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

Manufacturing-induced contamination in common multilayerdielectric gratings

Contamination of pulse compression gratings during the manufacturing process is known to give rise to reduced laser damage performance and represents an issue that has not yet been adequately resolved. The present work demonstrates that the currently used etching methods introduce carbon contamination inside the etched region extending to a 50- to 80-nm layer below the surface. This study was executed using custom samples prepared in both, a laboratory setting and by established commercial vendors, showing results that are very similar. The laser-induced-damage performance of the etched and unetched regions in the grating-like samples suggest that contaminants introduced by etching process are contributing to the reduction of the laser-induced damage threshold.

42 ENGINEERING↗
DOE OSTI2022

Gamma-radiation-induced negative nonlinear absorption in quartz glass

The effect of ionizing radiation on the nonlinear optical properties of materials needs to be considered for applications that employ high-power laser pulses in extreme radiation environments. The Heraeus Infrasil302 optical quartz glass was irradiated by gamma rays, and its nonlinear absorption was measured using the open-aperture Z-scan technique with nanosecond laser pulses. Irradiation results in a negative nonlinear absorption coefficient whose magnitude increases with irradiation dose. Nonlinear absorption coefficients of -0.78, -1.14, -1.29, and -1.88~ × ~10 -13 m/W are measured for gamma doses of 600 krad, 1.2 Mrad, 3.6 Mrad, and 10 Mrad, respectively. Thermal annealing restores the optical properties of quartz-glass to their unirradiated values. It is suggested that metallic impurities introduced by the manufacturing process have a role in inducing saturated absorption in irradiated quartz glass, which manifests as negative nonlinear absorption coefficient, and is demonstrated by comparing Infrasil302 quartz results to equivalent irradiated measurements for Spectrosil2000 quartz.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2019

Specific Energy Analysis for the Manufacturing of Light-Weight Automobile Body

This manuscript analyses the specific energy requirements to produce two hybridised vehicle structures on current automotive assembly lines. It provides quantitative and specific electric (kWhr/vehicle) and fossil-fuel (MMBtu/vehicle) energy predictions of the body-in-white (BIW) manufacturing processes including body panel forming, welding, painting, and final assembly, in addition to the facility heating ventilation and air conditioning or HVAC consumption. Two hybridised BIW design criteria are analysed; the first is based on minimising the added cost per unit weight saved (+$/-kg), while the second is based on maximising the percentage of weight saved (% -kg). Also a new criterion; that is the added specific-energy per unit weight-saved or (+kWhr/vehicle/-kg) is proposed. The light-weight structures comprise body parts made of aluminium and steel. To compute energy consumptions, the study utilises the energy performance index (EPI) stochastic model in addition to complementing it with a panel-forming energy model. Cost analysis is also provided for all the major vehicle body-panels using an in-house Excel macro. The study reverse engineers a passenger vehicle BIW using a full-size coordinate measuring machine (CMM). The presented work further highlights the monetary value of the associated emissions when increasing the specific energy.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Effects of Microstructural Composition, Porosity, and Microcracks on the Elastic Moduli of Nuclear Graphites

The elastic responses of nuclear graphite not only depend on the graphitic content itself but are largely dictated by the microstructural constitution of the material. The types of raw materials combined with the manufacturing processes used to produce the graphite yield the microstructural content that primarily includes graphite filler, graphitized pitch binder, and voids/defects that typically occupy approximately 20% of the volume. Among these microstructural components, porosity and microcracking (considered to be part of voids/defects) heavily influence the overall properties of the material, including the elastic moduli. It is widely accepted that the primary effect of oxidation is to increase porosity, but the related effect on the moduli cannot be explained satisfactorily by simply noting changes to porosity. Models describing the elastic moduli of porous, polycrystalline graphite materials have been developed to interpret experimental determinations of Young's modulus and shear modulus in oxidized graphites. Beyond porosity, the moduli are heavily influenced by microcracks, and their effects can be assessed using physical property models based on orientation distribution coefficients and microcrack-modified, single-crystal moduli to represent the combined effects of crystallite orientation and microcracking. This work demonstrates how most modulus measurements in nuclear graphites can be understood using relatively simple models that describe the effects of porosity and microcracking. We also present directions to be pursued to account for microstructure-related effects that occur as a result of neutron irradiation.

