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At least 1,513 records · Page 84

Analysis and design of sidestick controller systems for general aviation aircraft

A method to design sidestick controllers for general aviation aircraft with reversible flight controls is proposed. The use of a sidestick in this type of flight vehicle generally increases the stick forces required for maneuvering; this is due to a reduction in the moment arm of application of the force. In the present study, the reduction of stick forces is achieved by incorporating geared tabs in the control-surface design. A complete analysis using the rigid-body aircraft longitudinal equations of motion and stick-force equation in coupled form is carried out. Lateral stick forces are predicted by solving the single-degree-of-freedom roll approximation and aileron stick-force equations. Data are presented for configurations with various tab areas and a wide range of gearing ratios. The results indicate that the method can be used successfully for geared-tab design and stick-force prediction. It is shown that gearing-ratio selection is critical but that tab area does not have a significant impact on the magnitude of stick forces and stick force to stick deflection gradients.

Martin, Daniel M.↗

Acoustics of laminar boundary layers breakdown

Boundary layer flow transition has long been suggested as a potential noise source in both marine (sonar-dome self noise) and aeronautical (aircraft cabin noise) applications, owing to the highly transient nature of process. The design of effective noise control strategies relies upon a clear understanding of the source mechanisms associated with the unsteady flow dynamics during transition. Due to formidable mathematical difficulties, theoretical predictions either are limited to early linear and weakly nonlinear stages of transition, or employ acoustic analogy theories based on approximate source field data, often in the form of empirical correlation. In the present work, an approach which combines direct numerical simulation of the source field with the Lighthill acoustic analogy is utilized. This approach takes advantage of the recent advancement in computational capabilities to obtain detailed information about the flow-induced acoustic sources. The transitional boundary layer flow is computed by solving the incompressible Navier-Stokes equations without model assumptions, thus allowing a direct evaluation of the pseudosound as well as source functions, including the Lighthill stress tensor and the wall shear stress. The latter are used for calculating the radiated pressure field based on the Curle-Powell solution of the Lighthill equation. This procedure allows a quantitative assessment of noise source mechanisms and the associated radiation characteristics during transition from primary instability up to the laminar breakdown stage. In particular, one is interested in comparing the roles played by the fluctuating volume Reynolds stress and the wall-shear-stresses, and in identifying specific flow processes and structures that are effective noise generators.

Wang, Meng↗

Software Tools to Support Research on Airport Departure Planning

A simple, portable and useful collection of software tools has been developed for the analysis of airport surface traffic. The tools are based on a flexible and robust traffic-flow model, and include calibration, validation and simulation functionality for this model. Several different interfaces have been developed to help promote usage of these tools, including a portable Matlab(TM) implementation of the basic algorithms; a web-based interface which provides online access to automated analyses of airport traffic based on a database of real-world operations data which covers over 250 U.S. airports over a 5-year period; and an interactive simulation-based tool currently in use as part of a college-level educational module. More advanced applications for airport departure traffic include taxi-time prediction and evaluation of "windowing" congestion control.

Carr, Francis↗

Materials Science Research Rack Onboard the International Space Station

The Materials Science Research Rack (MSRR) is a research facility developed under a cooperative research agreement between NASA and ESA for materials science investigations on the International Space Station (ISS). MSRR was launched on STS-128 in August 2009 and currently resides in the U.S. Destiny Laboratory Module. Since that time, MSRR has logged more than 1000 hours of operating time. The MSRR accommodates advanced investigations in the microgravity environment on the ISS for basic materials science research in areas such as solidification of metals and alloys. The purpose is to advance the scientific understanding of materials processing as affected by microgravity and to gain insight into the physical behavior of materials processing. MSRR allows for the study of a variety of materials, including metals, ceramics, semiconductor crystals, and glasses. Materials science research benefits from the microgravity environment of space, where the researcher can better isolate chemical and thermal properties of materials from the effects of gravity. With this knowledge, reliable predictions can be made about the conditions required on Earth to achieve improved materials. MSRR is a highly automated facility with a modular design capable of supporting multiple types of investigations. The NASA-provided Rack Support Subsystem provides services (power, thermal control, vacuum access, and command and data handling) to the ESA-developed Materials Science Laboratory (MSL) that accommodates interchangeable Furnace Inserts (FI). Two ESA-developed FIs are presently available on the ISS: the Low Gradient Furnace (LGF) and the Solidification and Quenching Furnace (SQF). Sample Cartridge Assemblies (SCAs), each containing one or more material samples, are installed in the FI by the crew and can be processed at temperatures up to 1400C. ESA continues to develop samples with 14 planned for launch and processing in the near future. Additionally NASA has begun developing SCAs to support US PIs and their partners. The first of these Flight SCAs are being developed for investigations to support research in the areas of crystal growth and liquid phase sintering. Subsequent investigations are in various stages of development. US investigations will include a ground test program in order to distinguish the particular effects of the absence of gravity.

