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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 181 records · Page 10

Combining direct ink writing with reactive melt infiltration to create architectured thermoelectric legs

Here, we present a new additive-reactive synthesis method where inks – cast into molds or 3D-additively extruded into architectured shapes – are reacted into intermetallic thermoelectric compounds. The new method, as demonstrated for equiatomic TiNiSn, combines: (i) extrusion printing (or casting) of inks containing Ni and Ti powders, (ii) debinding and reactive sintering to form a porous NiTi network, (iii) network infiltration with liquid Sn and subsequent reaction to synthesize the TiNiSn phase. Thin plates, created through this method, show high phase purity and low residual porosity. A thermoelectric figure of merit zT = 0.47 ± 0.05 is achieved at 800 K, within the broad range of values (zT= 0.3–1.0) reported for TiNiSn created via traditional powder hot-pressing methods. Layered TiNiSn microlattices – after 3D ink-extrusion printing and infiltration – exhibit high relative densities and minimal undesirable secondary phase content, with a Seebeck coefficient on par with the ink-cast TiNiSn plates, demonstrating that thermoelectric legs with far-ranging architectural freedom can be created additively with this novel reactive manufacturing method. Numerous other thermoelectric (and other) compounds, currently limited to basic geometries due to brittleness, are amenable to this new method based on a sequence of reactive sintering/infiltration of cast or ink-extruded precursors.

36 MATERIALS SCIENCE↗

Reducing experimental uncertainty in the calculation of cavity swelling in a transmission electron microscope through crystallographically aided void volume tracking

Accurate measurement of cavity swelling in a transmission electron microscope is essential to define material performance under irradiation, and the conventionally applied spherical assumption for the calculation of cavity volumes in irradiated materials can result in errors ranging between a 25% underestimation and 72% overestimation of volume purely based on the assumption of shape. This assumption is undeniably expedient for calculation but does not sufficiently account for the 3D nature of polyhedral cavities and their shape projection in the transmission electron microscope, and therefore presents too large of an associated uncertainty in swelling determination for faceted cavities. This uncertainty has been defined for many common cavity shapes in FCC and BCC crystal systems, and has been tabulated across the cubic fundamental region. A revised methodology for crystallographically aided void volume tracking, or CAVV-T, is presented and demonstrated on a specimen of neutron irradiated Ni. In-depth discussion on the application of this technique is provided along with resources to allow for conversion between the spherical assumption and this revised method. This work seeks to increase experimental confidence in the characterization and quantification of critical aspects of irradiation damage in materials by applying a crystallographically-resolved approach for cavity swelling calculation.

Haag IV, James V. [Pacific Northwest National Labo↗

Influence of elongation and triangularity on plasma response to resonant magnetic perturbations

Abstract Systematic toroidal modeling of the plasma response to the n = 1–4 ( n is the toroidal mode number) resonant magnetic perturbation (RMP) field is carried out in order to understand the plasma-shaping effect on controlling the type-I edge-localized modes (ELMs) in tokamak experiments. Considered are large variations of the plasma elongation and triangularity at a fixed edge safety factor q a , for limiter plasmas with both single-null (SN) and double-null (DN) divertor-like boundary shapes. Numerical results assuming conformal 3D RMP coils show that (i) the optimum coil phasing between the upper and lower rows for ELM control becomes increasingly sensitive to the plasma elongation with higher- n toroidal spectra, (ii) the optimum coil phasing is however essentially independent of the plasma triangularity for all n = 1–4 RMP fields, (iii) with the same coil current and the optimum coil phasing, high elongation generally favors ELM control but it may be more challenging for plasmas with intermediate elongation and with lower- n ( n = 1–2) RMPs, and (iv) higher triangularity is generally always better for ELM control with all n = 1–4 fields for both DN and SN divertor-like plasma boundary shapes.

Physics↗

3D-printable engineered cementitious composites (3DP-ECC): Fresh and hardened properties

3D printing (3DP) is an emerging digital construction method for concrete materials. A major impediment to efficient 3D concrete printing (3DCP) is the need for steel reinforcement, the placement of which is incompatible with the 3DP process. Unlike plain concrete, ductile self-reinforced engineered cementitious composite (ECC) holds promise to remove the dependence on steel reinforcement. The objective of this research is to develop a 3D-printable ECC (3DP-ECC). The fresh rheological and hardened mechanical properties of 3DP-ECC are investigated. The robotically printed tensile specimens demonstrated the familiar multiple microcracking and strain-hardening behavior of conventionally cast ECC. Significant orthotropy is revealed in the compressive properties. The interface between printed layers is found to be toughened by a printed groove-tongue joint. The developed 3DP-ECC was used to print a twisted column with 150 layers, reaching a height of 1.5 m. This research lays the groundwork for efficient robotically 3D-printed structures of complex shapes.

