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DOE OSTI2026

Development of Composite Photocatalyst Materials that are Highly Selective for Solar Hydrogen Production and their Evaluation in Z-Scheme Reactor Designs

The key technology gap preventing a vertically stacked dual-bed particle suspension reactor from achieving the DOE MYRD&D ultimate cost target for H 2 production remains the lack of materials in particle form factor that exhibit ≥10% solar-to-H 2 energy conversion (STH) efficiency as a suspension. Therefore, our project goals centered around strategies to increase the STH efficiency by enhancing photophysical properties of perovskite oxide particles including increased visible-light absorption, increased selectivity for electrocatalysis of the H 2 evolution reaction (HER) and the O 2 evolution reaction (OER) through development of ultrathin oxide coatings, correlating composition and structure to function, and improving understanding of multiscale transport and kinetic processes.

08 HYDROGEN↗

NASA NTRS2017

Advanced Ceramic Matrix Composites: Science and Technology of Materials, Design, Applications, Performance and Integration

Overview of NASA Transformational Tools and Technologies Project's 2700F CMC/EBC Technology Challenge J. Hurst, NASA (National Aeronautics and Space Administration, Glenn Research Center, Cleveland, OH USA Key Words: ceramic matrix composites (CMCs), SiC/SiC composites, environmental barrier coatings (EBCs), CMC modeling, simulated engine testing As advanced gas turbine engine designs continue to move toward both higher operating temperatures and increased pressures, materials capable of functioning under these extreme conditions are being sought by both government and industry. As part of its mission, the NASA's Transformational Tools and Technologies Project, under the auspices of NASA's Aeronautics Research Mission Directorate, has been pursuing a five year Technology Challenge problem. This challenge problem has sought to develop high temperature materials for turbine engines that enable a 6% reduction in fuel burn for commercial aircraft, compared to current SOA materials. Specifically this is accomplished by the development and demonstration of a ceramic matrix composite (CMC) and environmental barrier coating (EBC) system capable of sustained performance at temperature of 2700F. The NASA Glenn Research Center has continued its two decade long interest in CMC/EBCs technology by pursuing this 2700F performance goal. This ambitious effort included an array of vendors, universities and engine companies. Included in this challenge was fiber development, fiber architecture considerations, ceramic matrix composition, environmental barrier compositions and processing routes as well as test development. Evaluation of the CMC/EBC materials included a variety of testing, from coupon testing for strength and creep resistance, to testing aimed at determining material behavior under more engine-like conditions. The development and validation of thermomechanical models and computational tools for design, analysis, and life prediction, have been an important part of this effort as well. Simulated engine testing of vane subcomponents by P&W was the final step following years of development. In addition to achieving the temperature goals and enhanced durability performance of the Tech Challenge, an additional goal achieved by this work was reaching a Technology Readiness Level of 5 for the 3-D CMC/EBC system. As this five year Technical Challenge comes to a conclusion, future development interests in environmental barrier coatings and environmental modeling are discussed.

SiC/SiC composites↗

DOE OSTI2024

Residual Stress Measurements of Cr-coated Cladding

Accident-tolerant fuel concepts for light-water reactor applications have been developed and tested in diverse research programs around the world. Industry teams have developed coated cladding concepts using different coating application methods, such as physical vapor deposition and coldspraying. Recently, variations in thickness and application method were investigated, and their effects on the microstructure and mechanical properties were reported. The results suggest an increase in performance in an unirradiated state, however, it remains unclear what phenomenon drove this performance. One explanation to this performance is associated with the coating process imparting a residual stress. Residual stress analysis was performed on coatings produced with various process parameters to understand how a thin layer of Cr impacts the mechanical properties after coating application and after simulated operating conditions. The gathered information is intended to address safety concerns or support margin identification related to accident-tolerant fuels and to support subsequent modeling and simulation efforts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Impact of Salt Chemistry and Interlayer Architecture on Solid Electrolyte Interphase Composition and Performance

Reversible lithium metal anodes require interphases that are chemically stable, mechanically robust, and compatible with scalable processing. Here, we use slot-die-coated, salt-rich PEO interlayers to design SEI nanolayers on Cu current collectors and isolate how salt anion chemistry controls interphase composition and lithium plating/stripping behavior in architectures relevant to Li plating and anode-free cells. Mesoscale modeling shows that dendrite initiation at SEI defects is governed by a tradeoff among interphase thickness, ionic conductivity, and stiffness through defect-driven current focusing, motivating controlled formation from thin precursor layers. Using UHV-transferred XPS and ToF-SIMS depth profiling after controlled Li deposition, we find that fluorinated sulfonylimide salts (LiTFSI, LiFSI) form mixed inorganic/organic interphases containing LiF and PEO-derived alkoxides, with LiFSI producing a more LiF-dominant Li-facing surface than LiTFSI under identical conditions. In contrast, LiNO 3 -containing interlayers yield a comparatively thick nitrate-derived interphase that reduces upon Li contact to an N-rich inorganic layer (Li–N/N 3− , LiN x O y ). In Cu| |Li cells, these designed interlayers reduce interfacial resistance and improve Coulombic efficiency (CE) and critical current density (CCD) relative to uncoated controls, with LiFSI- and LiNO 3 -based interlayers providing the highest CE/CCD. Overall, the results demonstrate a manufacturing-relevant approach to engineer SEI nanolayers by salt chemistry, providing pathways to improve reversible lithium metal anodes while reducing reliance on LiTFSI.

