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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

Predicting EBC Temperature Limits for Industrial Gas Turbines

Higher turbine inlet temperatures may require the use of ceramic matrix composites (CMC) such as SiC/SIC, which require environmental barrier coatings (EBCs) to protect them against the detrimental effect of water vapor. Here, the goal of this project is to determine the maximum bond coating temperature for EBCs for land-based turbines, where the minimum coating lifetime is 25,000 h. If the temperature exceeds the 1414°C melting point of the Si bond coating, then coatings without a bond coating also need to be evaluated. Thus, current Yb 2 Si 2 O 7 EBCs with a Si bond coating and next-generation EBCs without a Si bond coating are being evaluated in laboratory testing using 1-h cycles in air+90%H 2 O. For this initial work, coatings were deposited on CVD SiC coupons. Reaction kinetics at 1250°, 1300° and 1350°C have been evaluated by measuring the thickness of the thermally grown silica scale after 100–500 h exposures. For comparison, scale growth rates for uncoated SiC and Si specimens in dry and wet environments were included as minimum and maximum values, respectively. Based on a critical scale thickness failure criteria, estimated maximum temperatures were calculated for both EBC systems using this initial data.

42 ENGINEERING↗
DOE OSTI2024

Effect of Processing Parameters on Recrystallization During Hot Isostatic Pressing of Stellite-6 Fabricated Using Laser Powder Bed Fusion Technique

Crack-free Stellite-6 alloy was fabricated using the laser powder bed fusion technique equipped with a heating module as the first attempt. Single tracks were printed with a build plate heated to 400 °C to identify the processing window. Based on the melt pool dimensions, two combinations (sample A: 300 W/750 mm/s and sample B: 275 W/1000 mm/s) were identified to print the cubes. The as-printed microstructure comprised FCC-Co dendrites with M7C3 in the interdendritic region. W-rich M6C particles were found in the overlapping regions between the melt pools, matching the Scheil simulations. However, gas pores were observed due to the higher nitrogen and oxygen content of the feedstock requiring hot isostatic pressing (HIP) at 1250 °C and 150 MPa for 2 h. Sample A was partially recrystallized with slightly coarsened M7C3, while sample B underwent complete recrystallization followed by grain growth along with higher coarsening of the M7C3 after HIP. The varying recrystallization behavior can be attributed to the difference in residual stresses and grain aspect ratio in the as-built condition dictated by laser power and scanning speed. The microhardness after HIP was slightly higher than its wrought counterpart, indicating no severe impact of post-processing on the properties of Stellite-6 alloy.

Sridar, Soumya (ORCID:0000000306775408)↗
DOE OSTI2023

Sub‐Nanosecond Reconfiguration of Ferroelectric Domains in Bismuth Ferrite

Abstract Domain switching is crucial for achieving desired functions in ferroic materials that are used in various applications. Fast control of domains at sub‐nanosecond timescales remains a challenge despite its potential for high‐speed operation in random‐access memories, photonic, and nanoelectronic devices. Here, ultrafast laser excitation is shown to transiently melt and reconfigure ferroelectric stripe domains in multiferroic bismuth ferrite on a timescale faster than 100 picoseconds. This dynamic behavior is visualized by picosecond‐ and nanometer‐resolved X‐ray diffraction and time‐resolved X‐ray diffuse scattering. The disordering of stripe domains is attributed to the screening of depolarization fields by photogenerated carriers resulting in the formation of charged domain walls, as supported by phase‐field simulations. Furthermore, the recovery of disordered domains exhibits subdiffusive growth on nanosecond timescales, with a non‐equilibrium domain velocity reaching up to 10 m s −1 . These findings present a new approach to image and manipulate ferroelectric domains on sub‐nanosecond timescales, which can be further extended into other complex photoferroic systems to modulate their electronic, optical, and magnetic properties beyond gigahertz frequencies. This approach could pave the way for high‐speed ferroelectric data storage and computing, and, more broadly, defines new approaches for visualizing the non‐equilibrium dynamics of heterogeneous and disordered materials.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Visualizing Uranium Crystallization from Melt: Experiment-Informed Phase Field Modeling and Machine Learning

