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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 1,693 records · Page 94
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Rejection of low-molecular weight neutral organics is highly sensitive to reverse osmosis system design and operation

A computational model was developed to investigate the significance of system design and operating conditions on the rejection of neutral, low-MW organics by reverse osmosis for potable reuse. Here, the model demonstrated that the decrease in local rejection as net driving pressure decreases is substantially greater for moderately rejected compounds than for highly rejected compounds. At recovery values less than 70%, the local permeate concentration can exceed the pressure vessel feed concentration for moderately rejected compounds. System-level rejection of moderately rejected compounds is likewise substantially more sensitive to operating conditions than highly rejected compounds. The findings highlight a drawback of relying on rejection results from bench-scale testing that operates at low recovery, which invariably has higher rejection than full-scale systems operating at similar pressure. The analysis demonstrates a trade-off in which the low-pressure, high-recovery operation desired for potable reuse systems can be detrimental to the removal of low-MW neutral organics. The removal of low-MW neutral organics can be improved if organics rejection is explicitly evaluated during the design process.

42 ENGINEERING↗
DOE OSTI2019

Materials data analytics for 9% Cr family steel

A materials data analytics (MDA) methodology was developed in this study to evaluate publicly available information on 9% Cr family steel and to handle nonlinear relationships and the sparsity in materials data for this alloy class. The overarching goal is to accelerate the design process as well as to reduce the time and expense associated with qualification testing of new alloys for fossil energy applications. Data entries in the analyzed data set for 82 iron–base alloy compositions, several processing parameters, and results of tensile mechanical tests selected for this study were arranged in 34 columns by 915 rows. While detailed microstructural information was not available, it is assumed that the compositional space for the 9 to 12% Cr steels is limited such that all data entries have a tempered martensitic microstructure during service. Establishing a hierarchy of first–order trends in the publicly available data requires the MDA to filter out the biases. Complexity of the phase transformations and microstructure evolution in the multicomponent alloys (using 21 chemical elements) with major influence on mechanical properties, leads to inefficiency in direct application of unbiased linear regression across the entire data space. To address the nonlinearity, analyses of tensile data were performed in composition–based clusters. Clusters corresponding to moderately frequent patterns and maximized information gain were further refined by using p–norm distance measures, matching the alloy classification groups adopted by industry. Lastly, the evolutionary method of propagating an ensemble of competing cluster–based models proved to be a viable option in dealing with scarce, multidimensional data.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Design space exploration and decision‐making for a segmented ultralight morphing 50‐MW wind turbine

Abstract Wind turbine design encompasses many different aspects including aerodynamic, structural, electrical, and control system design. To achieve optimal plant performance, a system design approach is utilized in which the performance of the whole wind turbine is evaluated and quantified during operational scenarios with subsystem interactions. In this paper, the design for a Segmented Ultralight Morphing Rotor (SUMR) 50‐MW wind turbine is presented utilizing levelized cost of energy (LCOE) for design choices, with additional quantification of simulated performance shortcomings at the 50‐MW scale. The multi‐disciplinary design process results in a final ultra‐scale turbine configuration that outperforms other existing offshore wind farms regarding the LCOE.

Kianbakht, Sepideh↗
DOE OSTI2017

The best models of metabolism

Biochemical systems are among of the oldest application areas of mathematical modeling. Spanning a time period of over one hundred years, the repertoire of options for structuring a model and for formulating reactions has been constantly growing, and yet, it is still unclear whether or to what degree some models are better than others and how the modeler is to choose among them. In fact, the variety of options has become overwhelming and difficult to maneuver for novices and experts alike. This review outlines the metabolic model design process and discusses the numerous choices for modeling frameworks and mathematical representations. It tries to be inclusive, even though it cannot be complete, and introduces the various modeling options in a manner that is as unbiased as that is feasible. However, the review does end with personal recommendations for the choices of default models. WIREs Syst Biol Med 2017, 9:e1391. doi: 10.1002/wsbm.1391 This article is categorized under: Analytical and Computational Methods > Dynamical Methods Models of Systems Properties and Processes > Mechanistic Models Biological Mechanisms > Metabolism

