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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 1,477 records · Page 82
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Manufacturing Process Design of a Micro-Scale Liquid-Liquid Extractor and Multi-phase Separator

Advances in process innovation within the chemical process industry are impeded by the cost of producing new innovative components. In this paper, various manufacturing process routes were evaluated for scaling up a micro-scale liquid-liquid extractor and multi-phase separator capable of separating immiscible phases that are used for the extraction of a chemical product into a lower boiling point solvent to make downstream distillation easier. A manufacturing process design methodology was used to evaluate both photochemical machining and binder jetting as a means for producing the micropost arrays within the separator. Cost curves show that for a 0.3 mm deep micropost array, photochemical machining was found to be much cheaper than binder jetting. However, because binder jetting processes enable microposts with over 13 times higher depth-to-width aspect ratios, binder jetting was found to decrease the overall costs of the extractor/separator by more than half for a 500 barrel per day plant, with breakeven as low as 15 barrels per day. These economics were confirmed by building extractor/separator plates and characterizing them dimensionally and functionally. The binder jet plates were found to perform better than photochemical plates leading to the complete separation of the organic phase from water. The utilization of slower sintering cycles combined with surface grinding provided acceptable dimensional tolerances for the binder jet plates. Using pressurized air during depowdering improved the economics for the binder jetting process.

42 ENGINEERING↗
DOE OSTI2022

Small-scale mechanical testing and characterization of fuel cladding chemical interaction between HT9 cladding and advanced U-based metallic fuel alloy

Fuel cladding chemical interactions (FCCI) occurred on the interface between the nuclear metal fuel and cladding is the primary cause of cladding wastage, weakening cladding mechanical integrity, and placing fuel and cladding at risk. Although the microstructural and phase information of FCCI has been fairly understood, mechanical properties remain less studied due to limited reaction volume. Here, through a combining of advanced electron microscopy characterizations and small-scale mechanical testing techniques, including indentation and micro-tensile testing, this study investigated the microscale mechanical properties of FCCI between the ferritic/martensitic (F/M) HT9 cladding and an advanced Uranium (U)-based metallic fuel irradiated at the Advanced Test Reactor to 2.2% FIMA with peak inner cladding temperature reached to 650 °C. Mechanical testing results show significant hardening and embrittlement in the FCCI region. The brittle fracture of FCCI specimen is mainly attributed to the formation of nano-crystallized intermetallic σ-FeCr phase. Whereas mechanical softening was revealed in the unreacted HT9 matrix due to irradiation-induced microstructural and microchemical evolution, specifically, the disappearance of martensitic lath structure and the formation of Fe 2 Mo Laves phase precipitation which consumed the solid solution strengthening Mo from the F/M HT9 matrix. Due to the achieved high cladding temperature, this fuel pin is of particular significance for revealing the high-temperature irradiation effect on the mechanical properties of HT9 cladding. Therefore, the outcomes of this study are expected to contribute to the development of multi-scale mechanical behavior modeling of HT9 cladding for Generation IV reactors which requires cladding to run at higher temperature (above 600 ?).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Development of multi-scale computational frameworks to solve fusion materials science challenges

Over the past two decades, the US-DOE has funded multiple projects that rely on high-performance computing and exascale computing platforms to accelerate scientific discoveries and address grand scientific challenges, such as harnessing fusion energy. In this article, we review in detail one of these efforts aimed at enhancing our capability to model plasma-facing materials subject to plasma and high-energy ion/neutron irradiation. The plasma surface interactions project has built a multi-scale modeling framework where many of the plasma- and high-energy ion/neutron irradiation-induced effects occurring in tungsten are explored. Here, this knowledge is used to develop atomistically-informed, high-fidelity continuum and meso-scale models that can be validated against experiments. We review the developments within this project, with attention to experimental validation efforts, and specifically highlight activities associated with: helium bubble bursting and equation of state, and hydrogen-helium interactions in tungsten; atomistically-informed model development for beryllium-tungsten material mixing; coupling of scrape-of-layer plasma, sheath and material models; and coupling of stochastic cluster-dynamics and crystal plasticity models to address radiation effects in tungsten under stress. Finally, we present how the project is preparing for future computational architectures, for instance through efforts to adapt atomistic methods to exascale computing.

