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DOE OSTI2023

Carbon Additive Manufacturing with a Near-Replica “Green-to-Brown” Transformation

Nanocomposites containing nanoscale materials offer exciting opportunities to encode nanoscale features into macroscale dimensions, which produces unprecedented impact in material design and application. However, conventional methods cannot process nanocomposites with a high particle loading, as well as nanocomposites with the ability to be tailored at multiple scales. A composite architected mesoscale process strategy that brings particle loading nanoscale materials combined with multiscale features including nanoscale manipulation, mesoscale architecture, and macroscale formation to create spatially programmed nanocomposites with high particle loading and multiscale tailorability is reported. The process features a low-shrinking (<10%) “green-to-brown” transformation, making a near-geometric replica of the 3D design to produce a “brown” part with full nanomaterials to allow further matrix infill. Here, this demonstration includes additively manufactured carbon nanocomposites containing carbon nanotubes (CNTs) and thermoset epoxy, leading to multiscale CNTs tailorability, performance improvement, and 3D complex geometry feasibility. The process can produce nanomaterial-assembled architectures with 3D geometry and multiscale features and can incorporate a wide range of matrix materials, such as polymers, metals, and ceramics, to fabricate nanocomposites for new device structures and applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Bridging interfacial properties and cell performance: A multiscale model for proton-exchange-membrane fuel cells

Here, to elucidate the impact of local interfaces on mass-transport resistance and overall cell performance of low-loaded proton-exchange-membrane fuel cells (PEMFCs), we present a multiscale modeling framework incorporating a novel modified agglomerate model. The model considers three distinct Pt-electrolyte interfaces: Pt on the carbon surface covered by either ionomer or water film and Pt inside carbon nanopores. Detailed mass-transport voltage-loss breakdowns reveal that coupled agglomerate-interface-scale mass transport dominates the mass-transport loss. The ionomer poisons the exterior-Pt surface through suppressing O 2 adsorption and intrinsic ORR activity, leading to low current-density performance. Conversely, interior-Pt interface enhances the kinetic performance but limits high current-density performance due to its low interfacial permeability. The exterior-Pt/water interface demonstrates superior kinetic performance and mass transport, though its practical implementation requires ensuring proton transport. By coupling the multiscale CL properties with ink parameters, the model identifies an optimal I to C ratio of approximately 0.5, a moderate value where the ionomer content is sufficient to guarantee proton transport without fully covering the Pt surface and forming large agglomeration, thus allowing the utilization of the Pt-water interface and avoiding high mass-transport loss. Overall, the model helps unravel limiting phenomena across different operating regimes and provides routes for optimizing performance.

Cell diagnostic↗

DOE OSTI2023

Fracture of PC and PMMA cylinders in the Taylor tests

The present paper analyzes failure observed in polymer rods collided with a steel anvil under the Taylor cylinder impact experiments. The experimental and numerical analysis demonstrates that association of the failure patterns with the loading mode depends on the rod material. Two materials are considered in the paper, specifically, polymethylmethacrylate (PMMA) and polycarbonate (PC). Damage in PMMA rods at the Taylor tests is shown to be dominated by the shear load resulting in plastic deformation. In contrast, the major mechanism of damage in PC rods is governed by omni-directional (pressure) mode of load. Analysis of the damage in sections of the rods associated with the glass transition is also addressed in the present theoretical study. Failure in these polymers follows the traditional fracture wave mechanism for brittle glass-type materials due to load in the corresponding mode. Numerical analysis employs a two-phase model with improved inter-phase thermal balance accounting for the inter-phase mass, momentum, and heat exchanges during the glass phase transition, while damage being accumulated in time. In conclusion, the simulation results demonstrate a good correlation with the experimental results.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Enhancement of Thermal Conductivity of Bentonite Buffer Materials with Copper Wires/Meshes for High-Level Radioactive Waste Disposal

