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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

NASA Mission Operations Directorate Preparations for the COTS Visiting Vehicles

With the retirement of the Space Shuttle looming, a series of new spacecraft is under development to assist in providing for the growing logistical needs of the International Space Station (ISS). Two of these vehicles are being built under a NASA initiative known as the Commercial Orbital Transportation Services (COTS) program. These visiting vehicles ; Space X s Dragon and Orbital Science Corporation s Cygnus , are to be domestically produced in the United States and designed to add to the capabilities of the Russian Progress and Soyuz workhorses, the European Automated Transfer Vehicle (ATV) and the Japanese H-2 Transfer Vehicle (HTV). Most of what is known about the COTS program has focused on the work of Orbital and SpaceX in designing, building, and testing their respective launch and cargo vehicles. However, there is also a team within the Mission Operations Directorate (MOD) at NASA s Johnson Space Center working with their operational counterparts in these companies to provide operational safety oversight and mission assurance via the development of operational scenarios and products needed for these missions. Ensuring that the operational aspect is addressed for the initial demonstration flights of these vehicles is the topic of this paper. Integrating Dragon and Cygnus into the ISS operational environment has posed a unique challenge to NASA and their partner companies. This is due in part to the short time span of the COTS program, as measured from initial contract award until first launch, as well as other factors that will be explored in the text. Operational scenarios and products developed for each COTS vehicle will be discussed based on the following categories: timelines, on-orbit checkout, ground documentation, crew procedures, software updates and training materials. Also addressed is an outline of the commonalities associated with the operations for each vehicle. It is the intent of the authors to provide their audience with a better understanding of the mission assurance that MOD brings to commercial ventures to the ISS

Shull, Sarah A.↗
NASA NTRS2019

Building an Economical and Sustainable Lunar Infrastructure to Enable Human Missions

To enable return of human missions to the surface of the Moon sustainably, a new study was initiated to assess the feasibility of developing an evolvable, economical and sustainable lunar surface infrastructure using a public-private partnerships approach. This approach would establish partnerships between NASA and private industry to mutually develop lunar surface infrastructure capabilities to support robotic missions initially and later evolve to full-scale commercial infrastructure services in support of human missions. These infrastructure services may range from power systems, communication and navigation systems, thermal management systems, mobility systems, water and propellant production to life support systems for human habitats. The public-private partnerships approach for this study leverages best practices from NASA’s Commercial Orbital Transportation Services (COTS) program which introduced an innovative and economical approach for partnering with industry to develop commercial cargo transportation services to the International Space Station (ISS). In this approach, NASA and industry partners shared cost and risk throughout the development phase which led to dramatic reduction in development and operations costs of these transportation services. Following this approach, a Lunar COTS concept was conceived to develop cost-effective surface infrastructure capabilities in partnership with industry to provide economical, operational services for small-scale robotic missions. As a result, a self-contained lunar infrastructure system with power, thermal, communication and navigation elements was conceptually designed to increase capability, extend mission duration and reduce cost of small-scale robotic missions. To support human missions, this work has now been extended to analyze full-scale lunar infrastructure systems. This infrastructure system should have capabilities to support human missions from a few days to several months with minimal maintenance and replacement of parts. This infrastructure system should also maximize the use of existing lunar resources, such as, oxygen from regolith, water from ice deposits at the poles, and use of metals, such as iron and aluminum, from lunar regolith. The plan includes a buildup of these capabilities using a phased-development approach that will eventually lead to operational infrastructure services. By partnering with industry to develop and operate the infrastructure services using the COTS model, this plan should also result in significant cost savings and increased reliability. This paper will describe the Lunar COTS concept goals, objectives and approach for developing an evolvable, economical and sustainable human lunar infrastructure as well as the challenges and opportunities for development.

