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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Understanding the setting and hardening process of wollastonite-based brushite cement. Part 2: Influence of the boron and aluminum concentrations in the mixing solution

The mixing solution of wollastonite-based brushite cement is a phosphoric acid solution containing metallic cations and borax. This work complements a previous study devoted to the influence of the H{sub 3}PO{sub 4} concentration, Ca/P and liquid-to-solid (l/s) ratios on the setting and hardening process of the binder by providing new insight into the role of aluminum and boron. Boron retards the setting and decreases the heat released during the process. It also contributes to reduce the macroporosity of the hardened material but yields to poor compressive strength. With aluminum in the mixing solution, the mechanical properties are greatly improved thanks to the precipitation of an amorphous aluminophosphate which increases the density of the cement matrix. But aluminum alone leads to fast setting. A joint addition of boron and aluminum to the mixing solution makes it possible to get a material with optimized properties both in fresh and hardened states.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Aluminum-doped calcium manganite particles for solar thermochemical energy storage: Reactor design, particle characterization, and heat and mass transfer modeling

A two-step cycle is discussed for solar thermochemical energy storage based on particulate aluminum-doped calcium manganite reduction/oxidation reactions for direct integration into Air Brayton cycles. The two steps encompass 1) the storage of concentrated solar irradiation within endothermic reduction of aluminum-doped calcium manganite and 2) the delivery of heat to an Air-Brayton cycle via exothermic re-oxidation of oxygen-deficient aluminum-doped calcium magnanite. A 5 kW th scale solar thermochemical reactor operating under vacuum was designed, modeled, and optimized to thermally reduce a continuous, gravity-driven flow of aluminum-doped calcium manganite particles. The granular flows were characterized in a tilt-flow rig, and particle image velocimetry was used to determine flow properties via frictional and velocity scaling relationships. Flow properties were integrated into a detailed heat and mass transfer model of the solar thermochemical reactor. A reactor design with 31° inclination angle, 230 g/min of particles, and 5.2 kW th radiative input from the high-flux solar simulator was discovered to produce an outlet flow temperature of 1158 K, with stoichiometric deviations of 0.076 and a storage efficiency of 0.628 while avoiding particle overheating and promoting longer particle residence times.

14 SOLAR ENERGY↗
DOE OSTI2022

The influence of cooling rate on condensation of iron, aluminum, and uranium oxide nanoparticles

Fundamental observations of particle size distributions are needed to develop models that predict the fate and transport of radioactive materials in the atmosphere following a nuclear incident. The extent of material transport is influenced by the time scales of particle formation processes (e.g., condensation, coagulation). In this study, we investigated the influence of cooling time scales on size distributions of uranium, aluminum, and iron oxide particles that are synthesized separately under identical run conditions inside the controlled environment of an argon plasma flow reactor. Two distinct temperature distributions are imposed along the flow reactor by varying the argon flow rate downstream of the plasma torch. The vaporized reactants of uranium, aluminum, and iron are cooled from about 5000K to 1000K before they are collected on silicon wafers for ex situ scanning electron microscope analysis. The microscope images show that the sizes of the largest aluminum and iron oxide particles heavily depend on the cooling time scales, whereas significant size variation with cooling rate is not observed for uranium oxide particles. In addition, the size distribution of aluminum oxide particles exhibits the broadest range among all three metal oxides studied. We performed simulations of particle size distributions using a kinetic model that couples gas phase oxidation chemistry with particle formation processes, including nucleation, condensation, and coagulation. The model results demonstrate the strong sensitivity of particle size distribution to different cooling histories (i.e., temperature vs residence time) along the flow reactor. In conclusion, the kinetic model also helps identify directions for future research to improve the predictions.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Circular economy pathways for decarbonizing aluminum and steel automotive body sheet components in the United States