36 MATERIALS SCIENCE↗

Ensembles of Metastable States Govern Heterogeneous Catalysis on Dynamic Interfaces

Heterogeneous catalysis is at the heart of chemical industry. Being able to tune and design efficient catalysts for processes of interest is of an utmost importance, and for this, the molecular-level understanding of heterogeneous catalysts is the first step, and indeed a prime focus of the modern catalysis research. For a long time, a single most thermodynamically stable structure of the catalytic interface attained in reaction conditions had been envisioned as the reactive phase. However, some catalytic interfaces continue to undergo structural dynamics in the steady state, triggered by high temperatures, pressures, and binding and changing reagents. Among particularly dynamic interfaces are such widely-used catalysts as crystalline and amorphous surfaced supporting (sub-)nano metallic clusters. Recently, it became clear that this dynamic fluxionality causes the supported clusters to populate many distinct structural and stoichiometric states in catalytic conditions. Hence, the catalytic interface should be viewed as an evolving statistical ensemble of many (not one) structures. As such, every member in the ensemble contributes to the properties of the catalyst differently, and in proportion to its probability to be populated. This new notion flips the established paradigm and calls for new theory, modeling approaches, operando measurements, and updated design strategies. The statistical ensemble nature of surface-supported sub-nano cluster catalysts can be exemplified by oxide-supported and adsorbate-covered Pt, Pd, Cu, CuPd clusters, catalytic toward oxidative and non-oxidative dehydrogenation. They have access to a variety of 3D and quasi-2D shapes. The compositions of their thermal ensembles are dependent on the cluster size, leading to size-specific catalytic activities and the famous “every atom counts” phenomenon. The support and adsorbates affect catalyst structures, and state of the reacting species causes the ensemble to change in every reaction intermediate. The most stable member of the ensemble dominates the thermodynamic properties of the corresponding intermediate, whereas the kinetics can be determined by more active but less populated metastable catalyst states, and that suggests that many earlier studies might have overlooked the actual active sites. Both effects depend on the relative time-scales of catalyst restructuring and reaction dynamics. The catalyst may routinely operate off-equilibrium. Ensemble phenomena lead to surprising exceptions from established rules of catalysis, such as scaling relations, and Arrhenius behavior. Catalyst deactivation is also an ensemble property, and its extent of mitigation can be predicted through the new paradigm. These findings were enabled by advances in theory, such as global optimization and subsequent utilization of multiple local minima, and pathways sampling, as well as operando catalyst characterization. The fact that the per-site and per-species resolution is needed for the description and predicting of catalyst properties gives theory the central role in catalysis research, as most experiments provide ensemble-average information and cannot detect the crucial minority species that may be responsible for the catalytic activity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Understanding the Effect of Electrochemical Properties and Microstructure on the Microgalvanic Corrosion of Mg Alloys via Phase-Field Simulations

In this work, we apply a phase-field model to gain insights into the corrosion behavior of Mg alloys. Specifically, we study the effect of electrochemical properties of the materials and their environment and the spatial distribution of second phases in a magnesium alloy. To this end, we perform sensitivity analyses in which we separately vary the exchange current density and corrosion potential of the second phase, as well as the electrolyte conductivity. We describe the effects of these parameters on the corrosion current and the resulting corrosion-front morphology. We also confirm that the ratio between the Wagner length, calculated for the anodic phase, and the initial width of the anodic domain is a good predictor of the morphological characteristic of the corroding surface. In addition, we examine the effect of the microstructure on the corrosion behavior in both 2D and 3D systems by varying the shape, size, and distribution of the second-phase regions. Our findings provide insights into the influence of the two-phase microstructure on the corrosion behavior in a magnesium alloy.