anion chemistry↗

NASA NTRS1986

Development of high-efficiency solar cells on silicon web

Work is reported aimed at identifying and reducing sources of carrier recombination both in the starting web silicon material and in the processed cells. Cross-sectional transmission electron microscopy measurements of several web cells were made and analyzed. The effect of the heavily twinned region on cell efficiency was modeled, and the modeling results compared to measured values for processed cells. The effects of low energy, high dose hydrogen ion implantation on cell efficiency and diffusion length were examined. Cells were fabricated from web silicon known to have a high diffusion length, with a new double layer antireflection coating being applied to these cells. A new contact system, to be used with oxide passivated cells and which greatly reduces the area of contact between metal and silicon, was designed. The application of DLTS measurements to beveled samples was further investigated.

Meier, D. L.↗

NASA NTRS2019

Pot-ability Assessment of Litz Wires for High Power Density Electric Motor

An alternative process technique, namely vacuum-assisted axial injection potting (VaAIP), has been developed to pot the Litz wires in the stator winding of high power density electric motors for the future electrified aircrafts. Initial trials of the process showed significant improvement in potting quality with less voids, thus potential improvement in thermal management of the motors. As an initial effort of pot-ability assessment, microstructures, 2-D and 3-D, of the Litz wires including dimensions and distribution of conductor filament, coating, and open spaces; packing patterns; shape/configuration changes of each bundles or the overall cross-sections per degree of twist were determined and quantified successfully. The microstructure analyses were performed not only for effective potting process development but also for more realistic electro-thermal modeling solutions. This paper will present results of the microstructure analyses, potentials of the VaAIP process from the trials, and future plans for scale-up and implementation of the process into a full-scale prototype stator winding.

Electrified aircraft↗

NASA NTRS1985

Thermal barrier coating life-prediction model development

Life predictions are made for two types of strain-tolerant and oxidation-resistant Thermal Barrier Coating (TBC) systems produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma spray (LPPS) applied oxidation-resistant NiCrAlY bond coating and an air-plasma-sprayed yttria (8 percent) partially stabilized zirconia insulative layer, is applied by both Chromalloy and Klock. The second type of TBC is applied by the electron-beam/physical vapor deposition process by Temescal. Thermomechanical and thermochemical testing of the program TBCs is in progress. A number of the former tests has been completed. Fracture mechanics data for the Chromalloy plasma-sprayed TBC system indicate that the cohesive toughness of the zirconia layer is increased by thermal cycling and reduced by high temperature exposure at 1150 C. Eddy current technology feasibility has been established with respect to nondestructively measuring zirconia layer thickness of a TBC system. High pressure turbine blades have been coated with program TBC systems for a piggyback test in a TFE731-5 turbofan factory engine test. Data from this test will be used to validate the TBC life models.

Strangman, T. E.↗

NASA NTRS2009

Multiscale Computer Simulation of Tensile and Compressive Strain in Polymer- Coated Silica Aerogels

While the low thermal conductivities of silica aerogels have made them of interest to the aerospace community as lightweight thermal insulation, the application of conformal polymer coatings to these gels increases their strength significantly, making them potentially useful as structural materials as well. In this work we perform multiscale computer simulations to investigate the tensile and compressive strain behavior of silica and polymer-coated silica aerogels. Aerogels are made up of clusters of interconnected particles of amorphous silica of less than bulk density. We simulate gel nanostructure using a Diffusion Limited Cluster Aggregation (DLCA) procedure, which produces aggregates that exhibit fractal dimensions similar to those observed in real aerogels. We have previously found that model gels obtained via DLCA exhibited stress-strain curves characteristic of the experimentally observed brittle failure. However, the strain energetics near the expected point of failure were not consistent with such failure. This shortcoming may be due to the fact that the DLCA process produces model gels that are lacking in closed-loop substructures, compared with real gels. Our model gels therefore contain an excess of dangling strands, which tend to unravel under tensile strain, producing non-brittle failure. To address this problem, we have incorporated a modification to the DLCA algorithm that specifically produces closed loops in the model gels. We obtain the strain energetics of interparticle connections via atomistic molecular statics, and abstract the collective energy of the atomic bonds into a Morse potential scaled to describe gel particle interactions. Polymer coatings are similarly described. We apply repeated small uniaxial strains to DLCA clusters, and allow relaxation of the center eighty percent of the cluster between strains. The simulations produce energetics and stress-strain curves for looped and nonlooped clusters, for a variety of densities and interaction parameters.

