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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Friction stir welding of thick 7175 aluminium alloy plates for deepwater riser applications

To substantially reduce the cost of extracting petroleum from ultra-deepwater sources, manufacturing risers from 7175 aluminium (Al) alloys rather than steels is being considered. Friction stir welding (FSW), a solid-phase joining technique, is widely applied to 7XXX Al alloys because its mechanical properties are retained within the nugget zone. And, the primary technical objective of the current study is the development of high-strength, corrosion-resistant weldments that connect 7175 Al riser flanges and pipes. However, as the welding thickness increases, the welding speed can be greatly impeded, which lowers the manufacturing efficiency and weakens the mechanical properties in the heat affected zone (next to the nugget). Therefore, obtaining high-performance thick plate 7175 Al alloy joints via FSW is challenging. To overcome this dilemma, the current work optimises the tool design and welding parameters for achieving high-performance joints between 25.4 mm thick 7175 Al alloy plates in butt joint configuration.

Wang, Tianhao↗
DOE OSTI2025

Ultra-Fast 4H-SiC LGAD With Etched Termination and Field Plate

The design, fabrication, and demonstration of a novel Silicon Carbide Low Gain Avalanche Detector (4HSiC LGAD), exhibiting an ultra-fast time response and excellent time resolution, are reported. Here, the use of field plates is proposed to suppress the high electric field caused by the negative bevel-etched angle in 4H-SiC LGADs based on TCAD simulations. Experimental measurements confirm that the field plate significantly increases the breakdown voltage of the 4H-SiC LGADs. Gain and time resolution are measured by using the ultraviolet transient current technique (UV-TCT) showing that 4H-SiC LGADs possess excellent timing performance, with a time resolution better than 35 ps for the injected laser signal with single minimum ionizing particle (MIP) charges generation at room temperature. Additionally, the gain suppression effect in a 4H-SiC LGAD is observed for the first time.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Fast Charging of Li-Ion Cells: Part V. Design and Demonstration of Protocols to Avoid Li-Plating

Fast charging of Li-ion batteries would make “fueling” of electric vehicles comparable in time to fueling of gasoline-powered cars, increasing consumer appeal of the new technology. Taking the US Department of Energy goal of safe 6 C charging to 80% capacity as a guide, we describe approaches that can mitigate Li plating on the graphite anode. To make this possible, a variable-rate anode potential charging protocol has been implemented by using a microprobe reference electrode to continuously monitor and adjust the current, in this way avoiding low anode potentials that favor Li deposition. Various implementations of the anode potential control are considered using electrochemical modeling and compared with the experimental data. For charge to 80% capacity at 30 °C, an average C-rate of 4.97 C was obtained for an NCM523/graphite cell with 70 μ m thick graphite electrode and 7.40 C for a cell with 47 μ m thick graphite electrode. Our electrochemical model accounts for these observations and provides a means to extrapolate the approach to other cell designs and operation regimes, drawing the maximum average fast charging rates that can still avoid Li plating.

25 ENERGY STORAGE↗
DOE OSTI2022

Operando Synchrotron Studies of Inhomogeneity during Anode-Free Plating of Li Metal in Pouch Cell Batteries

Operando synchrotron X-ray diffraction (XRD) studies have not previously been used to directly characterize Li metal in standard batteries due to the extremely weak scattering from Li atoms. In this work, it is demonstrated the stripping and plating of Li metal can be effectively quantified during battery cycling in appropriately designed synchrotron XRD experiments that utilize an anode-free battery configuration in which a Li-containing cathode material of LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) is paired with a bare anode current collector consisting of either Cu metal (Cu/NMC) or Mo metal (Mo/NMC). In this configuration, it is possible to probe local variations in the deposition and stripping of Li metal with sufficient spatial sensitivity to map the inhomogeneity in pouch cells and to follow these processes with sufficient time resolution to track state-of-charge-dependent variations in the rate of Li usage at a single point. For the Cu/NMC and Mo/NMC batteries, it was observed that the initial plating of Li occurred in a very homogeneous manner but that severe macroscopic inhomogeneity arose on a mm-scale during the subsequent stripping of Li, contrasting with the conventional wisdom that the greatest challenges in Li metal batteries are associated with Li deposition.

