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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 OSTI2022

Experimental Investigation of Cavitation-Induced Erosion Using X-Ray Imaging and Tomography

High injection pressure in diesel engines can lead to cavitation-induced erosion in injector nozzles. One important factor affecting the severity of erosion is the fuel and its properties. Traditionally, modeling and simulation studies have used single-component representations of fuels, but realistic fuels feature a multitude of components and can even include volatile additives such as water and alcohol. To provide realistic benchmarks and comparisons, experimental measurements quantifying erosion characteristics were made using ultra-low sulfur diesel (ULSD) and two alternative diesel fuels (ADF). X-ray imaging and computed tomography were used to investigate cavitation-induced erosion onset and progression. Hard X-ray tomography revealed injector internal geometry, including details such as surface marks from the manufacturing process and erosion patterns from repeated injections. Erosion progression was measured using X-ray tomography and imaging performed between injections. The critical erosion site was found to be similar across different fuel blends, while the erosion rate and incubation time were sensitive to the fuel blend. The injector geometry and the erosion characteristics were also prepared for numerical model development and validation.

42 ENGINEERING↗
DOE OSTI2024

A novel open-source cultivation system helps establish the first full cycle chemosynthetic symbiosis model system involving the giant ciliate Zoothamnium niveum

Symbiotic interactions drive species evolution, with nutritional symbioses playing vital roles across ecosystems. Chemosynthetic symbioses are globally distributed and ecologically significant, yet the lack of model systems has hindered research progress. The giant ciliate Zoothamnium niveum and its sulfur-oxidizing symbionts represent the only known chemosynthetic symbiosis with a short life span that has been transiently cultivated in the laboratory. While it is experimentally tractable and presents a promising model system, it currently lacks an open-source, simple, and standardized cultivation setup. Following the FABricated Ecosystems (EcoFABs) model, we leveraged 3D printing and polydimethylsiloxane (PDMS) casting to develop simple flow-through cultivation chambers that can be produced and adopted by any laboratory. The streamlined manufacturing process reduces production time by 86% and cuts cost by tenfold compared to the previous system. Benchmarking using previously established optimal growth conditions, the new open-source cultivation system proves stable, efficient, more autonomous, and promotes a more prolific growth of the symbiosis. For the first time, starting from single cells, we successfully cultivated the symbiosis in flow-through chambers for 20 days, spanning multiple generations of colonies that remained symbiotic. They were transferred from chamber to chamber enabling long-term cultivation and eliminating the need for continuous field sampling. The chambers, optimized for live imaging, allowed detailed observation of the synchronized growth between the host and symbiont. Highlighting the benefit of this new system, we here describe a new step in the first hours of development where the host pauses growth, expels a coat, before resuming growth, hinting at a putative symbiont selection mechanism early in the colony life cycle. With this simple, open-source, cultivation setup, Z. niveum holds promises for comparative studies, standardization of research and wide adoption by the symbiosis research community.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Low-Temperature Annealing of Nanoscale Defects in Polycrystalline Graphite

Polycrystalline graphite contains multi-scale defects, which are difficult to anneal thermally because of the extremely high temperatures involved in the manufacturing process. In this study, we demonstrate annealing of nuclear graphite NBG-18 at temperatures below 28 °C, exploiting the electron wind force, a non-thermal stimulus. High current density pulses were passed through the specimens with a very low-duty cycle so that the electron momentum could mobilize the defects without heating the specimen. The effectiveness of this technique is presented with a significant decrease in electrical resistivity, defect counts from X-ray computed tomography, Raman spectroscopy, and nanoindentation-based mechanical characterization. Such multi-modal evidence highlights the feasibility of nanoscale defect control at temperatures about two orders of magnitude below the graphitization temperature.

