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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 OSTI1969

Application of Nuclear Technology to Art Identification Problems: First Annual Report

Throughout the centuries, as man has become increasingly affluent, his interest in antiquities and objects of art, and the price he has been willing to pay for them, has increased. Inevitably, one result has been to attract the unscrupulous to the production and sale of counterfeit paintings, sculptures, and other works of art. The skill of forgers varies but often is highly sophisticated. However, dealers, museum curators, and other experts have also become more skillful in the detection of forgeries. Scientific tools of increasing sensitivity and sophistication have gradually been applied to the examination of the materials of art and archaeology. Such tools frequently support and render more reliable the judgment of the experts. The quality of forgeries may improve further as their makers become acquainted with the new methods of detection and in turn learn to circumvent or confound the methods. Therefore, the development of still more advanced methods of examination has great utility in the art world. This is particularly true if the ultimate effect is to make circumvention of the methods of examination so costly that the economic incentives for producing forgeries may be substantially reduced, if not eliminated.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Material Plasma Exposure eXperiment (MPEX) High Heat Flux Bellows for Component Alignment in High Microwave Environment

The Material Plasma Exposure eXperiment (MPEX) device is a linear plasma device developed to perform plasma material interaction experiments under the conditions prototypic of a fusion reactor divertor. MPEX has multiple systems that must be precisely aligned to the plasma axis, including an electron cyclotron heating system that emits up to 400 kW of microwave power into the vacuum vessel. Five distinct systems require precise alignment on the MPEX device, thus requiring four bellows, all of which are adjacent to the plasma at a relatively high heat flux of approximately 47 kW/m2 and microwave power regions. The MPEX high heat flux bellows (HHFB) is designed to deliver 6 degrees of freedom positioning. The HHFB includes titanium–zirconium–molybdenum (TZM) inserts that are brazed into a Glidcop AL-15 body using a high-temperature braze alloy, thus blocking direct line of sight to an edge-welded bellows from the plasma and microwave screen to block microwaves from the bellows. Further, a custom ConFlat knife edge is machined into the Glidcop AL-15, so the vacuum flanges do not need a braze or weld joint on the vacuum interface. Fingerstock or copper mesh is used to restrict microwave power from entering the interstitial space between the water-cooled Glidcop AL-15 body and edge-welded bellows. Glidcop AL-15 was selected as the material of choice for the water-cooled body because it can maintain mechanical integrity at elevated temperatures, and it also allows for a high-temperature braze. TZM was selected for its machinability and compatibility with vacuum and plasma requirements. A test article is also being considered for a similarly shaped component, the MPEX limiter, that will demonstrate the integrity of the braze joint under high thermal load. Results from this testing will be extrapolated to deduce the lifetime and integrity of the HHFB design.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Creep resistant Ni-based superalloy casting and method of manufacture for advanced high-temperature applications

One or more embodiments relates to a method of casting a creep-resistant Ni-based superalloy and a homogenization heat treatment for the alloy. The method includes forming a feed stock having Nickel (Ni) and at least one of Chromium (Cr), Cobalt (Co), Aluminum (Al), Titanium (Ti), Niobium (Nb), Iron (Fe), Carbon (C), Manganese (Mn), Molybdenum (Mo), Silicon (Si), Copper (Cu), Phosphorus (P), Sulfur (S) and Boron (B). The method further includes fabricating the creep-resistant Ni-based superalloy in a predetermined shape using the feed stock and at least one process such as vacuum induction melting (VIM), electroslag remelting (ESR) and/or vacuum arc remelting (VAR).

Jablonski, Paul D.↗
DOE OSTI2024

High-Power Targetry R&D for Next-Generation Accelerator Target Facilities

Beam-intercepting devices such as beam windows and particle-production targets are critical components of accelerator target facilities for High Energy Physics (HEP) experiments. The high-power, pulsed structure of the particle beams used for these experiments leads to thermal shock and high-cycle fatigue in addition to radiation damage resulting from the accumulated particle fluence. This can lead to degradation of the target system s mechanical and thermal properties; considerably reducing their lifetimes and presenting substantial challenges to reliable operation of multi-MW class facilities. Recently several major accelerator facilities have been forced to operate at reduced power levels due to target survivability concerns. Furthermore, at Fermilab it is planned to increase the neutrino production beam power up to 2.4 MW in coming years. Therefore, timely R&D on the irradiated behavior of target system materials is critical to efficient operation of accelerator facilities and full utilization of recent accelerator power upgrades for HEP research. This talk will begin with an overview of high-power targetry, and the significant challenges presented by beam power increases expected for future HEP experiments. We will then cover several past materials irradiation studies that have been completed by the High-Power Targetry R&D group at Fermilab and its collaborators on common accelerator and target materials such as graphite, beryllium, titanium, and tungsten. Finally, we will conclude with a discussion of two novel materials investigations under way within the group; high-entropy alloys for beam window applications, and electrospun nanofibers to serve as particle production targets.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