The focus of this project was to observe and simulate the solidification of uranium metal at the crystallographic level from its molten state. Melting experiments were conducted at two different scales to observe microstructural evolution using either a laboratory-scale induction furnace (hundreds of grams of metal) or a microscope heating stage (hundreds of milligrams of metal), respectively. Experimental parameters and characterization data were then used to inform a phase field model of gamma-U crystal growth as dendrites with or without secondary phase impurities in the form of uranium carbide particles. Finally, training datasets were generated by the phase field model as inputs to a neural network, developed with the aim of providing a faster, cheaper surrogate model for microstructural simulations within a given parameter space. Progress is reported herein for each of these task areas. Ultimately, 1) an optical microscope heating stage capability has been stood-up for uranium metal solidification studies, 2) a phase field model was advanced to simulate multiple uranium grains growing in the presence of carbide impurity particles and 3) a neural network was constructed and optimized to predict the microstructure features of individually growing uranium crystals.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Quantitative Morphological Characterization of Carbide Inclusions in Uranium Metal

Uranium carbides (UCs) are prevalent inclusions in U metal that form during melting operations from interactions with crucible walls and the casting chamber atmosphere. Although UCs have been studied extensively since the beginning of U metal foundry operations, there are still unknowns regarding the effects of thermomechanical processing on their sizes and morphology. Here, we present the results of a series of controlled cooling experiments with molten uranium to elucidate the effect of cooling rate on inclusion morphology in a-U. Samples were melted using a vacuum induction melter and manually cooled at rates of 2.5, 1.7, 1.1, 0.8, 0.3 (± 1%) K/s from ~1600 K to <700 K in under 1 hour. Subsequent scanning electron microscopy (SEM) was performed on cross-sections of the samples, revealing a complex mixture of UC morphologies that are indicative of diffusion and growth influenced by the thermal processing of the U matrix. Image analysis using the Morphological Analysis of Materials (MAMA) software showed that UC sizes generally grew larger with slower cooling rates, and the two slowest cooling rates noticeably impacted the inclusion circularity and ellipse aspect ratio. These results indicate that UC morphology is sensitive to short cooling rates (<1 hour) and could therefore be controlled in the production of metallic nuclear fuels. Additionally, inclusion speciation and morphologies could potentially provide forensic clues about processing history of unknown metal samples. Understanding the driving forces involved in UC morphology evolution is beneficial for evaluating metal fuels for next generation nuclear reactors and for identifying signatures for nuclear forensics.

Athon, Matthew T.↗
DOE OSTI2023

Effect of surface roughness on phase transition timing in megaampere pulsed-power–driven exploding conductors

An understanding of material phase transitions in megaampere pulsed-power–driven exploding conductors is important for predicting the growth of hydrodynamic instabilities in magneto-inertial fusion concepts. Here, this study analyzes phase transitions in electrical conductor explosions using 1D Lagrangian and 2D arbitrary Lagrangian–Eulerian resistive magnetohydrodynamic simulations to show that micrometer-scale surface roughness can lead to the electrothermal instability (ETI), a feedback effect that concentrates resistive heating and leads to early melting and ablation. Simulations of the Mykonos electrothermal instability II (METI-II) experiment show melting begins 19% sooner for machined rods with micrometer-scale surface roughness than for rods without these features. The surface magnetic field is 41 T around the initial region of melt, representing a lower magnitude than both the 86 T from 1D simulations and the 85 T threshold reported elsewhere. In 2D simulations with micrometer-scale surface roughness, temperature measurements indicate the critical point temperature of aluminum is reached 17% faster in comparison with 1D simulations. Values from 2D simulations with surface roughness align with predictions from ETI theory, and the observed temperature redistribution further supports the ETI as an underlying mechanism. Simulation results are validated against experimental photonic Doppler velocimetry data. This study shows 1D simulations are adequate to model conductors with sub-micrometer-scale surface roughness in this high-energy-density regime; however, 2D or 3D simulations are required to capture the full range of physics for accurately describing phase transitions in conductors with micrometer-scale or larger surface roughness.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Nanoparticle Diffusion in Miscible Polymer Nanocomposite Melts