36 MATERIALS SCIENCE↗
DOE OSTI2022

In situ feature analysis for large-scale multiphase flow simulations

The study of multiphase flow is essential for designing chemical reactors such as fluidized bed reactors (FBR), as a detailed understanding of hydrodynamics is critical for optimizing reactor performance and stability. An FBR allows scientists to conduct different types of chemical reactions involving multiphase materials, especially interaction between gas and solids. During such complex chemical processes, the formation of void regions in the reactor, generally termed as bubbles, is an important phenomenon. The study of these bubbles has a deep implication in predicting the reactor’s overall efficiency. But physical experiments needed to understand bubble dynamics are costly and non-trivial due to the technical difficulties involved and harsh working conditions of the reactors. Therefore, to study such chemical processes and bubble dynamics, a state-of-the-art computational simulation MFIX-Exa is being developed. Despite the proven accuracy of MFIX-Exa in modeling bubbling phenomena, the large-scale output data prohibits the use of traditional post hoc analysis capabilities in both storage and I/O time. Herein, to address these issues and allow the application scientists to explore the bubble dynamics in an efficient and timely manner, we have developed an end-to-end analytics pipeline that enables in situ detection of bubbles, followed by a flexible post hoc visual exploration methodology of bubble dynamics. The proposed method enables interactive analysis of bubbles, along with quantification of several bubble characteristics, enabling experts to understand the bubble interactions in detail. Positive feedback from the experts has indicated the efficacy of the proposed approach for exploring bubble dynamics in very-large-scale multiphase flow simulations.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Pore-scale evidence of ion exclusion during methane hydrate growth and evolution of hydrate pore-habit in sandy sediments

Hydrate-bearing sediments constitute complex hydrological systems, within which the pore habit of hydrate significantly affects all physical properties. However, there is scarce pore-scale evidence of the evolution of hydrate growth in porous media and the influence of water salinity in the micro-morphology of hydrate. In this paper, we used X-ray computed micro-tomography (CT) to monitor three experiments of methane hydrate growth in sand partially saturated with either NaBr or KI brine under excess-gas conditions. Gas, brine and hydrate are observed to co-exist at the pore-scale during the evolution of hydrate pore-habit towards three-phase equilibrium. The experiments and data analysis reveal that (1) hydrate forms as a porous medium mixed with inclusions of brine and gas, where hydrate and brine evolve gradually into separate phases as hydrate cages exclude salt ions, (2) hydrate growth mobilizes water over fairly long distances resulting in heterogeneous hydrate distribution, and (3) hydrate can exhibit interconnecting pore-habit at local hydrate saturations higher than ~50%, even if grown under excess-gas conditions. The results imply that hydrate micro-morphology and pore habit evolve during hydrate formation and, we suggest, so do the physical properties of hydrate-bearing sediments. Furthermore, our findings provide new insights into the micro-morphology of hydrate and evolution of the properties of hydrate-bearing sediments synthesized in the laboratory and in natural systems.

Clathrate hydrate↗
DOE OSTI2026

Controlling homogenization length scales and microstructure in additively manufactured Ti-Ta functionally graded materials