Zuniga, Allison↗
DOE OSTI2024

CORE-CM in The Greater Green River and Wind River Basins: Transforming and Advancing a National Coal Asset (Final Report)

The following document summarizes project results from “CORE-CM in the Greater Green River and Wind River Basins: Transforming and Advancing a National Coal Asset”. This project is part of the U.S. Department of Energy’s (“DOE”) National Energy Technology Laboratory’s (“NETL”) Carbon Ore, Rare Earth Elements, and Critical Minerals (CORE-CM) Initiative. This report concludes that the Greater Green River and Wind River Basins (GGRB-WRB) Area-of-Interest (AOI 9) is the ideal region for continued research and development in progressing the broader CORE-CM goals outlined by the DOE. Based upon the extensive analyses of technical, social, and community criteria, this report illustrates that the GGRB-WRB hosts numerous potential CORE-CM feedstocks (both coal- and non-coal based), diverse opportunities for utilizing existing industrial waste streams, ample infrastructure and industry to support new CORE-CM-focused technologies, and a highly motivated, well educated, and adaptable workforce to further develop the regional and national CORE-CM supply chain. Additionally, some potential solutions for technological gaps suggest that the GGRB-WRB's diverse resources can play a significant role in achieving the national goal of critical materials independence. With full community participation, meaningful involvement of regional Tribal Nations, and building upon the stakeholder engagement demonstrated here, the GGRB-WRB region presents a unique opportunity for advancing the CORE-CM Initiative. This project was designed to bring together coal-based communities and stakeholders from across the GGRB-WRB to advance new industries for CORE-CM resources. The University of Wyoming (UWyo) School of Energy Resources (SER) led a project team of experts from the Colorado Geological Survey (CGS), Colorado School of Mines (CSM), Los Alamos National Lab (LANL), and local community colleges. Input from basinal, regional, and national experts bolstered the coalition in order to advance the mission of DOE’s CORE-CM initiative and develop the domestic CORE-CM supply chain. Phase I of this project was designed to address the goal of developing and catalyzing economic growth, job creation, and technology innovation in the GGRB-WRB of Wyoming and Colorado, by increasing the supply of CORE-CM to manufacturers of non-fuel Carbon Based Products (CBP) and products reliant upon CM. The GGRB-WRB CORE-CM project worked toward providing benefit through several avenues of performance and research. • Develop a coalition team to achieve project objectives • Complete detailed assessments, including State-of-the-Art (SOTA) Data acquisition of potential CORE-CM materials across the AOI, and meaningfully contributes to DOE’s CORE-CM goals nationally. • Strategic planning for regional economic growth, job creation, and associated technology innovation around coal materials, including plans to maximize the development of potential CORE-CM resources and technology by creating regional public-private partnerships. • Define regional economic growth potential around existing strengths, energy infrastructure, business and industry, including planning for the leveraging of highly trained workforces, existing and novel coal technologies, and energy infrastructure in development of CORE-CM supply chains. • Develop a preliminary strategic plan for increasing the supply of CORE-CM materials to manufacturers of non-fuel Carbon Based Products (CBP) and products reliant upon CM, focusing on regional strengths that result in an emerging diversified CORE-CM economy. • Assemble a committed network of stakeholders and communities that learn about, accept, and grow new energy technologies within coal regions. Additionally, the project team significantly contributed to the CORE-CM Initiative’s national goals, through cross-regional scoping, collaborating with CORE-CM projects in other AOIs, and including parallel regional project experts. In addition to active inclusion and meaningful engagement and contribution to DOE-led working groups, the project team focused on engaging with regional communities including Tribal Nations, economic development groups, and regional government organizations. The project’s CORE-CM development and commercialization plan identified diverse CORECM feedstocks, potential routes towards integration with existing industries, methods for supply-chain development that leverage existing infrastructure and businesses considering the regional economy, identified entry barriers for incorporating traditional and new technologies in those supply chains, recognized opportunities for public-private partnerships to develop technology innovation centers, identified diverse workforces, and conducted stakeholder outreach and education to build a community of understanding on CORE-CM potential in the GGRB-WRB region. Detailed task descriptions can be found in each chapter.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Deep learning-accelerated 3D carbon storage reservoir pressure forecasting based on data assimilation using surface displacement from InSAR

