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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 1,567 records · Page 87
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Correlation Between Structural Parameters and Mechanical Properties of Al5083 Sheets Processed by ECAR

In the paper, structural parameters and mechanical properties of Al5083 alloy sheet during equal channel angular rolling (ECAR) process and their relationship are studied. In order to evaluate the effect of ECAR process, Al5083 strips were subjected to the ECAR process for 1, 2, and 3 passes through the die channel angles 110°, 120°, and 130° at two routes. The effect of the process on the microstructural evolution of samples was investigated by means of x-ray diffraction and EBSD techniques. X-ray pattern has been analyzed using Rietveld method to compute structural parameters, including microstrain, average crystallite size, and dislocation density. The results showed that the dislocation density and microstrain were increased, and crystallite size was decreased during ECAR process. It was found that the behavior of variations in mechanical properties was in accordance with the dislocation density changes. This paper revealed that the increase in the strength of ECARed samples could be attributed to reduction in high-angle grain boundaries and the increase in dislocation density. Moreover, the yield strength estimated from Taylor equation was found in accordance very well with the experimentally measured yield strength of the samples.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Optimization of Process Parameters for the Axial Distortion and Distortion Range During Die Quenching of a Spiral Bevel Gear

The strength of high-duty gears can be improved by carburizing and quenching processes. Quenching distortion is inevitable during the process, and it has direct effects on the precision of the gear. For spiral bevel gear with big diameter and small thickness, die quenching process is applied in the manufacturing to control the distortion in axial direction. Die quenching parameters must be optimized to minimize the distortion while considering non-uniformity of chemical compositions and loads. In this paper, material models of gear material (22CrMoH) built based on the phase transformation kinetics, static mechanical properties and phase transformation plasticity equations. Finite element analysis (FEA) models are conducted to study the whole die quenching process based on the production process. Die quenching experiments and testing of microstructures and distortions are conducted to verify the accuracy of the FEA models. The effects of loads and bottom die obliquity on the final distortion are studied to set the appropriate range and control distortion. The distortion was very sensitive to the bottom die obliquity and some part of load ranges. The distortion changes little when the load of inner die was in the range of 1.38-2.07 MPa and the load of outer die was in the range of 2.07-2.76 MPa. The distortion range is fitted the production requirements by setting the inclination angle of bottom die between 0.12° and 0.29°.

36 MATERIALS SCIENCE↗
DOE OSTI2019

An Investigation of Process Parameter Modifications on Additively Manufactured Inconel 718 Parts

Additive manufacturing (AM) allows for the fabrication of complex parts via layer-by-layer melting of metal powder. Laser powder-bed AM processes use a variety of process parameters including beam power, beam velocity, and hatch spacing to control melting. Alterations to these parameters have often been attempted to reduce porosity, for example, but less work has been done to on comprehensive effects of process parameter modifications. This study looks at the effects of altering these parameters on microstructure, porosity, and mechanical performance of Inconel 718. The results showed that process parameter modifications that result in porosity formation can significantly reduce fatigue life, while microstructure changes were minimal and had little effect on tensile properties. The precipitate structure was not found to be changed significantly. These results can inform future process parameter modifications, as well as heat treatments to optimize mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Workability Characteristics and Deformation Mechanisms of Die-Cast AM60 and AZ91 Magnesium Alloys: Correlation with Processing Maps

