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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

An Assessment of Additively Manufactured Bonded Permanent Magnets for a Distributed Wind Generator

In this paper, we examine and compare the performance of a generator design optimized using additively manufactured NdFeB-SmFeN in nylon-polymer-bonded permanent magnets (PMs) against a generator design with conventional NdFeB sintered PMs. To realize this, a commercially available 15-kW wind generator's rotor is re-optimized using both additively manufactured and sintered NdFeB magnets using simple geometric parameterization that allowed for two specific magnet shapes, namely, arc-shaped and crown-shaped designs. Results showed that for a similar generator performance, the designs with additively manufactured bonded PMs are more cost-competitive in terms of the estimated PM material cost and also have negligible eddy current magnet losses.

additive manufacturing↗
DOE OSTI2014

Group Additivity Determination for Enthalpies of Formation of Carbenium Ions

Modeling of acid-catalyzed hydrocarbon conversion processes at the mechanistic level requires rate coefficients for a large number of reactions. The computational demand of finding activation energy barriers for each reaction is substantially reduced by employing structure–reactivity correlations such as the Evans–Polanyi relationship that correlates activation energy with the enthalpy of reaction. However, there are many species for which the enthalpies of formation are unknown. Therefore, group additivity methods to specify enthalpies of formation for each species involved in the reaction network are valuable. Quantum mechanical (QM) calculations and isodesmic reactions were used to calculate enthalpies of formation for a number of acyclic and cyclic carbenium ions, including allylic carbenium ions. These values compare favorably with experimental values, establishing Gaussian-4 as an accurate QM method for these calculations. Using these values, Benson-type group additivity values for enthalpies of formation were then derived through multiple linear regression. Enthalpies of formation values calculated from the group additivity scheme capture experimental and QM enthalpies of formation well and enhance the range of species that can be described by the group additivity approach.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2014

Improving Brush Polymer Infrared One-Dimensional Photonic Crystals via Linear Polymer Additives

Brush block copolymers (BBCPs) enable the rapid fabrication of self-assembled one-dimensional photonic crystals with photonic band gaps that are tunable in the UV-vis-IR, where the peak wavelength of reflection scales with the molecular weight of the BBCPs. Due to the difficulty in synthesizing very large BBCPs, the fidelity of the assembled lamellar nanostructures drastically erodes as the domains become large enough to reflect IR light, severely limiting their performance as optical filters. To overcome this challenge, short linear homopolymers are used to swell the arrays to ~180% of the initial domain spacing, allowing for photonic band gaps up to~1410 nm without significant opacity in the visible, demonstrating improved ordering of the arrays. Additionally, blending BBCPs with random copolymers enables functional groups to be incorporated into the BBCP array without attaching them directly to the BBCPs. The addition of short linear polymers to the BBCP arrays thus offers a facile means of improving the self-assembly and optical properties of these materials, as well as adding a route to achieving films with greater functionality and tailorability, without the need to develop or optimize the processing conditions for each new brush polymer synthesized.

Macfarlane, Robert J.↗
DOE OSTI2015

Effects of Zn additions to highly magnetoelastic FeGa alloys

Fe{sub 1−x}M{sub x} (M = Ga, Ge, Si, Al, Mo and x ∼ 0.18) alloys offer an extraordinary combination of magnetoelasticity and mechanical properties. They are rare-earth-free, can be processed using conventional deformation techniques, have high magnetic permeability, low hysteresis, and low magnetic saturation fields, making them attractive for device applications such as actuators and energy harvesters. Starting with Fe-Ga as a reference and using a rigid-band-filling argument, Zhang et al. predicted that lowering the Fermi level by reducing the total number of electrons could enhance magnetoelasticity. To provide a direct experimental validation for Zhang's hypothesis, elemental additions with lower-than-Ga valence are needed. Of the possible candidates, only Be and Zn have sufficient solubility. Single crystals of bcc Fe-Ga-Zn have been grown with up to 4.6 at. % Zn in a Bridgman furnace under elevated pressure (15 bars) in order to overcome the high vapor pressure of Zn and obtain homogeneous crystals. Single-crystal measurements of magnetostriction and elastic constants allow for the direct comparison of the magnetoelastic coupling constants of Fe-Ga-Zn with those of other magnetoelastic alloys in its class. The partial substitution of Ga with Zn yields values for the magnetoelastic coupling factor, −b{sub 1}, comparable to those of the binary Fe-Ga alloy.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2017