Fast forecasting of the reservoir pressure distribution during geologic carbon storage (GCS) by assimilating monitoring data is a challenging problem. Due to high drilling cost, GCS projects usually have spatially sparse measurements from few wells, leading to high uncertainties in reservoir pressure prediction. To address this challenge, we use low-cost Interferometric Synthetic-Aperture Radar (InSAR) data as monitoring data to infer reservoir pressure build up. We develop a deep learning-accelerated workflow to assimilate surface displacement maps interpreted from InSAR and to forecast dynamic reservoir pressure. Employing an Ensemble Smoother Multiple Data Assimilation (ES-MDA) framework, the workflow updates three-dimensional (3D) geologic properties and predicts reservoir pressure with quantified uncertainties. We use a synthetic commercial-scale GCS model with bimodally distributed permeability and porosity to demonstrate the efficacy of the workflow. A two-step CNN-PCA approach is employed to parameterize the bimodal fields. The computational efficiency of the workflow is boosted by two residual U-Net based surrogate models for surface displacement and reservoir pressure predictions, respectively. The workflow can complete data assimilation and reservoir pressure forecasting in half an hour on a personal computer.

25 ENERGY STORAGE↗
DOE OSTI2021

Storage Futures Study: Distributed Solar and Storage Outlook: Methodology and Scenarios

This report is one in a series of NREL’s Storage Futures Study (SFS) publications. The SFS is a multiyear research project that explores the role and impact of energy storage in the evolution and operation of the U.S. power sector. The SFS is designed to examine the potential impact of energy storage technology advancement on the deployment of utility-scale storage and the adoption of distributed storage, and the implications for future power system infrastructure investment and operations. The research findings and supporting data will be published as a series of reports, with each report being released on its completion. The table below lists the specific research topics planned for examination under the SFS and the associated publication formats. This report, the fourth in the SFS series, provides a set of scenarios for cost-effectiveness and customer adoption for a range of scenarios that include future technology costs and valuation of backup power. The SFS series provides data and analysis in support of the U.S. Department of Energy’s Energy Storage Grand Challenge, a comprehensive program to accelerate the development, commercialization, and utilization of next-generation energy storage technologies and sustain American global leadership in energy storage. The Energy Storage Grand Challenge employs a use case framework to ensure storage technologies can cost-effectively meet specific needs, and it incorporates a broad range of technologies in several categories: electrochemical, electromechanical, thermal, flexible generation, flexible buildings, and power electronics. More information, any supporting data associated with this report, links to other reports in the series, and other information about the broader study are available at https://www.nrel.gov/analysis/storage-futures.html.