Liu, Gongyuan↗
DOE OSTI2024

New Thermochemical Salt Hydrate System for Energy Storage in Buildings

This paper introduces an innovative design for an “inorganic salt-expanded graphite” composite thermochemical system. The storage unit is made of a perforated, compressed, expanded graphite block impregnated with molten CaCl 2 ∙6H 2 O; the humid air passes through the holes that allow the moisture to diffuse and react with the salt. The prepared block underwent 90 hydration-dehydration cycles. Although most of the performed cycles were carried out with salt overhydration and deliquescence, the treated samples have remained mechanically and thermally stable with no drop in energy density. The volumetric energy density of the composite ranged from 135.5 to 277.6 kWh/m 3 , depending on airflow rate and absolute humidity. To ensure composite material cycling stability, the energy density of the block was measured during hydration at similar conditions of absolute humidity, inlet temperature, and airflow rate (0.01 kg water /kg air , 20 °C, 400 l/min). The average energy density at these conditions was sustained at 219 kWh/m 3 . The block integrity was monitored by visual inspection after removing it from the reactor chamber every few cycles. Both the composite material and its manufacturing process are simple and easy to scale up for future commercialization.

25 ENERGY STORAGE↗
DOE OSTI2018

A Novel CAE Method for Compression Molding Simulation of Carbon Fiber-Reinforced Thermoplastic Composite Sheet Materials

Its high-specific strength and stiffness with lower cost make discontinuous fiber-reinforced thermoplastic (FRT) materials an ideal choice for lightweight applications in the automotive industry. Compression molding is one of the preferred manufacturing processes for such materials as it offers the opportunity to maintain a longer fiber length and higher volume production. In the past, we have demonstrated that compression molding of FRT in bulk form can be simulated by treating melt flow as a continuum using the conservation of mass and momentum equations. However, the compression molding of such materials in sheet form using a similar approach does not work well. The assumption of melt flow as a continuum does not hold for such deformation processes. To address this challenge, we have developed a novel simulation approach. First, the draping of the sheet was simulated as a structural deformation using the explicit finite element approach. Next, the draped shape was compressed using fluid mechanics equations. The proposed method was verified by building a physical part and comparing the predicted fiber orientation and warpage measurements performed on the physical parts. The developed method and tools are expected to help in expediting the development of FRT parts, which will help achieve lightweight targets in the automotive industry.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Additive Manufacturing of C/C-SiC Ceramic Matrix Composites by Automated Fiber Placement of Continuous Fiber Tow in Polymer with Pyrolysis and Reactive Silicon Melt Infiltration

An additive manufacturing process for fabricating ceramic matrix composites has been developed based on the C/C-SiC system. Automated fiber placement of the continuous carbon fibers in a polyether ether ketone matrix was performed to consolidate the carbon fibers into a printed preform. Pyrolysis was performed to convert the polymer matrix to porous carbon, and then Si was introduced by reactive melt infiltration to convert a portion of the carbon matrix to silicon carbide. The densities and microstructures were characterized after each step during the processing, and the mechanical properties were measured. The C/C-SiC composites exhibited a porosity of 10–20%, characteristic flexural strength of 234.91 MPa, and Weibull modulus of 3.21. The composites displayed toughness via a significant displacement to failure.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Mechanical and Tribological Performance of Additively Manufactured Nanocrystalline Aluminum via Cryomilling and Cold Spray

In this study, nanocrystalline (NC) aluminum (Al) and magnesium (Mg)-doped Al bulk components were fabricated using a hybrid manufacturing process that combines cryomilling and high-pressure cold spray (HPCS) additive deposition techniques. Yttria-stabilized zirconia (YSZ) was also added during the HPCS process to improve deposition efficiency and build-up thickness via peening. The evolution of morphology, crystallite size, and elemental composition of both cryomilled powders and cold-sprayed (CS’ed) components was systematically characterized using X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), and Transmission Electron Microscopy (TEM). Mechanical characterization was performed using Vickers microhardness and uniaxial tensile testing, while the tribological behavior was assessed using sliding wear tests under dry/lubricated conditions. XRD analysis revealed that increased cryomilling duration led to significant crystallite refinement, which directly correlated with enhanced hardness and strength. This mechanical strengthening was accompanied by an increase in coefficient of friction (COF) and lower wear rates. The results also showed that the Mg-doped Al exhibited superior hardness, tensile strength, and tribological performance compared to pure Al. The study further explores the underlying mechanisms responsible for these enhancements, highlighting the potential of solute-assisted grain boundary stabilization in tailoring high-performance NC Al alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2022