Reagan, Shawn↗

Materials Science Research Rack Onboard the International Space Station

The Materials Science Research Rack (MSRR) is a research facility developed under a cooperative research agreement between NASA and ESA for materials science investigations on the International Space Station (ISS). MSRR was launched on STS-128 in August 2009 and currently resides in the U.S. Destiny Laboratory Module. Since that time, MSRR has logged more than 1000 hours of operating time. The MSRR accommodates advanced investigations in the microgravity environment on the ISS for basic materials science research in areas such as solidification of metals and alloys. The purpose is to advance the scientific understanding of materials processing as affected by microgravity and to gain insight into the physical behavior of materials processing. MSRR allows for the study of a variety of materials, including metals, ceramics, semiconductor crystals, and glasses. Materials science research benefits from the microgravity environment of space, where the researcher can better isolate chemical and thermal properties of materials from the effects of gravity. With this knowledge, reliable predictions can be made about the conditions required on Earth to achieve improved materials. MSRR is a highly automated facility with a modular design capable of supporting multiple types of investigations. The NASA-provided Rack Support Subsystem provides services (power, thermal control, vacuum access, and command and data handling) to the ESA-developed Materials Science Laboratory (MSL) that accommodates interchangeable Furnace Inserts (FI). Two ESA-developed FIs are presently available on the ISS: the Low Gradient Furnace (LGF) and the Solidification and Quenching Furnace (SQF). Sample Cartridge Assemblies (SCAs), each containing one or more material samples, are installed in the FI by the crew and can be processed at temperatures up to 1400C. ESA continues to develop samples with 14 planned for launch and processing in the near future. Additionally NASA has begun developing SCAs to support US PIs and their partners. The first of these Flight SCAs are being developed for investigations to support research in the areas of crystal growth and liquid phase sintering. Subsequent investigations are in various stages of development. US investigations will include a ground test program in order to distinguish the particular effects of the absence of gravity.

Reagan, Shawn↗

Materials Science Research Rack Onboard the International Space Station

The Materials Science Research Rack (MSRR) is a research facility developed under a cooperative research agreement between NASA and ESA for materials science investigations on the International Space Station (ISS). MSRR was launched on STS-128 in August 2009 and currently resides in the U.S. Destiny Laboratory Module. Since that time, MSRR has logged more than 1400 hours of operating time. The MSRR accommodates advanced investigations in the microgravity environment on the ISS for basic materials science research in areas such as solidification of metals and alloys. The purpose is to advance the scientific understanding of materials processing as affected by microgravity and to gain insight into the physical behavior of materials processing. MSRR allows for the study of a variety of materials, including metals, ceramics, semiconductor crystals, and glasses. Materials science research benefits from the microgravity environment of space, where the researcher can better isolate chemical and thermal properties of materials from the effects of gravity. With this knowledge, reliable predictions can be made about the conditions required on Earth to achieve improved materials. MSRR is a highly automated facility with a modular design capable of supporting multiple types of investigations. The NASA-provided Rack Support Subsystem provides services (power, thermal control, vacuum access, and command and data handling) to the ESA-developed Materials Science Laboratory (MSL) that accommodates interchangeable Furnace Inserts (FI). Two ESA-developed FIs are presently available on the ISS: the Low Gradient Furnace (LGF) and the Solidification and Quenching Furnace (SQF). Sample Cartridge Assemblies (SCAs), each containing one or more material samples, are installed in the FI by the crew and can be processed at temperatures up to 1400C. ESA continues to develop samples with 14 planned for launch and processing in the near future. Additionally NASA has begun developing SCAs to support US PIs and their partners. The first of these Flight SCAs are being developed for investigations to support research in the areas of crystal growth and liquid phase sintering. Subsequent investigations are in various stages of development. US investigations will include a ground test program in order to distinguish the particular effects of the absence of gravity.