Voit, Eberhard O.↗
DOE OSTI2016

Component-based workflows for parallel thermomechanical analysis of arrayed geometries

Component-based simulation workflows can increase the agility of the design process by streamlining adaptation of new simulation methods. Here, we present one such workflow for parallel unstructured mesh-based simulations and demonstrate its usefulness in the thermomechanical analysis of an array of solder joints used in microelectronics fabrication. We automate the simulation process from problem specification to the solution of the underlying PDEs, including problem setup, domain definition, and mesh generation. We establish the utility of the proposed approach by demonstrating that qualitatively different stress concentrations are seen in solder joints near the center of such an array and a solder joint seen at the edge of the same array.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2018

Design of Circular, Square, Single, and Multi-layer Induction Coils for Electromagnetic Priming Using Inductance Estimates

Special induction coils used for electro magnetic priming of ceramic foam filters in liquid metal filtration have been designed using a combination of analytical and finite element modeling. Relatively simple empirical equations published by Wheeler in 1928 and 1982 have been used during the design process. The equations were found to accurately predict the z-component of the magnetic flux densities of both single- and multi-layer coils as verified both experimentally and by using COMSOL{sup ®} 5.1 multiphysics simulations.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Model Study of Blast Furnace Operation with Central Coke Charging

Blast furnace (BF) remains the dominant ironmaking process worldwide. Central coke charging (CCC) operation is a promising technology for stabilizing BF operations, but it needs reliable and quantified process design and control. In this work, a multi-fluid BF model is further developed for quantitatively investigating flow-thermal-chemical phenomena of a BF under CCC operation. This model features the respective chemical reactions in the respective coke and ore layers, and a specific sub-model of layer profile for the burden structure for the CCC operation. The simulation results confirm that the gas flow patterns and cohesive zone’s shape and location under the CCC operation are quite different from the non-CCC operation. Under the CCC operation, the heat is overloaded at the furnace center while the reduction load is much heavier at the periphery regions; the profiles of top gas temperature and gas utilization show bell-shape and inverse-bell-shape patterns, respectively. More importantly, these differences are characterized quantitatively. In this given case, when the CCC opening radius at the throat is 0.35 m, the cohesive zone top opening radius is around 0.50 m, and the isotherms of CCC operation become much steeper (~ 80 deg) than those of non-CCC operation (~ 60 deg) near BF central regions. In addition, it is confirmed that carbon solution-loss reaction rate can be decreased significantly at BF central regions under CCC operation. The model helps to understand CCC operation and provides a cost-effective method for optimizing BF practice.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Deposition Height Prediction in Directed Energy Deposition

Using 316L stainless steel as a model material, reduced-order models are developed to predict capture efficiency, deposition height, and site-specific hardness in directed energy deposition. Capture efficiency is predicted over a 15 to 55 pct range using a dimensionless number derived from processing conditions and thermophysical properties. Deposition height is predicted over a 0.3 to 1.3 mm range without in situ sensing or prior training data, using two models based on the same mass and energy-balance principles. Predictions are compared with machine learning approaches. A quantitative relationship links deposition height, primary dendrite arm spacing (PDAS), and hardness: heights of 0.3 to 1.1 mm correspond to PDAS values of 2.7 to 5.1 µm and Vickers hardness (HV) of 160 to 219. Thinner layers cool more rapidly, producing finer microstructures and higher hardness. Samples fabricated with in situ variations in deposition height exhibited up to 55 HV differences between thick and thin regions, demonstrating that local control of deposition height enables predictive, site-specific hardness within a single build. These results establish deposition height prediction as a pathway for a priori process design and property control in directed energy deposition for 316L stainless steel.