Thermo-mechanical deformation behavior of the die-cast AM60 and AZ91 alloys was assessed by performing uniaxial compression tests on Gleeble 3800 simulator under different temperatures and strain rate conditions. Low-temperature deformation behavior of both alloys was accessed at 25, 100, and 150 °C, at the strain rates of 0.1 and 1 s{sup −1}. Processing maps at a true strain of 0.5 were generated to study the intrinsic hot workability of AM60 and AZ91 alloys. Optimum processing windows were identified, and the evolution of microstructures and textures was correlated with the imposed deformation conditions. The processing map for the AM60 alloy exhibited three dynamic recrystallization (DRX) domains in the ranges: (1) 320-400 °C and 0.2-1.5 s{sup −1}, (1A) 300-325 °C and 0.1-0.2 s{sup −1}, and (2) 360-400 °C and 3-5 s{sup −1}. In Domain 1, DRX occurred predominantly by pyramidal slip and recovery mechanisms by cross-slip as confirmed by the randomized textures. Deformation in Domain 1A is by the combination of basal and prismatic slip. In Domain 2, dynamic recovery was a softening mechanism controlled by the climb. The processing map for AZ91 alloy exhibited two DRX domains in the ranges: (1) 260-310 °C and 0.1-0.5 s{sup −1} and (2) 325-350 °C and 0.8-3 s{sup −1}. The rate-controlling mechanism was climb by lattice self-diffusion in Domain 1 and by grain boundary self-diffusion in Domain 2. Both alloys exhibited flow instability at 200 and 250 °C, and therefore, they were unsuitable for processing at these temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Tailoring the Properties of a Ni-Based Superalloy via Modification of the Forging Process: an ICME Approach to Fatigue Performance

Traditionally, material design and property modifications are usually associated with compositional changes. However, subtle changes in the manufacturing process parameters can also have a dramatic effect on the resulting material properties. In this work, an integrated computational materials engineering (ICME) framework is adopted to tailor the fatigue performance of a Ni-based superalloy, RR1000. An existing fatigue model is used to identify microstructural features that promote enhanced fatigue life, namely a uniform, fine grain size distribution, random orientation, a distinct grain boundary distribution (specifically high twin boundary density and limited low-angle grain boundaries). A deformation mechanism map and process models for grain boundary engineering of RR1000 are used to identify the optimal thermo-mechanical processing parameters to realize these desirable microstructural features. For validation, small-scale forgings of RR1000 were produced and heat-treated to attain fine grain and coarse grain microstructures that represent the conventionally processed and grain boundary engineered (GBE) conditions, respectively. For each of the four microstructural variants of RR1000, the twin density and grain size were characterized and were in agreement with the desired microstructural attributes. In order to validate the deformation mechanisms and fatigue behavior of the material, high-resolution digital image correlation was performed to generate strain maps relative to the microstructural features. The high density of twin boundaries was confirmed to inhibit the length of slip bands, which is directly attributed to extended fatigue life. Thus, this study demonstrated the successful role of models, both process and performance, in the design and manufacture of Ni-based superalloy disk forgings.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Investigation of Remanufacturing Methods Utilizing Mechanically-Generated and Gas-Atomized Feedstock Production for Directed Energy Deposition Processing Through Specific Energy Consumption Modeling

The goal of this work was to assess the energy consumption of a novel remanufacturing method that utilizes mechanically-generated feedstock for directed energy deposition. Gas-atomization is the state-of-the-art production process for directed energy deposition feedstock, and for this work was incorporated into a remanufacturing process path to provide a comparison method. Specific energy consumption models of remanufacturing utilizing both of these proposed process paths were developed and applied to a case study to investigate energy saving opportunities for future manufacturing paradigms. The energy modelling was done in three stages. First, the mechanically-generated feedstock production energy consumption model was generated from experimental observation. Second, the gas-atomized feedstock production energy consumption model was generated from a combination of experimental observation, reported estimates from the manufacturer, and data found in the literature. Lastly, the energy consumption model of directed energy deposition was derived from experimental observation and compares favorably with reported estimates in the literature. With the models, the specific energy consumption in the two process paths were compared and their application was demonstrated by estimating the energy consumption to remanufacture a bracket. The two feedstock production methods had similar specific energy consumptions. The specific energy consumption of the directed energy deposition process was the greatest component in the respective remanufacturing paths by an order of magnitude; increasing deposition rate is the most important factor for lowering the overall specific energy consumption. The analyzed remanufacturing technologies were estimated to consume less energy than replacement when repairing up to approximately 15% of the original part’s mass.

