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At least 1,441 records · Page 80
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Coolant Channel Design for Additively Manufactured Reactor Cores

Additive manufacturing (AM) methods are currently being explored for applications in nuclear reactors to make advanced reactors more efficient, safe, and reliable. The Transformational Challenge Reactor (TCR) program has explored AM for nuclear by designing a high-temperature gas reactor (HTGR) using an AM silicon carbide fuel form with uranium nitride–tristructural isotropic fuel. In this study, we detail the design process for the TCR fuel form’s coolant channels using computational fluid dynamics models with conjugate heat transfer. Additionally, this work discusses how these models were interfaced with other design teams, project milestones, and the agile design method used to mature the reactor design. The methodology deployed was able to create a channel design with lower maximum fuel temperatures and thermal stresses in the fuel form over traditional channel designs that can be manufactured subtractively. These results were achieved with only small manufacturing penalties. Results are discussed and presented on lessons learned for designing AM components for nuclear reactors. Finally, areas of opportunity are discussed for advanced design tools to further automate design activities and optimize reactors with fewer built-in assumptions.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Effect of toolpath in large-format additive manufacturing with bio-derived composites

There has been growing interest in integrating bio-derived composites into Large-format additive manufacturing (LFAM) feedstocks to reduce the use of petroleum-derived materials and reduce the overall carbon footprint of LFAM. However, these materials present unique challenges during manufacturing due to their variability, which can lead to unintended deformations and failures attributable to suboptimal process conditions. While numerical modelling has been extensively employed to simulate numerous manufacturing processes, its application in LFAM with bio-derived composites remains limited. This study addresses this gap by systematically developing a numerical model to simulate the LFAM process using bio-based materials, specifically wood fiber-reinforced polylactic acid (PLA/WF). Experimental investigations were conducted to characterise the thermal and mechanical properties of additively manufactured PLA/WF specimens. Numerical simulations were performed to predict temperature profiles and deformations during LFAM. The effect of varying infill patterns, internal structures, and tool paths on the temperature distribution and deformation of printed parts was explored using the developed model. This article aims to advance the utilisation of bio-derived composites in LFAM systems and provide a comprehensive understanding of the LFAM process. The findings offer valuable insights for optimising process parameters and enhancing the performance of LFAM with bio-based composites.

Large-format additive manufacturing↗
DOE OSTI2017

Elastocaloric cooling of additive manufactured shape memory alloys with large latent heat

The stress-induced martensitic phase transformation of shape memory alloys (SMAs) is the basis for elastocaloric cooling. In this paper, we employ additive manufacturing to fabricate TiNi SMAs, and demonstrate compressive elastocaloric cooling in the TiNi rods with transformation latent heat as large as 20 J g -1 . Adiabatic compression on as-fabricated TiNi displays cooling ΔT as high as -7.5 °C with recoverable superelastic strain up to 5%. Unlike conventional SMAs, additive manufactured TiNi SMAs exhibit linear superelasticity with narrow hysteresis in stress–strain curves under both adiabatic and isothermal conditions. Microstructurally, we find that there are Ti 2 Ni precipitates typically one micron in size with a large aspect ratio enclosing the TiNi matrix. Finally, a stress transfer mechanism between reversible phase transformation in the TiNi matrix and mechanical deformation in Ti 2 Ni precipitates is believed to be the origin of the unique superelasticity behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A mesoscopic digital twin that bridges length and time scales for control of additively manufactured metal microstructures

We present our recent development of an integrated mesoscale digital twin (DT) framework for relating processing conditions, microstructures, and mechanical responses of additively manufactured (AM) metals. In particular, focusing on the laser powder bed fusion technique, we describe how individual modeling and simulation capabilities are coupled to investigate and control AM microstructural features at multiple length and time scales. We review our prior case studies that demonstrate the integrated modeling schemes, in which high-fidelity melt pool dynamics simulations provide accurate local thermal profiles and histories to subsequent AM microstructure simulations. We also report our new mechanical response modeling results for predicted AM microstructures. In addition, we illustrate how our DT framework has been validated through modeling–experiment integration, as well as how it has been practically utilized to guide and analyze AM experiments. Finally, we share our perspectives on future directions of further development of the DT framework for more efficient, accurate predictions and wider ranges of applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Additive manufacturing of multiscale NiFeMn multi-principal element alloys with tailored composition