25 ENERGY STORAGE↗
DOE OSTI2024

A Generalized Nuclear Code of Accounts for Cost Estimation Standardization

This is a joint INL-EPRI study. Link to corresponding page at the Electric Power Research Institute (EPRI): https://www.epri.com/research/products/000000003002028937 Recent Advanced Reactor (AR) designs typically offer features and attributes that depart from traditional water-cooled reactors in terms of fuel forms, coolants, structural materials, size, safety margins, and other important design and operational aspects. These departures, relative to the industry experience, will likely present a challenge for potential owner-operators when evaluating one or more AR designs for commercial deployment on a like-for-like basis. This is further exacerbated with new classes of reactors gaining prominence (e.g., microreactors) and new emerging applications (e.g., floating barge reactors or space propulsion reactors). The differences in design-specific technologies are compounded by the differences in approach to cost estimation. The lack of consistency in build up toward cost estimates creates a challenge when comparing competing concepts and evaluating their associated cost drivers. The outcome of a 2019 Scoping Study conducted by the Electric Power Research Institute (EPRI) indicated the need for a cost modeling guide (CMG), which would be underpinned by a technology-neutral and inclusive Generalized Nuclear Code of Accounts (GN-COA). A code of accounts (COA) is a tool by which costs are identified in even more specific categories, providing clarity on what specific costs are included in an estimate. A parallel independent effort was meanwhile taking place at Idaho National Laboratory via funding by the Systems Analysis Integration (SA&I) campaign of the Office of Nuclear Energy under the U.S. Department of Energy (U.S. DOE-NE) to also update the COA structure to enable more flexibility and encompass a wider variety of reactor technologies. After being made aware of these synergistic efforts, the two parties decided to combine efforts and develop a joint new standard format for nuclear cost estimation that builds on previous structures. This document describes the development of this joint GN-COA and provides guidance on the implementation of the tool, which is provided as the associated GN-COA Excel document. The main attributes of this novel COA format are that all items are functionally defined (in order to be technology and application agnostic) and grouped into logical arrangements that facilitate the tabulation of costs for reactor constructions under consideration. The intent is for the GN-COA to form a standard that is endorsed by future vendors and customers.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Analysis of Frost Formation and Novel Defrost Techniques for Commercial Refrigeration Applications (NFE-19-07879)

The purpose of this Cooperative Research and Development Agreement (CRADA) was to test a heat exchanger defrosting approach using radiant energy, including ultraviolet-C, -B, and -A. A preliminary test conducted at Oak Ridge National Laboratory demonstrated the concept of ultraviolet-based defrosting, which melts frost on the fin surface of a heat exchanger without increasing its overall temperature, thereby offering a new defrosting method that does not interrupt heat exchanger operation. Building on this key finding, this CRADA outlines a plan for upgrading the test equipment and for further testing to bridge the gap between the concept and its feasibility for industrial applications. This report also provides a brief review of existing defrosting technologies, the current state of the experimental system, and future parametric experiment plans.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Metabolic model-based ecological modeling for probiotic design

The microbial community composition in the human gut has a profound effect on human health. This observation has lead to extensive use of microbiome therapies, including over-the-counter ‘probiotic’ treatments intended to alter the composition of the microbiome. Despite so much promise and commercial interest, the factors that contribute to the success or failure of microbiome-targeted treatments remain unclear. We investigate the biotic interactions that lead to successful engraftment of a novel bacterial strain introduced to the microbiome as in probiotic treatments. We use pairwise genome-scale metabolic modeling with a generalized resource allocation constraint to build a network of interactions between taxa that appear in an experimental engraftment study. We create induced sub-graphs using the taxa present in individual samples and assess the likelihood of invader engraftment based on network structure. To do so, we use a generalized Lotka-Volterra model, which we show has strong ability to predict if a particular invader or probiotic will successfully engraft into an individual’s microbiome. Furthermore, we show that the mechanistic nature of the model is useful for revealing which microbe-microbe interactions potentially drive engraftment.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS2009

Low Cost Rapid Response Spacecraft, (LCRRS): A Research Project in Low Cost Spacecraft Design and Fabrication in a Rapid Prototyping Environment