In high-level radioactive waste disposal, a heat-generating waste canister is generally encased with a layer of bentonite-based buffer material acting as an engineered barrier to limit water percolation and radionuclide release. The low thermal conductivity of bentonite (~0.5 W/m∙K) combined with a high thermal loading waste package may result in a high surface temperature on the package that can potentially impact the structural integrity of the package itself as well as the surrounding buffer material. We show in this paper that the thermal conductivity of bentonite can be effectively enhanced by embedding copper wires/meshes across the buffer layer to form fully connected high heat conduction pathways. A simple calculation based on Rayleigh’s model shows that a required thermal conductivity of 5 W/m∙K for effective heat dissipation can be achieved simply by adding ~1 vol % of copper wires/meshes into bentonite. As a result, the peak surface temperature on a large waste package such as a dual-purpose canister can be reduced by up to 300°C, leading to a significant reduction in the surface storage time for waste cooling and therefore the overall cost for direct disposal of such waste packages. Because of the ensured full thermal percolation across the buffer layer, copper wires/meshes turn out to be much more effective than any other materials currently suggested (such as graphene or graphite) in enhancing the thermal conductivity of buffer material. Furthermore, the embedded copper wires/meshes can help reinforce the mechanical strength of the buffer material, thus preventing the material from a potential erosion by a possible intrusion of dilute groundwater.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Impact of Carbon Support Structure on the Durability of PtCo Electrocatalysts

High performing, low-Pt content fuel cell membrane electrode assemblies (MEAs) are critical to the economic viability of proton exchange membrane fuel cells (PEMFCs) for the transportation industry. Considerable research has been conducted to reduce the Pt content in fuel cells, leading to the development of transition metal alloys, such as Platinum-Cobalt (PtCo). The degree of degradation of PtCo catalysts can be impacted by the catalyst metal itself and its interactions with the carbon support. Several low-loaded PtCo MEAs were fabricated, with various combinations of porous and solid carbon cathode catalyst supports. The MEAs were subjected to an accelerated stress test (AST), and the catalyst degradation characterized using electrochemical, X-ray scattering, and electron microscopy techniques. Porous supports retain more of their electrochemically-active surface area (ECSA) and demonstrate higher performance after the AST. Overall, this is believed to be due to the ability of the porous supports to trap the metal particles within the pores, slowing their dissolution/precipitation, and agglomeration.

25 ENERGY STORAGE↗

DOE OSTI2023

WhatsCracking [SWR-23-03]

WhatsCracking can accurately predict cell fracture in crystalline silicon PV modules. The probability of PV module cell fracture is determined by a complicated interrelationship of module architecture, materials, and loading. WhatsCracking is a Finite Element Method tool which enables users to assess how module design impacts the propensity for cell fracture.

Deceglie, Michael↗

DOE OSTI2023

Review and Summary of Oxide Thickness Data for Aluminum-Clad Spent Nuclear Fuel

The U.S. Department of Energy (DOE) owns a large inventory of aluminum-clad spent nuclear fuel (ASNF) in interim storage pending ultimate disposition, with more being generated by currently operating research reactors. Dry storage in sealed DOE Standard Canisters is being investigated as an approach for long-term interim storage and/or disposition in a repository for ASNF. A primary challenge for ASNF storage is the presence of aluminum (oxy)hydroxide layers formed on the cladding surfaces during water exposure in the reactor and in wet storage, which forms a reservoir of chemisorbed water not readily removed at low (<100°C) drying temperatures. Free, physisorbed, and chemisorbed water are all susceptible to radiolytic breakdown under irradiation and can release hydrogen gas. Identifying the likely range of (oxy)hydroxide loadings on ASNF that may be placed in dry storage will help to ensure that the impact of the (oxy)hydroxide is adequately accounted for while avoiding over conservatism and enable mitigation strategies to be implemented where needed. The current report summarizes information on (oxy)hydroxide thicknesses and characteristics from the literature and from recent measurements taken in the present research campaign. In general, corrosion studies have indicated that the corrosion and oxide buildup on aluminum are affected by numerous conditions, including pH, temperature and heat flux, coolant flowrates, irradiation (in-reactor vs. unirradiated tests), duration of water exposure, and the amount of oxide already on the surface. Some of these factors are interrelated (e.g., the local temperature, heat flux, and coolant flowrate). Observations of the impact of irradiation (in-reactor versus ex-reactor measurements) on corrosion and oxide thickness are mixed, but multiple studies indicate that there is a significant difference between in-reactor and ex-reactor corrosion kinetics, even when other operating conditions such as pH, flowrate, heat flux, etc., simulate those in a reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Defining a Platform Approach and Market Participation: Data Driven Business Models for Solid State Transformer-Based Synthetic Inertia and Voltage Stability Controls (CRADA Final Report, Project 1, Mod 1)