25 ENERGY STORAGE↗
DOE OSTI2025

Neutron-Friendly Li-Ion Battery Coin Cell for In Situ 3D Visualization of Li Plating

Advanced battery characterization using in situ/operando neutron imaging is critical for uncovering degradation modes such as lithium (Li) plating in Li-ion batteries (LIBs). However, conventional LIBs hinder operando neutron radiography (NR) and in situ neutron micro-computed tomography (N-μCT) for visualizing Li plating near the graphite-separator interface due to strong attenuation from hydrogen-rich components like PP–PE–PP separators, electrolyte, and Fe-based spacers. In this work, we designed and tested a neutron-friendly battery (NFB) optimized for in situ Li detection during extreme fast charging (XFC). Guided by neutron attenuation cross-sections and material transmission, the NFB enables clear visualization at the graphite–separator interface, which is typically opaque in standard LIBs. Electrochemical tests show the NFB exhibits voltage/current responses like standard cells for up to 50 XFC cycles. However, its lower reversibility and capacity are likely due to Cu-coated Al spacer degradation from delamination or corrosion. We propose titanium spacers as a more stable alternative, albeit requiring custom machining. Using this optimized cell, we achieved simultaneous neutron tomography of multiple cells, capturing in situ 3D images of dead Li accumulation, particularly near graphite edges. These heterogeneous deposits and disconnected Li clusters suggest localized current density hotspots during XFC.

25 ENERGY STORAGE↗
DOE OSTI2021

Light-Induced Al Plating on Si for Fabrication of an Ag-Free All-Al Solar Cell

Light-induced electroplating of Al as the front electrode on the n-type emitter of Si solar cells is proposed as a substitute for screen-printed Ag. The advantages and disadvantages of Al over Cu as the front electrode are discussed. The power of a green laser used for patterning of the SiN x antireflection coating is optimized. Conditions for removal of laser damage and contamination on the laser-patterned surface are identified. The effect of plating temperature and post-annealing temperature on Al morphology and resistivity are investigated. Several plating additives are explored to improve the morphology and resistivity of the Al film. Nicotinic acid produces the lowest resistivity of 3.1 μ Ω-cm. However, the lowest contact resistivity between light-induced Al and Si is 69 mΩ-cm 2 due to laser-induced damage to the emitter. The Al film spikes through the thin n-type emitter when annealed at 500 °C causing cell failure. The process reproducibility is also poor due to atmospheric moisture.

14 SOLAR ENERGY↗
DOE OSTI2021

Deformation and fracture characteristics of zirconium plate produced via ultrasonic additive manufacturing

Abstract The microstructural evolution, deformation modes, and fracture mechanisms of zirconium plate produced using ultrasonic additive manufacturing (UAM) are presented. In addition to conventional tensile testing techniques, digital image correlation captured highly variable strain accumulation in specimens loaded perpendicular or parallel to the build height (Z). When tested in parallel to Z, delamination at prior foil/foil interfaces creates strain localization noticeable in strain rate maps, whereas specimens loaded perpendicular to Z illustrate conventional strain hardening until necking accelerates delamination. Although bond strengths are statistically and spatially variable, in situ electron backscattering diffraction tests illustrate the ability for grains near interfaces to accommodate strain with twinning and slip modes consistent with conventionally produced zirconium alloys. Finally, mixtures of ductile and delamination-induced fracture highlight the interface-driven failure modes of UAM zirconium plate in the as-built condition. Graphic abstract