High-Strain Rate Spall Strength Measurement for CoCrFeMnNi High-Entropy Alloy

In this study, we experimentally investigate the high stain rate and spall behavior of Cantor high-entropy alloy (HEA), CoCrFeMnNi. First, the Hugoniot equations of state (EOS) for the samples are determined using laser-driven CoCrFeMnNi flyers launched into known Lithium Fluoride (LiF) windows. Photon Doppler Velocimetry (PDV) recordings of the velocity profiles find the EOS coefficients using an impedance mismatch technique. Following this set of measurements, laser-driven aluminum flyer plates are accelerated to velocities of 0.5–1.0 km/s using a high-energy pulse laser. Upon impact with CoCrFeMnNi samples, the shock response is found through PDV measurements of the free surface velocities. From this second set of measurements, the spall strength of the alloy is found for pressures up to 5 GPa and strain rates in excess of 106 s−1. Further analysis of the failure mechanisms behind the spallation is conducted using fractography revealing the occurrence of ductile fracture at voids presumed to be caused by chromium oxide deposits created during the manufacturing process.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Deformation Behavior of Foam Laser Targets Fabricated by Two-Photon Polymerization

Two-photon polymerization (2PP), which is a three-dimensional micro/nano-scale additive manufacturing process, is used to fabricate component for small custom experimental packages (“targets”) to support laser-driven, high-energy-density physics research. Of particular interest is the use of 2PP to deterministically print millimeter-scale, low-density, and low atomic number (CHO) polymer matrices (“foams”). Deformation during development and drying of the foam structures remains a challenge when using certain commercial acrylic photo-resins. Acrylic resins were chosen in order to meet the low atomic number requirement for the foam; that requirement precludes the use of low-shrinkage organic/inorganic hybrid resins. Here, we compare the use of acrylic resins IP-S and IP-Dip. Infrared and Raman spectroscopy are used to quantify the extent of the polymerization during 2PP vs. UV curing. The mechanical strength of beam and foam structures is examined, particularly the degree of deformation that occurs during the development and drying processes. The magnitude of the shrinkage is quantified, and finite element analysis is used in order to simulate the resulting deformation. Capillary drying forces during development are shown to be small and are likely below the elastic limit of the foam log-pile structures. In contrast, the substantial shrinkage in IP-Dip (~5–10%) causes large shear stresses and associated plastic deformation, particularly near constrained boundaries and locations with sharp density transitions. Use of IP-S with an improved writing procedure results in a marked reduction in deformation with a minor loss of resolution.

Liu, Ying↗
DOE OSTI2019

Use of Thermistor Temperature Sensors for Cyber-Physical System Security

The last few decades have seen a large proliferation in the prevalence of cyber-physical systems. This has been especially highlighted by the explosive growth in the number of Internet of Things (IoT) devices. Unfortunately, the increasing prevalence of these devices has begun to draw the attention of malicious entities which exploit them for their own gain. What makes these devices especially attractive is the various resource constraints present in these devices that make it difficult to add standard security features. Therefore, one intriguing research direction is creating security solutions out of already present components such as sensors. Physically Unclonable Functions (PUFs) are one potential solution that use intrinsic variations of the device manufacturing process for provisioning security. In this work, we propose a novel weak PUF design using thermistor temperature sensors. Our design uses the differences in resistance variation between thermistors in response to temperature change. To generate a PUF that is reliable across a range of temperatures, we use a response-generation algorithm that helps mitigate the effects of temperature variation on the thermistors. We tested the performance of our proposed design across a range of environmental operating conditions. From this we were able to evaluate the reliability of the proposed PUF with respect to variations in temperature and humidity. We also evaluated the PUF’s uniqueness using Monte Carlo simulations.