The primary objective of this project is to determine the incremental value created with the medium voltage solid-state transformer (MV SST) technology to different stakeholders in view of the updated DER grid regulations. This includes studying the benefits of the MV SST technology in a range of use cases for EV and DER penetration including (1) “corridor charging” for EVs and (2) solar plus storage (FERC 2222). The potential customers of this technology include utilities for EV charging, DER installers who must meet utility interconnection requirements, balancing authorities, and DER aggregators. The traditional transformers on the grid could be a limiting factor for the EV-grid integration as the distribution transformers were not designed to handle the dynamic and fluctuating EV charging loads. Thus, the issues such as voltage fluctuations, increased losses and reduced efficiency [1] can negatively impact the grid operation. To address these challenges, transformers with flexibility and adaptability become imperative to meet the evolving energy demands. In this regard, the concept of Medium Voltage Solid-State Transformers.

14 SOLAR ENERGY↗

DOE OSTI2026

Fundamentals of Solar PV Bolted Joint Loosening and Prevention

The photovoltaic (PV) industry has long reported anecdotal accounts of systems exhibiting intermittent or chronic fastener loosening, including joints that fail to maintain preload despite multiple re-tightening attempts. These occurrences are frequently, and often incorrectly, attributed to installer errors, vibration, or loading beyond design expectations (e.g., extreme weather events). Loose fasteners have serious implications and can significantly impact solar PV systems’ performance, reliability, and safety. However, effective bolted joint design and proper assembly practices can mitigate or eliminate loosening. Until the US Department of Energy’s Solar Energy Technologies Office (SETO) funded research on fasteners and solar PV structures, there was a notable gap in understanding the causes of loosening in solar PV systems.

14 SOLAR ENERGY↗

DOE OSTI2026

Gaps in PV-Coupled Battery Modeling

With the rapid increase in battery attachment rates for PV systems and the continued qualification of storage for the ITC under OBBB, accurately characterizing PV-coupled batteries is becoming increasingly critical for the PV industry. This presentation will explore the key gaps in current best practices for modeling PV-coupled battery storage, including challenges such as battery thermal conditioning, the influence of dispatch strategies on battery value, the limitations of oversimplified degradation and performance models, and the absence of a centralized database containing sufficient battery parameters for accurate modeling. For behind-the-meter applications, we will also address issues like mismatched solar resource and load profiles, as well as uncertainties in future utility rates. Where applicable, we will quantify the impacts of these gaps on the accuracy and uncertainty of modeling efforts and highlight ongoing research aimed at addressing these challenges.

14 SOLAR ENERGY↗

NASA NTRS1992

A simple, effective media access protocol system for integrated, high data rate networks

The operation and performance of a dual media access protocol for integrated, gigabit networks are described. Unlike other dual protocols, each protocol supports a different class of traffic. The Carrier Sensed Multiple Access-Ring Network (CSMA/RN) protocol and the Circulating Reservation Packet (CRP) protocol support asynchronous and synchronous traffic, respectively. The two protocols operate with minimal impact upon each other. Performance information demonstrates that they support a complete range of integrated traffic loads, do not require call setup/termination or a special node for synchronous traffic control, and provide effective pre-use and recovery. The CRP also provides guaranteed access and fairness control for the asynchronous system. The paper demonstrates that the CSMA-CRP system fulfills many of the requirements for gigabit LAN-MAN networks most effectively and simply. To accomplish this, CSMA-CRP features are compared against similar ring and bus systems, such as Cambridge Fast Ring, Metaring, Cyclic Reservation Multiple Access, and Distributed Dual Queue Data Bus (DQDB).

