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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 OSTI2021

Laser-Interference Surface Preparation for Enhanced Coating Adhesion and Adhesive Joining of Multi-Materials (Final Project Report)

This report investigates a laser-interference surface treatment as a non-contact, i.e., without major solid/liquid medium application or abrasion, and non-chemical surface preparation method for aerospace coating systems. It was proposed to use the laser-interference technique to structure surfaces of Al and/or Ti, creating "rough" surfaces with pre-engineered series of ridges and valleys at submicron scale. The science goal of this study was to develop an understanding of the surface microstructure, topology, and physical mechanisms that would improve adhesion and corrosion protection of Al2024-T3. Microstructure analysis indicates that the laser-interference structuring (LIS) was found to reduce the formation of CuMn-rich precipitates in Al 2024-T3 over a 500-800 nm depth from top surface. The X-cut and cross-hatch coating adhesion ratings indicate that the LIS specimens meet the performance requirements in the coating adhesion specifications by having a higher or identical ranking to those specimens prepared with current state-of-the-art chemical conversion or sulfuric acid anodizing. After the ASTM B117 corrosion exposure, it was found that the laser processed specimens exhibited only few blisters. It was found that the corrosion damage was minimized at a laser rastering speed of 4 mm/s, for which only 33% of specimens developed very minor corrosion damage. The ASTM D1654 creepage ratings, used to evaluate corrosion damage along the scribe lines, were found to be at least nine for all coated panels. These results indicate that the laser-interference technique with the additional acetone wiping has the potential to be further developed as a minor chemical surface preparation technique for chromate-containing epoxy primers coatings.

36 MATERIALS SCIENCE↗
DOE OSTI2023

MXene/graphene oxide nanocomposites for friction and wear reduction of rough steel surfaces

Development of solid lubricant materials that render reliable performance in ambient conditions, are amenable to industrial size and design complexities, and work on engineered surfaces is reported. These coatings are composed of Ti 3 C 2 T x -Graphene Oxide blends, spray-coated onto bearing steel surfaces. The tribological assessment was carried out in ambient environmental conditions and high contact pressures in a ball-on-disc experimental set-up. The evaluation yielded that the use of Ti 3 C 2 T x -Graphene-Oxide coatings led to substantial reduction in friction down to 0.065 (at 1 GPa contact pressure and 100 mm/s) in comparison to the uncoated of single-component-coated surfaces, surpassing the state-of-the-art. The coatings also provided excellent protection against wear loss of the substrate and counter-face. The results were explained based on the observations from Raman spectroscopy, scanning electron microscopy, transmission electron microscopy, and nanoindentation measurements. In operando formation of a dense, hard and stiff, dangling-bond-saturated tribolayer was observed to be the reason for the sustained lubricity even at high test loads and sliding speeds. This report presents the holistic exploration and correlation of structure-property-processing pertaining to the advancement of solid lubrication science.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Conditioning the Surface and Bulk of High-Nickel Cathodes with a Nb Coating: An In Situ X-ray Study

Surface coating is commonly employed by industries to improve the cycling and thermal stability of high-nickel (Ni) transition metal (TM) layered cathodes for their practical use in lithium-ion batteries. Niobium (Nb) coating or substitution has been shown to be effective in stabilizing LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811) cathodes; in addition, the electrochemical performance of the final products varies depending on the postprocessing. In this follow-up study, we use in situ synchrotron X-ray diffraction to investigate the kinetic processes and the involved structural evolution in Nb-coated NMC811 upon heat treatment. Furthermore, quantitative structure analysis reveals thermally driven concurrent changes in the bulk and surface, in particular, the phase evolution of the coating layer and Nb/TM interdiffusion that facilitates penetration of Nb into the bulk and particle growth at the increased temperatures. Findings from this study highlight the new opportunities for the intended control of the structure and surface properties of high-Ni cathodes through surface coating in conjunction with postprocessing.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Highly Efficient and Stable Perovskite Solar Cells Enabled by Low‐Cost Industrial Organic Pigment Coating