The Low Cost Rapid Response Spacecraft (LCRRS) is an ongoing research development project at NASA Ames Research Center (ARC), Moffett Field, California. The prototype spacecraft, called Cost Optimized Test for Spacecraft Avionics and Technologies (COTSAT) is the first of what could potentially be a series of rapidly produced low-cost satellites. COTSAT has a target launch date of March 2009 on a SpaceX Falcon 9 launch vehicle. The LCRRS research system design incorporates use of COTS (Commercial Off The Shelf), MOTS (Modified Off The Shelf), and GOTS (Government Off The Shelf) hardware for a remote sensing satellite. The design concept was baselined to support a 0.5 meter Ritchey-Chretien telescope payload. This telescope and camera system is expected to achieve 1.5 meter/pixel resolution. The COTSAT team is investigating the possibility of building a fully functional spacecraft for $500,000 parts and $2,000,000 labor. Cost is dramatically reduced by using a sealed container, housing the bus and payload subsystems. Some electrical and RF designs were improved/upgraded from GeneSat-1 heritage systems. The project began in January 2007 and has yielded two functional test platforms. It is expected that a flight-qualified unit will be finished in December 2008. Flight quality controls are in place on the parts and materials used in this development with the aim of using them to finish a proto-flight satellite. For LEO missions the team is targeting a mission class requiring a minimum of six months lifetime or more. The system architecture incorporates several design features required by high reliability missions. This allows for a true skunk works environment to rapidly progress toward a flight design. Engineering and fabrication is primarily done in-house at NASA Ames with flight certifications on materials. The team currently employs seven Full Time Equivalent employees. The success of COTSATs small team in this effort can be attributed to highly cross trained engineering team. The engineers on the team are capable of functioning in two to three engineering disciplines which allows highly efficient interdisciplinary engineering collaboration. NASA Ames is actively proposing mission concepts to use the COTSAT platform to accomplish science. If the COTSAT team validates this approach, it will allow the possibility for remote sensing missions to produce a high science yield for minimal cost and reduced schedule. Another aim of this approach is to yield an accelerated pathway from a Phase A study to mission launch. Leaders in the aerospace industry have shown interest in this methodology. Several visits and tours have been given in the lab. Although the concept of low-cost development is initially met with skepticism from some within the prohibitive aerospace industry, the project's efforts have been highly praised for the accomplishments met within a limited time and budget. Overall the development has progressed tremendously well and the team is answering critical questions for current and future low-cost small satellite developments. COTSAT subsystems are not limited to a specific weight class and could be adapted to produce smaller platforms and to fit various launch vehicles.

Spremo, Stevan↗
NASA NTRS2014

Processor Units Reduce Satellite Construction Costs

As part of the effort to build the Fast Affordable Science and Technology Satellite (FASTSAT), Marshall Space Flight Center developed a low-cost telemetry unit which is used to facilitate communication between a satellite and its receiving station. Huntsville, Alabama-based Orbital Telemetry Inc. has licensed the NASA technology and is offering to install the cost-cutting units on commercial satellites.

Source record↗
NASA NTRS2019

Building an Economical and Sustainable Lunar Infrastructure to Enable Human Lunar Missions

To enable return of human missions to the surface of the Moon sustainably, a new study was initiated to assess the feasibility of developing an evolvable, economical and sustainable lunar surface infrastructure using a public-private partnerships approach. This approach would establish partnerships between NASA and private industry to mutually develop lunar surface infrastructure capabilities to support robotic missions initially and later evolve to full-scale commercial infrastructure services in support of human missions. These infrastructure services may range from power systems, communication and navigation systems, thermal management systems, mobility systems, water and propellant production to life support systems for human habitats. The public-private partnerships approach for this study leverages best practices from NASA's Commercial Orbital Transportation Services (COTS) program which introduced a new innovative and economical approach for partnering with industry to develop commercial cargo transportation services to the International Space Station (ISS). In this approach, NASA and industry partners shared cost and risk throughout the development phase which led to dramatically reducing development and operations costs of these transportation services. Following this approach, a Lunar COTS concept was conceived to follow this model and gradually develop cost-effective surface infrastructure capabilities in partnership with industry to provide economical, operational services for small-scale robotic missions. To support human missions, this work has now been extended to analyze full-scale lunar infrastructure systems. This infrastructure system will have capabilities to support human missions from a few days to several months and will also maximize the use of existing lunar resources, such as, water from ice deposits at the lunar poles. The plan includes a gradual buildup of these capabilities using a phased-development approach that will eventually lead to operational infrastructure services. By partnering with industry to develop and operate the infrastructure services using the COTS model, this plan will also result in significant cost savings, reduced risk and increased reliability. This paper will describe the Lunar COTS concept goals, objectives and approach for developing an evolvable, economical and sustainable human lunar infrastructure as well as the challenges and opportunities for development.