42 ENGINEERING↗
DOE OSTI2024

A Conceptual Design and Economic Assessment of a Chitin Biorefinery Based on Shrimp Processing Wastes

Due to the extensive production of shrimp in captivity, waste generation has increased significantly and has become an environmental problem. The recovery of biomolecules can be an important way to mitigate the environmental problems associated with processing in this sector. In this sense, the present work aimed to evaluate a biorefinery approach for valuing shrimp farming waste to obtain astaxanthin, chitin and chitosan. Stoichiometric segmentation was used as a tool to identify the process steps, whose information on process variables (fresh water consumption, flow rate and reaction conditions) was adapted from the literature. A biorefinery coupled to a shrimp processing plant was proposed for the immediate use of highly perishable biomass, to guarantee the quality of the extracted products and reduce storage and transportation costs. In practice, the biomass treatment sequence adopted (demineralization followed by deproteinization) eliminates the depigmentation step, as the chitin obtained has a lighter tone. The proposed route was evaluated for four scenarios based on two indicators: gross economic potential (EGP) and metrics for inspection of sales and reagents (MISR). The results indicate that economic viability is achieved only for the production of chitosan, resulting in a gross revenue of US$832.50/cycle and a MISR value > 1. The sale of astaxanthin promotes an increase of US$3.73/cycle in the EGP, considered too low for the inclusion of another stage in the process.

astaxanthin↗
DOE OSTI2025

A detailed study of pre-heating effects in electron beam melting powder bed fusion process

Metal-based additive manufacturing processes, such as powder bed fusion with electron beam (PBF-EB) process, also referred to as electron beam melting (EBM), can produce high-density parts with minimal residual stresses due to the uniform and coherent preheating of the powder bed. However, understanding and controlling the multiple stages of preheating is required to enable the production of high-quality, consistent parts of various materials. This work presents a large-scale, multi-layer, three-dimensional numerical analysis focused on studying the preheating stages for predicting thermal history during the PBF-EB process. The model follows a continuous multi-stage cyclic process, that incorporates all the main stages of the PBF-EB process for 316 L stainless steel. This includes the gradual deposition of a new powder layer, the first and second preheating levels of the powder bed, and the energy deposition during melting (excluding the actual melt-pool behavior simulation). The model employs an adaptive time-scaling approach that automatically adjusts the energy deposition for each solution time-increment. This allows for localized changes in time-resolution over an otherwise computationally expensive multi-layer procedure. The material property variations are also taken into account, with an emphasis on the subtle irreversible changes in powder effective thermal conductivity after the two requisite preheating stages of the powder bed. This effect is studied using simplified conductivity models from the literature for partially sintered powder, validated by a dedicated experiment and numerical simulation. The large-scale model is then used to estimate the actual temperatures during first and second preheating levels for 316 L steel, which is not yet fully supported commercially for PBF-EB. Model predictions are corroborated by experiments, using and analyzing IR images, taken at the completion of each layer by the machine’s built-in infrared camera. The current model also incorporates a qualitative assessment for the effects of conductivity change during pre-heating, as well as evaluates the applicability of the time-scaling approach.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Nitrogen balances and impacts on the algae cultivation-extraction-digestion-cultivation process

Anaerobic digestion of lipid extracted algae is a method for recycling nutrients to a cultivation system. Growth of algae on recycled nitrogen from these systems has been demonstrated. This study focuses on how the initial nitrogen concentration impacts each stage of an integrated cultivation-extraction-digestion-cultivation process; and how the nitrogen is distributed in each step. The entire process was performed at five different initial nitrogen concentrations, ranging from nutrient deplete to excess. Algae production and lipid content were measured to evaluate the impact of initial nitrogen concentration. A thorough nitrogen mass balance for every step of the process was completed. The results show that initial nitrogen concentration had significant impacts on the whole process. The nitrogen recoveries through the nutrient recycle process were all approximately 65% regardless of initial nitrogen concentration. All nitrogen balances closed within experimental error. As a result, the largest losses of nitrogen occurred in the extraction and cultivation steps.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Data processing pipeline for Tianlai experiment