Foudriat, E. C.↗

NASA NTRS2004

Aviation Communications Emulation Testbed

Aviation related applications that rely upon datalink for information exchange are increasingly being developed and deployed. The increase in the quantity of applications and associated data communications will expose problems and issues to resolve. NASA Glenn Research Center has prepared to study the communications issues that will arise as datalink applications are employed within the National Airspace System (NAS) by developing a aviation communications emulation testbed. The Testbed is evolving and currently provides the hardware and software needed to study the communications impact of Air Traffic Control (ATC) and surveillance applications in a densely populated environment. The communications load associated with up to 160 aircraft transmitting and receiving ATC and surveillance data can be generated in real time in a sequence similar to what would occur in the NAS.

Sheehe, Charles↗

NASA NTRS2004

Aviation Communications Emulation Testbed

Aviation related applications that rely upon datalink for information exchange are increasingly being developed and deployed. The increase in the quantity of applications and associated data communications will expose problems and issues to resolve. NASA s Glenn Research Center has prepared to study the communications issues that will arise as datalink applications are employed within the National Airspace System (NAS) by developing an aviation communications emulation testbed. The Testbed is evolving and currently provides the hardware and software needed to study the communications impact of Air Traffic Control (ATC) and surveillance applications in a densely populated environment. The communications load associated with up to 160 aircraft transmitting and receiving ATC and surveillance data can be generated in realtime in a sequence similar to what would occur in the NAS. The ATC applications that can be studied are the Aeronautical Telecommunications Network s (ATN) Context Management (CM) and Controller Pilot Data Link Communications (CPDLC). The Surveillance applications are Automatic Dependent Surveillance - Broadcast (ADS-B) and Traffic Information Services - Broadcast (TIS-B).

Sheehe, Charles↗

NASA NTRS2007

Artificial Gravity: Effects on Bone Turnover

The impact of microgravity on the human body is a significant concern for space travelers. Since mechanical loading is a main reason for bone loss, artificial gravity might be an effective countermeasure to the effects of microgravity. In a 21-day 6 head-down tilt bed rest (HDBR) pilot study carried out by NASA, USA, the utility of artificial gravity (AG) as a countermeasure to immobilization-induced bone loss was tested. Blood and urine were collected before, during, and after bed rest for bone marker determinations. Bone mineral density was determined by DXA and pQCT before and after bed rest. Urinary excretion of bone resorption markers (n-telopeptide and helical peptide) were increased from pre-bed rest, but there was no difference between the control and the AG group. The same was true for serum c-telopeptide measurements. Bone formation markers were affected by bed rest and artificial gravity. While bone-specific alkaline phosphatase tended to be lower in the AG group during bed rest (p = 0.08), PINP, another bone formation marker, was significantly lower in AG subjects than CN before and during bed rest. PINP was lower during bed rest in both groups. For comparison, artificial gravity combined with ergometric exercise was tested in a 14-day HDBR study carried out in Japan (Iwase et al. J Grav Physiol 2004). In that study, an exercise regime combined with AG was able to significantly mitigate the bed rest-induced increase in the bone resorption marker deoxypyridinoline. While further study is required to more clearly differentiate bone and muscle effects, these initial data demonstrate the potential effectiveness of short-radius, intermittent AG as a countermeasure to the bone deconditioning that occurs during bed rest and spaceflight. Future studies will need to optimize not only the AG prescription (intensity and duration), but will likely need to include the use of exercise or other combined treatments.

Heer, M.↗

NASA NTRS2010

Variability of Springtime Transpacific Pollution Transport During 2000-2006: The INTEX-5 Mission in the Context of Previous Years

We analyze the transport of pollution across the Pacific during the NASA INTEX-B (Intercontinental Chemical Transport Experiment Part 8) campaign in spring 2006 and examine how this year compares to the time period for 2000 through 2006. In addition to aircraft measurements of carbon monoxide (CO) collected during INTEX-B, we include in this study multi-year satellite retrievals of CO from the Measurements of Pollution in the Troposphere (MOPITT) instrument and simulations from the chemistry transport model MOZART-4. Model tracers are used to examine the contributions of different source regions and source types to pollution levels over the Pacific. Additional modeling studies are performed to separate the impacts of inter-annual variability in meteorology and .dynamics from changes in source strength. interannual variability in the tropospheric CO burden over the Pacific and the US as estimated from the MOPITT data range up to 7% and a somewhat smaller estimate (5%) is derived from the model. When keeping the emissions in the model constant between years, the year-to-year changes are reduced (2%), but show that in addition to changes in emissions, variable meteorological conditions also impact transpacific pollution transport. We estimate that about 113 of the variability in the tropospheric CO loading over the contiguous US is explained by changes in emissions and about 213 by changes in meteorology and transport. Biomass burning sources are found to be a larger driver for inter-annual variability in the CO loading compared to fossil and biofuel sources or photochemical CO production even though their absolute contributions are smaller. Source contribution analysis shows that the aircraft sampling during INTEX-B was fairly representative of the larger scale region, but with a slight bias towards higher influence from Asian contributions.