X-ray photon correlation spectroscopy measurements were used to quantify the dynamics of bare and bimodal grafted silica nanoparticles mixed with PEO melts of different molecular weights. In dilute polymer nanocomposite (PNC) samples, we find diffusive NP behavior as described by the Stokes–Einstein relationship so long as the adsorbed PEO polymer layer is taken into account in determining both the effective NP size and its role on composite viscosity. The size of this bound layer was found to be approximately 2R g , where R g is the chain radius of gyration. We also expanded our system to investigate how the dynamics of grafted NPs differ from bare NPs with an adsorbed layer. We showed that the dynamics again can be determined by an effective NP radius at a scale smaller than the effective interparticle spacing; however, at larger length scales, the morphology and grafting parameters play a major role in the system dynamics. These results allow us to quantify NP ordering driven by polymer crystallization. It has previously been speculated that behavior is controlled by the relative ratio of time scale of crystal growth and the diffusive time scale of the NPs, a Peclet number. When the former time scale is longer, then the NPs are expected to be segregated into the interlamellar amorphous zones, while the NPs are too slow to be reorganized in the opposite case. We show here that this conjecture is quantitatively correct and the demarcation in behavior occurs for Pe = 1. Thus, we provide a way to estimate a critical spherulite growth rate for any semicrystalline PNC, at which a given NP can be ordered. Together, the results of this study permit us to tunably design PNCs through directed dispersion of NPs in a polymer matrix.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2024

A Review of Modeling Approaches for Predicting Frost Growth and Defrosting on Tube-Fin Heat Exchangers: Preprint

Frost formation and growth on the evaporator surface is a common process that deteriorates the air-refrigerant heat transfer and restricts airflow. This degrades the performance of the vapor compression system by increasing temperature lift and air-side pressure drop. To accurately predict these effects during coil frosting, as well as the energy use and duration of the defrost process, there is a need to estimate the heat and mass transfer, momentum transport, and solid-liquid and liquid-vapor phase change. Therefore, in the past few decades, continuous effort has been made to model frosting and defrosting processes using approaches ranging from empirical correlations to computational fluid dynamic models. To provide a clearer overview for researchers, engineers, and manufacturers in this field, this paper provides a comprehensive literature review for frosting and defrosting models. The paper begins with theoretical background of frost formation and defrost processes, and then reviews the common modeling approaches in literature and their underlying assumptions when trying to account for various physical phenomenon. Based on the literature review, the most critical modeling effort for frost formation is the determination of frost densification rate and frost growth rate. Various methods to predict these two parameters are reviewed. Empirical correlations commonly used for frost density and thermal conductivity are presented and compared. For the defrost process, various multi-stage models have been proposed with different assumptions. Some assume the presence of air gap between the tube wall and the frost, while others consider the melted frost flow due to gravity. We also review physics-based and empirical approaches to integrate defrost models into heat pump models. We conclude by identifying research gaps and providing recommendations.

defrost↗
DOE OSTI2020

A New Method for Ice-Ice Aggregation in the Adaptive Habit Model

In this paper, a novel methodology for modeling ice-ice aggregation is presented. This methodology combines a modified hydrodynamic collection algorithm with bulk aggregate characteristic information from an offline simulator that collects ice particles, namely, the Ice Particle and Aggregate Simulator, and has been implemented into the Adaptive Habit Microphysics scheme in the Weather Research and Forecasting Model. Aggregates, or snow, are formed via collection of cloud ice particles, where initial ice characteristics and the resulting geometry determine aggregate characteristics. Upon implementation, idealized squall-line simulations are performed to examine the new methodology in comparison with commonly used bulk microphysics schemes. It is found that the adaptive habit aggregation parameterization develops snow and reduces ice mass and number concentrations compared to other schemes. The development of aggregates through the new methodology cascades into other interesting effects, including enhancements in ice and snow growth, as well as homogeneous freezing. Further microphysical analyses reveal varying sensitivities, where snow processes are most sensitive to the new parameterization, followed by ice, then cloud, rain, and graupel processes. Further, the new scheme results in enhancements in surface precipitation due to the persistence of snow at lower altitudes. This persistence is a result of shape-dependent melting and sublimation, increasing the residence time. Moreover, these low-level enhancements are reflected in increases in radar reflectivity at the surface and its spatial distribution. Finally, the ability to predict snow shape and density allows for the simulation of polarimetric radar quantities, resulting in signature enhancements compared to schemes that do not consider spatial and temporal variations in snow shape and density.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Cloud-atmosphere impacts on the central Arctic surface energy budget (Final Report)

