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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Electrical property enhancement of non-heat-treatable wrought aluminum alloys using graphene additives

With growing efforts of electrification, aluminum’s role as a light-weight conductor material has become increasingly prominent. There is a critical need to improve the electrical performance of aluminum at room temperature and high operating temperatures. In this study, the effect of graphene nanoparticle additives on the electrical performance of a non-heat treatable alloy were (AA3003) explored. Graphene’s unusual structure and electronic properties were used to improve AA3003 properties. Here, in this work, the effects of graphene on the evolution of electrical properties and microstructural features have been explored on lab scale hot extruded AA3003-graphene composites. Hot pressing schedules and extrusion temperatures were varied to investigate changes in intermetallic dispersion characteristics in the presence of dispersed graphene. We measured a reduction of 10.3 % in the temperature coefficient of resistance in the AA3003 sample with 0.05 wt% graphene extruded at 400 °C, along with a maximum increase of 1.1 % in electrical conductivity at 20 °C. Increasing the hot-pressing times up to 8 hours was also found to consistently increase the electrical conductivity, due to increased precipitation of intermetallic phases. Despite being a non-heat treatable alloy, AA3003 displays interesting precipitation dynamics and grain recrystallization trends that can be modulated with varying levels of heat treatment, graphene concentrations, and hot extrusion process parameters.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Microstructure analysis and machinability of additively manufactured A205 aluminum with heat treatments

A205 aluminum is one of the few high-strength aluminum alloys discovered for additive manufacturing (AM). The microstructure and heat treatment effects of AM A205 vary from those of its cast form, indicating possible differences in machinability during post-processing. Here, the objective of this research is to determine these variations of AM A205 and their effects on machinability using the cast condition as the baseline. As built and two heat-treated conditions (solution treatment and age hardening) were applied and compared in terms of their microstructures, micro-hardness, and machinability including vibration, specific cutting energy, chip morphology, and surface finish. The effects of print orientations on machinability were tested as well and found to be insignificant. AM as built had a higher hardness and slightly better machinability than its cast as built cast counterpart due to a smaller grain size (1 µm vs. 15 µm), eutectic θ-Al 2 Cu lattice and a fine, homogeneous TiB 2 distribution. The solution treatment dissolved this θ-Al 2 Cu lattice and increased the grain size (3 µm) which decreased the hardness, increased the ductility seen in the chips, and reduced the overall machinability. The presence of θ’-Al 2 Cu precipitates improved the machinability of aged AM A205. In addition, it was found that A205 exhibited both ductile and brittle behavior depending on the cutting speed, thus producing different machinability. The speed dependency is related to the material condition and heat treatment.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Enhancing fatigue life of aluminum alloy castings through cavitation water jet peening: Experiments and simulations

This study presents an investigation into the enhancement of the fatigue life of aluminum castings through the application of cavitation water-jet peening (CWJP). CWJP harnesses the impacts of water cavitation to induce surface compressive residual stress within metallic materials. In this work, CWJP was applied to a high pressure die-cast (HPDC) Al–Si alloy A380 with three different water-jet traverse velocities. The fatigue-life improvement, evaluated in a 4-point bending configuration (stress ratio R = 0.1), was found to vary with applied stress level and ranges from 1.6 to 10 times that of the parent alloy. The data also shows that decreasing the traverse velocity results in greater compressive residual stresses within the surface layer and a concurrent increase in surface roughness. This residual stress layer extends to a depth of 400 μm below the surface, as confirmed by through-thickness residual stress and microhardness measurements. CWJP treatment effectively slows down fatigue crack propagation, as evidenced by microstructural observations of narrower striation spacing. Simulations reveal that compressive residual stresses, in addition to surface hardening during CWJP, are key to improving fatigue life. A 20% increase in surface hardness and 150 MPa compressive residual stress imposed by CWJP process provides an average 5-fold enhancement of fatigue life across different stress levels. This study demonstrates the potential of CWJP as an effective surface treatment to enhance the fatigue life of aluminum castings, such as HPDC components for automotive applications.