Electrochemistry↗

recon3d

SAND2025-00533O recon3d is a software tool that provides automated 3D reconstruction and meshing capabilities. It processes labeled 3D image data from various sources, starting from image stacks, and calculates 3D feature distributions like size, shape, and location. The software also has tools for downscaling rectilinear grid data and creating tetrahedral meshes directly from image data. recon3d can be used by novice users via the command line with a properly formatted configuration file. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Emery, John↗

Numerical simulation of laminar-turbulent transition in a spatially-developing flat plate wake

Laminar-turbulent transition of an incompressible flat-plate wake is investigated by direct numerical integration of the Navier-Stokes equations. For the numerical integration, a combination of finite-difference and spectral methods along with an ADI/Crank-Nicolson/Adams-Bashforth time integration scheme is employed. Subject to 2D forcing, the wake exhibited a rapidly-growing fundamental disturbance that quickly saturated. This saturation was due partly to the stabilizing effect of the mean flow distortion. Downstream of the saturation point, disturbance energy was concentrated in the fundamental disturbance, the second harmonic, and the mean flow distortion component. At large amplitude levels, a Karman vortex street formed. Variations in the 2D forcing level did not alter the qualitative behavior of the disturbances. Simulations of 3D breakdown indicates that the presence of large-amplitude, 2D disturbances tends to initially suppress small-amplitude 3D disturbance growth. Following this initial suppression, a resumption of 3D growth is observed that may have been due to a secondary instability mechanism. For high levels of 3D disturbance energy, lambda-shaped vortical structures formed between adjacent Karman vortices.

Dratler, D. I.↗

Three-dimensional aerodynamic shape optimization of supersonic delta wings

A recently developed three-dimensional aerodynamic shape optimization procedure AeSOP(sub 3D) is described. This procedure incorporates some of the most promising concepts from the area of computational aerodynamic analysis and design, specifically, discrete sensitivity analysis, a fully implicit 3D Computational Fluid Dynamics (CFD) methodology, and 3D Bezier-Bernstein surface parameterizations. The new procedure is demonstrated in the preliminary design of supersonic delta wings. Starting from a symmetric clipped delta wing geometry, a Mach 1.62 asymmetric delta wing and two Mach 1. 5 cranked delta wings were designed subject to various aerodynamic and geometric constraints.

Burgreen, Greg W.↗

Orbital Debris Shape Characterization Project Abstract

I have been working on a project to further our understanding of orbital debris by helping create a new dataset previously too complex to be implemented in past orbital debris propagation models. I am doing this by creating documentation and 3D examples and illustrations of the shape categories. Earlier models assumed all orbital debris to be spherical aluminum fragments. My project will help expand our knowledge of shape populations to 6 categories: Straight Needle/Rod/Cylinder, Bent Needle/Rod/Cylinder, Flat Plate, Bent Plate, Nugget/Parallelepiped/Spheroid, and Flexible. The last category, Flexible, is still up for discussion and may be modified. These categories will be used to characterize fragments in the DebriSat experiment.

Pease, Jessie↗

Advanced multimaterial shape optimization methods as applied to advanced manufacturing of wind turbine generators

Abstract Currently, many utility‐scale wind turbine generator original equipment manufacturers are dependent on imported rare earth permanent magnets, which are susceptible to market risks from cost instability. To lower the production costs of these generators and stay competitive in the market, several small wind manufacturers are pursuing continuous improvements to both generator design and manufacturing. However, traditional design and manufacturing methods have yielded marginal improvements in wind power performance. This work presents novel methods to redesign a baseline 15‐kW wind turbine generator with reduced rare‐earth permanent magnets by leveraging cutting‐edge three‐dimensional (3D) printed polymer‐bonded permanent magnets and steel. Symmetric, asymmetric, and multimaterial‐magnet parametrization methods are introduced for shape optimization. We extend the symmetric and asymmetric methods to the back iron in the stator to further investigate the impact and opportunities for performance improvements with lesser active materials. We employ a design‐of‐experiments approach with parametric computer‐aided design for shape generation and evaluate different designs by magneto‐thermal modeling and finite‐element analysis. We use adaptive sampling technique to identify better performing designs with lesser magnet mass, higher efficiency, and lower cogging torque when compared with the baseline generator. Asymmetric pole designs resulted in a magnet mass in the range of 4.77–5.37 kg, which was 27%–35% lighter than the baseline generator, suggesting that a new design freedom exists that can be enabled by advanced manufacturing, such as 3D printing. Shaping the back iron in the stator resulted in material savings in electrical steel of up to 14.62 kg, which was 20% lighter than the baseline stator. We conducted a structural analysis to evaluate an optimized asymmetric rotor design from the point of view of mechanical integrity and air‐gap stiffness. The magnetically optimal shape profile was shown as having a positive impact on the radial stiffness, and an optimal solution was discovered to reduce the structural mass by nearly 30 kg, which was 29% lighter than the baseline.