Nanostructured multi-principal element alloys (MPEAs) have been explored as next-generation engineering materials due to unique mechanical and functional properties which have significant advantages over traditional dilute alloys. However, the practical applications of nanostructured MPEAs are still limited due to the lack of scalable processing approaches to prepare a large quantity of nanostructured MPEAs, as well as lack of an efficient pathway for high-throughput discovery of better functional nanostructured MPEAs within their vast compositional space. Here we tackle these challenges by presenting an integrated approach by combining direct-ink-writing-based additive manufacturing, solid-state sintering, and chemical dealloying to manufacture hierarchically porous MPEAs. The hierarchical structure is comprised of macro- and micro-scale pores introduced via extrusion printing and polymer decomposition during sintering, as well as nanoscale pores formed via chemical dealloying. The macro- and micro-scale pores allow efficient dealloying of a large mass of material as the diffusion length that the corroding medium must penetrate remains at the scale of the ligaments formed after sintering (∼10 μm), despite the large volume of the 3D-printed samples. In addition, this integrated approach enables versatile control of the alloy composition via precisely tuning the ratio of elemental powders in the starting ink, thus offering a pathway for high-throughput discovery of novel functional MPEAs. As a case study, multiscale macro/micro/nanoporous NiFeMn MPEAs with three different compositions were investigated as catalysts to reduce the overpotential of oxygen evolution reaction (OER), where NiFeMn-based electrocatalysts display composition-dependent performance such that the overpotential measured at a current of 0.5 A g −1 for OER increases in the order of Ni 58 Fe 29 Mn 13 ⩽ Ni 64 Fe 26 Mn 10 < Ni 76 Fe 18 Mn 6 . This introduced manufacturing process offers new opportunities for scalable fabrication and rapid screening of nanostructured multi-component complex alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Path Optimization Along Lattices in Additive Manufacturing Using the Chinese Postman Problem

Here, we develop a method for programming minimal time tool paths for single-bead-wide extrusions in additive manufacturing (AM) along an arbitrary lattice. We present a graphical model of the three-dimensional (3D) printing process and use the solution to the Chinese Postman Problem (CPP) to optimize the motion of an extruder on a given mesh. We present some graph theory background and explain how to solve the CPP. We then present experimental results, in which we demonstrate the implementation of the CPP in 3D printing. Last, we explain how our graphical understanding of AM can be further utilized to achieve greater optimization in additive research.

3D printing↗
DOE OSTI2023

Glass Additive and Subtractive Manufacturing of a Fiber Optic Rotary Encoder for Downhole Pressure Sensing

This article presents a fiber optic rotary encoder-based pressure sensor for downhole applications. The rotary encoder, which is composed of an encoding pad and an all-glass optical fiber sensing head, converts the rotation angles of a pressure transducer to digital codes. The optical fiber only serves as the telemetry channel to directly transmit the data in digital format such that the environmental temperature influence and the long-time drift are minimized. The glass additive and subtractive manufacturing (ASM) techniques are used to embed the multichannel optical fibers into a bulk-fused silica glass substrate. Because the fused silica glass shares a similar material property to the optical fiber (e.g., thermal expansion coefficient), the optical fiber sensing head is well sealed and fixed even at an elevated temperature. The picosecond laser blackening technique is used to fabricate the high reflectivity contrast encoding pad with high accuracy. Here, the proposed pressure sensor was manufactured and experimentally verified to have a signal-to-noise ratio (SNR) of 23 dB and a linear pressure response with a root-mean-square error (RMSE) of 0.37. During the 400-h 250 °C long-term stability test, there was no digital code variation. In addition, a mathematical model to study the relationships between the sensor’s performances and design parameters was established. According to the model, a 12-bit encoder (0.02% pressure sensitivity) can be achieved with a radius of 20 mm.