Al casting↗
DOE OSTI2021

Local damage in grain boundary stabilized nanocrystalline aluminum

The excess free volume in grain boundaries of pure nanocrystalline aluminum leads to the grain coarsening, which degrades their desirable mechanical properties. The preferential segregation of dopants to the grain boundaries has been proposed to enhance the stability of the nanostructure. Here, to shed light on the stabilization mechanisms, we present results from virtual mechanical tests on nanocrystalline aluminum samples with similar grain sizes but different magnesium dopant contents. The segregation of magnesium decreases the excess free volume within the grain boundaries and prohibits the nucleation and growth of intergranular cracks.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Enhanced toughness and tear resistance of thin-walled High-Pressure Die-Cast aluminum alloys through Friction stir processing

In this study, we investigate the toughness and resistance to tear of thin-wall high-pressure die-cast (HPDC) aluminum alloys in two different orientations following the implementation of friction stir processing (FSP). The FSP technique was applied to two different HPDC Al-Si alloys: the recyclable-grade, high iron, A380 alloy and the premium-quality, low iron, Aural-5 alloy. Our findings reveal significant tear resistance and strength enhancements for both alloys after FSP modification. Specifically, FSPed A380 alloy requires 126% higher energy to tear, and it has 49% higher tear strength than the HPDC counterpart. Similarly, the tear energy and tear strength of the Aural-5 alloy witness enhancements of 69% and 21%, respectively. In conclusion, these results highlight the potential of FSP as a viable method for augmenting the mechanical properties of HPDC aluminum alloys, thereby opening up new avenues for their utilization in diverse engineering applications for crack obstruction.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Synergy of carbonyl and azo chemistries for wide-temperature-range rechargeable aluminum organic batteries

Rechargeable aluminum organic batteries (RAOBs) are promising for developing cost-effective and sustainable energy storage devices due to the low cost, abundance, and high sustainability of aluminum and organic resources. In this study, we designed and synthesized a redox-active polymer bearing carbonyl and azo groups as a cathode material for RAOBs. The polymeric cathode exhibits a high reversible specific capacity, superior cyclic stability, fast charging capability, and a wide operation temperature range (₋40°C to 100°C). X-ray photoelectron spectroscopy (XPS), pair distribution function (PDF) analysis, and soft X-ray absorption near edge structure (XANES) were employed to gain fundamental insight into the carbonyl and azo chemistries in RAOBs, as well as the cathode electrolyte interphase (CEI) structure. We demonstrated a step-by-step alumination/de-alumination reaction for carbonyl and azo groups in the polymer cathode and unraveled a Al 2 O 3⁻ and AlN-rich CEI, which is critical for the impressive performance of RAOBs.

25 ENERGY STORAGE↗
DOE OSTI2023

Comparative assessment of different aluminum alloys for neutron beam window applications

The choice of an aluminum alloy window along a neutron beam requires careful consideration depending on the requirements of the instrument end station. The windows should generally be thin to minimize loss of neutrons from the beam due to scattering and absorption but still thick enough to be structurally sound for safety requirements. Further, the microstructure of the material is dependent on the alloy and the preparation method and may introduce scattering artifacts or smearing of the instrument resolution that are not desirable. In this manuscript, SANS and total cross section measurements of several different aluminum alloys will be presented and compared in order to provide some useful insight to engineers working on future neutron instrument design.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

The Monomeric Alanediyl : AlAr i Pr8 (Ar i Pr8 = C 6 H-2,6-(C 6 H 2 -2,4,6-Pr i 3 ) 2 -3,5-Pr i 2 ): An Organoaluminum(I) Compound with a One-Coordinate Aluminum Atom

