a tradeoff between peak power and energy density with varying copper and ammonia concentrations. Increasing the applied current density during discharge linearly raised the average power output, with a minimal reduction in energy density due to a balance between higher ohmic overpotential and reduced time for undesirable ammonia crossover. Furthermore, a comprehensive numerical sensitivity analysis of the complete Cu aq -TRAB system was performed. This analysis aimed to assess how the battery and the distillation column responded to changes in system input parameters, providing insights into optimal research directions for enhancing system performance. The analysis revealed that at room temperature, battery power was significantly more sensitive to ohmic losses than to mass transfer, with reaction rates having minimal impact. This trend continued even at higher temperatures. Also, the thermal energy required for ammonia separation was studied, showing that increased temperatures generally reduced energy requirements, except in low-pressure scenarios above 65 °C. An investigation into membrane performance in the Cu aq -TRAB was undertaken, given the significant impact of ammonia transport control and ohmic losses on system performance. Various membranes were evaluated to identify key performance metrics. Among the tested membranes, Selemion CMVN exhibited the highest performance, with a peak power density of 84 mW cm -2 and average values of 26 ± 6.8 mW cm -2 for power density and 2.9 Wh L -1 for energy density at an applied current density of 50 mA cm -2 . An economic assessment indicated a levelized cost of storage at $410 per MWh under optimal conditions, highlighting the commercial potential of the Cu aq -TRAB when utilizing cost-effective, readily available materials.

25 ENERGY STORAGE↗

DOE OSTI2023

Operating-Envelopes-Aware Decentralized Welfare Maximization for Energy Communities

We propose an operating-envelope-aware, prosumer-centric, and efficient energy community that aggregates individual and shared community distributed energy resources and transacts with a regulated distribution system operator (DSO) under a generalized net energy metering tariff design. To ensure safe network operation, the DSO imposes dynamic export and import limits, known as dynamic operating envelopes, on end-users' revenue meters. Given the operating envelopes, we propose an incentive-aligned community pricing mechanism under which the decentralized optimization of community members' benefit implies the optimization of overall community welfare. The proposed pricing mechanism satisfies the cost-causation principle and ensures the stability of the energy community in a coalition game setting. Numerical examples provide insights into the characteristics of the proposed pricing mechanism and quantitative measures of its performance.

distributed energy resources aggregation↗

DOE OSTI2023

FWP FEAA149: “Next Generation Environmental Barrier Coatings”

Environmental barrier coatings (EBCs) are required coatings for utilization of SiC/SiC ceramic matrix composite (CMC) components in gas turbines, where the EBC represents the life-limiting factor for such components. EBC/CMC systems have shown success in aero-engine applications with increased turbine inlet temperatures and improved efficiencies, which are achieved through higher temperature stability, lower density, and decreased reliance on cooling air compared to traditional superalloys. While industrial gas turbines (IGTs) do not currently utilize SiC/SiC CMCs, the current shift towards low-carbon or carbon-free fuel sources for power generation could result in a need for EBC/CMC components with higher temperature capabilities. In this work, three tasks were outlined to improve understanding of EBC lifetimes to encourage use in IGTs with carbon-free fuel such as hydrogen: 1. Define the bond coating oxidation kinetics and EBC failure criteria, 2. Measure thermal expansion coefficients of each layered material, and 3. Perform advanced characterization and modeling to assess EBC lifetimes. Cyclic steam oxidation tests were conducted on various EBC/Si/SiC chemistries and EBC/SiC architectures to define substrate oxidation kinetics and EBC failure modes. An open-source code was developed to quantify the undulating thermally grown oxide thickness with thousands of measurements from specimen cross-section images. Bond coating oxidation kinetics were determined and used to develop a kinetic and thermodynamic model for predicting EBC lifetimes. High-temperature Raman spectroscopy was utilized for determining the SiO 2 thermally grown oxide phase transformation as the life-limiting feature for EBCs. Model efforts supported the claim that the SiO 2 phase transformation causes elevated stress during thermal cycling with associated cracking that decreases the adhesion strength of the EBC, eventually resulting in coating spallation. The finite element model subroutine will be made publicly available upon internal review. Further development of an EBC lifetime model for IGTs involves definition of a critical SiO 2 thickness for EBC spallation and must also consider both environmental (gas velocity, pressure, etc.) and specimen (EBC dopants, layer architectures, etc.) effects into predicted bond coating oxidation kinetics for long-lifetime components.

36 MATERIALS SCIENCE↗

NASA NTRS1982

Stabilized Acoustic Levitation of Dense Materials Using a High-Powered Siren

Stabilized acoustic levitation and manipulation of dense (e.g., steel) objects of 1 cm diameter, using a high powered siren, was demonstrated in trials that investigated the harmonic content and spatial distribution of the acoustic field, as well as the effect of sample position and reflector geometries on the acoustic field. Although further optimization is possible, the most stable operation achieved is expected to be adequate for most containerless processing applications. Best stability was obtained with an open reflector system, using a flat lower reflector and a slightly concave upper one. Operation slightly below resonance enhances stability as this minimizes the second harmonic, which is suspected of being a particularly destabilizing influence.

Gammell, P. M.↗