Internet of Things (IoT)↗
DOE OSTI2023

Dose Response, Dosimetric, and Metabolic Evaluations of Replacement PFAS Perfluoro-(2,5,8-trimethyl-3,6,9-trioxadodecanoic) Acid (HFPO-TeA)

Few studies are available on the environmental and toxicological effects of perfluoroalkyl ether carboxylic acids (PFECAs), such as GenX, which are replacing legacy PFAS in manufacturing processes. To collect initial data on the toxicity and toxicokinetics of a longer-chain PFECA, male and female Sprague Dawley rats were exposed to perfluoro-(2,5,8-trimethyl-3,6,9-trioxadodecanoic) acid (HFPO-TeA) by oral gavage for five days over multiple dose levels (0.3–335.2 mg/kg/day). Clinically, we observed mortality at doses >17 mg/kg/day and body weight changes at doses ≤ 17 mg/kg/day. For the 17 mg/kg/day dose level, T3 and T4 thyroid hormone concentrations were significantly decreased (p < 0.05) from controls and HFPO-TeA plasma concentrations were significantly different between sexes. Non-targeted analysis of plasma and in vitro hepatocyte assay extractions revealed the presence of another GenX oligomer, perfluoro-(2,5-dimethyl-3,6-dioxanonanoic) acid (HFPO-TA). In vitro to in vivo extrapolation (IVIVE) parameterized with in vitro toxicokinetic data predicted steady-state blood concentrations that were within seven-fold of those observed in the in vivo study, demonstrating reasonable predictivity. The evidence of thyroid hormone dysregulation, sex-based differences in clinical results and dosimetry, and IVIVE predictions presented here suggest that the replacement PFECA HFPO-TeA induces a complex and toxic exposure response in rodents.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Cost Assessment of Future Tandem Perovskite-Silicon Modules and LCOE Comparison to Silicon Technologies in Europe

Tandem perovskite-silicon (TPS) photovoltaic (PV) technology is a promising pathway for achieving higher efficiencies than those of single-junction crystal-silicon (c-Si) technologies. In this work, a techno-economic assessment of a TPS module is performed considering a viable large-scale manufacturing process for two future scenarios in 2025 and 2030 which allowed us to identify the main cost drivers of the tandem module cost. Furthermore, to analyse the performance of tandem module-based utility-scale PV systems and understand their competitiveness in Europe, the levelized cost of electricity was compared to passivated emitter and rear cell as well as silicon heterojunction based PV systems. The aim of this work is to provide a cost and performance guidance for TPS modules which could contribute to future PV energy systems.

ENERGY PLANNING, POLICY, AND ECONOMY,SOLAR ENERGY↗
DOE OSTI2023

Develop a Fast Analysis Solver for Welding Sequence Optimization

During the shipbuilding manufacturing process, materials are exposed to significant stresses, as induced both thermally and mechanically, that alter the intended design and significantly affect the production schedule, labor hours (fitting, welding, rework, etc.), and material structural performance. The type and magnitude of deformation of a given structure depends on many factors such as the material, thickness and quality of components, the process heat input, preheat and inter-pass temperatures, type and size of welds, welding sequence and direction, location, sequence, and degree of fixturing. Numerical simulations using finite element analysis (FEA) have long been used to analyze welding-induced structural distortion. For large assemblies, transient thermal elastic-plastic analysis (TEPA) can take days or weeks to run, and optimization of welding sequence is not feasible. Simplified analysis methods were developed to reduce computational time. However, it is challenging to use these techniques to fully optimize welding sequencing because of their applied simplifications in modeling weld details. A fast analysis solver that could be used by the shipbuilding industry is being developed for optimizing welding sequences by taking full advantage of modern GPU-based HPC hardware and incorporating patented acceleration schemes. The accelerated processing factors are up to 2200 times greater for large, multi-pass welded structures.

Yang, Yu-Ping↗
DOE OSTI2026

Development and Validation of Low-Cost, High-Reflectance Composite CSP Facets: SIPS Final Report

This work investigates the various challenges associated with developing heliostat structural composite facets using 1 mm glass mirrors. Such facets are desirable for Concentrating Solar Power because 1 mm glass mirrors provide an absolute increase in reflectivity of 2-3 % over the industry standard of 4 mm glass mirrors. Prototypes of paraboloid composite facets with 1 mm glass mirrors were constructed that have a root mean square slope error on the order of 2 mrad while achieving greater than 96% reflectivity. These facets were constructed using a low-quality aluminum mold and a bill of materials that show potential to achieve cost parity with existing 4 mm glass mirrors supported by structural steel. The facets produced were able to survive up to 50 mm hail ball impacts and were robust against accelerated environmental cycling designed to expose durability concerns. Further work is needed to develop a scalable and cost-effective manufacturing process with a similar bill of materials.