Reduction of the aluminum iodide AlI 2 Ar i Pr8 ( 1 ; Ar i Pr8 = C 6 H-2,6-(C 6 H 2 -2,4,6-Pr i 3 ) 2 -3,5-Pr i 2 ) with 5% w/w Na/NaCl in hexanes gave a dark red solution from which the monomeric alanediyl : AlAr i Pr8 ( 2 ) was isolated in ca. 28% yield as yellow-orange crystals. Compounds 1 and 2 were characterized by X-ray crystallography, electronic and NMR spectroscopy, and theoretical calculations. The Al atom in 2 is one-coordinate, and the compound displays two absorptions in its electronic spectrum at 354 and 455 nm. It reacts with H 2 under ambient conditions to give the aluminum hydride {AlH(μ-H)Ar i Pr8 } 2 , probably via a weakly bound dimer of 2 as an intermediate.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Low-Temperature Pyrolysis of Aliphatic Polymers Using a Fluorinated Amorphous Silica–Alumina: Cooperative Reactivity between a Redox-Active Radical and an Aluminum Lewis Site

Fluorinated amorphous silica–alumina (F-ASA) prepared by the thermolysis of Krossing’s Al(OC(CF 3 ) 3 ) 3 (PhF) Lewis superacid supported on silica is a very reactive catalyst that promotes the pyrolysis (cracking) of aliphatic polymer melts to produce low molecular weight hyperbranched oils. Initial spectroscopic studies reported previously (Gao, J.; Perras, F. A.; Conley, M. P. J. Am. Chem. Soc . 2025 , 147, 18145–18154) showed that this material contains a distribution of four-, five-, and six-coordinate aluminum sites and a small amount of Brønsted acid sites, similar to typical amorphous silica–alumina materials that are far less reactive in the pyrolysis of aliphatic polymer melts. The objective of this study was to determine whether other active sites present in F-ASA could facilitate pyrolysis reactions. This study provides evidence for the presence of a redox-active silicon oxycarbide persistent radical ((≡Si) 3 C•) in F-ASA. Mims ENDOR EPR experiments show that (≡Si) 3 C• is located close to aluminum. Contacting F-ASA with thianthrene (Th) results in oxidation to form the [Th •+ ][F–ASA] ion-pair, while reactions with 1-hydroxy-2,2,6,6-tetramethylpiperidine (TEMPOH) result in H atom transfer to form TEMPO radical and F-ASA-H containing a mildly acidic (≡Si) 3 C–H. Poisoning studies show that both Lewis acidity and (≡Si) 3 C• are required for polymer pyrolysis reactivity. Finally, we propose that F-ASA promotes the formation of alkyl radicals in polymer melts, which are key intermediates in the thermal pyrolysis reactions of aliphatic polymers, involving the cooperative reactivity of both the Lewis acid and (≡Si) 3 C•.

aluminum↗
DOE OSTI2025

Deep chalcogen donors and electron localization in aluminum nitride

Abstract We show with hybrid density functional theory calculations that chalcogen donors other than oxygen (i.e. S N , Se N , and Te N ) give rise to deep donor states in aluminum nitride. These donors trap a localized electron in their neutral charge state, leading to deep ( + / 0 ) donor levels that are 0.45 eV or more from the conduction-band edge. As such, this behavior is distinct from the DX behavior leads to deep (+/−) levels which affects other donors such as O N and Si Al . We highlight how these results hint at the formation of small electron polarons in AlN, which are found to be unstable in the bulk, but metastable when bound to donor dopants like Si Al and the chalocogens, with activation energies on the order of 0.2–0.3 eV. These results indicate that S, Se, and Te are not shallow donor dopants in aluminum nitride and identify origins of the experimentally observed ∼200–300 meV activation energies for dopant activation in donor-doped samples.

aluminum nitride↗
DOE OSTI2025

Aluminum Boron Nitride Ferroelectric Field-Effect Transistors With ZnO Semiconductor Channel

