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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗
DOE OSTI2016

MATLAB/Simulink Framework for Modeling Complex Coolant Flow Configurations of Advanced Automotive Thermal Management Systems

The National Renewable Energy Laboratory's (NREL's) CoolSim MATLAB/Simulink modeling framework was extended by including a newly developed coolant loop solution method aimed at reducing the simulation effort for arbitrarily complex thermal management systems. The new approach does not require the user to identify specific coolant loops and their flow. The user only needs to connect the fluid network elements in a manner consistent with the desired schematic. Using the new solution method, a model of NREL's advanced combined coolant loop system for electric vehicles was created that reflected the test system architecture. This system was built using components provided by the MAHLE Group and included both air conditioning and heat pump modes. Validation with test bench data and verification with the previous solution method were performed for 10 operating points spanning a range of ambient temperatures between -2 degrees C and 43 degrees C. The largest root mean square difference between pressure, temperature, energy and mass flow rate data and simulation results was less than 7%.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Projecting Recent Advancements in Battery Technology to Next–Generation Electric Vehicles

Electric vehicles (EVs) have seen rapid growth in adoption over the last several years. Advancements to increase battery life and performance, policy shifts, and high charging rate are expected to further accelerate the development of next generation of EVs. Battery improvements continue to emerge, enabling increased driving range, total distance driven over the life of vehicles, and ability to charge at high rates. Herein, an analysis framework to provide insights into inclusive design metrics, such as specific energy of batteries, energy consumption of vehicles, and charging power infrastructure development, is developed. Various cell-level fast charge protocols to realistic battery designs to understand the infrastructure needs associated with achieving range replacement of 32.25 km min -1 (20 mi min -1 ) are also scaled. Additionally, by calculating scaled power and peak to average power ratio, it is found that there needs to be more distinct alignment between the research efforts focused at the cell level and what is being developed for EV charging infrastructure needs. Finally, impact of high direct current voltage architecture in next-generation EVs is discussed. The findings in this work provide an insight into recent advancements in battery technology to next-generation EVs.

20 mi/min↗
DOE OSTI2025

National Energy Water Treatment & Speciation (NEWTS): A Water & Critical Mineral Database and Dashboard

The scarcity of water resources, the need for beneficial water reuse, and the challenges of wastewater treatment are becoming increasingly pressing in economic, social, and environmental domains. Addressing these concerns requires effective treatment strategies to manage wastewater streams and tackle environmental and economic issues. Furthermore, the recovery of critical minerals from the waste streams associated with energy production holds the promise of offsetting treatment costs and securing local sources of valuable minerals. However, relevant data on these waste streams are dispersed and challenging to locate. The process of ingesting such data into modeling software often involves multiple steps, requiring data restructuring to meet software-input requirements. The non-standardized reporting of water data makes data aggregation and reformatting a time-consuming process. Additionally, essential attributes necessary for modeling water treatment and mineral scale formation are frequently missing. Moreover, data gaps vary depending on the region of interest. Consequently, there is a pressing need for high-quality energy-water composition data that can be easily imported into water chemistry modeling software. To address this need, the National Energy Technology Laboratory has created the National Energy Water Treatment and Speciation (NEWTS) Database and Dashboard—a free online tool catering to community leaders and water researchers. NEWTS facilitates a comprehensive understanding of the composition of energy-related wastewater streams in the United States. The datasets provide detailed concentrations and speciation of major and minor aqueous compounds in energy-related wastewater streams, including power plant leachate, acid mine drainage, brackish water, and oil and gas produced water across the United States. Many of the aqueous species are critical minerals (Li, REEs) in high demand to modernize the world’s energy infrastructure. Many of the datasets also contain volumetric flow-rates needed to model the treatment and reuse scenarios in advanced aqueous chemistry software programs. The NEWTS Database and Dashboard offer public access to hitherto challenging-to-access datasets, presented in a standardized format that is tailored for easy input into aqueous chemistry modeling software. By performing the work needed to transform dispersed, disparate data sources into unified, model-ready datasets, NEWTS serves as an essential resource in advancing water treatment research and sustainable water resource management.

produced water management↗
DOE OSTI2024

Next-Generation Desiccant-Based Gas Clothes Dryer Systems

The goal of the project is to develop an advanced gas clothes dryer system demonstrating significant improvements in fuel efficiency and drying performance compared to current gas clothes dryer technologies. The new system decouples latent and sensible loads to effectively utilize the latent heat associated with laundry moisture as an advantageous energy source. In other words, the system captures the waste latent heat from moisture produced during the fabric-drying process and reuses it to improve drying efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Investigating the effects of electron bounce-cyclotron resonance on plasma dynamics in capacitive discharges operated in the presence of a weak transverse magnetic field