Good, Brian↗

NASA NTRS2002

Influence of Cooling Channel Geometry on the Thermal Response in Silicon Nitride Plates Studied

Engine manufacturers are continually attempting to improve the performance and efficiency of internal combustion engines. Usually they raise the operating temperature or reduce the cooling air requirement for the hot section turbine components. However, the success of these attempts depends on finding materials that are lightweight, are strong, and can withstand high temperatures. Ceramics are among the top candidate materials considered for such harsh applications. They hold low-density, high-temperature strength, and thermal conductivity, and they are undergoing investigation as potential materials for replacing nickel-base alloys and superalloys that are currently used for engine hot-section components. Ceramic structures can withstand higher operating temperatures and a harsh combustion environment. In addition, their low densities relative to metals help reduce component mass. The long-term objectives of the High Temperature Propulsion Components (HOTPC) Project are to develop manufacturing technology, thermal and environmental barrier coatings (TBC/EBC), and the analytical modeling capability to predict thermomechanical stresses in minimally cooled silicon nitride turbine nozzle vanes under simulated engine conditions. Two- and three-dimensional finite element analyses with TBC were conducted at the NASA Glenn Research Center. Nondestructive evaluation was used to determine processing defects. The study included conducting preliminary parametric analytical runs of heat transfer and stress analyses under steady-state conditions to demonstrate the feasibility of using cooled Si3N4 parts for turbine applications. The influence of cooling-channel shapes (such as circular, square, and ascending-order cooling channels) on cooling efficiency and thermal stresses was investigated. Temperature distributions were generated for all cases considered under both cooling and no-cooling conditions, with air being the cooling medium. The table shows the magnitude of the maximum and minimum temperature obtained for the plates under air cooling. Each channel's cross-sectional shape delivered a different temperature; however, the two-dimensional analyses for circular and square or equal-side rectangular holes produced close results. Moreover, the model of the panel with ascending order cooling channels experienced the lowest temperature. A difference of near 260 C was found among the three cooling-hole configurations investigated. The ascending-order cooling channels arrangement showed superior performance by attaining the lowest temperature (1077 C) in comparison to the circular (1379 C) and square (1343 C) channels for the same cooling-hole size. This indicates that the panel with ascending-order cooling channels is the most suitable configuration regardless of the complexity involved in its manufacture. More details pertaining to this study are reported.

Abdul-Aziz, Ali↗

NASA NTRS2018

CMC Research at NASA Glenn in 2018: Recent Progress and Plans

As part of NASA's Aeronautics research, Glenn Research Center has developed SiC/SiC Ceramic Matrix Composites for 2700 °F turbine engine applications in the next generation of ultra-efficient aircraft. In this presentation, the development of fiber and matrix constituents and fabrication processes that enabled this advancement will be reviewed, and characterization of the resulting improvements in CMC mechanical properties and durability will be summarized. Progress toward the development and validation of models predicting the effects of the engine environment on durability of Ceramic Matrix Composites and Environmental Barrier Coatings will be summarized. Results from current collaborative research with industry and other government agencies will be reviewed. Research plans for 2018 and opportunities for future collaborations with NASA will also be summarized.

Ceramic Matrix Composites↗

NASA NTRS2018

CMC Research at NASA Glenn in 2018: Recent Progress and Plans

Ceramic Matrix Composites↗

NASA NTRS2018

CMC Research at NASA Glenn in 2018: Recent Progress and Plans

As part of NASA's Aeronautics research, Glenn Research Center has developed SiC/SiC Ceramic Matrix Composites for 2700Â°F turbine engine applications in the next generation of ultra-efficient aircraft. In this presentation, the development of fiber and matrix constituents and fabrication processes that enabled this advancement will be reviewed, and characterization of the resulting improvements in CMC mechanical properties and durability will be summarized. Progress toward the development and validation of models predicting the effects of the engine environment on durability of Ceramic Matrix Composites and Environmental Barrier Coatings will be summarized. Results from current collaborative research with industry and other government agencies will be reviewed. Research plans for 2018 and opportunities for future collaborations with NASA will also be summarized.

composites↗

NASA NTRS2019

CMC Research at NASA Glenn in 2019: Recent Progress and Plans

As part of NASA's Aeronautics research, Glenn Research Center has developed SiC/SiC Ceramic Matrix Composites (CMC) for 2700 degrees Fahrenheit turbine engine applications in the next generation of ultra-efficient aircraft. In this presentation, the development of fiber and matrix constituents and fabrication processes that enabled this advancement will be reviewed, and characterization of the resulting improvements in CMC mechanical properties and durability will be summarized. Progress toward the development and validation of models predicting the effects of the engine environment on durability of Ceramic Matrix Composites and Environmental Barrier Coatings will be summarized. Results from current collaborative research with industry and other government agencies will be reviewed. Research plans for 2019 and opportunities for future collaborations with NASA will also be summarized.