The discovery of ferroelectricity in hafnium zirconium oxide (HfxZr 1−x O2) and related fluorite materials has spurred interest in ferroelectric devices suitable for integration with silicon integrated circuits (ICs), especially those that can be embedded in the back-end-of-line (BEOL) process. More recently, ferroelectricity has been found in wurtzite aluminum nitride-based materials, such as scandium and boron-doped aluminum nitride (Al 1−x ScxN and Al 1−x BxN). Although these materials currently have undesirably large coercive electric fields, and small breakdown electric field-to-coercive electric field ratio, their low processing temperatures and large remanent polarization offer intriguing possibilities for device applications. Furthermore, we report ferroelectric field-effect transistors (FeFETs) with a 15 nm thick Al0.88B0.12N layer and an 11 nm ZnO semiconductor channel, achieving a memory window >1 V and switching voltages ( V switch ) <±10 V.

42 ENGINEERING↗
DOE OSTI2021

Engineering Scale Drying of Aluminum-Clad Spent Nuclear Fuel: Experiment Report

Engineering-scale tests were performed to evaluate the relative effectiveness of forced gas and vacuum-drying processes on aluminum-clad spent nuclear fuel (ASNF) in preparation for extended dry storage. Drying models were developed to improve confidence in the likely range of conditions at the start of dry storage and to understand the factors most significant to each process. Testing was performed at the Holtec International Forced Helium Dehydration training facility in Camden, New Jersey, by students from the University of South Carolina in collaboration with Idaho National Laboratory. A full-size Type 1a basket, with a full-diameter vessel configuration (based on the Department of Energy standardized canister design), was used in combination with a 10 assembly surrogate ASNF arrangement to provide a proxy for geometry. A resistance heater incorporated in one assembly simulated the influence of 100 W decay heat. This instrumented chamber allowed testing of the removal of bulk water, physisorbed water, and chemisorbed water over a range of operating parameters with either drying process. Thick oxide films were grown on aluminum test plates to mimic the ASNF surface chemistry. These one-use test plates were housed within select assemblies during drying. Post-test analysis of these plates gave a measure of the moisture removed during each test, which was compared to a control. Instrumentation provided detailed thermal, humidity, and gas or pressure data relevant to each test. Model simulations generally compared favorably to instrument data for the tests. While both processes were able to remove bulk water, removal of chemisorbed water was shown to depend heavily on local temperature. To the disadvantage of vacuum drying, operations approaching or exceeding 220°C achieved consistently more dehydroxylation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Milestone 1.2.11: H 2 Production from Surrogate Non-Native Corrosion Plumes on Aluminum 6061-T6 Fuel Cladding Surrogates

Thick, localized, “non-native” corrosion plumes have been identified on Advanced Test Reactor fuel elements, raising concern on their impact on the radiolytic formation of molecular hydrogen gas (H 2 ) from aluminum-clad spent nuclear fuel (ASNF) under proposed extended (> 50 years) dry storage conditions. Here, we report our findings on H 2 generation from the gamma irradiation (up to 52 MGy) of surrogate “non-native” corrosion plume coupons: ambient-temperature-corroded (~350 days in water) aluminum alloy 6061 (AA6061) coupons in helium gas environments with ~0% added relative humidity. Additionally, we provide a comparison of proposed ASNF drying techniques— vacuum drying only, vacuum drying + 100 °C for 4 hr, and vacuum drying + 220 °C for 4 hr—on the yield of H 2 from these surrogate systems. The presented data indicates that similar amounts of H 2 (~2 × 10–3 µmol J–1) are formed from gamma irradiated AA6061 coupons corroded under different temperature regimes, i.e., ambient/350 days vs. 90 C/30 days. These findings validate current, complimentary modelling predictions based on high-temperature-corrosion irradiation data only. Further, the application of a heat treatment procedure (100 and 220 °C), in conjunction with vacuum drying, accelerated the rate at which a steady-state H 2 yield was attained, in comparison to vacuum only, due to the removal of H 2 precursors in the form of adsorbed waters. Interestingly, within the confidence limits of our measurements, negligible difference in total H 2 yield was found between the two investigated heat treatment procedures.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2024