This project investigated how clouds and atmosphere-sea ice interactions shape the central Arctic surface energy budget using observations from the MOSAiC expedition and coordinated model experiments. Analyses focused on three themes. First, a new method applied to thermistor string data revealed that snow thermal conductivity is systematically higher than assumed in most models, strongly influencing conductive heat flux and sea ice growth, especially under clear skies. Second, a full annual cycle of surface energy budget observations, combined with detailed cloud microphysical retrievals, demonstrated how cloud regimes regulate radiative, turbulent, and conductive fluxes, driving seasonal contrasts in sea ice energy balance: in winter, radiative forcing elicits strong turbulent and conductive responses, while in summer excess energy is primarily partitioned into surface melt. Third, these observations were used to evaluate and improve regional and global forecast models. While some models captured key Arctic cloud-radiation states, most exhibited persistent deficiencies in representing liquid-containing clouds, snow-on-sea-ice processes, and flux responses to radiative forcing. Together, these results provide unprecedented benchmarks for understanding coupled Arctic processes, improve parameterizations of snow, sea ice, and cloud interactions, and highlight critical pathways by which atmospheric variability drives sea ice change in a rapidly evolving Arctic system. Lastly, the project was a resounding success, resulting in 38 peer-reviewed publications and dozens of presentations, while also supporting an early career scientist.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Montane forest productivity across a semiarid climatic gradient

Abstract High‐elevation montane forests are disproportionately important to carbon sequestration in semiarid climates where low elevations are dry and characterized by low carbon density ecosystems. However, these ecosystems are increasingly threatened by climate change with seasonal implications for photosynthesis and forest growth. As a result, we leveraged eddy covariance data from six evergreen conifer forest sites in the semiarid western United States to extrapolate the status of carbon sequestration within a framework of projected warming and drying. At colder locations, the seasonal evolution of gross primary productivity (GPP) was characterized by a single broad maximum during the summer that corresponded to snow melt‐derived moisture and a transition from winter dormancy to spring activity. Conversely, winter dormancy was transient at warmer locations, and GPP was responsive to both winter and summer precipitation such that two distinct GPP maxima were separated by a period of foresummer drought. This resulted in a predictable sequence of primary limiting factors to GPP beginning with air temperature in winter and proceeding to moisture and leaf area during the summer. Due to counteracting winter (positive) and summer (negative) GPP responses to warming, leaf area index and moisture availability were the best predictors of annual GPP differences across sites. Overall, mean annual GPP was greatest at the warmest site due to persistent vegetation photosynthetic activity throughout the winter. These results indicate that the trajectory of this region's carbon sequestration will be sensitive to reduced or delayed summer precipitation, especially if coupled to snow drought and earlier soil moisture recession, but summer precipitation changes remain highly uncertain. Given the demonstrated potential for seasonally offsetting responses to warming, we project that decadal semiarid montane forest carbon sequestration will remain relatively stable in the absence of severe disturbance.