Abstract Surface passivation of perovskite solar cells (PSCs) using a low‐cost industrial organic pigment quinacridone (QA) is presented. The procedure involves solution processing a soluble derivative of QA, N , N ‐bis(tert‐butyloxycarbonyl)‐quinacridone (TBOC‐QA), followed by thermal annealing to convert TBOC‐QA into insoluble QA. With halide perovskite thin films coated by QA, PSCs based on methylammonium lead iodide (MAPbI 3 ) showed significantly improved performance with remarkable stability. A PCE of 21.1 % was achieved, which is much higher than 18.9 % recorded for the unmodified devices. The QA coating with exceptional insolubility and hydrophobicity also led to greatly enhanced contact angle from 35.6° for the pristine MAPbI 3 thin films to 77.2° for QA coated MAPbI 3 thin films. The stability of QA passivated MAPbI 3 perovskite thin films and PSCs were significantly enhanced, retaining about 90 % of the initial efficiencies after more than 1000 hours storage under ambient conditions.

He, Qingquan↗
DOE OSTI2020

Highly Efficient and Stable Perovskite Solar Cells Enabled by Low‐Cost Industrial Organic Pigment Coating

Abstract Surface passivation of perovskite solar cells (PSCs) using a low‐cost industrial organic pigment quinacridone (QA) is presented. The procedure involves solution processing a soluble derivative of QA, N , N ‐bis(tert‐butyloxycarbonyl)‐quinacridone (TBOC‐QA), followed by thermal annealing to convert TBOC‐QA into insoluble QA. With halide perovskite thin films coated by QA, PSCs based on methylammonium lead iodide (MAPbI 3 ) showed significantly improved performance with remarkable stability. A PCE of 21.1 % was achieved, which is much higher than 18.9 % recorded for the unmodified devices. The QA coating with exceptional insolubility and hydrophobicity also led to greatly enhanced contact angle from 35.6° for the pristine MAPbI 3 thin films to 77.2° for QA coated MAPbI 3 thin films. The stability of QA passivated MAPbI 3 perovskite thin films and PSCs were significantly enhanced, retaining about 90 % of the initial efficiencies after more than 1000 hours storage under ambient conditions.

He, Qingquan↗
DOE OSTI2022

Managing Sn-Supply to Tune Surface Characteristics of Vapor-Diffusion Coating of Nb₃Sn

Nb₃Sn promises better RF performance (Q and E_{acc}) than niobium at any given temperature because of superior superconducting properties. Nb₃Sn-coated SRF cavities are now produced routinely by growing a few microns thick Nb₃Sn films inside Nb cavities via the tin vapor diffusion technique. Sn evaporation and consumption during the growth process notably affect the quality of the coating. Aiming at favorable surface characteristics that could enhance the RF performance, many coatings were produced by varying Sn sources and temperature profiles. Coupon samples were examined using different material characterization techniques, and a selected few sets of coating parameters were used to coat 1.3 GHz single-cell cavities for RF testing. The Sn supply’s careful tuning is essential to manage the microstructure, roughness, and overall surface characteristics of the coating. We summarize the material analysis of witness samples and discuss the performance of several Nb₃Sn-coated single-cell cavities linked to Sn-source characteristics and observed Sn consumption during the film growth process.

Pudasaini, U.↗
DOE OSTI2021

Managing Sn-supply to tune surface characteristics of vapor-diffusion coating of Nb3Sn

Nb₃Sn promises better RF performance (Q and E_{acc}) than niobium at any given temperature because of superior superconducting properties. Nb₃Sn-coated SRF cavities are now produced routinely by growing a few microns thick Nb₃Sn films inside Nb cavities via the tin vapor diffusion technique. Sn evaporation and consumption during the growth process notably affect the quality of the coating. Aiming at favorable surface characteristics that could enhance the RF performance, many coatings were produced by varying Sn sources and temperature profiles. Coupon samples were examined using different material characterization techniques, and a selected few sets of coating parameters were used to coat 1.3 GHz single-cell cavities for RF testing. The Sn supply’s careful tuning is essential to manage the microstructure, roughness, and overall surface characteristics of the coating. We summarize the material analysis of witness samples and discuss the performance of several Nb₃Sn-coated single-cell cavities linked to Sn-source characteristics and observed Sn consumption during the film growth process.