Recently, Patil et al. [Phys. Rev. Res. 4, 013059 (2022)] have reported the existence of an enhanced operating regime when a low-pressure (5 mTorr) capacitively coupled discharge (CCP) is driven by a very high radio frequency (60 MHz) source in the presence of a weak external magnetic field applied parallel to its electrodes. Their particle-in-cell simulations show that a significantly higher bulk plasma density and ion flux can be achieved at the electrode when the electron cyclotron frequency equals half of the applied radio frequency for a given fixed voltage. In the present work, we take a detailed look at this phenomenon and further delineate the effect of this “electron bounce-cyclotron resonance (EBCR)” on the electron and ion dynamics of the system. We find that the ionization collision rate and stochastic heating are maximum under resonance condition. The electron energy distribution function also indicates that the population of tail-end electrons is highest for the case where EBCR is maximum. Formation of electric field transients in the bulk plasma region is also seen at lower values of applied magnetic field. Finally, we demonstrate that the EBCR-induced effect is a low-pressure phenomenon and weakens as the neutral gas pressure increases. The potential utility of this effect to advance the operational performance of CCP devices for industrial purposes is discussed in this report.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2017

Performance Analysis of the Passive Residual Heat Removal System of an Integral Reactor

A demand for small modular reactors (SMRs) is gradually emerging worldwide, especially in Middle East Asia and Africa. SMART (System-integrated Modular Advanced ReacTor) developed by KAERI (Korea Atomic Energy Research Institute) is the first mover among several SMRs. It is designed to produce 100 MW of electricity, or 90 MW of electricity and 40,000 tons of desalinated water concurrently, which is sufficient for 100,000 residents. SMART is currently holding the initiative as the first licensed integral reactor in the world since 4 July 2012, when the standard design approval (SDA) was officially issued by the Nuclear safety and security commission (NSSC). After that, the SMART safety enhancement project was successfully conducted with intense support of the Government, resulting in an in-depth development of the most advanced safety features including the passive residual heat removal system (PRHRS). Recently, an agreement between KAERI and King Abdullah city for atomic and renewable energy (K.A. CARE) was officially signed for the pre-project engineering (PPE) in pursuit of the construction of SMART and developing human resources capability. Both parties are currently conducting a three-year preliminary study to review the feasibility of building SMART and to prepare for its commercialization. KAERI also takes responsibility to train R and D personnel chosen from Kingdom of Saudi Arabia. Sooner or later, SMART will open the global market of SMR and be the best competitive pioneer. Since the Fukushima accident, the passive cooling system of a nuclear reactor has received a great amount of attention. SMART is designed with passive systems in order to ensure the safety of the reactor. The PRHRS is one of the passive safety systems, which is activated after an accident to remove the residual heat from the core and the sensible heat of the reactor coolant system (RCS) through the steam generators (SGs) until the condition of the RCS reaches a safe shutdown condition. In the present study, the thermal performance of the PRHRS is predicted by using in-house code. Temperature of the RCS and the cooling rate of the RCS are traced with time to see if it is satisfactorily designed to meet the design requirements of the PRHRS. The dependency of the mass flow rate of the natural circulation on the filling ratio (FR) is also discussed. The FR is arbitrarily chosen from 0.22 to 0.50 and further parametric study is needed in the future.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Advancing Electric System Resilience with Distributed Energy Resources: Key Questions and Resources

This resource has two complementary parts: (1) A list of questions that offers an initial starting point for state public utility commissions (commissions) to frame how they review proposed utility investments and considerations that could offer resilience benefits; (2) A list of relevant resources to improve a regulator's ability to oversee resilience investments and obtain the best possible solutions for customers. The list of resources includes a synopsis of relevant topics covered in each resource. This document is not intended to offer a complete picture of resilience literature, but instead suggests strategies for state regulators to convene conversations and make decisions to achieve better resilience outcomes for customers. It is meant to serve as a starting point for commissions to understand and incorporate resilience into regulatory processes. The list of questions and resources will not be perfectly suited to the particular needs of each commission. As the resilience conversation advances, regulators will need to take advantage of available resources to build their capacity to assess resilience risks, compare investment options, and evaluate performance.