Reagan, Shawn↗

Materials Science Research Rack Onboard the International Space Station

The Materials Science Research Rack (MSRR) is a research facility developed under a cooperative research agreement between NASA and ESA for materials science investigations on the International Space Station (ISS). MSRR was launched on STS-128 in August 2009 and currently resides in the U.S. Destiny Laboratory Module. Since that time, MSRR has logged more than 1400 hours of operating time. The MSRR accommodates advanced investigations in the microgravity environment on the ISS for basic materials science research in areas such as solidification of metals and alloys. The purpose is to advance the scientific understanding of materials processing as affected by microgravity and to gain insight into the physical behavior of materials processing. MSRR allows for the study of a variety of materials, including metals, ceramics, semiconductor crystals, and glasses. Materials science research benefits from the microgravity environment of space, where the researcher can better isolate chemical and thermal properties of materials from the effects of gravity. With this knowledge, reliable predictions can be made about the conditions required on Earth to achieve improved materials. MSRR is a highly automated facility with a modular design capable of supporting multiple types of investigations. The NASA-provided Rack Support Subsystem provides services (power, thermal control, vacuum access, and command and data handling) to the ESA-developed Materials Science Laboratory (MSL) that accommodates interchangeable Furnace Inserts (FI). Two ESA-developed FIs are presently available on the ISS: the Low Gradient Furnace (LGF) and the Solidification and Quenching Furnace (SQF). Sample Cartridge Assemblies (SCAs), each containing one or more material samples, are installed in the FI by the crew and can be processed at temperatures up to 1400degC. ESA continues to develop samples with 14 planned for launch and processing in the near future. Additionally NASA has begun developing SCAs to support US PIs and their partners. The first of these Flight SCAs are being developed for investigations to support research in the areas of crystal growth and liquid phase sintering. Subsequent investigations are in various stages of development. US investigations will include a ground test program in order to distinguish the particular effects of the absence of gravity.

Reagan, S. E.↗

Modeling Relationships Between Flight Crew Demographics and Perceptions of Interval Management

The Interval Management Alternative Clearances (IMAC) human-in-the-loop simulation experiment was conducted to assess interval management system performance and participants' acceptability and workload while performing three interval management clearance types. Twenty-four subject pilots and eight subject controllers flew ten high-density arrival scenarios into Denver International Airport during two weeks of data collection. This analysis examined the possible relationships between subject pilot demographics on reported perceptions of interval management in IMAC. Multiple linear regression models were created with a new software tool to predict subject pilot questionnaire item responses from demographic information. General patterns were noted across models that may indicate flight crew demographics influence perceptions of interval management.

Remy, Benjamin↗

Numerical Simulation of a Simplified High-Lift CRM Configuration Embedded with Fluidic Actuators

Numerical simulations have been performed for a simplified high-lift configuration that is representative of a modern transport airplane. This configuration includes a leading-edge slat, fuselage, wing, nacelle-pylon and a simple hinged flap. The suction surface of the flap is embedded with multiple rows of fluidic actuators to reduce the extent of reversed flow regions and improve the aerodynamic performance of the configuration with flap in a deployed state. In the current paper, a Lattice Boltzmann Method based high-fidelity computational fluid dynamics (CFD) code, known as PowerFLOW® is used to simulate the entire flow field associated with this configuration, including the flow inside the actuators. A fully compressible version of the PowerFLOW® code that has been validated for high speed flows is used for the present simulations to accurately represent the transonic flow regimes that are encountered in the flow field generated by the actuators operating at higher mass flow (momentum) rates required to mitigate reverse flow regions on the suction surfaces of the main wing and the flap. The numerical solutions predict the expected trends in aerodynamic forces as the actuation levels are increased. More efficient active flow control (AFC) systems and actuator arrangement for lift augmentation are emerging based on the parametric studies conducted here prior to wind tunnel tests. These numerical solutions will be compared with experimental data, once such data becomes available.