Decarbonizing vehicle production is essential to reducing automotive sector emissions. This study quantifies greenhouse gas (GHG) emissions from aluminum and steel auto-body sheet components produced in the US. It evaluates the effectiveness of circular economy (CE) strategies (greater closed-loop recycling of pre-consumer scrap, post-consumer scrap, and increased manufacturing yields) to reduce supply chain emissions across different process technology and electricity grid decarbonization pathways. We combine dynamic material flow analysis (2025–2050) with cradle-to-gate life-cycle modeling to assess production emissions and the potential reductions associated with the CE strategies under frozen, moderate, and aggressive technology and grid decarbonization scenarios. Current emissions intensities are estimated at approximately 12.3 kg.CO₂eq/kg of aluminum and 4.3 kg.CO₂eq/kg of steel sheet embedded in the vehicle. Under the frozen decarbonization scenario and current levels of circularity, annual emissions attributable to US aluminum and steel auto-body sheet supply chains could rise by 54 % and 18 % respectively by 2050. Rapid deployment of the CE strategies can cut these annual emissions in 2050 by 52 % for aluminum and 44 % for steel. However, scrap quality constraints lead to saturation points, limiting these benefits unless addressed. Aggressive deployment of low-carbon production technologies and a low-carbon grid reduces the relative benefit of implementing the CE strategies; however, even under the aggressive technology and grid decarbonization scenario, the CE strategies reduce annual emissions by a further 23 %-54 % by 2050. These findings highlight the urgent need to integrate CE strategies into the sheet metal supply chain to support decarbonization efforts and help meet climate targets.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Visualization of Aluminum Ions at the Mica Water Interface Links Hydrolysis State-to-Surface Potential and Particle Adhesion

When hydrolyzable cations such as aluminum interact with solid-water interfaces, macroscopic interfacial properties (e.g., surface charge and potential) and interfacial phenomena (e.g., particle adhesion) become tightly linked with the microscopic details of ion adsorption and speciation. We use in situ atomic force microscopy to directly image individual aluminum ions at a mica-water interface and show how adsorbate populations change with pH and aluminum activity. Complementary streaming potential measurements then allow us to build a triple layer model (TLM) that links surface potentials to adsorbate populations, via equilibrium binding constants. Our model predicts that hydrolyzed species dominate the mica-water interface, even when unhydrolyzed species dominate the solution. Ab initio molecular dynamics (AIMD) simulations confirm that aluminum hydrolysis is strongly promoted at the interface. The TLM indicates that hydrolyzed adsorbates are responsible for surface-potential inversions, and we find strong correlations between hydrolyzed adsorbates and particle-adhesion forces, suggesting that these species mediate adhesion by chemical bridging.

Legg, Benjamin A.↗
DOE OSTI2025

Alteration history of aluminum-rich rocks at Jezero crater, Mars

Aluminum-rich clay minerals are detected across the ancient surface of Mars and record intervals of intense alteration by liquid water. On Earth, these clay minerals can form from hydrothermal alteration or rainfall-driven chemical weathering over thousands to millions of years, but how they formed on Mars remains a mystery. The Perseverance rover discovered light-toned, cobble-sized, aluminum-rich (30-45 wt% Al 2 O 3 ) “float” rocks (rock fragments), with some exhibiting spectral signatures of kaolinite, an aluminum-rich clay mineral. These rocks now enable an investigation into the ancient kaolinite-bearing terrains of Mars. To interpret their formation, we use data from the SuperCam and Mastcam-Z instruments onboard the rover to compare the chemistry and reflectance spectra of the float rocks with deeply weathered paleosols and hydrothermal kaolin deposits from Earth’s geological record. Aluminum and titanium enrichments coupled with depletion of iron and magnesium are unlike hydrothermal deposits and instead comparable to bleached horizons of paleosols that formed under high rainfall during past greenhouse climates on Earth. These rocks therefore likely represent some of the wettest intervals of Mars’ history.