Spicer, James B.↗
DOE OSTI2025

Influence of pre-existing defects on thermal transport in nuclear graphite

Nuclear graphite is a critical material in high-temperature nuclear reactors due to its superior thermal and mechanical properties. The manufacturing process leaves multi-scale ‘pre-existing’ defects that can affect thermal transport characteristics. Because these defects are remnant of graphitization temperature, they cannot be thermally annealed. This study employs a non-thermal electron wind force (EWF) annealing technique to avoid this obstacle. 2 min of EWF treatment of the as-received graphite IG-110 at temperatures below 100 °C led up to 67% increase in thermal diffusivity and ~ 35% decrease in electrical resistivity in average. Differential scanning calorimetry also showed similar outcome for specific heat. X-ray diffraction characterization was performed by fitting a bi-modal crystallite size distribution model to reveal the enhancement in crystallinity after the EWF treatment. The findings emphasize the potential of EWF annealing for optimizing thermal performance in nuclear graphite and its implications for reactor efficiency and safety.

Annealing↗
DOE OSTI2024

Advanced and functional composite materials via additive manufacturing: Trends and perspectives

Additive manufacturing (AM) has many advantages over conventional subtractive manufacturing methods. The cost-effective AM allows for precise fabrication of complex structures with less material waste, making it a popular manufacturing process in many applications. The recent development of AM materials has advanced significantly. Further, by precisely controlling material distribution and microstructural features, AM facilitates the creation of new composites with specific requirements. AM techniques have contributed considerably to integrating unique functionalities for various applications. This review emphasizes multiple categories of materials, including metal alloys, polymer-based composites, and sustainable composites, as well as applications of sensing materials and strategies and emerging artificial intelligence and machine learning.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Status and prospects of lithium iron phosphate manufacturing in the lithium battery industry

Abstract Lithium iron phosphate (LiFePO 4 , LFP) has long been a key player in the lithium battery industry for its exceptional stability, safety, and cost-effectiveness as a cathode material. Major car makers (e.g., Tesla, Volkswagen, Ford, Toyota) have either incorporated or are considering the use of LFP-based batteries in their latest electric vehicle (EV) models. Despite LFP’s well-researched status as a cathode material, it is expected to fulfill additional demands in electric vehicle applications, such as fast-charging capabilities, wide temperature range adaptability, and higher energy density. This perspective examines the LFP supply chain, synthetic approaches, manufacturing processes, market trends, recent advancements, and evolving demands to better understand its future role in the EV market. Graphical abstract

Lu, Yanying↗
DOE OSTI2023

Characterization of Additive Manufacturing Materials for String Assembly in Cleanroom

Beamline components, such as superconducting radio frequency cavities and focusing lenses, need to be assembled together in a string while in a cleanroom environment. The present contribution identifies and characterizes materials for additive manufacturing that can be used in a cleanroom. The well known advantages of additive manufacturing processes would highly benefit the design and development of tooling needed for the mechanical support and alignment of string components. Cleanliness, mechanical properties, and leak tightness of the chosen materials are the main focus of this contribution, which also paves the way for the integration of such materials in cryomodule assemblies. Results reported here were obtained in the framework of the PIP-II project at Fermilab.

43 PARTICLE ACCELERATORS↗
DOE OSTI2014

Light Metals Permanent Mold Casting

Current vehicles use mostly ferrous components for structural applications. It is possible to reduce the weight of the vehicle by substituting these parts with those made from light metals such as aluminum and magnesium. Many alloys and manufacturing processes can be used to produce these light metal components and casting is known to be most economical. One of the high integrity casting processes is permanent mold casting which is the focus of this research report. Many aluminum alloy castings used in automotive applications are produced by the sand casting process. Also, aluminum-silicon (Al-Si) alloys are the most widely used alloy systems for automotive applications. It is possible that by using high strength aluminum alloys based on an aluminum-copper (Al-Cu) system and permanent mold casting, the performance of these components can be enhanced significantly. This will also help to further reduce the weight. However, many technological obstacles need to be overcome before using these alloys in automotive applications in an economical way. There is very limited information in the open literature on gravity and low-pressure permanent mold casting of high strength aluminum alloys. This report summarizes the results and issues encountered during the casting trials of high strength aluminum alloy 206.0 (Al-Cu alloy) and moderate strength alloy 535.0 (Al-Mg alloy). Five engineering components were cast by gravity tilt-pour or low pressure permanent mold casting processes at CanmetMATERIALS (CMAT) and two production foundries. The results of the casting trials show that high integrity engineering components can be produced successfully from both alloys if specific processing parameters are used. It was shown that a combination of melt processing and mold temperature is necessary for the elimination of hot tears in both alloys.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2014