Vatsa, Veer N.↗

Regional Relative Risk, a Physics-Based Metric for Characterizing Airborne Infectious Disease Transmission

Airborne infectious disease transmission events occur over a wide range of spatial scales and can be an important means of disease transmission. Physics- and biology-based models can assist in predicting airborne transmission events, overall disease incidence, and disease control strategy efficacy. We describe a new theory that extends current approaches for the case in which an individual is infected by a single airborne particle, including the scenario in which numerous infectious particles are present in the air but only one causes infection. A single infectious particle can contain more than one pathogenic microorganism and be physically larger than the pathogen itself. This approach allows robust relative risk estimates even when there is wide variation in (i) individual exposures and (ii) the individual response to that exposure (the pathogen dose-response function can take any mathematical form and vary by individual). Based on this theory, we propose the regional relative risk—a new metric, distinct from the traditional relative risk metric, that compares the risk between two regions. In theory, these regions can range from individual rooms to large geographic areas. In this paper, we apply the regional relative risk metric to outdoor disease transmission events over spatial scales ranging from 50 m to 20 km, demonstrating that in many common cases minimal input information is required to use the metric. Also, we demonstrate that the model predictions are consistent with data from prior outbreaks. Future efforts could apply and validate this theory for other spatial scales, such as transmission within indoor environments. This work provides context for (i) the initial stages of an airborne disease outbreak and (ii) larger-scale disease spread, including unexpected low-probability disease “sparks” that potentially affect remote populations, a key practical issue in controlling airborne disease outbreaks.

54 ENVIRONMENTAL SCIENCES↗

Predicting the Rate of Degradation Related to Oxygen Electrode Delamination in Solid Oxide-Ion Electrolyzers

One of the leading causes for the performance degradation in H 2 -producing solid oxide electrolytic cells (SOECs) is the gradual delamination of oxygen electrode (OE) from the electrolyte under a strong anodic polarization. Identification of the key factor that controls the rate of OE delamination is of paramount importance to achieve long-term stable operation of SOECs. Here we show from thousands of hours of testing data that the exchange current density (i°) of OE can be leveraged as a predictor for the rate of delamination. To obtain i°, we apply DC-biased electrochemical impedance spectroscopy on a three-electrode symmetrical cell to measure polarization resistance (R p ) of OE as a function of current density (i) and time (t). The collected R p -i-t raw data are then converted to overpotential ( η )-i-t, from which i° is extracted from the “low-field” approximation. An analytical relationship between i° and time-to-delamination (TTD) is further established from the established i°-i-t relationship. We show that under a constant anodic polarization current density i, the greater the ratio i/i°, the faster the delamination. Therefore, we conclude that the exchange current density of an OE, i°, can be used to predict the rate of OE degradation in solid oxide-ion electrolyzers.

25 ENERGY STORAGE↗

Chespa: Streamlining Expansive Chemical Space Evaluation of Molecular Sets

Thousands of chemical properties can be calculated for small molecules, which can be used to place the molecules within the context of a broader “chemical space.” These definitions vary based on compounds of interest and the goals for the given chemical space definition. Here, we introduce a customizable (i.e., modular) Python module, chespa, built to easily assess different chemical space definitions through cluster-ing of compounds in these spaces and visualize trends of these clusters. To demonstrate this, chespa currently streamlines prediction of vari-ous molecule descriptors (predicted chemical properties, molecular substructures, AI-based chemical space, and chemical class ontology) in order to test 6 different chemical space definitions. Furthermore, we investigated how these varying definitions trend with mass spectrometry (MS)-based observability, i.e., the ability of a molecule to be observed with MS (e.g., as a function of the molecule ionizability), using an example data set from the U.S. EPA's Non-Targeted Analysis Collaborative Trial (ENTACT), where blinded samples had been analyzed previously, providing 1,398 data points. Improved understanding of observability would offer many advantages in small molecule identifica-tion, such as (i) a priori selection of experimental conditions based on suspected sample composition, (ii) the ability to reduce the number of candidate structures during compound identification by removing those less likely to ionize, and, in turn, (iii) a reduced false discovery rate and increased confidence in identifications. Factors controlling observability are not fully understood, making prediction of this property non-trivial and a prime candidate for chemical space analysis. Chespa is available at github.com/pnnl/chespa.

Nunez, Jamie↗

A Matlab-Based Graphical User Interface for Simulation and Control Design of a Hydrogen Mixer

A Graphical User Interface (GUI) that facilitates prediction and control design tasks for a propellant mixer is described. The Hydrogen mixer is used in rocket test stand operations at the NASA John C. Stennis Space Center. The mixer injects gaseous hydrogen (GH2) into a stream of liquid hydrogen (LH2) to obtain a combined flow with desired thermodynamic properties. The flows of GH2 and LH2 into the mixer are regulated by two control valves, and a third control valve is installed at the exit of the mixer to regulate the combined flow. The three valves may be simultaneously operated in order to achieve any desired combination of total flow, exit temperature and mixer pressure within the range of operation. The mixer, thus, constitutes a three-input, three-output system. A mathematical model of the mixer has been obtained and validated with experimental data. The GUI presented here uses the model to predict mixer response under diverse conditions.