Materials with smooth compositional gradients or functionally grade materials (FGMs) produced via additive manufacturing (AM), enables joining dissimilar materials and optimizing multiple properties in advanced engineering applications. However, as-printed AM microstructures exhibit micro-segregation and solidification defects which, when combined with controlling macroscale gradient properties, complicates necessary post-processing. Here, we use CALPHAD-informed diffusion modelling to design post-processing heat treatments for lightweight to refractory FGMs. Ti-Ta (0 to 85 at. % Ta) FGMs were fabricated using laser-based directed energy deposition AM. Post-processing heat treatments at 1000° C and 1500° C were designed to promote homogenization across specific length scales and experimentally validated. Investigation of chemical segregation and microstructures demonstrated that the length scale of homogenization is controlled as a function of time, temperature, and local composition. Ta-rich regions exhibited incomplete homogenization compared to Ti-rich layers. Unmelted Ta particles were found to completely dissolve at 1500 °C. By controlling cooling rate (200 °C/min), martensitic structures were produced between 14–36 at. % Ta, consistent with martensite-start temperatures calculations, while furnace cooling (2 °C/min) produced α+β morphologies. This work establishes a validated predictive framework for designing post-processing to tailor microstructure and chemical architecture in AM FGMs, facilitating their deployment in demanding environments.

Materials science↗
DOE OSTI2021

Recent advances in the mechanical characterization of shales at nano-to micro-scales: A review

Understanding geomechanical properties of shales, such as stiffness properties and fracture toughness, is important in different areas of petroleum industry-related activities. Nanoscale to microscale experiments on shale samples require a much smaller sample compared to macroscale experiments. This is a major advantage because irregularly-shaped drill cuttings from shales can be used for experimental analyses, such as nanoindentation or atomic force microscopy (AFM). However, characterization of mechanical properties at the nano- to micro-scale is a relatively new addition to classical geomechanical experiments on shales, and there is still a lack of both fundamental knowledge and standard procedures for conducting experiments at this scale. The theoretical principles of nanoindentation-based (Gridded Nanoindentation and Modulus Mapping) and AFM-based experimental methods (PeakForce QNMTM and AFM-IR), a review of the literature results and the major findings are explained in Sections 2 and 3, respectively. These experimental techniques are compared in Section 4. Overall, nanoindentation experiments reveal the anisotropy of organic matter (OM)-rich shales at the nanoscale, and it is shown that gridded nanoindentation is capable of characterizing different minerals with respect to their stiffness properties. The capability of AFM (PeakForce QNMTM) to differentiate between different minerals within OM-rich shales with distinct mechanical properties, in particular stiffness, is also demonstrated. It is shown that AFM-based methods are more straightforward than gridded-nanoindentation to characterize OM-rich shales based on the stiffness of different constituent minerals of OM-rich shales, but nanoindentation can apply higher loads than AFM-based methods. Therefore, they can measure creep properties and fracture toughness of OM-rich shales. Here, it is shown that the OM is the most compliant part of the OM-rich shales, but it is still unclear if thermal maturation has an impact on the stiffness of OM. It is necessary to investigate if there is a relationship between the OM type (kerogen, bitumen, etc.) and mechanical properties such as Young’s modulus and Creep rate.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Self-regulating behavior of hybrid membrane systems as demonstrated in an element-scale forward osmosis-reverse osmosis hybrid system

Hybrid membrane systems can be difficult to design due to the requisite flow rate matching between up- and downstream unit operations. In this work, we use a forward osmosis-reverse osmosis (FO-RO) hybrid system to demonstrate how some membrane systems can exhibit self-regulating behavior due to osmotic coupling. This can reduce the need for complex control systems for flow balancing. We show this behavior using a module-scale test bed that can mimic the behavior of larger scale operations. The system shows permeate flow rate near-convergence between the FO and RO modules after startup or when perturbed by a change in RO module pressure. The behavior of this hybrid system demonstrates that some membrane operations can exploit osmotic interdependence, rather than expensive control systems, to achieve steady state operation.