Catalytic Transformation of Waste CO 2 into Valuable Products

Novomer’s novel materials contain up to 50% by mass CO 2 and provide a unique platform for re-using CO 2 from waste industrial sources and converting it into useful products. This Report covers the progress made by Novomer during the DOE funded project (DOE Award #: DE-FE0002474) under the “Carbon Capture and Sequestration from Industrial Sources and Innovative Concepts for Beneficial CO 2 Use” program. This includes Phase 1 and Phase 2, including all three subphases of the latter. Novomer completed all technical and commercial objectives in both Phase 1 and Phase 2, including the six Phase 2 Objectives outlined in the SOPO within budget by the project end date of September 30, 2013. These are: validating the economics are competitive, validate the carbon footprint, validate acceptable product performance, verify robust manufacturing process, validate large markets exist, and qualify at least 3 products with customers.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2014

Advanced Simulation & Computing FY15 Implementation Plan Volume 2, Rev. 0.5

The Stockpile Stewardship Program (SSP) is a single, highly integrated technical program for maintaining the surety and reliability of the U.S. nuclear stockpile. The SSP uses nuclear test data, computational modeling and simulation, and experimental facilities to advance understanding of nuclear weapons. It includes stockpile surveillance, experimental research, development and engineering programs, and an appropriately scaled production capability to support stockpile requirements. This integrated national program requires the continued use of experimental facilities and programs, and the computational enhancements to support these programs. The Advanced Simulation and Computing Program (ASC) is a cornerstone of the SSP, providing simulation capabilities and computational resources that support annual stockpile assessment and certification, study advanced nuclear weapons design and manufacturing processes, analyze accident scenarios and weapons aging, and provide the tools to enable stockpile Life Extension Programs (LEPs) and the resolution of Significant Finding Investigations (SFIs). This requires a balance of resource, including technical staff, hardware, simulation software, and computer science solutions. As the program approaches the end of its second decade, ASC is intently focused on increasing predictive capabilities in a three-dimensional (3D) simulation environment while maintaining support to the SSP. The program continues to improve its unique tools for solving progressively more difficult stockpile problems (sufficient resolution, dimensionality, and scientific details), quantify critical margins and uncertainties, and resolve increasingly difficult analyses needed for the SSP. Where possible, the program also enables the use of high-performance simulation and computing tools to address broader national security needs, such as foreign nuclear weapon assessments and counternuclear terrorism.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2014

Analysis of dust samples collected from spent nuclear fuel interim storage containers at Hope Creek, Delaware, and Diablo Canyon, California

Potentially corrosive environments may form on the surface of spent nuclear fuel dry storage canisters by deliquescence of deposited dusts. To assess this, samples of dust were collected from in-service dry storage canisters at two near-marine sites, the Hope Creek and Diablo Canyon storage installations, and have been characterized with respect to mineralogy, chemistry, and texture. At both sites, terrestrially-derived silicate minerals, including quartz, feldspars, micas, and clays, comprise the largest fraction of the dust. Also significant at both sites were particles of iron and iron-chromium metal and oxides generated by the manufacturing process. Soluble salt phases were minor component of the Hope Creek dusts, and were compositionally similar to inland salt aerosols, rich in calcium, sulfate, and nitrate. At Diablo Canyon, however, sea-salt aerosols, occurring as aggregates of NaCl and Mg-sulfate, were a major component of the dust samples. The seasalt aerosols commonly occurred as hollow spheres, which may have formed by evaporation of suspended aerosol seawater droplets, possibly while rising through the heated annulus between the canister and the overpack. The differences in salt composition and abundance for the two sites are attributed to differences in proximity to the open ocean and wave action. The Diablo Canyon facility is on the shores of the Pacific Ocean, while the Hope Creek facility is on the shores of the Delaware River, several miles from the open ocean.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Advanced Simulation and Computing Implementation Plan, FY15, Rev. 1