14 SOLAR ENERGY↗
DOE OSTI2024

Advancing Insights into Electrochemical Pre‐Treatments of Supported Nanoparticle Electrocatalysts by Combining a Design of Experiments Strategy with In Situ Characterization

Activation, break-in, and/or pre-treatment protocols are generally applied to energy conversion devices before regular operation to reach stable performance. There remains much to understand about the relationships among physical properties, performance, and electrochemical pre-treatments. Here, a design-of-experiments (DoE) strategy is employed to address this gap by demonstrating the influence of five pre-treatment parameters for carbon-supported Pt-nanoparticle catalysts on the electrocatalytic oxygen reduction reaction (ORR). A subset of pre-treatments, developed using a central composite design, are tested in a flow cell combined with an inductively-coupled plasma mass spectrometer (on-line ICP-MS). The DoE-based approach facilitates comprehensive insights from two orders of magnitude fewer experiments than a conventional grid search. The coupled on-line ICP-MS setup enables effective catalysis and real-time catalyst dissolution data. Leveraging insights from DoE for on-line ICP-MS and additional characterization, a model is built between the degradation of a multi-dimensional supported Pt surface, its performance, and applied electrochemical parameters. These investigations identify surface modifications, such as oxidation, and subsequent restructuring of Pt during pre-treatment as a primary cause of performance deterioration during ORR. By combining DoE with advanced characterization techniques, a powerful approach is demonstrated to gain a mechanistic understanding of pre-treatment protocols that can be broadly adapted to various reaction chemistries.

Platinum↗
DOE OSTI2022

Modularity-at-scale for advanced reactors presentation

Modularity options have been limited for traditional nuclear energy deployment due to the conventional light water reactor (LWR) safety requirements, such as high pressure retaining heavy and robust containment structures. However, a relatively new regulatory approach called ‘Functional Containment’ has potential to allow less expensive and more flexible designs for non-LWRs. Functional containment provides flexibility in design and deployment based on risk-informed and performance-based criteria, so that reactors are not over-designed. Non-nuclear industry has successfully used modular design approaches in automotive, aerospace, chemical processing, building construction, and ship building. These industries have shown that modular construction reduces construction time by around 30% - 50% compared to the conventional stick-built approach. The nuclear industry can use similar approaches to reduce construction time and costs, balanced with safety requirements, using the functional containment approach. This paper discussing the background of modularity in nuclear energy, examples of less learned, modularity approaches in non-nuclear industries and the potential of cost and schedule savings through the emerging regulatory design flexibilities potentially enabling combination of modular deployment at different scales.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Design and performance of a variable gap system for thermal conductivity measurements of high temperature, corrosive, and reactive fluids

We report high-temperature fluids such as molten salts, liquid metals, and gasses are being proposed for many advanced energy systems including thermal energy storage devices, concentrating solar plants, and advanced nuclear reactor designs. However, the chemical behavior and thermophysical properties of many of these fluids have not been well characterized, which hinders the design, modeling, safety analysis, and deployment of these systems. Thermal conductivity is a property that is especially limited by existing measurement capabilities, which are subject to errors caused by convection, material interaction, radiative heat transfer, and instrument degradation. Therefore, there is a lack of standard, systematic measurement techniques for high-temperature, reactive, and corrosive fluids. In this work, the development of a variable gap thermal conductivity measurement system is detailed. The system is designed to measure the thermal conductivity of highly corrosive and reactive fluids, and survive operation between 100 °C and 800 °C. The effects of convection are minimized by limiting the thickness of the specimen to thin sizes (<0.3 mm). Corrections for radiative heat transfer were included in the working equations to consider specimens with varying optical properties. The design, construction, instrumentation, operating principles, and data analysis techniques are discussed in detail. The system was tested up to 500 °C using helium gas and molten KNO 3 -NaNO 3 to verify the measurement technique and determine the sources of error. At 300 and 400 °C KNO 3 -NaNO 3 , results showed maximum relative error of 6% when compared to results in the literature. The helium results were within 13% of those in the literature at 300 and 400 °C. Higher errors were observed at 500 °C for both fluids, and the sources of these errors are discussed.