The Tianlai project is a 21cm intensity mapping experiment for detecting dark energy by measuring the baryon acoustic oscillation (BAO) features in the large scale structure power spectrum. This experiment provides an opportunity to test the data processing methods for cosmological 21cm signal extraction, which is still a great challenge in current radio astronomy research. The 21cm signal is much weaker than the foregrounds and easily aected by the imperfections in the instrumental responses. Furthermore, processing the large volumes of interferometer data poses a practical challenge. We have developed a data processing pipeline called tlpipe to process the drift scan survey data from the Tianlai experiment. It performs oine data processing tasks such as radio frequency interference (RFI) agging, array calibration, binning, and map-making, etc. It also includes utility functions needed for the data analysis, such as data selection, transformation, visualization and others. A number of new algorithms are implemented, for example the eigenvector decomposition method for array calibration and the Tikhnov regularization for m-mode analysis. In this paper we describe the design and implementation of the pipeline and illustrate its functions with some analysis of real data. Finally, we outline directions for future development of this publicly code.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2017

MKK4 activates non-canonical NFκB signaling by promoting NFκB2-p100 processing

The NFκB family of transcription factors is crucial for innate or adaptive immunity, inflammation, and diseases including cancer. The two NFκB signaling pathways (canonical and non-canonical) differ from each other in extracellular signals, membrane receptors, signaling adaptors, and dimer subunits. The p52 (NFκB2) subunit, which participates in the non-canonical pathway, is generated by ubiquitin-mediated processing of the p100 precursor. Here, we found that NFκB2 processing and activation were mediated by mitogen-activated protein kinase kinase-4 (MKK4) and its substrate c-Jun N-terminal kinase (JNK). In MKK4-null mouse embryonic fibroblasts (MEFs), serum- and lymphotoxin β receptor (LTβR) antibody-induced processing of p100 and nuclear translocation of p52 were found to be defective. Serum and LTβR antibody activated the MKK4-JNK signaling pathway, and SP600125, a JNK inhibitor, blocked p100 processing. Cellular senescence, one of the responses regulated by the non-canonical NFκB pathway, was observed more frequently in MKK4-null MEFs than in wildtype cells. These results suggest that the MKK4/JNK-dependent pathway regulates NFκB2 processing/activation and, through this mechanism, MKK4 and NFκB2 control cellular growth and senescence. - Highlights: • MKK4 is required for processing and activation of non-canonical NFκB2-p100. • Nuclear translocation of NFκB2-p52 is dependent on ERK activity. • MKK4 depletion and NFκB2 inactivation induces cellular senescence.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2019

Bioremediation of a Common Product of Food Processing by a Human Gut Bacterium

Dramatic increases in processed food consumption represent a global health threat. Maillard reaction products (MRPs), which are common in processed foods, form upon heat-induced reaction of amino acids with reducing sugars and include advanced glycation end products with deleterious health effects. To examine how processed foods affect the microbiota, we fed gnotobiotic mice, colonized with 54 phylogenetically diverse human gut bacterial strains, defined sugar-rich diets containing whey as the protein source or a matched amino acid mixture. Whey or ϵ-fructoselysine, an MRP in whey and many processed foods, selectively increases Collinsella intestinalis absolute abundance and induces Collinsella expression of genomic loci directing import and metabolism of ϵ-fructoselysine to innocuous products. This locus is repressed by glucose in C. aerofaciens, whose abundance decreases with whey, but is not repressed in C. intestinalis. Finally, identifying gut organisms responding to and degrading potentially harmful processed food components has implications for food science, microbiome science, and public health.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2018

A temperature threshold to identify the driving climate forces of the respiratory process in terrestrial ecosystems