02 PETROLEUM↗
DOE OSTI2011

New Developments in Nb3Sn PIT Strand: The Effects of Titanium and Second Phase Additions on the Superconducting Properties

We report the effect of titanium on the transport properties of multifilament PIT strand. In addition, the effect of second phase yttrium additions on the microstructure and the bulk pinning force are reported for PIT Nb{sub 3}Sn mono-core wires. High resolution SEM, EDS, magnetization, and transport measurements were utilized to evaluate the superconducting properties.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Thermal Management System for an Electric Machine With Additively Manufactured Hollow Conductors With Integrated Heat Pipes

Here, this paper discusses steps taken to develop a novel thermal management system for an aircraft propulsion electric machine containing additively manufactured coils integrated with heat pipes aimed at boosting its specific power. Experimental setups are used to size and characterize heat pipes for the application and 3D thermal finite element analysis is used to determine optimum heat transfer coefficient of the convective boundaries. For some of the convective boundaries, fin-based surface area enhancement is required to reach a target combined overall heat transfer coefficient and surface area performance (UA). This enhancement is worked out using a combination of the Engineering Equation Solver tool and 3D thermal FEA. The thermal management system's UA, and by extension its specific power, sensitivity to coolant temperature is explored. Temperature distribution plots of optimized machine components are also presented and discussed. Lastly, additional heat pipe testing is carried out to study its maximum heat transfer capability's sensitivity to condenser coolant temperature and configuration.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Net shape processing of alnico magnets by additive manufacturing

Alternatives to rare earth permanent magnets, such as alnico, will reduce supply instability, increase sustainability, and could decrease the cost of permanent magnets, especially for high temperature applications, such as traction drive motors. Alnico magnets with moderate coercivity, high remanence, and relatively high energy product are conventionally processed by directional solidification and (significant) final machining, contributing to increased costs and additional material waste. Additive manufacturing (AM) is developing as a cost effective method to build net-shape three-dimensional parts with minimal final machining and properties comparable to wrought parts. This work describes initial studies of net-shape fabrication of alnico magnets by AM using a laser engineered net shaping (LENS) system. High pressure gas atomized (HPGA) pre-alloyed powders of two different modified alnico “8” compositions, with high purity and sphericity, were built into cylinders using the LENS process, followed by heat treatment. The magnetic properties showed improvement over their cast and sintered counterparts. The resulting alnico permanent magnets were characterized using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), electron backscatter diffraction (EBSD), and hysteresisgraph measurements. Furthermore, these results display the potential for net-shape processing of alnico permanent magnets for use in next generation traction drive motors and other applications requiring high temperatures and/or complex engineered part geometries.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Preliminary Assessment of Additively Manufactured Cooling Channel Performance for Helium-Cooled Blanket Concepts

Sufficient cooling of the blanket first wall remains a critical challenge for the design and deployment of fusion power plants. Helium has been targeted as a potential blanket coolant due to its inertness and low neutron interactivity, among other advantages. However, the low thermal mass of helium creates a need for heat transfer enhancements in coolant channels to provide adequate cooling to the blanket’s first wall. Toward this end, a series of ribbed flow channels of various rib cross sections and configurations has been produced via additive manufacturing (AM) to study the efficacy of AM for first wall heat transfer enhancement and the optimization of heat transfer geometries. Helium cooling performance is studied in AM test articles at 4 MPa operating pressure, Reynolds numbers up to 197 000, and outer surface heat fluxes up to 42 kW/m 2 in the recently commissioned helium flow loop experiment (HFLE). Preliminary results of this study are presented herein. Heat transfer performance of nominally smooth (i.e., featureless) AM channels is quantified via measured Nusselt numbers and friction factors and compared to off-the-shelf smooth pipe experiments. Results are compared to existing correlations and used to discuss the effects of the AM processes on thermal-hydraulic performance. It is seen that the inherent roughness of the AM channels leads to an increase in both heat transfer coefficient and pressure drop when compared to the conventional pipe. In conclusion, recommendations are made for future studies based on these findings and additional considerations for the deployment of AM blanket cooling components.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Resource selection functions based on hierarchical generalized additive models provide new insights into individual animal variation and species distributions