Knowles, John F.↗
DOE OSTI2022

Integrated Pest Management (IPM) for Early Detection Algal Crop Protection. Final Report

During large-scale, outdoor algal biomass growth, production strain(s) are subject to attack by pathogens, predators, and non-productive competitors, compromising the biomass yield. The project team at UCSD developed and demonstrated the effectiveness of Volatile Organic Compound, VOC, analysis via mass spectrometry (MS) as an early detection system for the presence of production algal ponds infection. The MS detection can then trigger high-resolution melt analysis (HRMA) and enhanced quantitative PCR (qPCR) to identify predatory or pathogenic species precisely. This study gathered the foundational data informing how wholly automated systems monitor the health of production ponds. By detecting the presence of low molecular weight VOCs in the air space above ponds, the instrument was able to mimic “sniffing” the health of the algae pond. This early warning system will be free growers from time-consuming and costly regular surveillance of ponds with the current techniques, such as qPCR and flow-cam assays, which are slower, less sensitive, and not easily fully automated, resulting in increased production efficiency through the reduction of crop loss. This project demonstrated that Chemical Ionization Mass Spectrometry, CIMS, could serve as a real-time monitor of ponds health tracking up to 100 different VOCs simultaneously for continuous periods up to 60 days without interruption, signaling infection within an algal crop 24 to 36 hours prior to techniques such as qPCR and microscopy. While mass spectrometry is an expensive tool, this simple VOC sampling system proved not only to be sensitive and robust but could to multiplexed to monitor several ponds, lowering the overall cost serially. This technology demonstrated a reduction in biomass production cost by approximately 50% compared to growers not employing any detection methodology.

09 BIOMASS FUELS↗
DOE OSTI2021

Microstructural evolution in Cu-Nb processed via friction consolidation

Immiscible alloys, whether in well-mixed or layered forms, are of increasing interest based on their novel structural and functional properties, such as enhanced thermal stability against grain growth or radiation-induced defect trapping at the interfaces. To address the need for new approaches to tailor microstructures, the microstructural development of an immiscible Cu-Nb alloy processed via friction consolidation of elemental powders is investigated. Friction consolidation is a solid-phase processing technique that imparts severe plastic strain into a deforming volume resulting in elevated temperatures below the melting temperature of the alloy. Two distinct processing pathways were chosen to understand the effect of thermomechanical conditions on the final microstructure. The microstructure was characterized using scanning electron microscopy, scanning transmission electron microscopy, and X-ray diffraction techniques. Path 1 exhibited larger strain, strain rate, and temperature as compared with path 2. In path 1, agglomerated Nb particles were present in the recrystallized ultrafine-grained Cu matrix, while in path 2 extremely fine and dispersed Nb particles were present in a highly deformed Cu matrix. In both pathways, supersaturation of Cu in Nb lattices was noted, but not vice-versa. The asymmetry in mixing is explained based on deformation-based, thermodynamic and kinetic factors. These findings provide a pathway for creation of novel tailored microstructures and improved properties in any number of binary immiscible alloy systems.

Cu-Nb alloys, Microstructural refinement, Friction↗
DOE OSTI2023

Self-Patterning Tetrathiafulvalene Crystalline Films

Tetrathiafulvalene (TTF) crystals grown from the melt are organized as spherulites in which helicoidal fibrils growing radially from the nucleation center twist in concert with one another. Alternating bright and dark concentric bands are apparent when films are viewed between crossed polarizers, indicating an alternating pattern of crystallographic faces exposed at the film surface. Band-dependent reorganization of the TTF crystals was observed during exposure to methanol vapor. Crystalline growth appears on bright bands at the expense of the dark bands. After a 24 h period of exposure to methanol vapor, the original spherulites were completely restructured, and the films comprise isolated, concentric circles of crystallites whose orientations are determined by the initial TTF crystal fibril orientation. While the surface of these outgrowths appears faceted and smooth, cross-sectional SEM images revealed a semiporous inner structure, suggesting solvent-vapor-induced recrystallization. Collectively, these results show that crystal twisting can be used to rhythmically redistribute material. Crystal twisting is a common and often controllable phenomenon independent of molecular or crystal structure and therefore offers a generalizable path to spontaneous pattern formation in a wide range of materials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