Richter, Hanz↗

Deciphering Distinct Overpotential-Dependent Pathways for Electrochemical CO 2 Reduction Catalyzed by an Iron–Terpyridine Complex

[Fe(tpyPY2Me)] 2+ ([Fe] 2+ ) is a homogeneous electrocatalyst for converting CO 2 into CO featuring low overpotentials of <100 mV, near-unity selectivity, and high activity with turnover frequencies faster than 100 000 s -1 . To identify the origins of its exceptional performance and inform future catalyst design, we report a combined computational and experimental study that establishes two distinct mechanistic pathways for electrochemical CO 2 reduction catalyzed by [Fe] 2+ as a function of applied overpotential. Electrochemical data shows the formation of two catalytic regimes at low (η TOF/2 of 160 mV) and high (η TOF/2 of 590 mV) overpotential plateaus. We propose that at low overpotentials [Fe] 2+ undergoes a two-electron reduction, two-proton-transfer mechanism (electrochemical-electrochemical-chemical-chemical, EECC), where turnover occurs through the dicationic iron complex, [Fe] 2+ . Computational analysis supports the importance of the singlet ground-state electronic structure for CO 2 binding and that the rate-limiting step is the second protonation in this low-overpotential regime. When more negative potentials are applied, an additional electron-transfer event occurs through either a stepwise or proton-coupled electron-transfer (PCET) pathway, enabling catalytic turnover from the monocationic iron complex ([Fe] + ) via an electrochemical-chemical-electrochemical-chemical (ECEC) mechanism. Comparison of experimental kinetic data obtained from variable controlled potential electrolysis (CPE) experiments with direct product detection with calculated rates obtained from the energetic span model supports the PCET pathway as the most likely mechanism. Moreover, we build upon this mechanistic understanding to propose the design of an improved ligand framework that is predicted to stabilize the key transition states identified in our study and explore their electronic structures using an energy decomposition analysis. Finally, taken together, this work highlights the value of synergistic computational/experimental approaches to decipher mechanisms of new electrocatalysts and direct the rational design of improved platforms.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Data from: "Ecophysiological variation in two provenances of Pinus flexilis seedlings across an elevation gradient from forest to alpine"

This archive contains data used to support conclusions drawn in “Ecophysiological variation in two provenances of Pinus flexilis seedlings across an elevation gradient from forest to alpine”, by Reinhardt et al., 2011. Data were collected over one summer season in plots within the Alpine Treeline Warming Experiment (ATWE), before climate manipulations began. The experiment was located on Niwot Ridge, in the Front Range of the Colorado Rocky Mountains. This data package includes five comma-separated-values (.csv) files, five Microsoft Excel (.xlsx) files, one .pdf file, and two types of geospatial files: keyhole markup language (.kml), and ESRI shapefiles (.shp). .csv files can be opened using any simple text-editing software (such as Notepad and TextEdit), R, and Microsoft Excel. .xlsx files can only be opened using Microsoft Excel. The .pdf file can be opened using Adobe Acrobat Reader or any other compatible file viewing software. The .kml file can be opened using Google Earth and Google Maps, and shapefiles can be opened using any software compatible with the file type, such as ESRI’s ArcGIS suite and QGIS.Data archived contain gas exchange and plant physiology measurements, non-structural carbohydrate data, among others. Geospatial files are also provided for additional locational context. The files and their contents in this data package are summarized under "Data Summary" in the included Data User's Guide. All files (excluding geospatial) are available in both Microsoft Excel and in .csv format, and are indicated in the Data Summary list as well.-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------Climate change is predicted to cause upward shifts in forest tree distributions, which will require seedling recruitment beyond current forest boundaries. However, predicting the likelihood of successful plant establishment beyond current species’ ranges under changing climate is complicated by the interaction of genetic and environmental controls on seedling establishment. To determine how genetics and climate may interact to affect seedling establishment, we transplanted recently germinated seedlings from high- and low-elevation provenances (HI and LO, respectively) of Pinus flexilis in common gardens arrayed along an elevation and canopy gradient from subalpine forest into the alpine zone and examined differences in physiology and morphology between provenances and among sites. Plant dry mass, projected leaf area and shoot:root ratios were 12–40% greater in LO compared with HI seedlings at each elevation. There were no significant changes in these variables among sites except for decreased dry mass of LO seedlings in the alpine site. Photosynthesis, carbon balance (photosynthesis/respiration) and conductance increased >2× with elevation for both provenances, and were 35–77% greater in LO seedlings compared with HI seedlings. There were no differences in dark-adapted chlorophyll fluorescence (Fv/Fm) among sites or between provenances. Our results suggest that for P. flexilis seedlings, provenances selected for above-ground growth may outperform those selected for stress resistance in the absence of harsh climatic conditions, even well above the species’ range limits in the alpine zone. This indicates that forest genetics may be important to understanding and managing species’ range adjustments due to climate change.