58 GEOSCIENCES↗
DOE OSTI2019

Ion–ion interactions enhance aluminum solubility in alkaline suspensions of nano-gibbsite (α-Al(OH) 3 ) with sodium nitrite/nitrate

Despite widespread industrial importance, predicting metal solubilities in highly concentrated, multicomponent aqueous solutions is difficult due to poorly understood ion–ion and ion–solvent interactions. Aluminum hydroxide solid phase solubility in concentrated sodium hydroxide (NaOH) solutions is one such case, with major implications for ore refining, as well as processing of radioactive waste stored at U.S. Department of Energy legacy sites, such as the Hanford Site, Washington State. The solubility of gibbsite (α-Al(OH) 3 ) is often not well predicted because other ions affect the activity of hydroxide (OH – ) and aluminate (Al(OH) 4 – ) anions. In the study reported herein, we systematically examined the influence of key anions, nitrite (NO 2 – ) and nitrate (NO 3 – ), as sodium salts on the solubility of α-Al(OH) 3 in NaOH solutions taking care to establish equilibrium from both under- and oversaturation. Rapid equilibration was enabled by use of a highly pure and crystalline synthetic nano-gibbsite of well-defined particle size and shape. Measured dissolved aluminum concentrations were compared with those predicted by an α-Al(OH) 3 solubility model derived for simple Al(OH) 4 – /OH – systems. Specific anion effects were expressed as an enhancement factor (Al enhc ) conveying the excess of dissolved aluminum. At 45 °C, NaNO 2 and NaNO 3 -containing systems exhibited Al enhc values of 2.70 and 1.88, respectively, indicating significant enhancement. The solutions were examined by Raman and high-field 27 Al NMR spectroscopy, indicating specific interactions including Al(OH) 4 – –Na + contact ion pairing and Al(OH) 4 – –NO 2 – /NO 3 – ion–ion interactions. Dynamic evolution of the α-Al(OH) 3 particles including growth and agglomeration was observed revealing the importance of dissolution/reprecipitation in establishing equilibrium. These studies indicate that incomplete ion hydration, as a result of the low water activity in these concentrated electrolytes, results in: (i) enhanced reactivity of the hydroxide ion with respect to α-Al(OH) 3 ; (ii) increased concentrations of Al(OH) 4 – in solution; and (iii) stronger ion–ion interactions that act to stabilize the supersaturated solutions. This information on the mechanisms by which α-Al(OH) 3 becomes supersaturated is essential for more energy-efficient aluminum processing technologies, including the treatment of millions of gallons of Al(OH) 4 – -rich high-level radioactive waste.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Aluminum Alloy (6061-O, 5052-O, and 1100) Dissolution Rate Testing

The dissolution rates of two aluminum alloys (6061-O and 5052-O) were tested to determine which would be able to replace an aluminum alloy that was difficult to procure (6063-T6). The findings of this memo conclude that the dissolution rates of 6061-O and 5052-O are two orders of magnitude slower than 6063-T6. Therefore, it is unlikely that 6061-O and 5052-O would be adequate replacements for 6063-T6 based on similar dissolution rates in a Hg-catalyzed, nitric acid solution. Another area of interest was how temperature variation would influence the dissolution rate of an aluminum alloy (specifically 1100). This separate study found that the dissolution rate of the aluminum alloy below 86 °C was approximately 0.0014 % of the dissolution rate at 94.5°C and above. Therefore, at or below 86 °C the dissolution rate reduces significantly which translates to much longer dissolution times.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Process Intensification for Nanostructure Aluminum Extrusions