Kunkel, William [Univ. of Wisconsin, Madison, WI (↗
DOE OSTI2019

Application of the Mixed-Mode Model for Numerical Simulation of Pearlitic Transformation

The multiscale model of pearlitic transformation, including the finite element solution of the second Fick’s equation with moving boundary in the microscale and Fourier equation in the macroscale, is presented in this paper. According to the mixed-mode approach, both the volume diffusion and the interface mobility were considered. Model describes sidewise and frontal growth of cementite and ferrite plates in a single grain of the austenite. Assessment of the possibility of the developed model application to determine the key parameters in terms of strength properties of pearlitic steel, i.e., pearlite grain size and colony size as well as interlamellar spacing for various cooling conditions, was the main aim of this work. The model was validated and verified on the basis of experimental tests performed for two eutectoid steels. In practice, developed model can support design process for a technology of high-strength rods and long products manufacturing. Rails were selected as a case study in this work, and therefore, numerical simulations of accelerated cooling of the rail head were performed and the relationship between the parameters of heat treatment, parameters of the structure and properties of the finished product was determined on the basis of obtained results.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Process model for multilayer slide coating of polymer electrolyte membrane fuel cells

Slide coating is a precision method suitable for depositing multiple liquid-film layers simultaneously. Originally developed in the photographic film industry, it has been deployed for manufacturing of other products that benefit from multilayer coatings. One emerging application is the manufacture of polymer electrolyte membrane fuel cells (PEMFCs), which are used to produce electricity through electrochemical reactions of hydrogen and oxygen gas. The membrane-electrode assembly (MEA), in which key electrochemical reactions occur, consists of three layers that are typically deposited separately in serial fashion and then laminated together to form the three-layer MEA, i.e., three sequential steps of coat and dry. Adapting the process to simultaneous, multilayer slide coating of all three layers will save equipment cost and space while minimizing possible exposure to contaminants during transition between the steps. We are developing a three-layer slide coating model to aid the manufacturing process design of PEMFC. The model accounts for rheology of each layer, which typically exhibit shear thinning behavior. Model predictions are used to investigate simultaneous coatability of catalyst inks and to determine the best layer-by-layer ink selection.

25 ENERGY STORAGE↗
DOE OSTI2019

Additively Manufactured Single-Use Molds and Reusable Patterns for Large Automotive and Hydroelectric Components

Additive manufacturing (AM) has the potential to reduce costs in the casting industry, particularly for large parts (i.e., components with any dimension > 12 in.). In this study, pilot-scale production case studies of hydroelectric and automotive parts were used to evaluate two AM-enabled casting methods: the direct printing of sand molds by binder jet and printing of reusable cope and drag patterns for sand casting. An additional benefit was found when additively manufactured patterns were used in combination with heat-treat free aluminum alloys, to produce castings of complex hydrodynamic surfaces. These parts previously required production via subtractive machining due to part distortion induced by the quench step of heat treatments. The machine types used for the three case studies are sand-binder jet, high-resolution polymer fused deposition modeling (FDM), and big area additive manufacturing (BAAM) FDM in combination with CNC machining. Each method demonstrated distinct advantages over traditional casting practices in particular use cases. Single-use molds show great reductions in start-up cost to produce one-off or legacy parts, and additively manufactured impression patterns show promise for innovating the tooling design process for complex geometry and large castings.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Additive Manufacturing in the Nuclear Reactor Industry

This article discusses the application of additive manufacturing in the nuclear reactor industry.Additive manufacturing for nuclear applications increased significantly in the late 2010s due to rapid progress in technology, particularly with methods using metals and ceramics.Because these manufacturing technologies are uniquely data-rich, they allow for an advanced understanding of materials, and they offer the potential to predict part performance based on build data. The inherent characteristics of additive manufacturing technologies allow for rapid prototyping and geometric freedom, making it possible to implement an accelerated agile design process for advanced nuclear reactor applications. Predictive high-fidelity multiphysics simulations are crucial to fully leverage this geometric flexibility. Qualification and regulator acceptance ultimately determine the breadth and scope of applications for these technologies. The US Department of Energy Office of Nuclear Energy Transformational Challenge Reactor program integrates many of these elements to accelerate the deployment of additive manufacturing technologies to industry.

