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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 19 records

Multilayer Silicon Carbide Composite Material Technology for High-Temperature Concentrated Solar-Thermal Power Components

In 2012, the U.S Department of Energy defined aggressive targets to achieve lower component costs and higher system efficiencies for concentrated solar-thermal power (CSP), and this, in turn, has led to the exploration of technology options that can operate at higher temperatures [1]. These next-generation CSP options, referred to as Generation 3 (a.k.a. Gen3), are targeting temperatures at or above 700 °C for the energy being delivered to the power cycle, and the more challenging plant conditions have necessitated a review and selection of alternative receiver heat transfer fluids as well as a search for materials that can meet the associated high-temperature component requirements. Nickel-based alloys are currently being considered, but these generally experience a significant drop in strength at temperatures > 775 °C [2] and may not be able to achieve corrosion and other lifetime requirements. Furthermore, these alloys are expensive, frequently have cost and schedule volatility, and offer little potential for lower cost at high production volumes. As an alternative, Ceramic Tubular Products, LLC (CTP) has developed a multilayer silicon carbide composite that can complement or replace alloys currently being considered for these Gen3 CSP applications.

14 SOLAR ENERGY

GRIDCERF - Geospatial Raster Input Data for Capacity Expansion Regional Feasibility

The Geospatial Raster Input Data for Capacity Expansion Regional Feasibility (GRIDCERF) data package is a high-resolution product to evaluate siting suitability for renewable and non-renewable power plants in the conterminous United States. GRIDCERF offers hundreds of individual suitability layers for use with both renewable and non-renewable power plant technology configurations in a harmonized format that can be easily ingested by geospatially-enabled modeling software. It also provides pre-compiled technology-specific suitability layers and allows for user customization to robustly address science objectives when evaluating varying future conditions. GRIDCERF data can be directly used with the CERF (Capacity Expansion Regional Feasibility) model to site power plants at a 1km resolution. GRIDCERF includes composite technology siting suitability raster layers for the following utility scale technology configurations. Note that, in addition to technology sub-types shown below, various cooling types are also included (recirculating, pond, once-through, recirculating-seawater, dry-hybrid, or dry) for various technologies. Biomass Conventional (with or without CCS) IGCC (with or without CCS) Coal Conventional (with or without CCS) IGCC (with or without CCS) Natural Gas Combined-cycle (CC) (with or without CCS) Turbine Geothermal Enhanced Geothermal Systems (EGS) - Class 1 through Class 5 resource potential Nuclear Gen 2 Light Water Reactor (LWR) Gen 3 Small Modular Reactor (SMR) Gen 3 AP1000 Refined Liquids Combined-cycle (CC) (with or without CCS) Turbine Solar Photovoltaic (PV) - for capacity factors in the range of 6-18% Utility-scale Concentrating Solar Power (CSP) - for capacity factors in the range of 24-46% Tower Wind (Onshore) - for capacity factors in the range of 5-50% 80m hub height 100m hub height 120m hub height 140m hub height Wind (Offshore) - for capacity factors in the range of 25-60% 100m hub height 140m hub height 160m hub height

capacity expansion

High-Speed Layup and Forming of Automotive Composite Components

This Project is focused on the design and manufacture of automotive components that meet functional and environmental requirements of an existing automotive application at a cost of ≤ $\$$11.00 per kilogram weight reduction. This project fosters the development of composite material technologies suitable for high volume automotive processes and run rates as well as industry workforce development with these technologies. Current automotive manufacturing involves utilizing steel or aluminum in sheet form which is rapidly stamped into components at rates up to 3600 per hour. The metallic sheets are available in many different thicknesses, strength levels, and manufacturing rates are reasonable independent of part size. While composite materials are available for use in automotive applications, the material cost, labor to manufacture and the processing of the waste far exceed the cost compared to metallic designs. Typical composite layer by layer layup procedures don’t meet the desired 60 second layup time that current automotive processes require and are also restricted by part size. Due to these factors, composites have not yet made advances into today’s high volume automotive applications. Industry partners DURA, BASF, Ford, and IACMI core innovation partner MSU collaborated to develop a manufacturing process technology that is capable of manufacturing composite blanks at high volume and independent of part size. IACMI core innovation partner Purdue provided FEA analysis and cost modelling. The objective of this project was to demonstrate a composite sheet layup and consolidation process that can be commercialized for high volume requirements, identify potential layup equipment suppliers, and develop a process of 60 second layup, forming, and trimming of a continuous fiber automotive component for the mainstream market.