Debottlenecking↗
DOE OSTI2021

Property enhancement of CoCrNi medium-entropy alloy by introducing nano-scale features

CoCrNi -medium-entropy alloy (MEA) has been widely investigated due to its superior mechanical properties that overcome strength-ductility tradeoff. Here we show further property enhancement of CoCrNi MEA by introducing nano-scale features. Both CoCrNi and oxide dispersion strengthened (ODS) CoCrNi are fabricated by mechanical alloying and spark plasma sintering. Microstructural characterization and mechanical testing of these nanostructured MEAs revealed that the nano-scale features significantly improves the strength of the alloys. In ODS-CoCrNi MEA, Y 2 Ti 2 O 7 oxides with an average diameter of 7.3 ± 3.2 nm are incoherent with the matrix, and a specific orientation relationship exists between Y 2 Ti 2 O 7 and the matrix, which is [011] Y 2 Ti 2 O 7 //[011]Matrix, (400) Y 2 Ti 2 O 7 //(200)Matrix and ($22\bar2$) Y 2 Ti 2 O 7 //($11\bar1$)Matrix. The recrystallization and grain growth processes are effectively suppressed by the introduction of Y 2 Ti 2 O 7 nanoparticles. Strengthening mechanism analyses indicate that the strength improvement of ODS-CoCrNi is mainly ascribed to the precipitation strengthening of Y 2 Ti 2 O 7 .

36 MATERIALS SCIENCE↗
DOE OSTI2022

Breaking $\mathrm{OER}$ and $\mathrm{CER}$ scaling relations via strain and its relaxation in $\mathrm{RuO}$ 2 (101)

Green hydrogen production from abundant water sources is an important component of renewable energy storage. Water oxidation catalysts are typically considered bound by adsorbate scaling relations, limiting their activity for the oxygen evolution reaction (OER) as well as selectivity between OER and the chlorine evolution reaction (CER) that compete in saline water streams. RuO 2 is highly active for both reactions, and recent measurements have shown the OER activity is greater on undercoordinated, high index facets compared to the lowest-energy (110) facet often studied. The growth of such orientations as epitaxial films, however, can result in appreciable strain and potential surface faceting via its relaxation. Here, we find the activity and selectivity towards OER and CER vary with thickness in epitaxial (101) RuO 2 thin films: OER activity decreases 4x as film thickness increases from 8 nm to 48 nm, while CER activity is comparable. Thus, strain and its relaxation can be used to break scaling relationships between OER and CER, highlighting the important role that defects play in selective oxidation processes on RuO 2 in chloride-containing media.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Damage detection in a laboratory-scale wellbore applying Time Reversal and Nonlinear Elastic Wave Spectroscopy (TR NEWS)

We report Time Reversal and Nonlinear Elastic Wave Spectroscopy (TR-NEWS) has been used to focus acoustic energy, and make measurements correlated with damage in a variety of industrial materials. Most studies using TR-NEWS have focused on relatively small objects and may have multiple acoustic sources. In Earth, within energy extraction and carbon sequestration settings, the structure and scale of wellbores makes acoustic focusing challenging, as has been demonstrated through numerical simulations. This paper explores the feasibility of applying TR NEWS for damage detection in wellbores by constructing a laboratory-scale wellbore, and using TR to focus and make dynamic linear and nonlinear elastic measurements on it. During successive cycles of localized mechanical damage induced in the sample, the hysteretic nonlinear elastic parameter α increased with progressive mechanical damage. In addition to these strain-dependent changes in α, the width and peak amplitude of the time reversal focused energy changed near the damage site.

58 GEOSCIENCES↗
DOE OSTI2024

Detachment scalings derived from 1D scrape-off-layer simulations

Fusion power plants will require detachment to mitigate sputtering and keep divertor heat fluxes at tolerable levels. Controlling detachment on these devices may require the use of real-time scrape-off-layer modeling to complement the limited set of available diagnostics. In this work, we use the configurable Hermes-3 edge modeling framework to perform time-dependent, fixed-fraction-impurity 1D detachment simulations. Although currently far from real-time, these simulations are used to investigate time-dependent effects and the minimum physics set required for control-relevant modeling. We show that these simulations reproduce the expected rollover of the target ion flux — a typical characteristic of detachment onset. We also perform scans of the input heat flux and impurity concentration and show that the steady-state results closely match the scalings predicted by the 0D time-independent Lengyel–Goedheer model. This allows us to indirectly compare to SOLPS simulations, which find a similar scaling but a lower value for the impurity concentration required for detachment for given upstream conditions. We use this result to suggest a series of improvements for the Hermes simulations, and finally show simulations demonstrating the impact of time-dependence.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