Betzler, Benjamin↗
DOE OSTI2026

A transport-based framework for solidification cracking in Ni-based superalloys processed by laser powder bed fusion

Solidification cracking remains a persistent barrier to laser powder bed fusion (LPBF) processing of solid-solution-strengthened (SSS) Ni-based superalloys and is commonly attributed to carbide formation, liquation-type failure, or elemental segregation. In this work, the cracking behavior of three SSS Ni-based superalloys—Inconel 625 (625), Inconel 617 (617), and Haynes 230 (230)—is examined under comparable LPBF conditions to evaluate the origins of their cracking susceptibility. Carbides were present in both 625 and 230, yet cracking behavior differed significantly. MC-type carbides in 625 remain discrete and preserve liquid connectivity, whereas Cr-rich M23C6 carbides in 230 form at cellular triple junctions that bottleneck the interdendritic liquid network, influencing cracking through liquid connectivity rather than as an independent cause. Alloy 617 exhibited anomalous segregation without resolvable secondary phases yet cracked mildly, indicating that extensive carbide formation is not a prerequisite for cracking. To rationalize these observations, a transport-limited framework is proposed in which cracking occurs when terminal-liquid feeding cannot accommodate solidification-induced strain; among the mechanisms evaluated, this framework is most consistent with the physical constraints imposed by LPBF solidification. Transport-based crack-susceptibility indexes incorporating permeability, viscosity, and solidification kinetics distinguish the alloy hierarchy; permeability ratios Krat increased from approximately 7 (625) to 11.5 (617) and 14.5 (230), with corresponding increases in the μ-weighted mushy zone risk index (CSIMZRM). These results are consistent with transport-limited liquid feeding as a rate-limiting contributor to solidification cracking in LPBF-processed SSS Ni-based superalloys, providing a physically grounded basis for alloy and process design.

Hyer, Holden [ORNL] (ORCID:0000000343915561)↗
DOE OSTI2017

A fast, efficient direct slicing method for slender member structures

We describe a method for quickly and efficiently slicing structures consisting of a large number of slender members called struts connected at node positions called joints. Previous research on periodic lattice structures shows these structures are highly mechanically efficient with exceptionally high stiffness- and strength-to-weight ratios. Additive manufacturing technologies allow the construction slender member structures with complicated macroscale shapes. These structures could consist of thousands or millions of geometric primitives describing the struts. Structures with large numbers of geometric objects cause the conventional methods for manipulating, storing, and slicing the geometry of these parts via STL files to be highly inefficient. This work describes an alternate design process for slender member structures using efficient methods for manipulating, storing, and slicing the geometry of the part. These new methods, in particular a fast, efficient direct slicing method, enable printing slender member structures with over one hundred thousand struts. The slicing algorithm is nearly perfectly parallel so it could extend to handle structures with over one million struts, helping to facilitate the adoption of slender member structures for engineering-scale applications.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Designing for Big Area Additive Manufacturing

Additive manufacturing (AM), more commonly referred to as 3D printing, is revolutionizing the manufacturing industry. With any new technology comes new rules and guidelines for the optimal use of said technology. Big Area Additive Manufacturing (BAAM), developed by Cincinnati Incorporated and Oak Ridge National Laboratory’s Manufacturing Demonstration Facility, requires a host of new design parameters compared to small-scale 3D printing to create large-scale parts. However, BAAM also creates new possibilities in material testing and various applications in the manufacturing industry. Most of the design constraints of small-scale polymer 3D printers still apply to BAAM. Beyond those constraints, new rules and limitations exist because BAAM’s large-scale system significantly changes the thermal properties associated with small-scale AM. Here, this work details both physical and software-related design considerations for additive manufacturing. After reading this guide, one will have a better understanding of slicing software’s capabilities and limitations, different physical characteristics of design and how to apply them appropriately for AM, and how to take the inherent nature of AM into consideration during the design process.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Size-dependent stochastic tensile properties in additively manufactured 316L stainless steel