42 ENGINEERING

Composite Sorbents: Enabling Economical Biomethane Production (CRADA Final Report)

The research performed under this CRADA enhanced the understanding of the performance of LLNL’s composite sorbent technology in the presence of raw biogas with H 2 S contamination, the long-term CO 2 removal performance stability of the composite sorbent in simulated biogas, and highlighted some of the challenges to overcome for further scale-up of material production and system design for deployment. Further development of the technology is of benefit to the public by enabling biogas upgrading from small sources for which existing commercial technologies are not suited, providing additional sources of renewable natural gas and diversifying our energy supply.

09 BIOMASS FUELS

Active Learning for Rapid Targeted Synthesis of Compositionally Complex Alloys

The next generation of advanced materials is tending toward increasingly complex compositions. Synthesizing precise composition is time-consuming and becomes exponentially demanding with increasing compositional complexity. An experienced human operator does significantly better than a novice but still struggles to consistently achieve precision when synthesis parameters are coupled. The time to optimize synthesis becomes a barrier to exploring scientifically and technologically exciting compositionally complex materials. This investigation demonstrates an active learning (AL) approach for optimizing physical vapor deposition synthesis of thin-film alloys with up to five principal elements. We compared AL-based on Gaussian process (GP) and random forest (RF) models. The best performing models were able to discover synthesis parameters for a target quinary alloy in 14 iterations. We also demonstrate the capability of these models to be used in transfer learning tasks. RF and GP models trained on lower dimensional systems (i.e., ternary, quarternary) show an immediate improvement in prediction accuracy compared to models trained only on quinary samples. Furthermore, samples that only share a few elements in common with the target composition can be used for model pre-training. We believe that such AL approaches can be widely adapted to significantly accelerate the exploration of compositionally complex materials.

Chemistry

Wind Turbine Materials Recycling Prize Phase 2 (Commercialization of Wind Turbine Blade Waste (WTBW)-Based, Lightweight, Cementitious Composite Materials): Cooperative Research and Development Final Report, CRADA Number CRD-24-31305

The National Laboratory of the Rockies (NLR) and AltiSora, LLC., will develop new lightweight cementitious composite material technologies that will utilize wind turbine blade waste as a raw material to; (1) allow a high value addition (2) at low cost, enabling (3) a significant waste consumption volume; while (4) consuming the entire wind turbine blade, without (5) creating any waste or emissions and to also (6) offer specific benefits to communities involved.

17 WIND ENERGY

Solid, structured composite neutron detectors with high dynamic range capability

Neutron detectors are essential across disciplines such as fundamental science, nuclear security, safeguards, and civilian applications. While 3 He-filled gas proportional counters have long been revered for their efficacy in detecting thermal neutrons and praised for their efficiency, neutron/gamma discrimination, and stability, the scarcity of 3He has spurred a search for alternatives. Here, we explore a solid structured scintillating particle composite (SPC) consisting of 6 Li-containing scintillating glass particles within an acrylic matrix as a neutron detector for high dynamic range applications. We show for the first time that an SPC neutron detector can boast an intrinsic detection efficiency of 0.261% for pure 252 Cf fission neutrons and an overall neutron detection efficiency of (0.546 ± 0.003)% at the Neutron Free-in-Air facility while being able to function in an intense gamma-ray environment. We also show that the SPC neutron detector supports fast neutron capture times and enables a dual-readout scheme that extends the detector dynamic range to high incident neutron fluxes. A scalable fabrication process allows for tailoring the SPC detector properties to the requirements of specific applications. Good agreement is found between the experimental results taken with a National Institute of Standards and Technology traceable 252 Cf source and the coupled MCNP6 and optical-ray-tracing simulations.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND

Enhancing low-temperature sintering in the MgO-LiF system: Mechanistic insights

In the present article, we provide compelling evidence that minor (1 wt%) additions of micron and nanometre-sized LiF particles in MgO decompose leading to free Li diffusing into MgO surfaces enhancing vacancy production during direct current sintering. The addition of nanometre-sized LiF particles leads to a > 500 °C reduction in the sintering temperature and over 99 % theoretical density of final consolidated compacts. Correlating differential scanning calorimetry with in-situ x-ray diffraction, together with Schottky calculations, post sintering electron microscopy and laser induced breakdown spectroscopy, we uncover critical insights into this impressive reduction in sintering temperature. Our quantitative analysis reveals that MgO and LiF interact at low temperatures with the diffusion of Li into the surface of MgO particles due to the intrinsic structural disorder of the LiF and MgO crystallites. Nanometre-sized LiF particles were found to react the most at low temperatures due to their increased structural disorder. Our multimodal characterization points to a Li-promoted densification and sintering mechanism. This impressive reduction in sintering temperature can be harnessed to promote low-temperature fabrication of MgO-based composites for technological applications.

36 MATERIALS SCIENCE

Recyclable Thermoset Polymers From Lignin Derived Phenols

Spero Renewables has successfully developed bio-based thermoset polymers that can be decomposed and recycled under mild conditions while maintaining physical properties comparable to traditional BPA-based thermosets. Key accomplishments include the optimization of thermoset synthesis with over 50% bio-based content, the establishment of recycling conditions for both thermosets and carbon fiber-reinforced composites, and the demonstration of CFRC recyclability. The project also included a techno-economic analysis (TEA), which revealed significant cost reductions through carbon fiber recycling, and a lifecycle analysis (LCA), which showed that Spero's bio-based CFRCs could reduce greenhouse gas emissions by up to 74% compared to conventional fossil-based CFRCs. This work positions Spero Renewables at the forefront of sustainable thermoset and composite material technologies.

36 MATERIALS SCIENCE

Characterizing Copper-Graphene Composites (Abstract)

In this project, Pacific Northwest National Laboratory (PNNL) will measure the electrical and mechanical properties of the metal composite samples provided by MetalKraft Technologies, LLC. PNNL will also use multimodal methods for characterizing the microstructure of MetalKraft Technologies, LLC’s copper graphene composites. PNNL will work with MetalKraft Technologies, LLC as part of the CABLE Manufacturing Prize efforts under a CRADA. The voucher from DOE has a budget of $100,000 over a period of 6 months. PNNL will be the primary place of performance for the property and microstructure characterization efforts.

36 MATERIALS SCIENCE

Numerical framework for integrated additive manufacturing-compression molding (AM-CM) of thermoplastic composites

Additive manufacturing-compression molding (AM-CM) has emerged as a transformative technology in advanced composite manufacturing. Additive manufacturing (AM) offers high design flexibility and the ability to produce complex geometries with precisely aligned fibers in the preferred orientation. Compression molding (CM) enhances composite materials by providing excellent dimensional stability, reduced porosity, high production rates, and a smooth surface finish. Despite these advantages, extensive integrated analysis is required to optimize processing conditions for improved fiber orientation distribution (FOD) and porosity control. Here, this study develops a comprehensive numerical model to simulate the AM-CM manufacturing process. The model isolates the effects of both the AM and CM phases while also capturing their integration. Additionally, it accounts for heat transfer, temperature-dependent viscosity, and fiber orientation in the extruded fiber-filled polymer, accurately representing material behavior during processing. This approach enables the analysis of interactions between deposited beads of complex strand shapes and their interface regions after full compression. Moreover, the model predicts key parameters such as polymer flowability, fiber orientation, and temperature evolution in AM-CM parts. By optimizing processing conditions, it facilitates a controlled and predictable microstructure.