One hundred years into the study of ecotypes, new advances are being made through large-scale field experiments in perennial plant systems

A hundred years after Turesson first clearly described how locally adaptive variation is distributed within species, plant biologists are making major breakthroughs in our understanding of mechanisms underlying adaptation from local populations to the scale of continents. Although the genetics of local adaptation has typically been studied in smaller reciprocal transplant experiments, here it is being evaluated with whole genomes in large-scale networks of common garden experiments with perennial switchgrass and poplar trees. These studies support the hypothesis that a complex combination of loci, both with and without adaptive trade-offs, underlies local adaptation and that hybridization and adaptive introgression play a key role in the evolution of these species. Future studies incorporating high-throughput phenotyping, gene expression, and modeling will be used to predict responses of these species to climate change.

Trade-off↗
DOE OSTI2020

A large-scale, agent-based simulation of metropolitan freight movements with passenger and freight market interactions

This study summarizes the first stage in the implementation of an agent-based freight modeling system that has a global representation of agents and detailed modeling of a large-scale transportation network. The model is used to evaluate the transportation and energy impacts of goods movement across urban and national scales. The framework is implemented within POLARIS, a C++-based Planning and Operations Language for Agent-based Regional Integrated Simulation, which consists of an activity-based modeling (ABM) and dynamic traffic assignment (DTA) system that has robust features for passenger travel. This platform provides a tool to model interactions among consumers, producers, and the transportation system. The main objective of this initial implementation is to implement a freight model within POLARIS following an agent-based paradigm with behavioral and simulation methods. This paper presents the initial framework and illustrates the application of the model. Building upon earlier works, a parcel location assignment algorithm for business establishments in the population is documented, along with a method for estimating establishment production and consumption volumes. In addition to population generation, other features of the model include push-pull supply chains, multimodal path choice, choice of transportation logistics node, and dynamic traffic assignment. A module with e-commerce supply and demand was also developed to analyze the effects of e-commerce delivery on last-mile energy use and congestion.

agent-based freight↗
DOE OSTI2022

Wind turbine response in waked inflow: A modelling benchmark against full-scale measurements

Predicting the power and loads of wind turbines in waked inflow conditions still presents a major modelling challenge. It requires the accurate modelling of the atmospheric flow conditions, wakes of upstream turbines and the response of the turbine of interest. Rigorous validations of model frameworks against measurements of utility-scale wind turbines in such scenarios remain limited to date. In this study, six models of different fidelity are compared against measurements from the DanAero experiment. The two benchmark cases feature a full-wake and partial-wake scenario, respectively. The simulations are compared against local pressure forces and inflow velocities measured on several blade sections of the downstream turbine, as well as met mast measurements and standard SCADA data. Regardless of the model fidelity, reasonable agreements are found in terms of the wake characteristics and turbine response. For instance, the azimuth variation of the mean aerodynamic forces acting on the blade was captured with a mean relative error of 15-20%. Additionally, while various model-specific deficiencies could be identified, the study highlights the need for further full-scale measurement campaigns with even more extensive instrumentation. Furthermore, it is concluded that validations should not be limited to integrated and/or time-averaged quantities that conceal characteristic spatial or temporal variations.