Corrosion properties of powder bed fusion additively manufactured 17-4 PH stainless steel

The corrosion susceptibility of a laser powder bed fusion (LPBF) additively manufactured alloy, UNS S17400 (17-4 PH), was explored compared to conventional wrought material. Microstructural characteristics were characterized and related to corrosion behavior in quiescent, aqueous 0.6 M NaCl solutions. Electrochemical measurements demonstrated that the LPBF 17-4 PH alloy exhibited a reduced passivity range and active corrosion compared to its conventional wrought counterpart. Lastly, a micro-electrochemical cell was employed to further understand the effects of the local scale and attributed the reduced corrosion resistance of the LPBF material to pores with diameters ≥ 50 µm.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Divergences in hydraulic conductance and anatomical traits of stems and leaves in three temperate tree species coping with drought, N addition and their interactions

Drought and N addition have been shown to affect tree hydraulic traits, but few studies have been made on their interactions across species with different wood types or leaf forms. We examined the responses of hydraulic conductance and xylem anatomical traits of Quercus mongolica (ring-porous with simple-leaves), Fraxinus mandshurica (ring-porous with compound-leaves), and Tilia amurensis (diffuse-porous with simple-leaves) to drought, N addition and their interactions. Drought stress decreased current-year xylem-specific conductivity in stems (Ksx) and leaf hydraulic conductance (Kleaf), but N addition affected Ksx and Kleaf differently among species and watering regimes. These divergent effects were associated with different responses of anatomical traits and leaf forms. Higher mean vessel diameter in stems (Dstem) and lower vessel density in leaves (VDvein) were observed with N addition. The three-way interactive effects of drought, N addition and tree species were significant for most values of anatomical traits. These results were also reflected in large differences in vessel diameter and density among species with different wood types or leaf forms. The two-way interactive effects of drought and N addition were significant on Kleaf and predawn water potential (?pd), but not Ksx, indicating that leaves were more sensitive than stems to a combination of drought stress and N addition. Our results provide mechanistic insight into the variable responses of xylem water transport to the interactions of drought and N availability.

Hydraulic conductance, hydraulic architecture, N f↗
DOE OSTI2015

Grain-Size Based Additivity Models for Scaling Multi-rate Uranyl Surface Complexation in Subsurface Sediments

This study statistically analyzed a grain-size based additivity model that has been proposed to scale reaction rates and parameters from laboratory to field. The additivity model assumed that reaction properties in a sediment including surface area, reactive site concentration, reaction rate, and extent can be predicted from field-scale grain size distribution by linearly adding reaction properties for individual grain size fractions. This study focused on the statistical analysis of the additivity model with respect to reaction rate constants using multi-rate uranyl (U(VI)) surface complexation reactions in a contaminated sediment as an example. Experimental data of rate-limited U(VI) desorption in a stirred flow-cell reactor were used to estimate the statistical properties of multi-rate parameters for individual grain size fractions. The statistical properties of the rate constants for the individual grain size fractions were then used to analyze the statistical properties of the additivity model to predict rate-limited U(VI) desorption in the composite sediment, and to evaluate the relative importance of individual grain size fractions to the overall U(VI) desorption. The result indicated that the additivity model provided a good prediction of the U(VI) desorption in the composite sediment. However, the rate constants were not directly scalable using the additivity model, and U(VI) desorption in individual grain size fractions have to be simulated in order to apply the additivity model. An approximate additivity model for directly scaling rate constants was subsequently proposed and evaluated. The result found that the approximate model provided a good prediction of the experimental results within statistical uncertainty. This study also found that a gravel size fraction (2-8mm), which is often ignored in modeling U(VI) sorption and desorption, is statistically significant to the U(VI) desorption in the sediment.