36 MATERIALS SCIENCE↗
DOE OSTI2020

Simulations of Sweeping Wave Propagation in a Boron Carbide Plate

In February 2020, experiments were conducted at Los Alamos National Laboratory measuring the propagation of a sweeping wave through a plate of boron carbide which was induced by detonating an adjacent charge of high explosive. Six such shots were red and in each case progress of the wave along the exposed surface of the plate was tracked using photon doppler velocimetry (PDV). In this report we discuss calculations performed using the Lagrangian hydrocode FLAG to model data taken from these experiments. We discuss the models chosen for the different experimental components, the choice of mesh (focusing on, both, two- and three-dimensional geometries), and compare the results from these calculations to experimentally-extracted PDV traces. Notably, we find that the PDV traces for this experiment are most faithfully reproduced using the full three-dimensional geometry, even when the mesh resolution for the three-dimensional calculations was significantly lower than the resolution for the corresponding two-dimensional calculations. We attribute this to the geometry of the experimental setup. Moreover, we find only negligible differences for the PDV traces obtained using the sesame table equation of state for boron carbide and the Gruneisen equation of state.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Empirical Formula for Puncture Energy of Flat Metal Plates by a Cylindrical Flat Punch

Impact problems of plate-like parts by punch-like objects with relatively large mass moving at slow speeds of a few feet per second constitute a subset of impact problems of interest at Sandia. This is in contrast to small objects moving in the range of hundreds or thousands of feet per second or higher. The objective of this work is to develop a simple formula that can be used to estimate a lower bound for the puncture energy of metal plates impacted by cylindrical, essentially rigid punches of circular cross-section and at nose. Such geometry is used as a basis in the design of puncture mitigation barriers or procedures. This was accomplished by deriving an expression using non-dimensional analysis and then calibrating it based on tests results in the range of speeds of interest. Lower bounds can then be determined based on confidence intervals or factors of safety.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Thermal-Mechanical Elastic-Plastic and Ductile Failure Model Calibrations for 6061-T651 Aluminum Alloy from Plate

Numerical simulations of metallic structures undergoing rapid loading into the plastic range require material models that accurately represent the response. In general, the material response can be seen as having four interrelated parts: the baseline response under slow loading, the effect of strain rate, the conversion of plastic work into heat and the effect of temperature. In essence, the material behaves in a thermal-mechanical manner if the loading is fast enough so when heat is generated by plastic deformation it raises the temperature and therefore influences the mechanical response. In these cases, appropriate models that can capture the aspects listed above are necessary. The matters of interest here are the elastic-plastic response and ductile failure behavior of 6061-T651 aluminum alloy under the conditions described above. The work was accomplished by first designing and conducting a material test program to provide data for the calibration of a modular $J_2$ plasticity model with isotropic hardening as well as a ductile failure model. Both included modules that accounted for temperature and strain rate dependence. The models were coupled with an adiabatic heating module to calculate the temperature rise due to the conversion of plastic work to heat. The test program included uniaxial tension tests conducted at room temperature, 150 and 300 C and at strain rates between 10 –4 and 10 3 1/s as well as four geometries of notched tension specimens and two tests on specimens with shear-dominated deformations. The test data collected allowed the calibration of both the plasticity and the ductile failure models. Most test specimens were extracted from a single piece of plate to maintain consistency. Notched tension tests came from a possibly different plate, but from the same lot. When using the model in structural finite element calculations, element formulations and sizes different from those used to model the test specimens in the calibration are likely to be used. A brief investigation demonstrated that the failure model can be particularly sensitive to the element selection and provided an initial guide to compensate in a specific example.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Large Plate Experiment of Chloride-induced Stress Corrosion Cracking in Spent Nuclear Fuel Storage Canisters