36 MATERIALS SCIENCE

Investigations into the Ternary NaF-KF-UF4 Salt System – Phase A

A knowledge gap exists in the data and understanding of fresh fuel salt and irradiated multicomponent fuel salt systems thermophysical properties. Quantifying these properties is necessary for the design and construction of test reactors, as well as the licensing of future commercial molten-salt reactors. To facilitate thermal property determination on a proposed fuel salt composition for Seaborg Technologies, several samples containing depleted uranium tetrafluoride (UF4), sodium fluoride (NaF), and potassium fluoride (KF) were blended, and a melt temperature analysis was performed. From the melting temperature analysis, it was determined that sample Seaborg-7, a ternary salt composition of 26.4UF4-24.7KF-48.9NaF (mol%), was very near a ternary eutectic point. Therefore, thermal properties such as melting temperature, salt stability, density, heat capacity, thermal diffusivity, and viscosity were experimentally determined on the Seaborg-7 salt. These measurements document the baseline properties of fresh fuel salt as a function of temperature, where future experiments on irradiated fuel salt will provide a holistic perspective on the change of thermophysical properties during reactor operations. Several precision instruments were used to collect property data, and instrument calibrations and data collection were performed and documented in a standardized and reproducible manner with meticulous detail. This process ensured that the measurement procedures and resulting data can readily be duplicated elsewhere. The Seaborg-7 salt was shown to be stable at temperatures up to 900°C, as no mass change was observed upon repeated heating and cooling. The peak melting temperature was determined to be 547°C (557°C endset). The enthalpy of fusion (??H?_fus^o) was determined to be 167.5 ± 2.7 J/g while the enthalpy of crystallization (??H?_c^o) was determined to be -147.8 ± 13.3 J/g. In addition to the eutectic melting peak, upon heating, several pre eutectic peaks were observed, occurring at 470°C (onset) and 499°C (peak). Specific heat capacity measurements showed a slightly increasing trend with respect to temperature in the solid phase, while the liquid-specific heat capacity showed a somewhat flat trend with an average value of 106.1 ± 1.24 J/mol·K between 600 to 800°C. Three independent trials using the Seaborg-7 salt determined the density to be ?(T) = 4.908 – 0.000363·T(°C), validated between 32 to 200°C, and ?(T) = 4.808 – 0.00113·T(°C), validated between ~575 to 850°C. Thermal diffusivity was determined for the liquid state and is represented by the linear equation y = 0.1581 + 0.000207·T(°C) between 550 to 850°C. The viscosity was determined from 600 to 800°C and is represented by the exponential fit equation, ? (mPa·s) = 736.58e^(-0.006·T(°C)). This report documents the conclusion of fuel salt thermophysical property measurements for the Seaborg SPP, Phase A project.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS

Decomposing sources of value for electricity and negative emissions technologies in net-zero power systems

Deep decarbonization of the US power system would require rapid deployment of variable renewable energy (VRE) resources, which are projected to provide a substantial share of electricity generation at the time of net-zero emissions. However, the exact share of generation met by VRE and the roles of other technologies in supplying key electricity services—energy and firm capacity—remain uncertain. This study employs a detailed model of the US power sector to decompose the provision and value of electricity services, including negative emissions, by technology across a range of deep decarbonization scenarios. Results indicate that while technology deployment and the share of services provided by each technology vary significantly depending on future technological and market conditions, the value composition and future roles of individual technologies remain consistent. These findings offer guidance for research and development priorities and provide insights to inform electricity policy and planning.

29 ENERGY PLANNING, POLICY, AND ECONOMY

Shear Assisted Processing and Extrusion of Magnesium Alloy Machining Chips

The Pacific Northwest National Laboratory (PNNL) utilized Shear Assisted Processing and Extrusion (ShAPE) to convert magnesium alloy machining chips directly into wrought material. PNNL fabricated 0.25” and 0.50” round rod from cold compacted briquettes pressed from dry-machined chips by Loukus Technologies. The alloy composition is proprietary and protected by a Materials Transfer Agreement (MTA) between PNNL and Loukus. Extrusions were fabricated using the ShAPE 2.0 machine, tooling, and process. PNNL is evaluating tensile properties per ASTM E8 and microstructure for grain size, texture, and porosity using Scanning Electron Microscopy (SEM) and Electron Backscatter Diffraction (EBSD). Tensile properties and microstructure results were not available at the time of writing this document. Extruded rods have also been sent to Loukus for evaluation.

36 MATERIALS SCIENCE

Fast-rate joining of thermoplastic composites using integrated additive manufacturing and compression molding process

The integration of additive manufacturing (AM) technology with compression molding (CM), has emerged as a high-performance composite manufacturing technology in recent years. In the AM-CM process, quickly deposited AM preform on a mold undergoes a rapid compaction cycle to fabricate structurally robust composite parts due to highly controlled fiber alignment (from AM) and reduced porosity (from CM). Currently, AMCM-based part size is limited by the size of the mold volume, thus posing a challenge to manufacture scalable parts. Here, this work focuses on joining techniques developed to enable fast rate joining of short fiber-reinforced thermoplastic composite parts using the AM-CM process. Acrylonitrile butadiene styrene resin reinforced with 20 wt% short carbon fiber composites was printed onto a flat mold and pressed under a hydraulic press. Fabricated panels were joined by the (a) mechanical impression at the joining interface and (b) over-molded continuous carbon fiber (CCF) sheet. Tensile tests were performed to characterize the joining strength of both mechanical impression-based joints and CCF over molded joints. Among the mechanical impression-based joints, a U-shape channel allowed the fibers to flow between two joint parts, and 280 % increased mechanical properties were observed. The continuous carbon fiber-based over molded joint CCF showed 350 % increase in tensile strength compared to the butt joints.