54 ENVIRONMENTAL SCIENCES↗

Modular Hydronic Room Conditioning System (CRADA NFE-24-10120 Final Report)

This project presents the development and validation of high-fidelity numerical models for fin-tube heat exchangers to enable accurate performance prediction and informed design optimization. The modeling framework integrates detailed geometric specifications, thermophysical property data, and system-level constraints to simulate the heat exchanger’s behavior under a range of operating conditions. The model is calibrated using real-world product specifications and validated against experimental data collected from controlled cooling and heating tests. In cooling mode, the model captures the overall trends in capacity and outlet air temperature but tends to underpredict latent effects, especially at lower air flow rates. In heating mode, the simulation consistently overestimates both the thermal capacity and outlet air temperature, indicating the need for refinement in air-side heat transfer assumptions. Despite these deviations, the model provides a solid foundation for optimization, allowing key design variables to be tuned within physical and performance-based constraints. This research advances the ability to simulate, validate, and optimize fin-tube heat exchanger designs with greater confidence and efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Modular Hydronic Room Conditioning System

This project presents the development and validation of high-fidelity numerical models for fin-tube heat exchangers to enable accurate performance prediction and informed design optimization. The modeling framework integrates detailed geometric specifications, thermophysical property data, and system-level constraints to simulate the heat exchanger’s behavior under a range of operating conditions. The model is calibrated using real-world product specifications and validated against experimental data collected from controlled cooling and heating tests. In cooling mode, the model captures the overall trends in capacity and outlet air temperature but tends to underpredict latent effects, especially at lower air flow rates. In heating mode, the simulation consistently overestimates both the thermal capacity and outlet air temperature, indicating the need for refinement in air-side heat transfer assumptions. Despite these deviations, the model provides a solid foundation for optimization, allowing key design variables to be tuned within physical and performance-based constraints. This research advances the ability to simulate, validate, and optimize fin tube heat exchanger designs with greater confidence and efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Establishment of a Vertically Integrated Domestic Manufacturing Process for Production of Substrates Needed for Manufacture of Gas Diffusion Layers

In this project, AvCarb, LLC evaluated the baseline performance metrics of commercial carbon veils and their corresponding Gas Diffusion Layers (GDLs) with the goal of establishing an optimized, vertically integrated production system for wet-laid nonwoven substrates used in gas diffusion media for electrochemical energy storage and conversion devices. Mechanical testing and microstructural characterization were conducted and used to develop a multiscale computational model capable of simulating and predicting the performance of GDLs in fuel cells. Although the project successfully generated foundational transport and modeling data, it was terminated prior to identifying the critical GDL design parameters necessary for full optimization. The program aimed to improve carbon veil fabrication through enhanced fiber dispersion, fiber-fiber adhesion control, and improved web formation, enabling the production of high-quality, uniform substrates. Simulations were intended to guide mixing and solution delivery system design and process conditions, followed by production-scale trials to evaluate fiber dispersion, web uniformity, and mechanical robustness. At full deployment, the proposed production line would have been capable of producing approximately 650,000 m² of carbon veil annually. This capability remains strategically important, as the United States currently lacks a domestic source of wet-laid nonwoven carbon substrates that satisfy the stringent quality requirements for fuel-cell GDLs and electrolyzers representing an ongoing supply-chain vulnerability. Beyond supply-chain benefits, the project established a robust benchmarking dataset for existing commercial carbon veils while advancing next-generation material concepts targeting improved performance and manufacturing consistency.

Olson, Cynthia Lemay↗