Pudasaini, U.↗
DOE OSTI2019

Encapsulation of thermal energy storage media

In one embodiment, a method for depositing metal on a polymer surface, the method includes coating the polymer surface with a binding metal to render the polymer surface solvophillic and/or hydrophilic and depositing a further metal on the binding metal-coated polymer surface.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Lower Temperature Annealing of Vapor Diffused Nb₃Sn for Accelerator Cavities

Nb₃Sn is a next-generation superconducting material for the accelerator cavities with higher critical temperature and superheating field, both twice compared to Nb. It promises superior performance and higher operating temperature than Nb, resulting in significant cost reduction. So far, the Sn vapor diffusion method is the most preferred and successful technique to coat niobium cavities with Nb₃Sn. Although several post-coating techniques (chemical, electrochemical, mechanical) have been explored to improve the surface quality of the coated surface, an effective process has yet to be found. Since there are only a few studies on the post-coating heat treatment at lower temperatures, we annealed Nb₃Sn-coated samples at 800 C - 1000 C to study the effect of heat treatments on surface properties, primarily aimed at removing surface Sn residues. This paper discusses the systematic surface analysis of coated samples after annealing at temperatures between 850 C and 950 C.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

Engineering diamond interfaces free of dark spins

Nitrogen-vacancy (NV) centers in diamond are utilized extensively as quantum sensors for imaging fields at the nanoscale. The ultrahigh sensitivity of NV magnetometers has enabled the detection and spectroscopy of individual electron spins, with potentially far-reaching applications in condensed matter physics, spintronics, and molecular biology. However, the surfaces of these diamond sensors naturally contain electron spins, which create a background signal that can be hard to differentiate from the signal of the target spins. In this study, we develop a surface modification approach that eliminates the unwanted signal of these so-called dark electron spins. Our surface passivation technique, based on coating diamond surfaces with a thin titanium oxide (Ti⁢O 2 ) layer, reduces the dark spin density. The observed reduction in dark spin density aligns with our findings on the electronic structure of the diamond-Ti⁢O 2 interface. The reduction, from a typical value of 2000 μm −2 to a value below that set by the detection limit of our NV sensors (200 μm −2 ), results in a twofold increase in Hahn-echo coherence time of near surface NV centers. Furthermore, we derive a comprehensive spin model that connects dark spin relaxation with NV coherence, providing additional insights into the mechanisms behind the observed spin dynamics. Our findings are directly transferable to other quantum platforms, including nanoscale solid-state qubits and superconducting qubits.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2021

Detection and Aggregation of Listeria Monocytogenes Using Polyclonal Antibody Gold-Coated Magnetic Nanoshells Surface-Enhanced Raman Spectroscopy Substrates

Magnetic nanoshells with tailored surface chemistry can enhance bacterial detection and separation technologies. This work demonstrated a simple technique to detect, capture, and aggregate bacteria with the aid of end-functionalized polyclonal antibody gold-coated magnetic nanoshells (pAb-Lis-AuMNs) as surface-enhanced Raman spectroscopy (SERS) probes. Listeria monocytogenes were used as the pathogenic bacteria and the pAb-LisAuMNs, 300 nm diameter, were used as probes allowing facile magnetic separation and aggregation. An optimized covalent bioconjugation procedure between the magnetic nanoshells and the polyclonal antibody was performed at pH six via a carbodiimide crosslinking reaction. Spectroscopic and morphological characterization techniques confirmed the fabrication of stable pAb-Lis-AuMNs. The resulting pAb-Lis-AuMNs acted as a SERS probe for L. monocytogenes based on the targeted capture via surface binding interactions and magnetically induced aggregation. Label-free SERS measurements were recorded for the minimum detectable amount of L. monocytogenes based on the SERS intensity at the 1388 cm -1 Raman shift. L. monocytogenes concentrations exhibited detection limits in the range of 10 4 –10 7 CFU ml -1 , before and after aggregation. By fitting these concentrations, the limit of detection of this method was ~10 3 CFU ml -1 . Using a low-intensity magnetic field of 35 G, pAb-LisAuMNs aggregated L. monocytogenes as demonstrated with microscopy techniques, including SEM and optical microscopy. Overall, this work presents a label-free SERS probe method comprised of a surface-modified polyclonal antibody sub-micron magnetic nanoshell structures with high sensitivity and magnetic induced separation that could lead to the fabrication of multiple single-step sensors.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2021