Lunar Surface Systems↗
NASA NTRS2022

The Standardization of In-space and Surface Docking Systems

The International Docking System Standard (IDSS) was developed and establish to aid on-orbit crew rescue and joint operations between different spacecraft. For the International Space Station (ISS), the IDSS has successfully enabled Global interoperability for Commercial Crew and it is now being extended to the Artemis campaign. Similarly, as more companies, agencies, and nations announce their intentions to explore and occupy Low Earth Orbit (LEO) and Cis-Lunar space, including the Lunar surface, it is a natural supposition that new, vehicle interface standards will be required to support the build-up of infrastructure for campaign-based exploration or permanent occupation by national and multi-national Agencies, Industries, and Companies. A surface version of the IDSS, a.k.a. IDSS-Surface (IDSS-S), is under consideration at the NASA Johnson Space Center (JSC) by the docking discipline leads responsible for the leadership of technical development and negotiation of the original IDSS over a decade ago. The IDSS-S, like its predecessor, will ultimately detail the physical geometric mating interface and design load requirements to ensure physical interoperability and to support a broad set of design reference missions which, if accommodated, increases the probability of successful Lunar surface docking between different modules enabling the accessibility and inclusivity required for multi-national, sustainable Lunar exploration.

Docking↗
DOE OSTI2025

Project Title: Demonstration High Temperature Superconducting NonPlanar Stellarator Magnet with Advanced Manufactured Assemblies