17 WIND ENERGY↗

Accommodation of Posture Variations in Lower Head for Maxillofacial Protective Equipment Design

In order to optimize maxillofacial protective equipment design for Soldiers, the face shape and size were analyzed for changes from a baseline neutral pose to functional poses or jaw motions. A dynamic 3D scanner captured the head and face shapes in several different poses, for example, pronouncing vowel sounds or mimicking yawning or chewing. The face landmarks showed unique excursion patterns, not represented in “static” anthropometry, for example, a 49 mm downward chin motion when yawning. A design demo was simulated to show the mandible shield size required to accommodate the different poses.

Han Kim↗

Influence of crystal structure on constitutive anisotropy of silica sand at particle-scale

In spite of recent advanced geotechnical research regarding the influence of particle-scale morphology and fabric on the constitutive behavior of silica sands, there is still no published literature that investigated the influence of crystal structure of sand particles on their constitutive behavior. The main constituent of silica sand particles is quartz mineral, which has a trigonal crystal system and hexagonal lattice. This paper investigates the influence of quartz crystal structure on the constitutive response of silica sand particles using 3D X-ray diffraction (3DXRD), synchrotron micro-computed tomography (SMT), and 3D finite element (FE) analysis. Here, unconfined uniaxial compression experiments on single particles of synthetic silica cubes exposed the notion of constitutive anisotropy caused by the crystal structure of quartz. Since the silica cubes have simple regular geometry (1 mm) 3 , they were loaded in different directions with respect to their crystal local planes. The crystal structure was also identified for a natural silica sand specimen composed of 2705 particles and loaded in confined uniaxial compression. Physical limitations of the experimental measurements made a strong case for the use of 3D FE analysis to study how the change in crystal local orientation of individual sand particles can fundamentally produce anisotropy in the constitutive response of natural sand specimens. The 3D FE analysis was validated to accurately model the crystal-based constitutive anisotropy in silica particles using the results of the silica cube experiments. The analysis was then executed on 3D FE meshes that closely matched the physical shape and fabric of the 2705 particles in the natural sand specimen. Both the experiments and 3D FE analysis showed that the crystal structure of quartz essentially causes a directional anisotropy in the constitutive behavior of silica particles.

58 GEOSCIENCES↗

REGULATORY TESTING AND 3D SCANNING METHODOLOGY OF THE DPP-1 TYPE SHIPPING CONTAINER FOR NCT AND HAC TESTS

The safe transportation of radioactive material using appropriately designed and certified transportation packages is important to protect the public and environment. In the United States of America all transportation of radioactive material is regulated by the Department of Transportation (DOT) along with input by the Nuclear Regulatory Commission (NRC). All packages that contain radioactive material requires that it be transported and regulated by the requirements set by the DOT Class 7 hazardous material transportation. Federal regulations place strict administrative controls on the transport of radioactive materials. The two main goals for transporting radioactive materials are 1. Safety should be the primarily focused on the package because it is the first line of defense. 2. Package integrity should be directly related to the degree of the hazard of the radioactive material contents. The two-part goal ensures that the right package is used. Type B packages are designed to transport radioactive materials with the highest level of radioactivity. Examples of material transported in Type B packagings include spent nuclear fuel, high-level radioactive waste, and high concentrations of other radioactive materials. The purpose of this test protocol is to determine the effects of drop and thermal testing on package performance in a Type B shipping package (DPP-1). Required physical tests for the DPP-1 package include free drop, crush, puncture, penetration, compression, vibration, water spray, water immersion, and thermal. The preparation, regulatory testing, and post-test evaluation of a Type B shipping package tested to the 10 CFR 71.71 and 10 CFR 71.73 requirements will be presented. Six packages were tested and the responses when subjected to the HAC sequence of free drop, puncture, and thermal tests according to 10 CFR 71.73(c)(1), (c)(2), (c)(3) and (c)(4) were measured. The Free Drop, Crush and Puncture tests were performed at the NTRC in Knoxville, TN, and the Thermal tests were performed Southwest Research Institute in San Antonio, TX. The test units were subjected to a pre-operational leak testing before the NCT and HAC tests and a post-operational leak test and a helium leak test once regulatory testing was complete. Finally, all test units were scanned with a handheld blue light scanner to capture a 3D CAD geometry of the test units in the deformed shape. The handheld scanner provided the most effective and reliable way to acquire accurate 3D measurements of the test unit. The scanned geometry was sectioned in areas with deformation and the cross-section profile was measured to determine accurate and repeatable results of the deformed shape of the test units.