Modeling Approach for the Aluminum-clad Dry Storage Pilot using HFIR Fuel

To confirm that the dry storage of aluminum-clad research reactor spent nuclear fuel (ASNF) will remain within the safety envelope after applied drying schemes and that the resulting evolution of the gas space composition, temperature, and pressure conditions are understood, a dry storage pilot project is being established. The pilot will incorporate an instrumented lid for discrete interval or for on-demand gas composition and temperature monitoring of two DOE Standard Canisters (DSCs) loaded with three High Flux Isotope Reactor (HFIR) inner cores per DSC. Each DSC would be subjected to a separate alternative candidate drying scheme. Canisters will undergo 1 to 5 years of monitoring, including internal temperature and gas sampling to track pressure and composition changes. This report outlines the approach for modeling the ASNF-in-canister behavior in terms of evolving gas space conditions for the ASNF dry storage pilot using HFIR fuel. The ASNF has an adherent surface oxyhydroxide layer comprised of boehmite/bayerite that generates hydrogen when subjected to irradiation. Three-dimensional multi-physics computational fluid dynamics simulations will be executed to compute the thermal field within the DSC and provide inputs to a chemical model employed to compute pressure buildup as hydrogen is generated in the system. Implemented in Cantera, the chemical model solves gas phase and aluminum oxyhydroxide surface-mediated radiolysis reactions. Gas phase reactions are sourced from Wittman and Hanson (2015), whereas surface-mediated reactions are incorporated by fitting experimental data using an optimization algorithm (Abboud, 2023). Water radiolysis reactions from Wren and Ball (2001) are adopted with modifications as described in Abboud (2023c). Understanding the effect of the hydrogen buildup over time is important for long-term storage safety considerations. Modeling results will include the canister pressure, temperature, and composition evolution from the initial helium backfill with the addition of radiolytically-evolved chemical species (e.g., hydrogen and oxygen). The specific HFIR cores for the pilot program have not yet been selected, and the overall design is still in development. The CFD-chemical model used for this work will be based on prior models with necessary updates to allow for improved accuracy and efficiency. The experimental data obtained from the HFIR demonstration will be used to improve and validate the computational models to predict the ASNF-in-canister behavior.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

ON PROCESS STABILITY IN WAAM-CMT OF ALUMINUM ALLOYS

Wire-arc additive manufacturing (WAAM) has become a cost-efficient metal additive manufacturing process. However, depositing aluminum with WAAM is challenging due to its sensitivity to heat input (linear energy density), which can cause undesirable surface topology waviness if not controlled. Thus, a process window is needed that can produce stable geometry and deposition conditions while minimizing production times. In this study, 5183 aluminum alloy wire is used to deposit 10-layer walls with varying wire feed speeds (WFS) and traverse speeds (TS) (at a constant WFS/TS ratio) and varying interpass temperature (IPT). In-situ process data consisting of optical contact-tip-workpiece-distance (CTWD) and current/voltage measurements are collected to determine process condition stability throughout the build. Part geometry is measured using a 3D scanner and build porosity is characterized via digital X-ray. A process window is identified that produces stable surface topology and process conditions at a minimal production time.

aluminum alloy↗
DOE OSTI2020

Microstructural Assessment of a Multiple-Intermetallic-Strengthened Aluminum Alloy Produced from Gas-Atomized Powder by Hot Extrusion and Friction Extrusion