36 MATERIALS SCIENCE

Formation of Composite SiC/SiC Joints by Embedded Wire Chemical Vapor Deposition

The joining of ceramic monoliths or composites to date has primarily been limited to the formation of brittle monolithic joints using heterogeneous (dissimilar) materials, similar to brazing in metals. The development of a damage-tolerant joint layer by SiC fiber reinforcements is demonstrated here. Tube workpieces made of SiC fiber-SiC matrix composite are joined using a nonwoven SiC fiber mat densified by embedded wire chemical vapor deposition (EWCVD), creating a fiber-reinforced weld-like joint by homogeneous joining. EWCVD uses a localized heating method to target deposition and growth to the joint region specifically, while minimizing thermal damage to the surrounding composite tube material. X-ray computed tomography (XCT) is used to nondestructively characterize as-made joints for relative density, adhesion, and composition. In situ XCT analysis during mechanical testing revealed crack deflections in the bonding layer, which indicates a toughening mechanism typical of ceramic matrix composite phase. Gas permeation testing of these proof-of-concept composite joints identified relatively high leak rates in comparison to fully coated SiC/SiC composite tube workpieces. In conclusion, the novelty of the composite joining method and current technology challenges, including gas permeability, are discussed in comparison with traditional ceramic joints and materials.

SiC

Microbial Community Analysis & Functional Evaluation in Soils

The overall objective of this proposal was to develop technologies to alter the composition and function of important members of microbial communities. In particular, the overall objective of the microbial community editing portion of the proposal focuses on developing foundational tools and understanding required to predict, alter and design grass rhizosphere communities impacting DOE missions. Specifically, the project is centered on the Microbial Community Analysis & Functional Evaluation in Soils (m-CAFES) to manipulate microbial consortia associated with plants of interest for the bioenergy sector, under the presumption that bacterial communities can be manipulated to enhance plant health. For tasks of specific interest to us, we are focusing on developing novel Clustered Regularly Interspaced Short Palindromic Repeats (CRISPR) based technologies (primarily focusing on Aim 1) and their delivery modalities (notably subaim 1.2) to edit specific bacterial genomes of interest to enhance their functionalities, and programmably ablate specific undesirable members of bacterial communities for plant health. We are focusing on engineering bacteriophages (bacterial viruses, for subaim 1.2) to carry programmable CRISPR-Cas systems (subaim 1.1) to target (ablate) or alter (edit) genomes of interest. This will enable us to carry out microbial perturbations that will impact community composition and function and ultimately plant growth and health, to enable the next phase of the project by deploying them in situ (subaims 1.3 and 1.4).

59 BASIC BIOLOGICAL SCIENCES

Colloidal quantum dots for optoelectronics

Colloidal quantum dots (QDs) are semiconductor nanocrystals that have unique size-tunable optoelectronic properties and are suitable for wet processing. QD research aims to answer fundamental questions about the chemical and physical properties of nanoscale materials and use these tools for technological applications ranging from bio-imaging to quantum optics. At the core of this field is a set of synthetic, processing and analytical methods designed to produce QDs in uniform ensembles that meet the highest performance standards. Here, this Primer reviews QD fabrication methods with a focus on the applications of QDs in printed optoelectronics and quantum optics. After outlining the current state-of-the-art QD syntheses, the experimental and computational analysis of QDs is discussed. These topics are then connected to the methodologies, processes and concepts required for developing QD-based photodetectors, light-emitting devices and quantum optics applications. Special attention is paid to challenges in reproducibility and current limitations of the field, such as the need to balance non-restricted material composition with high performing technology while achieving long-term stability in QD devices under operating conditions. Finally, the ongoing advancement in QD synthesis, precise atomic-level analysis and computational methodologies are highlighted as key drivers towards rational QD design, particularly in understanding how structural changes under loading impact QD properties.

optical materials