42 ENGINEERING↗
DOE OSTI2022

Hierarchical microstructures: a potential route to enhanced stability in structural materials for advanced nuclear reactors

The drive to increase efficiency in nuclear energy systems is leading to the need for materials that operate at higher temperatures and stress levels for extended periods, while maintaining stable microstructures to ensure their performance is not compromised. A novel route to producing materials that can perform well in such environments is the creation of hierarchical microstructures. A hierarchical microstructure is a microstructure in which features are present at multiple length scales simultaneously. In this work, a hierarchical microstructure is fabricated in a nickel-base superalloy, featuring nanometer-size gamma precipitates inside larger gamma-prime particles, which are in turn embedded in the gamma matrix phase. The hierarchical features of the microstructure lead to enhanced stability of the gamma-prime precipitates during annealing; the particle size does not follow the expected t^(1/3) growth law predicted by the classic LSW theory. Phase-field simulations are used to understand the unexpected stability of the gamma-prime precipitates.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Hierarchical microstructures: a potential route to enhanced stability in structural materials for advanced nuclear reactors

The drive to increase efficiency in nuclear energy systems is leading to the need for materials that operate at higher temperatures and stress levels for extended periods, while maintaining stable microstructures to ensure their performance is not compromised. A novel route to producing materials that can perform well in such environments is the creation of hierarchical microstructures. A hierarchical microstructure is a microstructure in which features are present at multiple length scales simultaneously. In this work, a hierarchical microstructure is fabricated in a nickel-base superalloy, featuring nanometer-size gamma precipitates inside larger gamma-prime particles, which are in turn embedded in the gamma matrix phase. The hierarchical features of the microstructure lead to enhanced stability of the gamma-prime precipitates during annealing; the particle size does not follow the expected t^(1/3) growth law predicted by the classic LSW theory. Phase-field simulations are used to understand the unexpected stability of the gamma-prime precipitates.

36 - MATERIALS SCIENCE↗
DOE OSTI2020

ASCR@40: Highlights and Impacts of ASCR’s Programs

A report compiled by the ASCAC Subcommittee on the 40-year history of ASCR for the U.S. Department of Energy’s Office of Advanced Scientific Computing Research. The Office of Advanced Scientific Computing Research (ASCR) sits within the Office of Science in the Department of Energy (DOE). Per their web pages, “the mission of the ASCR program is to discover, develop, and deploy computational and networking capabilities to analyze, model, simulate, and predict complex phenomena important to the DOE.” This succinct statement encompasses a wide range of responsibilities for computing and networking facilities; for procuring, deploying, and operating high performance computing, networking, and storage resources; for basic research in mathematics and computer science; for developing and sustaining a large body of software; and for partnering with organizations across the Office of Science and beyond. While its mission statement may seem very contemporary, the roots of ASCR are quite deep—long predating the creation of DOE. Applied mathematics and advanced computing were both elements of the Theoretical Division of the Manhattan Project. In the early 1950s, the Manhattan Project scientist and mathematician John von Neumann, then a commissioner for the AEC (Atomic Energy Commission), advocated for the creation of a Mathematics program to support the continued development and applications of digital computing. Los Alamos National Laboratory (LANL) scientist John Pasta created such a program to fund researchers at universities and AEC laboratories. Under several organizational name changes, this program has persisted ever since, and would eventually grow to become ASCR.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2019

Subtask 2.5 – Syngas Testing of NETL's Advanced Precombustion CO2 Capture Solvent

U.S. Department of Energy (DOE) National Energy Technology Laboratory (NETL) on-site researchers have been examining and developing a novel solvent for precombustion capture that has the potential for improved performance and lower costs compared to Selexol™ and Rectisol®. In Subtask 2.5, the Energy & Environmental Research Center (EERC) conducted actual comparison tests on actual coal-derived syngas of a PEGDME (polyethylene glycol dimethyl ether) Selexol-type solvent and three other solvents provided by NETL. One was a new hybrid PEG–PDMS (poly[dimethylsiloxane]) solvent engineered by NETL. In addition, two commercially available chemicals that are projected to have good CO2 capture abilities were also selected for testing on actual coal-derived syngas. These tests were conducted in the EERC high-pressure fluid-bed gasifier (HPFBG) system utilizing an existing gas-sweetening absorption system (GSAS) to test the solvents. The four solvents tested were Solvent 1 – AGR II from Coastal Chemical Co., LLC, NETL Solvent 2 – XG-3229 Bis(methoxytriethyleneoxypropyl)hexamethyltrisiloxane, as manufactured by Gelast, Inc.; Solvent 3 – CASSH-1 (diethyl sebacate), procured from Sigma Aldrich; and Solvent 4 – TBP (tributyl phosphate), purchased from ThermoFisher Scientific. The solvents were all tested at a consistent syngas flow and composition at approximately 50 bar to make direct comparisons easier; two solvent flow rates which would bracket 90% CO2 capture; and, temperatures of 10°, 25°, 40°, and 55°C to determine the effects of temperature on CO2 uptake and CO2 to H2 selectivity. Figure E-1 shows the results for CO2 uptake and selectivity for the various solvents. These data show that the CO2 uptake for the Selexol-type solvent for the PEG-PDMS-3 and CASHH-1 solvents at higher operating temperatures around 40°C was better than the Selexol-type solvent was able to achieve at the lower operating temperature of 10°C. Selectivity of CO2 over H2 was at least as good as Selexol for the PEG-PDMS-3 solvent and even better than Selexol for the CASSH-1 solvent. The TBP solvent also displayed good CO2 uptake; however, CO2/H2 selectivity was worse than for the Selexol-type solvent. Operation of precombustion CO2 solvents at temperatures above ambient can provide a 2% process efficiency improvement along with a significant capital cost reduction since refrigeration and solvent dehydration equipment is not required. The excellent results from these tests warrant further longer-duration testing with one or both superior NETL-provided solvents to determine if longer-term exposure to any coal-derived syngas trace species may have an adverse impact on solvent performance. This project was funded through the EERC–DOE Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FE0024233.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1999