This report is the comprehensive description of the completed experiment to evaluate the corrosion behavior of a large section of welded plate material harvested from the Sandia National Laboratories’ (SNL) full-size mockup of a spent nuclear fuel (SNF) dry storage canister. The plate was subjected to conditions aggressive to chloride-induced stress corrosion cracking for a total time of 2 years. The details of the establishment of this experiment, and the corrosion results are reported. This work is intended to inform aging management programs for SNF canisters under conditions of extended dry storage.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Summary of Chloride-induced Stress Corrosion Cracking Experiments with a Spent Fuel Storage Canister Large Plate

This report provides a comprehensive summary of the crack growth rate testing and the experiments to evaluate the corrosion behavior of welded plate material taken from the Sandia National Laboratories’ full-size mockup of a spent nuclear fuel (SNF) dry storage canister. The information includes that previously reported, and new work on detailed surface characterization of the corrosion attack from the large plate experiment. The work and the results inform aging management programs for the SNF canisters.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

First-Principles Studies of Tritium Species Dissociability & Diffusivity Across the Interface of Nickel-Plated Zircaloy-4

Zirconium (Zr) and its alloys (Zircaloy-4) are widely used in nuclear reactors due to their low neutron adsorption cross-section and excellent corrosion resistance. In tritium-producing burnable absorber rods (TPBARs), the metal getter tube located between the cladding and the γ-LiAlO 2 pellets is composed of nickel (Ni)-plated Zircaloy-4, which is used to capture tritium ( 3 H) species (mainly 3 H 2 and 3 H 2 O) generated from γ-LiAlO 2 pellets during irradiation. The 3 H-related products transfer to the surface of metal Ni upon adsorption and dissociation to form new 3 H species and diffuse into the Zircaloy-4 getters to form metal hydrides (Zr 3 H x ). Therefore, exploring 3 H species ( 3 H 2 , 3 H 2 O) dissociation on the surface of Ni and diffusion across the interface of Ni-plated Zircaloy-4 getters can provide a better understanding of 3H species formation and transport from pellets into the getters.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Neutron Absorber Plate Characterization Plan for Criticality Experiments Design [Slides]

The goal of this presentation is to show the feasibility of performing a critical experiment with a B 4 C/Aluminum alloy neutron absorber plate. The motivation of this experiment is to provide integral data on modern neutron absorber product “Boralcan” by Rio Tinto. In 2020, used in about 20% of spent fuel pools in the US, and in casks for storage and transportation in the US and in Europe. The added value of this experiment: Neutron absorber plate modeling method verification: homogeneous or not, a lot of potential savings by relaxing boron loading credit limits. No available critical benchmark involving Boralcan, other boron-related experiments are relatively old. Nuclear data validation for B, C, and Al in the form of B 4 C in Al matrix.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Design and Analysis of 10” Parallel Plate Relief Device

All Cryomodule (CM) and Cryogenic Distribution System (CDS) relieving into Helium Low Pressure (LP) return header, which is connected to compressor suction so, helium can be preserved during small flow relieving event and recirculated to system. However, during worst case scenario, Helium LP header requires a parallel plate relief device to relieve excess pressure from header. To complete the CDS Warm piping header, a new design for a 10 parallel plate relief device is necessary to relieve outside of the tunnel into atmosphere.

Chicas, Kelly↗
DOE OSTI2026

In Situ Li Seed Formation Enables Uniform Plating in Anode-Free Solid-State Batteries