Recent work in metal additive manufacturing (AM) suggests that mechanical properties may vary with feature size; however, these studies do not provide a statistically robust description of this phenomenon, nor do they provide a clear causal mechanism. Because of the huge design freedom afforded by 3D printing, AM parts typically contain a range of feature sizes, with particular interest in smaller features, so the size effect must be well understood in order to make informed design decisions. This work investigates the effect of feature size on the stochastic mechanical performance of laser powder bed fusion tensile specimens. A high-throughput tensile testing method was used to characterize the effect of specimen size on strength, elastic modulus and elongation in a statistically meaningful way. The effective yield strength, ultimate tensile strength and modulus decreased strongly with decreasing specimen size: all three properties were reduced by nearly a factor of two as feature dimensions were scaled down from 6.25 mm to 0.4 mm. Hardness and microstructural observations indicate that this size dependence was not due to an intrinsic change in material properties, but instead the effects of surface roughness on the geometry of the specimens. Finite element analysis using explicit representations of surface topography shows the critical role surface features play in creating stress concentrations that trigger deformation and subsequent fracture. The experimental and finite element results provide the tools needed to make corrections in the design process to more accurately predict the performance of AM components.

316L stainless steel↗
DOE OSTI2022

The effects of SO 2 exposure on three-way catalysts for passive SCR operation

We report efficient lean-burn gasoline engines cannot employ traditional three-way catalysts (TWCs) to control NO X emissions due to excess oxygen. Passive selective catalytic reduction (pSCR) is a process designed to control NOx by generating NH 3 over the TWC during fuel-rich operation, storing it on a downstream SCR, and then converting NOx during fuel-lean operation. This work is focused on studying sulfur effects on this promising strategy. Two hydrothermally-aged commercial catalysts were studied for their effectiveness in the presence of SO 2 : a Pd-based TWC and a TWC with NO X storage. The sulfated samples were evaluated in a flow reactor under pSCR conditions and with targeted reactions. SO 2 inhibited the water gas shift and steam reforming reactions, decreasing (but not eliminating) NH 3 production; however, initial activity is recoverable after a simple thermal treatment at 650 °C. This work will prove valuable in understanding, mitigating, and even reversing the effects of SO 2 inhibition on real pSCR systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

A comparative techno-economic analysis of renewable methanol synthesis from biomass and CO 2 : Opportunities and barriers to commercialization

Global demand for methanol as both a chemical precursor and a fuel additive is rising. At the same time, numerous renewable methanol production pathways are under development, which, if commercialized, could provide significant environmental benefits over traditional methanol synthesis pathways. However, it is difficult to compare technologies at different maturity levels, with differing feedstocks, and with significant differences in overall process design. Thus, there is a need to harmonize the analyses of renewable pathways using a consistent techno-economic approach to evaluate the potential for commercialization of various pathways. This analysis uses a novel cross-comparison method to assess near-term and long-term viability of both low- and high-maturity level technologies. Furthermore, the techno-economic assessment considers cost factors critical to market acceptance combined with carbon- and energy-efficiency assessments of three renewable pathways compared with a commercial baseline. We find that biomass gasification to methanol represents a near-term viable pathway with a high technology readiness level and commercially competitive market price. If cost-reducing technological improvements can be realized and scaled up in the CO 2 electrolysis pathways, the potential for higher carbon efficiencies may help drive market adoption of these more modular, direct conversion pathways in future markets as they present an opportunity to better support global decarbonization efforts through efficient waste carbon utilization.

09 BIOMASS FUELS↗