Habitat selection studies are designed to generate predictions of species distributions or inference regarding general habitat associations and individual variation in habitat use. Such studies frequently involve either individually indexed locations gathered across limited spatial extents and analyzed using resource selection functions (RSFs) or spatially extensive locational data without individual resolution typically analyzed using species distribution models. Both analytical methodologies have certain desirable features, but analyses that combine individual- and population-level inference with flexible non-linear functions may provide improved predictions while accounting for individual variation. Here, we describe how RSFs can be fit using hierarchical generalized additive models (HGAMs) using widely available software, providing a means to explore individual variation in habitat associations and to generate species distribution maps. We used GPS tracking data from golden eagles Aquila chrysaetos from across eastern North America with four environmental predictors to generate monthly distribution models. We considered three model structures that assumed different amounts of individual variation in the functional relationship between predictors and habitat use and used k-fold cross-validation to compare model performance. Models accounting for individual variability in shape and smoothness of functional responses performed best. Eagles exhibited the least amount of individual variation in response to land cover variables during winter months, with most individuals more closely adhering to the population-level trend. During the summer months, eagles exhibited more substantial individual variation in shape and smoothness of the functional relationships, suggesting some need to account for individual variation in eagle habitat use for both inferential and predictive purposes, during this time of year. Because they allow users to blend flexible functions with random effects structures and are well-supported by a variety of software platforms, we believe that HGAMs provide a useful addition to the suite of analyses used for modeling habitat associations or predicting species distributions.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Using remote sensing to quantify the additional climate benefits of California forest carbon offset projects

Abstract Nature‐based climate solutions are a vital component of many climate mitigation strategies, including California's, which aims to achieve carbon neutrality by 2045. Most carbon offsets in California's cap‐and‐trade program come from improved forest management (IFM) projects. Since 2012, various landowners have set up IFM projects following the California Air Resources Board's IFM protocol. As many of these projects approach their 10th year, we now have the opportunity to assess their effectiveness, identify best practices, and suggest improvements toward future protocol revisions. In this study, we used remote sensing‐based datasets to evaluate the carbon trends and harvest histories of 37 IFM projects in California. Despite some current limitations and biases, these datasets can be used to quantify carbon accumulation and harvest rates in offset project lands relative to nearby similar “control” lands before and after the projects began. Five lines of evidence suggest that the carbon accumulated in offset projects to date has generally not been additional to what might have otherwise occurred: (1) most forests in northwestern California have been accumulating carbon since at least the mid‐1980s and continue to accumulate carbon, whether enrolled in offset projects or not; (2) harvest rates were high in large timber company project lands before IFM initiation, suggesting they are earning carbon credits for forests in recovery; (3) projects are often located on lands with higher densities of low‐timber‐value species; (4) carbon accumulation rates have not yet increased on lands that enroll as offset projects, relative to their pre‐enrollment levels; and (5) harvest rates have not decreased on most project lands since offset project initiation. These patterns suggest that the current protocol should be improved to robustly measure and reward additionality. In general, our framework of geospatial analyses offers an important and independent means to evaluate the effectiveness of the carbon offsets program, especially as these data products continue improving and as offsets receive attention as a climate mitigation strategy.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2012

Effect of Dysprosia Additive on the Consolidation of CeO2 by Spark Plasma Sintering

The influence of dysprosia addition on the sintering and resulting microstructure of nano-grained CeO2 ceramics was investigated as functions of the spark plasma sintering (SPS) parameters. The addition of Dy2O3 (forming a solid solution) resulted in an increase in relative density and a decrease in grain size. The relative density of samples with Dy2O3 content of 6 and 10 mol% was over 95% when sintered at 1050 C under 500 MPa for holding times as short as 5 minutes. The application of high pressure facilitated the consolidation to relatively high densities with minimal grain growth. Heating rate and holding time, however, had insignificant effect on density but a measurable effect on grain size.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2012