Pfister, G. G.↗

NASA NTRS2015

Finite Element Modeling Techniques for Analysis of VIIP

eye (anatomy)↗

NASA NTRS2016

The Effect of Golden Pothos in Reducing the Level of Volatile Organic Compounds in a Simulated Spacecraft Cabin

The impact of Golden Pothos on indoor air quality was studied against a simulated spacecraft trace contaminant load model, consistent with the International Space Station (ISS), containing volatile organic compounds (VOCs) and formaldehyde. Previous research provides inconclusive results on the efficacy of plant VOC removal which this projects seeks to rectify through a better experimental design. This work develops a passive system for removing common VOC's from spacecraft and household indoor air and decreasing the necessity for active cabin trace contaminant removal systems.

Ursprung, Matthew↗

NASA NTRS2016

Probabilistic Modeling Of Ocular Biomechanics In VIIP: Risk Stratification

Visual Impairment and Intracranial Pressure (VIIP) syndrome is a major health concern for long-duration space missions. Currently, it is thought that a cephalad fluid shift in microgravity causes elevated intracranial pressure (ICP) that is transmitted along the optic nerve sheath (ONS). We hypothesize that this in turn leads to alteration and remodeling of connective tissue in the posterior eye which impacts vision. Finite element (FE) analysis is a powerful tool for examining the effects of mechanical loads in complex geometries. Our goal is to build a FE analysis framework to understand the response of the lamina cribrosa and optic nerve head to elevations in ICP in VIIP. To simulate the effects of different pressures on tissues in the posterior eye, we developed a geometric model of the posterior eye and optic nerve sheath and used a Latin hypercubepartial rank correlation coef-ficient (LHSPRCC) approach to assess the influence of uncertainty in our input parameters (i.e. pressures and material properties) on the peak strains within the retina, lamina cribrosa and optic nerve. The LHSPRCC approach was repeated for three relevant ICP ranges, corresponding to upright and supine posture on earth, and microgravity [1]. At each ICP condition we used intraocular pressure (IOP) and mean arterial pressure (MAP) measurements of in-flight astronauts provided by Lifetime Surveillance of Astronaut Health Program, NASA Johnson Space Center. The lamina cribrosa, optic nerve, retinal vessel and retina were modeled as linear-elastic materials, while other tissues were modeled as a Mooney-Rivlin solid (representing ground substance, stiffness parameter c1) with embedded collagen fibers (stiffness parameters c3, c4 and c5). Geometry creationmesh generation was done in Gmsh [2], while FEBio was used for all FE simulations [3]. The LHSPRCC approach resulted in correlation coefficients in the range of 1. To assess the relative influence of the uncertainty in an input parameter on the peak strains, we ranked and then normalized these coefficients, considering that normalized values 0.5 implied a substantial influence on the range of the peak strains in the optic nerve head (ONH). IOP and ICP were found to have a major influence on the peak strains in the ONH, as did optic nerve and LC stiffness. Interestingly, the stiffness of the sclera far from the scleral canal did not have a large influence on peak strains in ONH tissues; however, the collagen fiber stiffness in the peripapillary sclera and annular ring both influenced the peak strains within the ONH. We have created a physiologically relevant model that incorporated collagen fibers to study the effects of elevated ICP. Elevated ICP resulted in strains in the optic nerve that are not predicted to occur on earth: the upright or supine conditions. We found that IOP, ICP, lamina cribrosa stiffness and optic nerve stiffness had the highest association with these extreme strains in the ONH. These extreme strains may activate mechanosensitive cells that induce tissue remodeling and are a risk factor for the development of VIIP.

biomechanics↗