An aluminum (Al) matrix with various transition metal (TM) additions is an effective alloying approach for developing high-specific-strength materials for use at elevated temperatures. Conventional fabrication processes such as casting or fusion-related methods are not capable of producing Al–TM alloys in bulk form. Solid phase processing techniques, such as extrusion, have been shown to maintain the microstructure of Al–TM alloys. In this study, extrusions are fabricated from gas-atomized aluminum powders (≈100–400 µm) that contain 12.4 wt % TM additives and an Al-based matrix reinforced by various Al–Fe–Cr–Ti intermetallic compounds (IMCs). Two different extrusion techniques, conventional hot extrusion and friction extrusion, are compared using fabricating rods. During extrusion, the strengthening IMC phases were extensively refined as a result of severe plastic deformation. Furthermore, the quasicrystal approximant IMC phase (70.4 wt % Al, 20.4 wt % Fe, 8.7 wt % Cr, 0.6 wt % Ti) observed in the powder precursor is replaced by new IMC phases such as Al3.2Fe and Al45Cr7-type IMCs. The Al3Ti-type IMC phase is partially dissolved into the Al matrix during extrusion. The combination of linear and rotational shear in the friction extrusion process caused severe deformation in the powders, which allowed for a higher extrusion ratio, eliminated linear voids, and resulted in higher ductility while maintaining strength comparable to that resulting from hot extrusion. Results from equilibrium thermodynamic calculations show that the strengthening IMC phases are stable at elevated temperatures (up to ≈ 600 °C), thus enhancing the high-temperature strength of the extrudates.

36 MATERIALS SCIENCE↗
DOE OSTI2022

On the Nature of Extra-Framework Aluminum Species and Improved Catalytic Properties in Steamed Zeolites

Steamed zeolites exhibit improved catalytic properties for hydrocarbon activation (alkane cracking and dehydrogenation). The nature of this practically important phenomenon has remained a mystery for the last six decades and was suggested to be related to the increased strength of zeolitic Bronsted acid sites after dealumination. We now utilize state-of-the-art infrared spectroscopy measurements and prove that during steaming, aluminum oxide clusters evolve (due to hydrolysis of Al out of framework positions with the following clustering) in the zeolitic micropores with properties very similar to (nano) facets of hydroxylated transition alumina surfaces. The Bronsted acidity of the zeolite does not increase and the total number of Bronsted acid sites decreases during steaming. O 5 Al(VI)-OH surface sites of alumina clusters dehydroxylate at elevated temperatures to form penta-coordinate Al 1 O 5 sites that are capable of initiating alkane cracking by breaking the first C-H bond very effectively with much lower barriers (at lower temperatures) than for protolytic C-H bond activation, with the following reaction steps catalyzed by nearby zeolitic Bronsted acid sites. This explains the underlying mechanism behind the improved alkane cracking and alkane dehydrogenation activity of steamed zeolites: heterolytic C-H bond breaking occurs on Al-O sites of aluminum oxide clusters confined in zeolitic pores. Our findings explain the origin of enhanced activity of steamed zeolites at the molecular level and provide the missing understanding of the nature of extra-framework Al species formed in steamed/dealuminated zeolites.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2021

Shear Assisted Processing and Extrusion of Aluminum Alloy 7075 Tubing at High Speed

Conventional extrusion of aluminum alloy 7075 is limited to 1-2 meters per minute in order to avoid surface tearing and cracking. An emerging technique called Shear Assisted Processing and Extrusion (ShAPE) was used to extrude aluminum alloy 7075 tubing at a speed of 7.4 meters per minute without inducing surface defects. The faster extrusion speed is attributed to the unique flow characteristics inherent to the ShAPE process compared to conventional extrusion. Tubes with an inner diameter of 10 mm, outer diameter of 12 mm, and length of 2 meters were extruded at temperatures ranging from 340°C to 466°C. Tensile testing was performed per ASTM B557-15 with strain measured using digital image correlation. An ultimate tensile strength of 565 ± 4.6 MPa, yield strength of 496 ± 8.7 MPa, and elongation of 16.4 ± 1.0 % were measured for extrusion made at 362°C and heat treated to the T6 condition.

Shear Assisted Processing and Extrusion, Friction ↗