Zhang, Xiaoying↗
DOE OSTI2018

Lithium Difluorophosphate as a Dendrite-Suppressing Additive for Lithium Metal Batteries

The growth of lithium (Li) dendrite and the low Coulombic efficiency (CE) of Li anode during repeated Li plating/stripping processes are the two major obstacles to the development of rechargeable Li metal batteries (LMBs). Introducing a dendrite-suppressing additive into the nonaqueous electrolyte is one of the facile and effective solutions to promote the commercialization of LMBs. Herein, Li difluorophosphate (LiPO2F2, LiDFP) is used as an electrolyte additive to suppress the growth of Li dendrites by forming a vigorous and stable solid electrolyte interphase layer on the Li metal surface. Moreover, the Li CE can be largely improved from 84.6% for the conventional LiPF6-based electrolyte to 95.2% by the addition of an optimal concentration of LiDFP at 0.15 M. The optimal LiDFP-containing electrolyte can allow the Li||Li symmetric cells to cycle stably for more than 500 and 200 h at 0.5 and 1.0 mA cm-2, respectively, much longer than the control electrolyte without LiDFP additive. Meanwhile, this LiDFP-containing electrolyte can also greatly enhance the cycle life of the Li||LiNi1/3Co1/3Mn1/3O2 cells with a moderately high mass loading of 9.7 mg cm-2. These results demonstrate that LiDFP has extensive application prospects as a dendrite-suppressing additive in advanced LMBs.

Shi, Pengcheng↗
DOE OSTI2016

Boosting the Performance of Ionic-Liquid-Based Supercapacitors with Polar Additives

Recent years have witnessed growing interests in both the fundamentals and applications of electric double layer capacitors (EDLCs), also known as supercapacitors. A number of strategies have been explored to optimize the device performance in terms of both the energy and power densities. Because the properties of electric double layers (EDL) are sensitive to ion distributions in the close vicinity of the electrode surfaces, the supercapacitor performance is sensitive to both the electrode pore structure and the electrolyte composition. In this work, we study the effects of polar additives on EDLC capacitance using the classical density functional theory within the framework of a coarse-grained model for the microscopic structure of the porous electrodes and room-temperature ionic liquids. The theoretical results indicate that a highly polar, low-molecular-weight additive is able to drastically increase the EDLC capacitance at low bulk concentration. Additionally, the additive is able to dampen the oscillatory dependence of the capacitance on the pore size, thereby boosting the performance of amorphous electrode materials. The theoretical predictions are directly testable with experiments and provide new insights into the additive effects on EDL properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Additive Manufacturing for Powering the Blue Economy Applications: A Tidal Turbine Blade Case Study: Preprint

As the marine renewable energy industry continues to expand, innovation in the manufacturing space must grow accordingly to reduce costs and ensure the economic feasibility of new technologies. Additive manufacturing, more commonly known as 3D printing, provides an alternative for rapid prototyping of marine hydrokinetic technologies, particularly supporting Powering the Blue Economy initiatives of the U.S. Department of Energy Water Power Technologies Office. This study explores the application of additive manufacturing in the development of marine hydrokinetic structures, focusing on material and printing method selection, design, and analysis of a 3D-printed spar for an axial-flow tidal turbine blade. Corrosion-resistant metals were deemed ideal due to the loads and harsh marine environment the blade would experience. Laser metal deposition methods were determined to be the most effective and scalable for the considered scale. The designed spar adapts its geometry to the blade - a feature uniquely suited to additive manufacturing - and is intended to serve as the blade's primary structural component. A finite element model was used to study stresses and deformations under loading conditions. The spar was manufactured using 316L stainless steel through direct energy deposition, and defects were assessed and recorded. Future efforts will include mechanical testing of the spar. This research establishes a benchmark process for using additive manufacturing in developing marine hydrokinetic structures, paving the way for future optimization and techno-economic analysis.

additive manufacturing↗
DOE OSTI2018

Dendrite-Free and Performance-Enhanced Lithium Metal Batteries through Optimizing Solvent Compositions and Adding Combinational Additives