Enhancing Steam-Side Heat Transfer via Microdroplet Ejection using Inorganic Coatings

During condensation of water on a superhydrophobic nanostructured surfaces, droplets coalesce and jump (droplet ejection) due to the release of excess surface energy. Meticulously designed nanostructured surfaces or coatings capable of droplet ejection can enhance heat transfer performance by easy removal of droplets during condensation. In the present work, the capabilities of the Nelumbo droplet ejection coatings technology currently used in commercial heat exchangers are explored and optimized for materials and conditions relevant to steam condensers. Specifically, this includes (1) adapting and optimizing the procedures and chemistries to deposit droplet ejecting coatings on materials used in the steam condenser, (2) testing of the heat transfer, durability, and fouling of the fabricated coatings under a variety of steam condenser relevant conditions, and (3) modeling of the impact of droplet dynamics and interfacial properties on heat transfer in steam condensers. We experimentally demonstrated that at low supersaturation conditions (S~1.02), developed superhydrophobic nanostructured surface gives a 40% higher peak heat transfer flux and a 17% higher peak overall heat transfer coefficient (U) with droplet ejection mechanism compared to the dropwise condensation mechanism on the same nanostructured surface. Though the experimentally observed droplet ejection mechanism was short-lived (~3 min) due to the limitation of the chiller to maintain a constant supersaturation condition in fabricated steam condenser. And large variations in water inlet temperature (+ to - 2 degrees C) caused flooding of nanostructure (Wenzel state) at higher supersaturation (S > or = 1.12). This is an important finding because typical supersaturation levels in field operation are over 1.8 and as such, either the flooding potential for these materials should be improved or operation at lower supersaturation may be required to maximize heat transfer efficiency. If supersaturation conditions can be maintained reliably in the steam condenser in addition to droplet ejection mechanism during condensation, this could provide a potential 2% reduction in water flow rate which equates to a savings of over 3900 gallons of water per minute for a 500 MW steam turbine and over $0.3MM savings annually given a 0.02 cent marginal water withdrawal cost. It is also worth noting that these savings are based on improvement of droplet ejection coatings over coatings capable of performing consistent dropwise mechanism in in-field surface condensers. Savings due to the droplet ejections coatings when compared to bare substrates could be much higher. Additionally, the present work provides the importance of steam condenser operating conditions and insights into the challenges in modeling the condensing droplet dynamics on surfaces.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

VitriEdge: Repairable & Durable Vitrimer Coatings for Wind Turbine Blade Leading Edges

The primary goal of this Level 1b incubator project was to explore the use of vitrimer coatings for repair of leading-edge erosion on end-of-life wind turbine blade surfaces, beyond coating strength of adhesion which has previously been demonstrated in the Level 1a project. Uniform vitrimer coatings (thickness: 400 µm) were applied to two end-of-life wind turbine blades for flexural, fatigue, and laminate tensile testing where the addition of the coating did not produce any statistical variation in tensile properties with minor drops in flexural strength for some laminate formulations. However, a <2% variation in storage modulus was measured for laminate structures (i.e., blade samples with vitrimer coatings) across 100,000 flexural cycles and upon laminate tensile failure, the vitrimer coatings displayed no visible signs of delamination. In addition, three methods to heal vitrimer coating damage was displayed: oven heating, addition of hot water, and a forced convection heat gun. All three heating and healing mechanisms demonstrated significant healing with scratch depths decreasing between 79-91% at healing times ranging between 1-min and 10-minutes. Finally, a water jet machine was used to simulate rain erosion for both the blade surfaces and vitrimer-coated blade surfaces where the diameter and depth of the damage was recorded as a function of exposure time, water pressure, height of exposure, and angle of exposure. Of interest, while the vitrimer coating did not significantly lessen the damage experienced during rain erosion, the addition of vitrimer composite coatings(5 wt.% mica addition) did result in a crack-resistant, durable coating capable of self-healing behavior and in all cases the angle of rain exposure was the most critical parameter explored. It is crucial to continue exploring this space where vitrimer coatings are of interest for both their self-healing properties and potential use as reversible adhesives.