Composites↗

NASA NTRS2020

CMC / EBC Research at NASA Glenn in 2020: Recent Progress and Plans

As part of NASA's Aeronautics research, Glenn Research Center has developed SiC/SiC Ceramic Matrix Composites for 2700°F turbine engine applications in the next generation of ultra-efficient aircraft. In this presentation, the development of fiber and matrix constituents and fabrication processes that enabled this advancement will be reviewed, and characterization of the resulting improvements in CMC mechanical properties and durability will be summarized. Progress toward the development and validation of models predicting the effects of the engine environment on durability of Ceramic Matrix Composites and Environmental Barrier Coatings will be summarized. Results from current collaborative research with industry and other government agencies will be reviewed. Research plans for 2020 and opportunities for future collaborations with NASA will also be summarized.

Grady, Joseph E.↗

NASA NTRS2020

CMC / EBC Research at NASA Glenn in 2020: Recent Progress and Plans

As part of NASA's Aeronautics research, Glenn Research Center has developed SiC/SiC Ceramic Matrix Composites for 2700 °F turbine engine applications in the next generation of ultra-efficient aircraft. In this presentation, the development of fiber and matrix constituents and fabrication processes that enabled this advancement will be reviewed, and characterization of the resulting improvements in CMC mechanical properties and durability will be summarized. Progress toward the development and validation of models predicting the effects of the engine environment on durability of Ceramic Matrix Composites and Environmental Barrier Coatings will be summarized. Results from current collaborative research with industry and other government agencies will be reviewed. Research plans for 2020 and opportunities for future collaborations with NASA will also be summarized.

Grady, Joseph↗

DOE OSTI2021

Gas hydrate deposit formation in transient flowloop tests and mitigation with a surface treatment

Thermodynamic and thermal mitigation strategies are traditionally utilized to prevent gas hydrate formation but may be rendered ineffective for certain unplanned, extended shut-in scenarios. Unfortunately, the current knowledge regarding transient gas hydrate formation has been extremely limited to only a few studies and unable to address this complex issue adequately. This work, conducted in a lab-scale flowloop, aims to add to the understanding of this area by delving into the implications of transient conditions on gas hydrate formation mechanisms, while also exploring a possible mitigation strategy of a surface treatment. Specifically, the effects of phase separation on gas hydrate formation locations, transportability, and plugging are presented for an oil-dominated system. An omniphobic surface treatment is shown to affect initial gas hydrate deposition and its wall adherence strength, as well as the overall plugging outcome. Overall, this work combines observational information with process data measurements to provide a better understanding of phase separated gas hydrate systems and passive deposition mitigation strategies. This can further aid advanced gas hydrate modeling efforts, which currently do not adequately address transient flow effects on phase separation/dispersion. Here, it offers representative gas hydrate testing for coatings, which have exclusively been limited to non-flowing and/or bench-scale analysis, to give confidence in their potential application as advanced deposition prevention tools.

03 NATURAL GAS↗

NASA NTRS1989

Scattering by a two dimensional groove in a ground plane

Higher order boundary conditions involve derivatives of the fields beyond the first and were recently shown to be more effective than traditional first order conditions in modeling dielectric coatings and layers. In this report an application of a third order generalized boundary condition to scattering by a filled rectangular groove is presented. Deficiencies of such higher order boundary conditions are addressed and a correction is proposed for the present case. As part of the process of examining and improving the accuracy of the proposed generalized boundary conditions, an exact solution is developed and a comparison is provided with a solution based on the standard impedance boundary condition.

Barkeshli, K.↗

NASA NTRS1992

Determining The Degree Of Graphitization In Carbon Composites

Method for determining degree of graphitization of carbon/carbon composite material combines infrared spectral experimental technique with thermodynamical theoretical model of solubility. By interrupting manufacturing process at almost any time and applying method, one can judge quality of composite and monitor chemical transformations taking place during process. Also computes effective solubility parameter for composite considered as unitary material. Parameter significant for subsequent fabrication steps involving chemical treatments; e.g., coating or joining with adhesives.

Lawson, Daniel D.↗