The instability of lithium (Li) metal anode due to the dendritic growth and low Coulombic efficiency hinders the practical application of the well-regarded high-energy-density Li metal batteries. Here we report the systematic studies of improving the stability of Li metal anode and the electrochemical performances of the related Li metal batteries through the addition of combinational additives and the optimization of solvent compositions in dual-salt/carbonate electrolytes. A dendrite-free and high Coulombic efficiency of 98.1% for Li metal anode is achieved. The well protection of the Li metal anode and the excellent cyclability and rate capability of the 4-V Li metal batteries have been obtained. This is attributed to the formation of a robust, denser, more polymeric and higher ionic conductive surface film on the Li metal anode via the electrochemical reductive decompositions of the electrolyte components and the ring-opening polymerization of additives and cyclic carbonate solvents. The key findings of this work emphasize that the optimization of solvent compositions and the manipulation of the additives are facile and effective to enhance the Li metal battery performances.

Li metal batteries, dual-salt electrolyte, additiv↗
DOE OSTI2018

Low Molecular Weight Polymethacrylates as Multi-Functional Lubricant Additives

Low molecular weight, moderately polar polymethacrylate polymers are explored as potential multi-functional lubricant additives. The performance of these novel additives in base oil is characterized in terms of their viscosity index, shear stability, friction and wear, and compared to two benchmarks, a base oil containing a typical polymeric viscosity modifier and a fully-formulated oil. Results show that the best performing of these polymers exhibit viscosity index and friction comparable to that of both benchmarks, far superior shear stability to either benchmark (as much as 15x lower shear), and wear reduction significantly better than a typical viscosity modifier (lower by a factor of 2-3) but not as good as that of the fully formulated oil. The findings also suggest that the polarity and molecular weight of the polymers affect their performance which suggests future synthetic strategies which may enable this new class of additives to replace multiple additives in typical lubricant formulations.

Cosimbescu, Lelia↗
DOE OSTI2016

Workshop Report on Additive Manufacturing for Large-Scale Metal Components - Development and Deployment of Metal Big-Area-Additive-Manufacturing (Large-Scale Metals AM) System

Additive manufacturing (AM) is considered an emerging technology that is expected to transform the way industry can make low-volume, high value complex structures. This disruptive technology promises to replace legacy manufacturing methods for the fabrication of existing components in addition to bringing new innovation for new components with increased functional and mechanical properties. This report outlines the outcome of a workshop on large-scale metal additive manufacturing held at Oak Ridge National Laboratory (ORNL) on March 11, 2016. The charter for the workshop was outlined by the Department of Energy (DOE) Advanced Manufacturing Office program manager. The status and impact of the Big Area Additive Manufacturing (BAAM) for polymer matrix composites was presented as the background motivation for the workshop. Following, the extension of underlying technology to low-cost metals was proposed with the following goals: (i) High deposition rates (approaching 100 lbs/h); (ii) Low cost (<$10/lbs) for steel, iron, aluminum, nickel, as well as, higher cost titanium, (iii) large components (major axis greater than 6 ft) and (iv) compliance of property requirements. The above concept was discussed in depth by representatives from different industrial sectors including welding, metal fabrication machinery, energy, construction, aerospace and heavy manufacturing. In addition, DOE’s newly launched High Performance Computing for Manufacturing (HPC4MFG) program was reviewed. This program will apply thermo-mechanical models to elucidate deeper understanding of the interactions between design, process, and materials during additive manufacturing. Following these presentations, all the attendees took part in a brainstorming session where everyone identified the top 10 challenges in large-scale metal AM from their own perspective. The feedback was analyzed and grouped in different categories including, (i) CAD to PART software, (ii) selection of energy source, (iii) systems development, (iv) material feedstock, (v) process planning, (vi) residual stress & distortion, (vii) post-processing, (viii) qualification of parts, (ix) supply chain and (x) business case. Furthermore, an open innovation network methodology was proposed to accelerate the development and deployment of new large-scale metal additive manufacturing technology with the goal of creating a new generation of high deposition rate equipment, affordable feed stocks, and large metallic components to enhance America’s economic competitiveness.

36 MATERIALS SCIENCE↗