A new technology called Shear Assisted Processing and Extrusion (ShAPE™), pioneered at the Pacific Northwest National Laboratory (PNNL), has the potential to revolutionize the US extrusion industry. Maturation of the ShAPE™ process would create a new cross cutting US manufacturing technology that advances three key the objectives within AMO; namely, nanomaterials processing, process intensification, and materials for extreme and harsh environments. PNNL and SCM Metals Products, Inc. (SCM), a division of Kymera International, will collaborate to mature the ShAPE™ extrusion process beyond TRL 3 to increase the likelihood of its adoption by industry. PNNL’s custom (one-of-a-kind in the world) ShAPE™ machine will be used to extrude round rods of high strength aluminum alloy feedstock powder provided by SCM. As proof-of-concept, PNNL has previously extruded 5 mm diameter rods with SCM aluminum alloy powder AL-12.4TM. This project aims to scale up the process to a diameter of 25 mm while retaining the excellent mechanical properties achieved for the 5 mm diameter rods. The degree of process intensification with ShAPE™ will also be estimated. The primary objectives of this project are as follows. 1) Fabricate 25 mm diameter nanostructured extrusions in bulk, directly from AL-12.4TM aluminum alloy powder without the need for canning, degassing, compaction, and other intermediate steps typical of powder metallurgy extrusion. 2) Achieve a microstructure with an ultrafine grained (UFG <1 µm) aluminum matrix having refined and homogenously distributed nanoscale second phases. 3) Show that the ram force can be significantly reduced compared to conventional powder metallurgy extrusion of the same material and estimate the extent of process intensification that may be possible with ShAPE™. 4) Demonstrate improved high-temperature mechanical properties compared to conventional extrusion of the same material. The following tasks will be undertaken to achieve these objectives. PNNL will develop the die set and process parameters necessary to fabricate Al-12.4TM extrusions with a 25 mm diameter. Microstructural analysis will be performed by PNNL while mechanical testing will be conducted by SCM. With information learned from the process development and characterization, PNNL will perform an estimate of the degree of process intensification that may be possible with ShAPE™.

42 ENGINEERING↗
DOE OSTI2025

Enhanced Hanford High-Aluminum Waste Glass Property Data Development

This study investigated the effects of aluminum concentration on simulated high level waste glass properties to eventually establish an aluminum limit (as single-component or multiple-component constraints) for glass formulations for high-aluminum Hanford wastes. A test matrix of 25 high-aluminum glasses (20 = Al 2 O 3 = 28.57 wt%) was generated, and the chemical compositions were measured. The following properties were measured: crystal formation after centerline canister cooling, crystallinity as a function of temperature, density, viscosity, electrical conductivity, toxic leaching characteristics using the Toxicity Characteristic Leaching Procedure, product consistency using the Product Consistency Test, and SO 3 solubility. These results are reported here.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Miniature Coil for Wireless Power and Data Transfer through Aluminum

This paper presents the design and development of miniature coils for wireless power and data transfer through metal. Our coil has a total size of 15 mm × 13 mm × 6 mm. Experimental results demonstrate that we can harvest 440 mW through a 1 mm-thick aluminum plate. Aluminum and stainless-steel barriers of different thicknesses were used to characterize coil performance. Using a pair of the designed coils, we have developed a through-metal communication system to successfully transfer data through a 1 mm-thick aluminum plate. A maximum data rate of 100 bps was achieved using only harvested power. To the best of our knowledge, this is the first report that demonstrates power and data transfer through aluminum using miniature coils.

42 ENGINEERING↗
NASA NTRS1967

Study of crevice-galvanic corrosion of aluminum

Corrosion effects of aluminum-copper and aluminum-nickel couples in oxygenated distilled water, and aluminum alloys in oxygenated copper sulfate solution were studied. One of each of the couples had a water tight seal, and showed no substantial corrosion, and of the unsealed couples, only the aluminum-copper developed corrosion.

Draley, J. E.↗
NASA NTRS1970

Optimum outgassing cycles for aluminum and stainless steel

Outgassing rates were measured for a modified 7075T6 aluminum and 304L stainless steel, for two degrees of finish, at temperatures of 285 deg F to 392 deg F, for times of 0.5 to 72 hours. The results were analyzed to determine optimum time and temperature cycles for outgassing. Optimum cycles were determined with and without the limitations of a graph. The graph related allowable time at temperature to a 5 percent or less reduction in room temperature properties of 7075T6 aluminum. For aluminum, within the limits set by reduction in mechanical properties, the optimum cycle tested was 40 hours at 285 deg F. Disregarding the limits, optimum outgassing was achieved at the highest temperatures and longest times tested, for both aluminum and stainless steel.