Martinez, Oscar↗

Robust Containment Queries over Collections of Trimmed NURBS Surfaces via Generalized Winding Numbers

Here, we propose a containment query that is robust to the watertightness of regions bound by trimmed NURBS surfaces, as this property is difficult to guarantee for in-the-wild CAD models. Containment is determined through the generalized winding number (GWN), a mathematical construction that is indifferent to the arrangement of surfaces in the shape. Applying contemporary techniques for the 3D GWN to trimmed NURBS surfaces requires some form of geometric discretization, introducing computational inefficiency to the algorithm and even risking containment misclassifications near the surface. In contrast, our proposed method leverages properties of the 3D solid angle to solve the relevant surface integral using a boundary formulation with rapidly converging adaptive quadrature. Batches of queries are further accelerated by memoizing (i.e., caching and reusing) quadrature node positions and tangents as they are evaluated. We demonstrate that our GWN method is robust to complex trimming geometry in a CAD model, and is accurate up to arbitrary precision at arbitrary distances from the surface. The derived containment query is therefore robust to model non-watertightness while respecting all curved features of the input shape.

97 MATHEMATICS AND COMPUTING↗

Algorithms for Haptic Rendering of 3D Objects

Algorithms have been developed to provide haptic rendering of three-dimensional (3D) objects in virtual (that is, computationally simulated) environments. The goal of haptic rendering is to generate tactual displays of the shapes, hardnesses, surface textures, and frictional properties of 3D objects in real time. Haptic rendering is a major element of the emerging field of computer haptics, which invites comparison with computer graphics. We have already seen various applications of computer haptics in the areas of medicine (surgical simulation, telemedicine, haptic user interfaces for blind people, and rehabilitation of patients with neurological disorders), entertainment (3D painting, character animation, morphing, and sculpting), mechanical design (path planning and assembly sequencing), and scientific visualization (geophysical data analysis and molecular manipulation).

Basdogan, Cagatay↗

Three-dimensional unstructured grid generation via incremental insertion and local optimization

Algorithms for the generation of 3D unstructured surface and volume grids are discussed. These algorithms are based on incremental insertion and local optimization. The present algorithms are very general and permit local grid optimization based on various measures of grid quality. This is very important; unlike the 2D Delaunay triangulation, the 3D Delaunay triangulation appears not to have a lexicographic characterization of angularity. (The Delaunay triangulation is known to minimize that maximum containment sphere, but unfortunately this is not true lexicographically). Consequently, Delaunay triangulations in three-space can result in poorly shaped tetrahedral elements. Using the present algorithms, 3D meshes can be constructed which optimize a certain angle measure, albeit locally. We also discuss the combinatorial aspects of the algorithm as well as implementational details.

Barth, Timothy J.↗

Correlating 3D Surface Atomic Structure and Catalytic Activities of Pt Nanocrystals

Active sites and catalytic activity of heterogeneous catalysts is determined by their surface atomic structures. However, probing the surface structure at an atomic resolution is difficult, especially for solution ensembles of catalytic nanocrystals, which consist of heterogeneous particles with irregular shapes and surfaces. In this study, we constructed 3D maps of the coordination number (CN) and generalized CN ($\bar{C}\bar{N}$) for individual surface atoms of sub-3 nm Pt nanocrystals. Our results reveal that the synthesized Pt nanocrystals are enclosed by islands of atoms with nonuniform shapes that lead to complex surface structures, including a high ratio of low-coordination surface atoms, reduced domain size of low-index facets, and various types of exposed high-index facets. 3D maps of $\bar{C}\bar{N}$ are directly correlated to catalytic activities assigned to individual surface atoms with distinct local coordination structures, which explains the origin of high catalytic performance of small Pt nanocrystals in important reactions such as oxygen reduction reactions and CO electro-oxidation.

3D atomic structure↗