The Stockpile Stewardship Program (SSP) is a single, highly integrated technical program for maintaining the surety and reliability of the U.S. nuclear stockpile. The SSP uses nuclear test data, computational modeling and simulation, and experimental facilities to advance understanding of nuclear weapons. It includes stockpile surveillance, experimental research, development and engineering programs, and an appropriately scaled production capability to support stockpile requirements. This integrated national program requires the continued use of experimental facilities and programs, and the computational enhancements to support these programs. The Advanced Simulation and Computing Program (ASC) is a cornerstone of the SSP, providing simulation capabilities and computational resources that support annual stockpile assessment and certification, study advanced nuclear weapons design and manufacturing processes, analyze accident scenarios and weapons aging, and provide the tools to enable stockpile Life Extension Programs (LEPs) and the resolution of Significant Finding Investigations (SFIs). This requires a balance of resource, including technical staff, hardware, simulation software, and computer science solutions. As the program approaches the end of its second decade, ASC is intently focused on increasing predictive capabilities in a three-dimensional (3D) simulation environment while maintaining support to the SSP. The program continues to improve its unique tools for solving progressively more difficult stockpile problems (sufficient resolution, dimensionality, and scientific details), quantify critical margins and uncertainties, and resolve increasingly difficult analyses needed for the SSP. Where possible, the program also enables the use of high-performance simulation and computing tools to address broader national security needs, such as foreign nuclear weapon assessments and counter-nuclear terrorism.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2015

Structural Testing of the Blade Reliability Collaborative Effect of Defect Wind Turbine Blades

Two 8.3-meter (m) wind turbine blades intentionally constructed with manufacturing flaws were tested to failure at the National Wind Technology Center (NWTC) at the National Renewable Energy Laboratory (NREL) south of Boulder, Colorado. Two blades were tested; one blade was manufactured with a fiberglass spar cap and the second blade was manufactured with a carbon fiber spar cap. Test loading primarily consisted of flap fatigue loading of the blades, with one quasi-static ultimate load case applied to the carbon fiber spar cap blade. Results of the test program were intended to provide the full-scale test data needed for validation of model and coupon test results of the effect of defects in wind turbine blade composite materials. Testing was part of the Blade Reliability Collaborative (BRC) led by Sandia National Laboratories (SNL). The BRC seeks to develop a deeper understanding of the causes of unexpected blade failures (Paquette 2012), and to develop methods to enable blades to survive to their expected operational lifetime. Recent work in the BRC includes examining and characterizing flaws and defects known to exist in wind turbine blades from manufacturing processes (Riddle et al. 2011). Recent results from reliability databases show that wind turbine rotor blades continue to be a leading contributor to turbine downtime (Paquette 2012).

17 WIND ENERGY↗
DOE OSTI2015

Initial Probabilistic Evaluation of Reactor Pressure Vessel Fracture with Grizzly and Raven

The Grizzly code is being developed with the goal of creating a general tool that can be applied to study a variety of degradation mechanisms in nuclear power plant components. The first application of Grizzly has been to study fracture in embrittled reactor pressure vessels (RPVs). Grizzly can be used to model the thermal/mechanical response of an RPV under transient conditions that would be observed in a pressurized thermal shock (PTS) scenario. The global response of the vessel provides boundary conditions for local models of the material in the vicinity of a flaw. Fracture domain integrals are computed to obtain stress intensity factors, which can in turn be used to assess whether a fracture would initiate at a pre-existing flaw. These capabilities have been demonstrated previously. A typical RPV is likely to contain a large population of pre-existing flaws introduced during the manufacturing process. This flaw population is characterized stastistically through probability density functions of the flaw distributions. The use of probabilistic techniques is necessary to assess the likelihood of crack initiation during a transient event. This report documents initial work to perform probabilistic analysis of RPV fracture during a PTS event using a combination of the RAVEN risk analysis code and Grizzly. This work is limited in scope, considering only a single flaw with deterministic geometry, but with uncertainty introduced in the parameters that influence fracture toughness. These results are benchmarked against equivalent models run in the FAVOR code. When fully developed, the RAVEN/Grizzly methodology for modeling probabilistic fracture in RPVs will provide a general capability that can be used to consider a wider variety of vessel and flaw conditions that are difficult to consider with current tools. In addition, this will provide access to advanced probabilistic techniques provided by RAVEN, including adaptive sampling and parallelism, which can dramatically decrease run times.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

Safire-Safe impact resistant electrolyte

The goal of this project is to demonstrate the feasibility of the SAFIRE concept in transportation batteries and demonstrate a pathway to incorporate this technology into existing battery manufacturing processes. When successful we will have demonstrated a method to make electrolytes safer for transportation applications. This increased safety will enable us to reduce the mass associated with the impact protection systems incorporated within vehicles thereby increasing the vehicles range.

25 ENERGY STORAGE↗