Garrison, R. L.↗
NASA NTRS1975

Explosive welding technique for joining aluminum and steel tubes

Silver sheet is wrapped around aluminum portion of joint. Mylar powder box is wrapped over silver sheet. Explosion welds silver to aluminum. Stainless-steel tube is placed over silver-aluminum interface. Mylar powder box, covered with Mylar tape, is wrapped around steel member. Explosion welds steel to silver-aluminum interface.

Wakefield, M. E.↗
NASA NTRS1974

Boron aluminum crippling strength shows improvement

Results are presented from an experimental program directed toward improving boron aluminum crippling strength. Laminate changes evaluated were larger filament diameter, improved processing, shape changes, adding steel-aluminum cross plies, reduced filament volume in corners, adding boron aluminum angle plies, and using titanium interleaves. Filament diameter and steel-aluminum cross plies have little effect on crippling. It is shown that better processing combined with appropriate shape changes improved crippling over 50 percent at both room temperature and 600 F. Tests also show that crippling improvements ranging from 20 to 40 percent are achieved using angle plies and titanium interleaves.

Otto, O. R.↗
NASA NTRS1974

Eutectic bonding of boron-aluminum structural components. II

Eutectic bonding is a diffusion brazing process developed for fabricating boron-aluminum components from composite monolayer. This process relies on the diffusion of a thin surface film of copper into the aluminum matrix to form a liquid phase when heated above the copper-aluminum eutectic temperature of 1018 F. This type of fabrication offers design flexibility in that skin thickness may be varied, the stiffness geometry and orientation can be varied, and local reinforcement can be added. In addition, this type of boron-aluminum structure offers high efficiency. Also, this method of construction can be cost-comparative with complex titanium shapes; simple tooling permits easy layup, bonding is a one-step operation, and little finish machining is required.

Niemann, J. T.↗
NASA NTRS1975

Carbide coated fibers in graphite-aluminum composites

The NASA-supported program at the Los Alamos Scientific Laboratory (LASL) to develop carbon fiber-aluminum matrix composites is described. Chemical vapor deposition (CVD) was used to uniformly deposit thin, smooth, continuous coats of TiC on the fibers of graphite tows. Wet chemical coating of fibers, followed by high-temperature treatment, was also used, but showed little promise as an alternative coating method. Strength measurements on CVD coated fiber tows showed that thin carbide coats can add to fiber strength. The ability of aluminum alloys to wet TiC was successfully demonstrated using TiC-coated graphite surfaces. Pressure-infiltration of TiC- and ZrC-coated fiber tows with aluminum alloys was only partially successful. Experiments were performed to evaluate the effectiveness of carbide coats on carbon as barriers to prevent reaction between alluminum alloys and carbon. Initial results indicate that composites of aluminum and carbide-coated graphite are stable for long periods of time at temperatures near the alloy solidus.

Imprescia, R. J.↗
NASA NTRS1975

Carbide coated fibers in graphite-aluminum composites

Thin, uniform coats of titanium carbide, deposited on graphite fibers by chemical vapor deposition with thicknesses up to approximately 0.1 microns were shown to improve fiber strength significantly. For greater thicknesses, strength was degraded. The coats promote wetting of the fibers and infiltration of the fiber yarns with aluminum alloys, and act as protective barriers to inhibit reaction between the fibers and the alloys. Chemical vapor deposition was used to produce silicon carbide coats on graphite fibers. In general, the coats were nonuniform and were characterized by numerous surface irregularities. Despite these irregularities, infiltration of these fibers with aluminum alloys was good. Small graphite-aluminum composite samples were produced by vacuum hot-pressing of aluminum-infiltrated graphite yarn at temperatures above the metal liquidus.

Imprescia, R. J.↗