This is the final report for the project “Demonstration High Temperature Superconducting Non- Planar Stellarator Magnet with Advanced Manufactured Assemblies”, funded by DOE, and performed by Type One Energy from September, 2020, to March 2024 involving the Fusion Technology Institute at the University of Wisconsin–Madison, the Plasma Science and Fusion Center (PSFC) at the Massachusetts Institute of Technology (MIT) and Commonwealth Fusion Systems (CFS) to design and fabricate the first non-planar HTS (REBCO) coil for a high-field stellarator based on the SPARC tokamak’s VIPER cable concept. Stellarators at high fields make high-temperature superconducting magnets necessary for a compact fusion device. But the asymmetric and non-planar nature of its components, especially the magnets make it difficult for scalable producibility. To address these challenges, two promising technologies have emerged: advanced manufacturing (AM) for the supporting plates for forming the magnets, and high-temperature superconducting (HTS) cables inside the plates. AM has advanced enough to produce stellarator components with the necessary geometric complexity, size, and the precision, leading to potentially significant reductions in production time, cost, and waste. The cost of HTS tape has decreased dramatically, and progress in HTS planar magnet development has reached a point where it can be proposed for application to complex 3D non-planar magnets. The main objective of this project is to develop, demonstrate and pre-commercialize a novel, non-planar HTS coil shape that remains superconducting to achieve production scalable reductions in time and cost and performance. The proposed technology is based on the novel concept of a precision sub-scale HTS nonplanar coil assembly. This project focuses on the design, fabrication, material optimization of cable design, and validation and demonstration of the high current carrying capability of superconducting magnets and their support in a complex 3D shape needed for application to stellarator magnetic plasma confinement. The specific objectives of this research program include: (1) The successful application of metal AM to build a precision sub-scale HTS nonplanar coil, (2) An HTS cable and cross-section design that can conform to the required nonplanar coil shape (bend radii as tight as 10-cm) and remains superconducting at an engineering current density of 1.35 kA/cm 2 at 77 K and 1 tesla at the conductor (5 kA in the cable). To achieve the above challenging goals, we have formed a multidisciplinary research team consisting of members from Type One Energy and UW-Madison, MIT PSFC and CFS with complementary skills and strong facilities. The team worked collaboratively on fundamental and applied research on the following three major technical areas: (1) Design, fabrication, and optimization of non-planar HTS Cable The ultimate goal of the project is to determine if commercial REBCO tapes and additive manufacturing can be used to fabricate high field (≥ 10T) non-planar coils with tight bending radii (≃ 100mm) and with a degradation of the critical current (Ic) smaller than 20% with respect to the expected performance. We started with shorter length cable to evaluate the scalability of the production process and eventually reached multiple turns for higher magnetic fields. Our findings suggest that a stellarator coil system of a relevant size, characterized by its asymmetric and non-planar components, can be fabricated using a formed cable in plate method. This system can be simulated using a large-scale modeling approach. The use of hybrid modeling 3 techniques will be pivotal in reducing the complexity of the model and in assessing expected performance in designs. (2) Modeling and simulation of the non-planar HTS Cable Multiphysics simulations are performed using the commercial software and are carried out in self-field conditions, involving 2D and 3D models and twisted around one slot of twist-pitched VIPER cable. Multiphysics simulations are mainly focused on the coil for the critical current evaluation, the magnetic field map, self-Lorentz forces and mechanical, and magnetothermal behavior and the quench dynamics. The detailed model and prediction of the superconducting performance of a stellarator-relevant demonstration cable from numerical simulations supports the results from the actual testing backing the results. A detailed description and results are provided in the later sections. (3) Design, fabrication, and optimization of support for the non-planar HTS Cable The team developed an additive manufactured (AM) coil positioning plate that formed into the required non-planar geometry (with bend radii as tight as 10-cm) and to acceptable tolerances required for a stellarator magnet: (+0.25-mm from ideal on dimensions of coil positioning plates and up to +1-mm from ideal for position of wound coil). The plate materials is also included in this selection process from fabrication and 3D printing perspective and commensurate with eventual application to a fusion reactor. From the cost effectiveness point of view, the HTS coil and plate has the potential to cost less than that made in conventional methods with less waste (<75% waste) reducing time (<50%) and cost (<50%), especially as the AM field matures. The application of advanced manufacturing in the construction of the support plates will also lead to cost reduction, as the cables can be easily replaced, thereby making the assembly modular. With such high primary cost and time savings, high current densities and magnetic field, the funded R&D work has validated the designs, proven the feasibility, and characterized the performance of the HTS coil and plate assembly, paving the way for a relevant-size stellarator coil system.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

A Green, Fire–Retarding Ether Solvent for Sustainable High–Voltage Li–Ion Batteries at Standard Salt Concentration

Lithium-ion batteries (LIBs) are increasingly encouraged to enhance their environmental friendliness and safety while maintaining optimal energy density and cost-effectiveness. Although various electrolytes using greener and safer glyme solvents have been reported, the low charge voltage (usually lower than 4.0 V vs Li/Li + ) restricts the energy density of LIBs. Herein, tetraglyme, a less-toxic, non-volatile, and non-flammable ether solvent, is exploited to build safer and greener LIBs. It is demonstrated that ether electrolytes, at a standard salt concentration (1 m), can be reversibly cycled to 4.5 V vs Li/Li + . Anchored with Boron-rich cathode-electrolyte interphase (CEI) and mitigated current collector corrosion, the LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811) cathode delivers competitive cyclability versus commercial carbonate electrolytes when charged to 4.5 V. Synchrotron spectroscopic and imaging analyses show that the tetraglyme electrolyte can sufficiently suppress the overcharge behavior associated with the high-voltage electrolyte decomposition, which is advantageous over previously reported glyme electrolytes. The new electrolyte also enables minimal transition metal dissolution and deposition. NMC811||hard carbon full cell delivers excellent cycling stability at C/3 with a high average Coulombic efficiency of 99.77%. In conclusion, this work reports an oxidation-resilient tetraglyme electrolyte with record-high 4.5 V stability and enlightens further applications of glyme solvents for sustainable LIBs by designing Boron-rich interphases.