Phase stability of cubic pyrochlore rare earth tantalate pinning additives in YBa2Cu3O7- superconductor

Phase stability of cubic-pyrochlore-structured RE3TaO7 (RTO, where RE = rare earth elements) pinning additives in YBa2Cu3O7- (YBCO) superconductor and the pinning properties influenced by RTO addition into YBCO films were investigated. RTO completely reacts with YBCO and is converted to cubic-double-perovskite-structured Ba2RETaO6 (BRETO), a more thermodynamically stable tantalate phase within YBCO. In RTO-doped YBCO films, BRETO self-assembled nanocolumnns align along the c-axis of the film and play a major role in the improvement of flux pinning and Jc performance over wide magnetic field and angular ranges.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Additive Manufacturing of Bi-Continuous Piezocomposites With Triply Periodic Phase Interfaces for Combined Flexibility and Piezoelectricity

An additive manufacturing-enabled bi-continuous piezocomposite architecture is presented to achieve mechanical flexibility and piezoelectricity simultaneously in piezoelectric materials. This architecture comprises an active ferroelectric ceramic phase and a passive flexible polymer phase, which are separated by a tailorable phase interface. Here, triply periodic minimal surfaces were used to define the phase interface, due to their excellent elastic properties and load transfer efficiency. A suspension-enclosing projection-stereolithography process was used to additively manufacture this material. Postprocesses including polymer infiltration, electroding, and poling are introduced. Piezoelectric properties of the piezocomposites are numerically and experimentally studied. The results highlight the role of tailorable triply periodic phase interfaces in promoting mechanical flexibility and piezoelectricity of bi-continuous piezocomposites.

42 ENGINEERING↗
DOE OSTI2021

Kinematics of a Cable-Driven Robotic Platform for Large-Scale Additive Manufacturing

Concrete additive manufacturing (AM) is a growing field of research. However, on-site, large-scale concrete additive manufacturing requires motion platforms that are difficult to implement with conventional rigid-link robotic systems. This article presents a new kinematic arrangement for a deployable cable-driven robot intended for on-site AM. The kinematics of this robot are examined to determine if they meet the requirements for this application, the wrench feasible workspace (WFW) is examined, and the physical implementation of a prototype is also presented. Data collected from the physical implementation of the proposed system are analyzed, and the results support its suitability for the intended application. The success of this system demonstrates that this kinematic arrangement is promising for future deployable AM systems.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A Scalable Compact Additively Manufactured Molten Salt to Supercritical Carbon Dioxide Heat Exchanger for Solar Thermal Application

Design of an additively manufactured molten salt (MS) to supercritical carbon dioxide (sCO 2 ) primary heat exchanger (PHE) for solar thermal power generation is presented. The PHE is designed to handle temperatures up to 720 °C on the MS side and an internal pressure of 200 bar on the sCO 2 side. In the core, MS flows through a three-dimensional periodic lattice network, while sCO 2 flows within pin arrays. The design includes integrated sCO 2 headers located within the MS flow, allowing for a counterflow design of the PHE. The sCO 2 headers are configured to enable uniform flow distribution into each sCO 2 plate while withstanding an internal pressure of 200 bar and minimizing obstruction to the flow of MS around it. The structural integrity of the design is verified on additively manufactured (AM) 316 stainless steel sub-scale specimens. An experimentally validated, correlation-based sectional PHE core thermofluidic model is developed to study the impact of flow and geometrical parameters on the PHE performance, with varied parameters including the mass flowrate, surface roughness, and PHE dimensions. A process-based cost model is used to determine the impact of parameter variation on build cost. The model results show that a heat exchanger with a power density of 18.6 MW/m 3 (including sCO 2 header volume) and effectiveness of 0.88 can be achieved at a heat capacity rate ratio of 0.8. As a result, the impact of design and AM machine parameters on the cost of the PHE are assessed.

14 SOLAR ENERGY↗