Kinetic Study on Alloying Element Transfer During an Electroslag Remelting Process

Experimental and theoretical studies have been carried out to investigate the effects of slag on the alloying elements in ingots during the electroslag remelting (ESR) process with a focus on developing a mass-transfer model to understand the mechanism of slag-metal reaction. Stainless steel 1Cr21Ni5Ti was used as the electrode and remelted with two different kinds of slags using a 50-kg ESR furnace. The contents of sulfur, aluminum, titanium and silicon along the axial direction of the produced ingots were analyzed. On the basis of the penetration and film theories, the theoretical model developed in this work elucidates the kinetics of the slag-metal reaction revealing the mechanism of alloying element transfer during the ESR process. The calculation results obtained from the model agree well with the experimental results. The model indicates that the resultant [O] coming from the desulfurization reaction of (O{sup 2−}) + [S] = (S{sup 2−}) + [O] causes the oxidation of alloying elements in steel by [M] + [O] = (MO). The distribution ratio of sulfur L{sub S} decreases with the increase of slag temperature in the first slag-temperature-rising period, and the concentration of sulfur in the ingot at the beginning of the ESR process is lower than in the rest of the process because of the combination of the large distribution ratio of sulfur L{sub S} and excellent kinetic conditions. The concentration of aluminum along the height of the ingot has an increasing trend in the first slag-temperature-rising period, while it has a decreasing trend in the rest of the process. Two methods can solve this problem: one is starting up the ESR furnace by high temperature molten slag technology and the other is continually adding extra titania into the molten slag in the first slag-temperature-rising period.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A New Efficient Quantitative Multi-component Phase Field: Lattice Boltzmann Model for Simulating Ti6Al4V Solidified Dendrite Under Forced Flow

Ti6Al4V is a widely used, multi-component alloy in additive manufacturing, during which the fluid flow in the molten pool significantly affects the solidified dendrites. To predict and further control the microstructure, modeling and simulating the microstructure evolution play a critical role. In this study, a newly developed, efficient, quantitative multi-component phase-field (PF) model is coupled with a lattice Boltzmann (LB) model to simulate Ti6Al4V solidified dendrite evolution under fluid flow. The accuracy and convergence behavior of the model is validated by the Gibbs–Thomson relation at the dendrite tip. Single and multiple two-dimensional (2D) equiaxed dendrite evolution cases under forced flow were simulated. Results show that the dendrite pattern is influenced remarkably by the fluid flow. Underlying mechanisms of the asymmetrical evolution are revealed by discussing the interaction among the flow, composition distribution and dendrite morphology, quantitatively. The dendrite kinetics are also derived, which ascertains the relationship between tip velocity and undercooling and inlet velocity and is the foundation for larger-scale simulation. We believe that the coupled quantitative multi-component PF–LB framework employed in this study helps in investigating the solidified dendrite morphology evolution in a deep and quantitate manner.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Agglomeration Mechanism of Complex Ti-Al Oxides in Liquid Ferrous Alloys Considering High-Temperature Interfacial Phenomenon

This work presents the agglomeration mechanism of complex Ti-Al oxides in the liquid ferrous alloy. Cluster characteristics were investigated using Al and Ti/Al-complex deoxidation method in lab scale. The time-dependent size distribution, total number per volume, average size, and circularity of the clusters were quantitatively analyzed. Furthermore, high-temperature confocal laser scanning microscopy was utilized to directly observe the cluster formation of Ti-Al oxides. A capillary force model including wettability parameters was applied to compare the agglomeration capabilities of different types of non-metallic inclusions. When a low Ti is added into melt, the agglomeration of TiO{sub x}·FeO liquid inclusions is one of the key factors to decrease the frequency of cluster formation. When the Al is added into melt, the heterogeneous precipitation on TiO{sub x}·FeO surfaces is the main reaction process. Ti-Al oxides have lower agglomeration ability than that of Al{sub 2}O{sub 3}, which in turn, contribute to a low agglomeration frequency as well.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Grain boundary segregation in BCC vanadium-based alloys: Quantum-accurate computed segregation spectra and targeted experimental validations

Grain boundaries are critically important to the material performance of fusion reactor materials such as vanadium, particularly mechanical properties and irradiation resistance. A key challenge to the design and control of grain boundaries in vanadium alloys is the lack of quantitative data on grain boundary segregation. In this study, we combine computational and experimental methods to address this gap. Furthermore, using a machine learning-accelerated quantum mechanics/molecular mechanics approach, we calculated the segregation spectra for 28 transition metal elements in polycrystalline vanadium, and validated these predictions experimentally for a subset of solutes that sample a range of segregation behavior, specifically zirconium, titanium, and tungsten, using analytical transmission electron microscopy. Furthermore, the agreement between experiment and theory highlights the predictive capability of our approach. Critically, this work provides a comprehensive database of quantum-accurate solute segregation enthalpies in vanadium, enabling the development of advanced alloys for fusion reactors applications.