14 SOLAR ENERGY↗
DOE OSTI2026

Tandem Photovoltaics Core Program Final Technical Report

The Tandem Photovoltaics Core Program was a multi-year initiative aimed at advancing hybrid tandem solar cell technologies to enhance solar module efficiency beyond the limits of single junction devices. This project focused on the development, testing, and scaling of prototype photovoltaic devices, with the goal of achieving commercial relevance and driving industry adoption. The work was divided into three tasks: 1) Comparative Analysis of Tandem Technologies: This task focused on quantifying energy yield under real-world conditions and assessing economic viability of tandems relative to silicon-based modules. The project's modeling framework incorporated performance data, cost of materials, and manufacturing process impacts to optimize tandem designs 2) Tandem Integration and Prototyping: In this task, we developed innovative tandem designs by combining metal halide perovskite (MHP) top cells and silicon (Si) bottom cells. The project focuses on both mechanical integration and direct deposition techniques to enable compatibility with commercially relevant Si technologies, such as passivated contact or PERC cells. 3) Scale-up and Reliability: This task addressed the challenges of large-area fabrication by developing scalable deposition methods and robust interconnection schemes for tandems. The project looked at different accelerated testing such as thermal cycling, damp heat exposure, and potential induced degradation, to ensure long-term stability of devices in field conditions. Tandem solar cells can greatly increase module efficiency beyond conventional single junction (SJ) devices, which are approaching their theoretical limit. There are many ways to fabricate a tandem cell or module in terms of materials used, configuration, and terminal connection. This SETO core project focused critical factors in enabling tandems to enter the market, including hardware integration, technoeconomic analysis (TEA), and energy yield analysis. We focused on MHP/Si hybrid tandem solar cells and modules as a model system for their versatility in module design comparisons, providing valuable insights for other tandem options. While champion cells with areas <1cm2 are regularly demonstrated by groups around the world, it is significantly more challenging to translate these advances into modules, and fewer institutions and companies are working at the module level. This project addressed questions about module fabrication, testing, and reliability that are hard to answer without actually fabricating prototypes. We also performed analysis and road-mapping activities to understand the potential for a wider variety of tandems, including all-perovskite tandems fabricated in collaboration with the Perovskite PV core program. Detailed technical results from this project are described for each task in Section 7.

14 SOLAR ENERGY↗
DOE OSTI2017

Sensitivity analysis for III–V/Si tandem solar cells: A theoretical study

Material and structural parameters may affect the efficiency of a tandem solar cell differently from the way they do in a single-junction solar cell. Here, we fabricated a III–V/Si four-terminal tandem solar cell and developed an opto-electronic model simulating this device. The optical properties were simulated with the transfer matrix method, while the electrical properties were simulated using the numerical device simulator PC1D. For this simulated tandem structure, we determined the parameters which have the largest potential impact on the device efficiency. A sensitivity analysis of the impact of these parameters on the device efficiency was also performed. Furthermore, to reduce the cost of the tandem solar cells, we identified the parameters that do not require tight control during the manufacturing process. The Si cell was simulated both as a single-junction cell and as the bottom cell of a tandem device. Lastly, we determined those device parameters that are more critical in a tandem configuration than in a single-junction configuration.

14 SOLAR ENERGY↗
NASA NTRS1963

Component design, construction and evaluation for satellites

Components for a high-reliability system such as the Telstar project are obtained by: (a) design of the component for the required environment, (b) careful control of manufacturing processes, (c) elimination of potential early failures by screening tests, and (d) selection of the most stable components. For passive components, these methods could be applied by using design parameters, suppliers and screening techniques established in the earlier submarine cable program, with consideration being given to the additional effects of the satellite launch and orbit environments. Semiconductor component designs were selected by qualification tests using accelerated electrical and environmental stress conditions. Screening tests were applied to eliminate early failures, and resulting components were aged from two to six months before selection for the satellite. The recognition of the effect of ionizing radiation on transistors caused the addition of a radiation qualification test, or a screening to assure selection of the least sensitive devices. Tests have shown this screening to be effective for the radiation intensity expected. Experience with the passive components, and evaluation of the accelerated test results and aging data of the semiconductor devices, indicate that the reliability objective was obtained.

TELSTAR SATELLITE↗