Terrestrial ecosystem respiration (R e ) is the second largest carbon flux between the biosphere and atmosphere. Therefore, climate-driven changes of Re greatly impact on future atmospheric CO 2 concentration. The aim of this study was to derive an air temperature threshold to identify the driving climate forces of the respiratory process in terrestrial ecosystems within different temperature zones. A global dataset of 647 site-years of ecosystem flux data and related variables were collected at 152 sites. The quantile regression was applied to evaluate relationships between the maximum realizable Re rates and mean annual air temperature (MAT) as well as other micrometeorological factors (i.e., atmospheric CO 2 concentration, atmospheric water content, soil heat flux, sensible heat flux, latent heat flux, precipitation, relative humidity, and soil water content). Our analysis revealed an ecosystem threshold of MAT of 11 ± 2.3 °C. In ecosystems with MATs lower than the threshold, the maximum R e rates were primarily dependent on temperature and respiration was mainly a temperature-driven process. In ecosystems with MATs higher than the threshold, besides MAT, other factors, such as water availability and surface heat flux, became significant driving forces of the maximum Re rates and respiration was a multi-factor-driven process. Temperature played the key role in generation of the maximum R e rates in the terrestrial ecosystems, while other driving forces reduce the maximum R e rates and the temperature sensitivity of the respiratory process. According to a regression tree analysis, MAT was also the most influencing factor of mean R e rates among the climate forces. The information from this study should be useful to predict the respiratory process in terrestrial ecosystems with different temperatures under the climate change.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

CO 2 conversion to syngas via electrification of endothermal reactors: Process design and environmental impact analysis

CO 2 utilization via reverse water gas shift (rWGS) reaction has been proposed as a path to the sustainable utilization. Here this work presents a detailed process modelling study where steam methane reforming (SMR) generated hydrogen was combined with rWGS to produce syngas (CO + H 2 ) with various hydrogen-to-carbon oxide ratios. To further decrease CO 2 emissions that may offset the benefits of CO 2 converted in rWGS, electrification of endothermal reactors, both SMR and rWGS was considered where CO 2 emitting fuel burning in the furnace was replaced by the emerging ohmic (resistive) heating. Material and energy inventory obtained from process design calculations was used to perform Life Cycle Analysis (LCA) to calculate environmental impacts of CO 2 consumption and reactor electrification. The results showed that greenhouse gas emissions, in CO 2 kg equivalent, were the lowest when both SMR and rWGS were heated using wind-generated electricity, decreasing from 25 to 10 kg CO 2 equivalent for H 2 :CO = 2:1 while the conventional electricity mix used for furnace electrical heating across the board of scenarios generated highest environmental impacts, much higher than those that used natural gas as fuel. Process economics calculations suggested that, when both SMR and rWGS were electrically heated, the process only showed product syngas cost parity with the conventional fuel heated design when electricity cost was ~$0.008/kWh. This suggests that CO 2 utilization scenarios involving process electrification need to be carefully considered from the total design perspective so they do not produce more greenhouse gases than in conventional non-electrified scenarios.

42 ENGINEERING↗
DOE OSTI2019

Integrating terrestrial and aquatic processes toward watershed scale modeling of dissolved organic carbon fluxes

Dissolved organic carbon (DOC) is not only a critical component of global and regional carbon budgets, but also an important precursor for carcinogenic disinfection byproducts (DBP) generated during drinking water disinfection process. The lack of process based watershed scale model for carbon cycling has been a limiting factor impeding effective watershed management to control DOC fluxes to source waters. Here, we integrated terrestrial and aquatic carbon processes into the widely tested Soil and Water Assessment Tool (SWAT) watershed model to enable watershed-scale DOC modeling (referred to as SWAT-DOC hereafter). The modifications to SWAT mainly fall into two groups: (1) DOC production in soils and its transport to aquatic environment by different hydrologic processes, and (2) riverine transformation of DOC and their interactions with particular organic carbon (POC), inorganic carbon and algae (floating and bottom). We tested the new SWAT-DOC model in the Cannonsville watershed, which is part of the New York City (NYC) water supply system, using long-term DOC load data (from 1998 to 2012) derived from 1399 DOC samplings. The calibration and verification results indicate that SWAT-DOC achieved satisfactory performance for both streamflow and DOC at daily and monthly temporal scales. The parameter sensitivity analysis indicates that DOC loads in the Cannonsville watershed are controlled by the DOC production in soils and its transport in both terrestrial and aquatic environments. Further model uncertainty analysis indicates high uncertainties associated with peak DOC loads, which are attributed to underestimation of high streamflows. Therefore, future efforts to enhance SWAT-DOC to better represent runoff generation processes hold promise to further improve DOC load simulation. Overall, the wide use of SWAT and the satisfactory performance of SWAT-DOC make it a useful tool for DOC modeling and mitigation at the watershed scale.