Anode-free solid-state batteries (AFSSBs) are a promising route toward achieving high energy density. In these cells, the anode contains no pre-stored lithium (Li). Instead, all Li inventory originates from the cathode and is freshly deposited onto a bare current collector during charging. However, achieving uniform and defect-free Li plating on this bare current collector remains a major challenging, often resulting in low Li plating/stripping efficiency and rapid capacity decay. Here, for the first time, operando neutron imaging is employed to visualize Li plating/stripping behavior in an anode-free full cell with LiNi 0.82 Mn 0.07 Co 0.11 O 2 (NMC) as the cathode. Operando measurements reveal that complete stripping of Li leaves isolated Li residues on the current collector, which degrades interfacial contact between the current collector and solid-state electrolyte. To mitigate this interfacial issue and promote more uniform Li deposition, we implement a discharge cutoff voltage strategy that intentionally retains a thin residual Li layer after stripping. This thin Li layer, serving as an in situ–formed seed layer, not only enables more homogeneous subsequent Li plating but also improves interfacial contact. As a result, the anode-free cell with a controlled discharge voltage of 3.5 V exhibits excellent long-term cycling stability, maintaining a discharge capacity of 116 mAh g -1 with a retention rate of 83.4% and an average Coulombic efficiency of approximately 99.9% after 430 cycles at 0.25 C. In contrast, the cell with a conventional discharge cutoff voltage of 2.8 V exhibits rapid capacity decay, retaining only 59.7 mAh g -1 after 50 cycles with a capacity retention of 40.7%. This work offers a practical strategy to unlock the long-term viability of anode-free solid-state batteries.

25 ENERGY STORAGE↗
DOE OSTI2025

2 kV Al 0.64 Ga 0.36 N-channel high electron mobility transistors with passivation and field plates

Abstract High voltage (∼2 kV) Al 0.64 Ga 0.36 N-channel high electron mobility transistors were fabricated with an on-resistance of ∼75 Ω. mm (∼21 mΩ. cm 2 ). Two field plates of variable dimensions were utilized to optimize the breakdown voltage. The breakdown voltage reached >3 kV (tool limit) before passivation however it reduced to ∼2 kV after Si 3 N 4 surface passivation and field plate deposition. The breakdown voltage and on-resistance demonstrated a strong linear correlation in a scattered plot of ∼50 measured transistors. The fabricated transistors were electrically characterized and benchmarked against the state-of-the-art high-voltage (> 1 kV) Al-rich (>40%) AlGaN-channel transistors in breakdown voltage and on-resistance, indicating significant progress.

Alam, Md Tahmidul (ORCID:000900086556839X)↗
DOE OSTI2023

Effects of Accident Thermal Loading on In-Plane Shear Behavior of Steel-Plate Composite Walls

Structural walls in safety-related nuclear facilities are required to be designed for seismic and accident thermal (due to postulated high-energy pipe break events) loading combination. Current U.S. and international codes provide limited guidance for analysis and design of walls for this loading combination. This paper describes the experimental results and observations from tests conducted on a laboratory-scale (1:4 to 1:5) test unit representing steel-plate composite (SC) walls subjected to combined in-plane (seismic) and accident thermal loading. The test unit was subjected to surface temperatures of up to 450°F in combination with cyclic in-plane loading. Results of similar experiments recently conducted in Japan are also summarized (with surface temperatures up to 570°F). Surface heating combined with the low thermal conductivity and high specific heat of concrete resulted in nonlinear thermal gradients through the thickness of the specimens. These nonlinear thermal gradients and the associated self- or internal restraint led to extensive concrete cracking. This concrete cracking reduced the initial and secant stiffness of the specimens. The initial stiffness of the heated specimens reduced to 30 to 40% of the initial stiffness of the control (unheated) specimen. The secant stiffness of the heated specimens reduced up to 50% of the secant stiffness of the control (unheated) specimen. However, the in-plane shear strength of the heated SC specimens was still approximately 10 to 30% greater than the nominal in-plane shear strength calculated, for the limit state of steel plate von Mises yielding, using AISC N690 equations and measured material properties. Evaluation of the experimental results and observations suggests that the in-plane shear strength of SC walls subjected to typical accident surface temperatures (up to 570°F) can be estimated conservatively using the current provisions of AISC N690. The stiffness for accident thermal loading combinations can be considered to reduce from cracked composite stiffness at ambient temperature to fully cracked—that is, steel-only stiffness as the surface temperature increases up to typical accident value.

Construction & Building Technology↗