Fusion materials↗
DOE OSTI2026

High temperature stabilization of ultrafine grain tungsten alloys through synergistic compositional complexities

Thermally-stabilized fine-grained microstructures in tungsten provide a pathway to harnessing enhanced properties such as a reduced ductile-to-brittle transition temperature and improved strength while mitigating the adverse effects of grain growth and recrystallization. Here, in this study, we employ a material design strategy that relies on grain boundary segregation in the nanocrystalline state driven by alloy thermodynamics balanced with impurity scavenging through in situ formation of kinetically-stabilizing metal carbides. A W-Ti-Cr alloy is designed through lattice Monte Carlo methods and subsequently synthesized in a single-phase nanocrystalline state, which upon annealing, evolves into an ultrafine grained microstructure containing chromium grain boundary segregation collectively with a dispersed TiX (X=C,O) phase through the reaction of titanium with carbon and oxygen impurities. In situ synchrotron X-ray diffraction experiments demonstrate that increased Ti promotes stabilization across a larger temperature range but with diminishing returns above 10 at.% Ti. Long-term stability was confirmed through the retention of the ultrafine grained microstructure for a total of 8 days (192 h) at 1300 °C without grain/carbide growth and/or recrystallization. Our results demonstrate that, through strategic tailoring of composition and microstructure, one can harness the benefits of both thermodynamic and kinetic stabilization mechanisms, opening pathways for future alloy formulations that expand the window of stability.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Joining Study for Formed Plate Heat Exchangers (CRADA Final Report)

Plate heat exchangers (PHEs) have been used in numerous industrial applications, such as HVAC systems, power generation, transportation and manufacturing. The performance of plate heat exchangers is frequently undermined by corrosion, fouling, and scaling. These phenomena not only diminish heat transfer efficiency but also lead to increased operational costs, maintenance demands, and reduced equipment lifespan. In this project, the team addressed the widespread challenges of corrosion, fouling, and scaling, and explored alternative material solutions. While commonly used materials like stainless steel and titanium offer notable benefits, they can still experience corrosion under certain operating conditions. The advancement of new materials and surface engineering technologies, such as advanced coating, ceramics, composites materials, and high entropy alloys are promising for can help solve these issues, enable longer lifetime and high performance of plate heat exchangers.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Joining Study for Formed Plate Heat Exchangers (Final Report)

Plate heat exchangers (PHEs) have been used in numerous industrial applications, such as HVAC systems, power generation, transportation and manufacturing. The performance of plate heat exchangers is frequently undermined by corrosion, fouling, and scaling. These phenomena not only diminish heat transfer efficiency but also lead to increased operational costs, maintenance demands, and reduced equipment lifespan. In this project, the team addressed the widespread challenges of corrosion, fouling, and scaling, and explored alternative material solutions. While commonly used materials like stainless steel and titanium offer notable benefits, they can still experience corrosion under certain operating conditions. The advancement of new materials and surface engineering technologies, such as advanced coating, ceramics, composites materials, and high entropy alloys are promising for can help solve these issues, enable longer lifetime and high performance of plate heat exchangers.

36 MATERIALS SCIENCE↗
DOE OSTI2026

The effect of varying powder feedstock chemistry and printing atmosphere on the microstructure of additively manufactured nickel-based ODS alloys: Role on stabilization of cellular structures vs. oxide dispersion formation

Nickel-based alloys have a wide variety of structural applications due to their high corrosion resistance and mechanical strength which depend on solid solution strengthening, or the formation of oxides and/or intermetallic precipitation for their properties. In this study, the microstructure of six Ni–Cr–Y–Ti–Al powder batches designed for the production of oxide dispersion strengthened nickel were compared. These batches varied in chemistry and atomization technique used which included Gas Atomization Reactive Synthesis (GARS). The batches of powder were then consolidated via Additive Manufacturing (AM) Powder Bed Fusion using Laser Beam (PBF-LB) and characterized via transmission electron microscopy to elucidate the influence of powder feedstock (i.e. synthesis methodology and chemistry) on the PBF-LB microstructure. The study investigates (i) how the amount of yttrium and titanium additions in the powder feedstock and the addition of oxygen during the processing (through GARS) affect the microstructure of the powder itself and the AM printed microstructure, and (ii) how the control of oxygen addition in the printing atmosphere during the PBF-LB printing process itself is another important parameter for achieving the formation of the wanted oxide dispersion versus the stabilization of the cellular structure (often observed in AM processed alloys). Microstructural characterization of both powder particles and additively manufactured nickel alloys in this study provide important insights into the movement of yttrium within the material upon solidification, particularly along cell boundaries, and how yttrium behaves depending on alloy chemistry. When a threshold of yttrium content is reached within the system, yttrium consistently reacts to form an intermetallic along cell boundaries instead of forming oxide nanoparticles.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Highly processable single crystal nickel alloys