36 MATERIALS SCIENCE↗
DOE OSTI2022

High-throughput, in situ imaging of multi-layer powder-blown directed energy deposition with angled nozzle

Laser metal additive manufacturing (AM) has become an increasingly popular technology due to its flexibility in geometry and materials. As one of the commercialized additive processes, powder-blown directed energy deposition (DED) has been used in multiple industries such as aerospace, automotive, medical device, etc. However, a lack of fundamental understanding remains for this process, and many opportunities for alloy development and implementation can be identified. A high-throughput, in situ DED system capable of multi-layer builds that can address these issues is presented here. In this work, implications of layer heights and energy density are investigated through an extensive process parameter sweep, showcasing the power of a high-throughput setup while also discussing multi-layer interactions.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Convection in Scaled Turbine Internal Cooling Passages With Additive Manufacturing Roughness

Abstract Additive manufacturing processes, such as direct metal laser sintering (DMLS), enable the creation of novel turbine cooling internal passages and systems. However, the DMLS method produces a significant and unique surface roughness. Previous work in scaled passages analyzed pressure losses and friction factors associated with the rough surfaces, as well as investigated the velocity profiles and turbulent flow characteristics within the passage. In this study, the heat transfer characteristics of scaled additively manufactured surfaces were measured using infrared (IR) thermography. Roughness panels were CNC machined from plates of aluminum 6061 to create near isothermal roughness elements when heated. Fluid resistance differences between the aluminum roughness panels and roughness panels constructed from ABS plastic using the same roughness patterns from McClain et al. (2020, “Flow in a Simulated Turbine Blade Cooling Channel With Spatially Varying Roughness Caused by Additive Manufacturing Orientation,” ASME Turbo Expo 2020, Turbomachinery Technical Conference and Exposition, Virtual Conference, Sept. 21–25, GT2020-16069) were investigated. Finally, the overall thermal performance enhancements and friction losses were assessed through the calculation of surface averaged “global thermal performance” ratios. The global thermal performance characterizations indicate results in-line with those found for traditional commercial roughness and slightly below traditional internal passage convection enhancement methods such as swirl chambers, dimples, and ribs. The passages investigated in this study do not include compressibility effects or the long-wavelength artifacts and channel geometric deviations observed by Wildgoose et al. (2020, “Impact of Additive Manufacturing on Internal Cooling Channels with Varying Diameters and Build Directions,” ASME Turbo Expo 2020, Turbomachinery Technical Conference and Exposition, Virtual Conference, Sept. 21–25, GT2020-15049). However, the results of this study indicate that, based on the roughness augmentation alone, artificial convective cooling enhancers such as turbulators or dimples may still be required for additively manufactured turbine component cooling.

Engineering↗
DOE OSTI2024

Studies on Printability Methodologies and Directed-Energy-Deposition-Fabricated Iron Alloys for Nuclear Applications

This report provides results from a printability study of laser directed energy deposition (DED)-based additive manufacturing of nuclear-grade stainless steels as well as DED process parameter development for austenitic Alloy 709 (A709) and ferritic/martensitic Grade 91 (G91) and Grade 92 (G92) steels. The printability study includes the use of machine learning and physics-based modeling via commercial software such as FLOW-3D for insights into the impact of the alloy composition, particularly the carbon content, on the printability of stainless steels during the DED process. In the DED process development work, 1 cm 3 alloy blocks were deposited with broad ranges of laser powers, scan speeds, and hatch spacings to optimize the build quality, resulting in densities of more than 99.8% for all three alloys. The microstructure and mechanical properties were characterized using electron microscopy, X-ray diffraction, and Vickers hardness measurements. Further, tensile samples were extracted from DED-fabricated alloys utilizing the optimized process parameters. The present work provides guidance and progress towards the successful deployment of the DED process for the fabrication of structural components of nuclear reactors.

36 MATERIALS SCIENCE↗