High Energy Density Regenerative Fuel Cell Systems for Terrestrial Applications

Regenerative Fuel Cell System (RFCS) technology for energy storage has been a NASA power system concept for many years. Compared to battery-based energy storage systems, RFCS has received relatively little attention or resources for development because the energy density and electrical efficiency were not sufficiently attractive relative to advanced battery systems. Even today, RFCS remains at a very low technology readiness level (TRL of about 2 indicating feasibility has been demonstrated). Commercial development of the Proton Exchange Membrane (PEM) fuel cells for automobiles and other terrestrial applications and improvements in lightweight pressure vessel design to reduce weight and improve performance make possible a high energy density RFCS energy storage system. The results from this study of a lightweight RFCS energy storage system for a remotely piloted, solar-powered, high altitude aircraft indicate an energy density up to 790 w-h/kg with electrical efficiency of 53.4% is attainable. Such an energy storage system would allow a solar-powered aircraft to carry hundreds of kilograms of payload and remain in flight indefinitely for use in atmospheric research, earth observation, resource mapping. and telecommunications. Future developments in the areas of hydrogen and oxygen storage, pressure vessel design, higher temperature and higher- pressure fuel cell operation, unitized regenerative fuel cells, and commercial development of fuel cell technology will improve both the energy density and electrical efficiency of the RFCS.

Burke, Kenneth A.↗
NASA NTRS1991

Synthesis of high performance ceramic fibers by chemical vapor deposition for advanced metallics reinforcing

The chemical vapor deposition (CVD) synthesis of fibers capable of effectively reinforcing intermetallic matrices at elevated temperatures which can be used for potential applications in high temperature composite materials is described. This process was used due to its advantage over other fiber synthesis processes. It is extremely important to produce these fibers with good reproducible and controlled growth rates. However, the complex interplay of mass and energy transfer, blended with the fluid dynamics makes this a formidable task. The design and development of CVD reactor assembly and system to synthesize TiB2, CrB, B4C, and TiC fibers was performed. Residual thermal analysis for estimating stresses arising form thermal expansion mismatch were determined. Various techniques to improve the mechanical properties were also performed. Various techniques for improving the fiber properties were elaborated. The crystal structure and its orientation for TiB2 fiber is discussed. An overall view of the CVD process to develop CrB2, TiB2, and other high performance ceramic fibers is presented.

Revankar, Vithal↗
DOE OSTI2020

Integrated performance of large HDC-capsule implosions on the National Ignition Facility

In this paper, we report on eight, indirect-drive, deuterium–tritium-layered, inertial-confinement-fusion experiments at the National Ignition Facility to determine the largest capsule that can be driven symmetrically without relying on cross-beam energy transfer or advanced Hohlraum designs. Targets with inner radii of up to 1050 μm exhibited controllable P 2 symmetry, while larger capsules suffered from diminished equatorial drive. Reducing the Hohlraum gas-fill-density from 0.45 mg/cm 3 to 0.3 mg/cm 3 did not result in a favorable shift of P 2 amplitude as observed in preceding tuning experiments. Reducing the laser-entrance-hole diameter from 4 mm to 3.64 mm decreased polar radiation losses as expected, resulting in an oblate symmetry. The experiments exhibited the expected performance benefit from increased experimental scale, with yields at a fixed implosion velocity roughly following the predicted 1D dependence. With an inner radius of 1050 μm and a case-to-capsule-ratio of 3.0, experiment N181104 is the lowest implosion-velocity experiment to exceed a total neutron yield of 10 16 .

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