17 WIND ENERGY↗
DOE OSTI2023

A flexible polymer-based luminescent ink for combined thermographic phosphors and digital image correlation (TP+DIC)

Recent work on the development of integrated thermographic phosphors and digital image correlation (TP+DIC) for combined thermal–mechanical measurements has revealed the need for a flexible, stretchable phosphor coating for metal surfaces. Herein, we coat stainless steel substrates with a polymer-based phosphor ink in a DIC speckle pattern and demonstrate that the ink remains well bonded under substrate deformation. In contrast, a binderless phosphor DIC coating produced via aerosol deposition (AD) partially debonded from the substrate. DIC calculations reveal that the strain on the ink coating matches the strain on the substrate within 4% error at the highest substrate loads (0.05 mm/mm applied substrate strain), while the strain on the AD coating remains near 0 mm/mm as the substrate deforms. Spectrally resolved emission from the phosphor is measured through the transparent binder throughout testing, and the ratio method is used to infer temperature with an uncertainty of 1.7 °C. In conclusion, this phosphor ink coating will allow for accurate, non-contact strain and temperature measurements of a deforming surface.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Wettability and CHF limits of Accident-Tolerant nuclear fuel cladding materials in light water reactor conditions

Here, we present the results of experimental investigations aimed at evaluating the thermal–hydraulic performance of chromium-coated zircaloy, i.e., one of the most promising accident tolerant fuel (ATF) cladding material for light water nuclear reactors. Precisely, we investigate the wettability and critical heat flux (CHF) limits of chromium-coated and conventional zircaloy surfaces in prototypical reactor conditions. For both surface types, we measure the contact angle in a vapor-saturated atmosphere from ambient pressure to the operating pressure of pressurized water reactors (PWRs), i.e., ~15 MPa. We measure the ambient-pressure steady-state flow boiling CHF with a spatially uniform heat flux. We measure the high-pressure steady-state flow boiling CHF with a cosine shape heat flux (up to 20 MPa) and with a uniform heat flux (up to 15 MPa), also exploring the effect of CRUD deposits on the chromium-coated surface. Our results reveal that the chromium surface and the bare zircaloy surface have similar wettability and both become super-hydrophilic in PWR conditions, and that there is practically no difference in the steady-state CHF limits, both at low-pressure and high-pressure conditions, also when the chromium-coated surface is covered by a CRUD deposit. However, while the chromium-coating does not improve the CHF compared to the bare zircaloy surface, it improves the post-CHF behavior. The chromium coating prevents the reaction between zircaloy and steam, which results in the formation of a brittle zirconium oxide through the surface of the cladding. We also measure the transient CHF under exponentially escalating heat flux inputs of a nano-smooth and a rough surface mimicking a chromium-coated zircaloy cladding. Interestingly, the results of the transient heat flux tests suggest that the CHF limit for very short periods (i.e., fast transients) is independent of the surface finish, being the same for a rough chromium surface or a nano-smooth surface.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Damage to Polystyrene Polymer Film by Shock Wave Induced Bubble Collapse

Metallic surfaces that are in contact with solutions are commonly used in numerous applications where these surfaces can be damaged by shock wave induced bubble collapse. Use of polymer films that coat such surfaces to prevent them from damage requires a better understanding of how much harm collapsing bubbles produce in the films. In this study, we report the results from coarse-grained molecular dynamics simulations to study the damage to polystyrene (PS) films coating a hard surface. The damage was caused by a collapsing nanobubble located in the proximity of the film and interacting with an impinging shock wave. This collapse produces a high-speed water jet that impacts the PS film with a greater force than the shock front and creates cavities/pits in the PS film. We observed that polymer molecules located in the jet vicinity undergo conformational extension in the direction perpendicular to the jet motion, while chain molecules in the rest of the film undergo compression. Furthermore, we also observed that damage to the film is sensitive to the strength of the shock wave.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