17 WIND ENERGY↗
DOE OSTI2025

A review of Geological Thermal Energy Storage for seasonal, grid-scale dispatching

Energy storage is essential for the decarbonization of the U.S. energy grid, especially with the increasing deployment of variable renewable energy sources like solar and wind. Geological thermal energy storage (GeoTES) has emerged as a promising long duration, grid scale solution, providing stability and security through flexible operations and valuable grid services. GeoTES utilizes subsurface reservoirs to store thermal energy for power generation and direct-use heating and cooling. This approach significantly enhances the use of low-temperature reservoirs, which would otherwise be unsuitable for geothermal power plants. It also aligns well with depleted oil and gas reservoirs, concentrating solar power, non-flexible renewables (photovoltaic and wind), and geothermal-related power cycles. Given the favorable marginal costs of GeoTES as storage duration increases, it becomes particularly competitive for seasonal, grid-scale dispatch, where few technologies are viable. This paper provides a comprehensive review of GeoTES systems and the research underpinning itsr development. This analysis begins by defining and categorizing the unique characteristics of thermal energy storage techniques, setting GeoTES apart from other technologies. The various components, configurations, subsurface characteristics, and modeling efforts that guide GeoTES development are then explored. Finally, challenges in GeoTES research, development, and deployment are discussed, along with mitigation strategies and lessons from related technologies. Beyond their economic benefits, GeoTES systems support grid resilience and decarbonize industrial processes. Their scalability, broad distribution, seasonal storage potential, and flexible dispatch capacity make GeoTES a valuable tool for expanding renewable energy deployment and addressing climate change.

15 - GEOTHERMAL ENERGY↗
DOE OSTI2022

Soil pH influences the structure of virus communities at local and global scales

The influence of biotic and abiotic factors on viral communities across environmental gradients in soil is relatively unknown. While soil pH strongly influences microbial community structure, it is unclear whether there is a similar influence on soil viruses. In this study, prokaryotic and viral communities were characterized in soils from a long-term pH-manipulated soil gradient (pH 4.5 and 7.5), and viral populations also compared to those of other soils ranging in pH (4.0–7.5). Viral communities were significantly influenced by pH at the local scale with 99% of viral operational taxonomic units restricted to pH 4.5 or 7.5 soil only. Analysis of viromes from six other European and North American soil systems demonstrated that a selection of viral clusters from acidic and neutral pH soils were more associated with those from the local gradient pH 4.5 or 7.5 soils, respectively. While direct pH effects on virion integrity and indirect selection via host composition were not distinguished, the results reveal that soil pH is a factor in structuring viral communities at local and global scales.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

A non-intrusive optical (NIO) approach to characterize heliostats in utility-scale power tower plants: Methodology and in-situ validation

No reliable in-situ optical characterization tool is available that can efficiently and accurately measure various optical errors of individual heliostats in a utility-scale power-tower plant. Here, an innovative non-intrusive optical (NIO) approach is proposed to measure mirror surface slope error, mirror facet canting error, and heliostat tracking error based on reflection images using the natural target—the tower—in a heliostat field. The NIO approach adopts various techniques in photogrammetry, reflectometry, and geometrical optics to first determine the camera position and the actual tower position with respect to the heliostat. Then, Snell’s law is applied to find the surface normal at the reflection point or line of a reflection image and derive the surface slope error, mirror facet canting error, and heliostat tracking error accordingly. In addition, an in-situ validation is performed to demonstrate the feasibility of the NIO approach. Analysis with multiple sets of reflection images on one single heliostat of interest demonstrates that the NIO method can achieve a measurement uncertainty of 0.22 mrad for mirror facet slope error (root-mean-square) at the given test conditions. The sensitivity of measurement uncertainty to various parameters will be presented in a separate work. In the future, state-of-the-art unmanned aerial systems (UAS) are planned to perform the efficient image collection with a goal to complete the survey across a utility-scale field of over 10,000 heliostats within one or a few days depending on the number of UASs. The development of the NIO approach is expected to fill the critical gap for successful solar-field operation and maintenance, which is necessary for the global growth of the solar power-tower technology. The NIO approach can also be applied to any relevant industry requiring high-precision mirror surface shape characterization.

14 SOLAR ENERGY↗