Dissolved Organic Carbon, non-point source polluti↗
DOE OSTI2018

Techno-economic evaluation of a process for direct conversion of methane to aromatics

Natural gas is widely abundant and relatively inexpensive. As such, large quantities are flared every year. This presents an opportunity to use natural gas as a chemical feedstock. Non-oxidative dehydroaromatization of methane, the major component of natural gas is proposed as an option to monetize natural gas. This study evaluates the economics of the methane to benzene process. A catalytic membrane reactor model written in MATLAB has been directly implemented in an Aspen Plus V9 process model using CAPE-OPEN interoperability. Minimum utility requirements and heat exchanger designs were identified in Aspen Energy Analyzer, and process economics for a variety of feed and product prices were assessed using Aspen Process Economic Analyzer. The results indicate that the venture is profitable (profitability index of 1.17, IRR of 35.5%, NRR of 18.2%). The capital cost was found to be $35,500 per daily standard barrel of benzene. Additionally, the process remains economically attractive so long as either the price of benzene remains above $470/ton, or the price of hydrogen remains above $0.8/kg.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Optical vibrational spectroscopic signatures of ammonium diuranate process parameters

Ammonium diuranate (ADU) is commonly encountered in the nuclear fuel cycle; however, previous investigations have shown that ADU is a complex mixture of distinct compounds. Moreover, production parameters are known to heavily influence the composition of the resulting ADU. Here, we examine four samples of ADU prepared at Oak Ridge National Laboratory (ORNL), and one sample of ADU made at Pacific Northwest National Laboratory (PNNL), with the goal of further characterizing and elucidating the effect of processing parameters such as stir rate, strike direction, and temperature on material composition. Process parameters during ADU precipitation at ORNL and PNNL were well documented, and we relate process variables to optical vibrational spectroscopic signatures observed using Raman and infrared (IR) spectroscopy. In addition, powder X-ray diffraction (PXRD) reveals differences in the solid-phase composition of ADU precipitates, but we find that the primary phase is similar to the uranyl oxyhydroxyhydrate mineral metaschoepite. Despite the significant phase contributions of a metaschoepite-like phase, spectroscopic evidence of both nitrate and ammonium are observed for all samples. To gain a more holistic understanding of spectroscopic features of process parameters in ADU, principal component analysis (PCA) is employed and results in observable signatures that relate to the stir rate used during synthesis. These results provide further information about the process-dependence of ADU precipitate composition.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Investigations of effect of phase change mass transfer rate on cavitation process with homogeneous relaxation model

The super high fuel injection pressure and micro size of nozzle orifice has been an important development trend for the fuel injection system. Accordingly, cavitation transient process, fuel compressibility, amount of noncondensable gas in the fuel and cavitation erosion have attracted more attention. Based on the fact of cavitation in itself is a kind of thermodynamic phase change process, this paper takes the perspective of the cavitation phase change mass transfer process to analyze above mentioned phenomenon. The two-phase cavitating turbulent flow simulations with VOF approach coupled with HRM cavitation model and U-RANS of standard k-ε turbulence model were performed for investigations of cavitation phase change mass transfer process. It is concluded the mass transfer time scale coefficient in the Homogenous Relaxation Model (HRM) representing mass transfer rate should tend to be as small as possible in a condition that ensured the solver stable. At very fast mass transfer rate, the phase change occurs at very thin interface between liquid and vapor phase and condensation occurs more focused and then will contribute predictably to a more serious cavitation erosion. Both the initial non-condensable gas in fuel and the fuel compressibility can accelerate the cavitation mass transfer process.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