Alloys, processes for preparing the alloys, and articles including the alloys are provided. The alloys can include, by weight, about 4% to about 7% aluminum, 0% to about 0.2% carbon, about 7% to about 11% cobalt, about 5% to about 9% chromium, about 0.01% to about 0.2% hafnium, about 0.5% to about 2% molybdenum, 0% to about 1.5% rhenium, about 8% to about 10.5% tantalum, about 0.01% to about 0.5% titanium, and about 6% to about 10% tungsten, the balance essentially nickel and incidental elements and impurities.

Gong, Jiadong↗
DOE OSTI2022

On the Prediction of Uniaxial Tensile Behavior Beyond the Yield Point of Wrought and Additively Manufactured Ti-6Al-4V

In this paper, phenomenological relationships are presented that permit the prediction of the plastic regime of stress–strain curves using a limited number of parameters. These relationships were obtained from both conventional (wrought + β annealed) and additively manufactured (i.e., “3D printed”) Ti-6Al-4V. Three different methods of additive manufacturing have been exploited to produce the materials, including large-volume electron beam additive manufacturing, large-volume laser hot wire additive manufacturing, and small-volume selective laser melting. The general fundamental expressions are independent not only of the additive manufacturing process, but also of a wide variety of post-deposition heat treatments, however the coefficients are specific to material states. Thus, this work demonstrates that it is possible to predict not only the ultimate tensile strength, but also the full true stress, true strain curves, if certain parameters of the material are known. In general, the prediction of ultimate tensile strength are within 5% of the experimentally measured values across all additive manufacturing variants and subsequent heat treatments. The absolute values of ultimate tensile strength range from ~ 910 MPa to ~ 1170 MPa for the single alloy Ti-6Al-4V. Data representing 113 explicit samples are included in this work.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Modulating the Pseudoelastic Response of Nitinol Using Ion Implantation

This work explores whether ion beam modification can be used to modulate the austenite to martensite phase transformation in Nickel-Titanium (NiTi), thereby achieving novel or localized transformation properties in near-surface regions. We report this could provide alternatives to laser shot peening or other surface treatment methods and possibly expand applications in biomedical, aerospace, and other fields. Irradiation induces defects and internal stress that can serve as nucleation and/or pinning sites for the phase transformation. Thus, it can augment more convention- al approaches, including alloying, severe mechanical work, grain size reduction, and precipitation of coherent precipitates. A range of outcomes is possible in principle, including a shift of the critical stress or temperature for onset of the transformation, linearization, reduction of hysteresis, stabilization, and extent of transformation strain.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Manufacturability Advancement of Low-Temperature Titanium Electroplating Methods

Three tasks were proposed for this work. All three were completed. The tasks were as follows: Task 1: A larger plating system will be purchased for process scale-up. TiF 3 will be tested as the metal precursor in an effort to reduce water sensitivity of the process. Task 2: Ti on steel samples will be created at PNNL and shipped to Atlas Technologies. Atlas Technologies will diffusion bond the samples to aluminum and test the bond strength. The results will be reported to PNNL. Task 3: Investigation into DOE mission relevant Ti and Zr alloys and demonstration on larger scale work pieces.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Pursuing small-scale measures of penetration resistance in Ti-5553 alloy

This work was originally proposed to illustrate the performance of a particular set of differently processed Ti-5553 plates under dynamic threats. It became clear that the larger question, at present, is whether the small-scale shaped charge design of an RP-4 detonator can be employed to efficiently explore the dynamic penetration resistance of representative test articles. The initial penetration testing that employed three variants of thermomechanical processing of Ti-5553 plates appeared to demonstrate that there was a noticeable difference in their performance. The remaining pertinent question was regarding the variation in the shaped charge performance and how it compares to the variation from the three titanium plate tests. Based on the limited testing presented here the RP-4 shaped charge detonator appears to have an average depth of penetration in 6061 aluminum of 90mm with a 1.5CD stand off.

shaped charge penetration↗