X-ray diffraction of metastable structures from supercooled liquid hydrogen

We report time resolved observations of the crystallization from liquid hydrogen, supercooled to temperatures below the melting point, using 11.2 keV X-ray diffraction from the Linac Coherent Light Source (LCLS). Changes to the metastable solid and liquid structure factors have been dynamically measured. This allows for a direct determination of the lowest energy crystal polymorphs, the stacking probabilities, as well as the liquid and solid densities and temperatures. Such measurements provide experimental evidence of an Arrhenius-like growth kinetics along the stacking direction during supercooling.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Columnar-to-equiaxed transition in a laser scan for metal additive manufacturing

In laser powder bed fusion additive manufacturing (LPBFAM), different solidification conditions, e.g., thermal gradient and cooling rate, can be achieved by controlling the process parameters, such as laser power and laser speed. Tailoring the behaviour of the columnar to equiaxed transition (CET) of the printed alloy during fabrication can facilitate the production of highly customized microstructures. In this study, effective analytical solutions for both thermal conduction and solidification are employed to model solidifying melt pools. Microstructure textures and solidification conditions are evaluated for numerous combinations of laser power and laser speed under bead-on-plate conditions. This analytical-based high-throughput tool was demonstrated to select specific process parameters that lead to desired microstructures. Two selected process conditions were examined in detail by a highly parallelized microstructural solidification model to reveal both nucleation and grain growth. Both numerical solutions agree well with experiments that are performed based on bead-on-plate conditions, indicating that these numerical models aid evaluation of the nucleation parameters, providing insights for controlling CET during the LPBFAM processing.

Lang, Yuan↗
DOE OSTI2022

Molecular Alignment of a Meta-Aramid on Carbon Nanotubes by In Situ Interfacial Polymerization

Molecularly organized nanocomposites of polymers and carbon nanotubes (CNTs) have great promise as high-performance materials; in particular, conformal deposition of polymers can control interfacial properties for mechanical load transfer, electrical or thermal transport, or electro/chemical transduction. However, controllability of polymer-CNT interaction remains a challenge with common processing methods that combine CNTs and polymers in melt or in solution, often leading to nonuniform polymer distribution and CNT aggregation. In this work, we demonstrate CNTs within net-shape sheets can be controllably coated with a conformal coating of meta-aramid by simultaneous capillary infiltration and interfacial polymerization. We determine that π-interaction between the polymer and CNTs results in chain alignment parallel to the CNT outer wall. Subsequent nucleation and growth of the precipitated aramid forms a smooth continuous layered sheath around the CNTs. These findings motivate future investigation of mechanical properties of the resulting composites, and adaptation of the in situ polymerization method to other substrates.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2026

Influence of preheating on tungsten damage under pulsed hydrogen plasma exposure

Preheated tungsten plate behavior under multiple pulsed hydrogen plasma irradiations in the PW-7 plasma accelerator was investigated. The preheating temperature was 973 K, which is above the ductile to brittle transition temperature (DBTT ≈ 673 K). The plate was exposed to three consecutive series of 13 plasma pulses each. Preheating sufficiently suppressed surface cracking at the early irradiation stage: after 13 pulses, cracks were rare, localized, and did not form extensive fractures. During subsequent irradiation series, the area fraction of fine cracks increased by ∼ 2% due to accumulation of dislocations around the pre-existing defects. However, their width remained nearly constant, averaging 0.2–0.3 μm, with rare cracks up to 1 μm in size. Repeated plasma exposure resulted in pronounced surface roughening associated with multiple melting cycles, crater formation and blister rupture, with roughness reaching ∼ 204 nm and a recorded sample mass loss of ∼ 2.8 mg. These results indicate that controlling tungsten preheating well above DBTT effectively reduces damage. However, the surface condition during initial irradiation significantly influences its subsequent morphological evolution. Preheating to 773 K, selected regarding the minimum DBTT value, has previously been demonstrated to be an effective approach for limiting crack growth. A further increase in temperature of approximately ∼ 1000 K did not qualitatively improve results: crack still formed and widths did not decrease. At the same time, the absence of further crack coarsening indicates that the limiting effect of preheating has been reached. Considering the increased energy costs, further increasing the preheating temperature seems unjustified.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