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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Superior electrochemical performance and reduced heat generation in 3D printed vs. 2D tape-casted NMC622 electrodes

This study compares the charge storage mechanisms, thermodynamics behavior, ion transport, and heat generation in NMC622 electrodes fabricated using a novel 3D printing process and the conventional 2D tape casting process. First, potentiometric entropy measurements revealed that the charge storage mechanisms for both types of electrodes consisted of lithium deintercalation in a homogeneous solid solution of NMC622 followed by a transition from a hexagonal (H1) phase to another hexagonal (H2) phase through a monoclinic (M) phase. Both types of electrodes had similar thermodynamics behavior with overlapping entropic potential profiles. Furthermore, operando isothermal calorimetry at high C-rates indicated that the 3D printed electrodes featured larger specific capacity and better rate performance than the 2D tape-casted electrodes. The better performance of 3D printed electrodes was attributed to their larger electrode/electrolyte interfacial surface area and electrical conductivity as well as their faster lithium ion transport. As a result, the instantaneous heat generation rates were smaller in 3D printed electrodes than in 2D tape-casted electrodes, thus resulting in lower overall specific electrical energy and thermal energy dissipation per unit charge stored. Overall, additive manufacturing techniques offer great potential in producing electrodes with superior electrochemical performance and reduced heat generation for fast charging batteries.

25 ENERGY STORAGE↗
DOE OSTI2024

Application of printed strain gauges in prototypical nuclear reactor conditions

This report discusses the current development and testing of additively manufactured temperature sensors and resistive/ capacitive strain gauges. This has potential to improve the sensor design and manufacturing techniques to meet the requirements of in-pile monitoring of mechanical properties and structural health of materials and specimens in current and advanced nuclear test reactors (i.e., in terms of environment conditions, sample geometry, and materials compatibility). The developmental additively manufactured strain gauges are exposed to separate effects testing (i.e., mechanical strain (up to 1000 µe), high temperature (up to 700 °C)) to determine environmental factors that affect the performance of the strain gauge. The robustness and integrity of a printed strain gauge layer exposed to a molten salt environment for up to 500 hours was evaluated, with the goal of assessing material compatibility of printed strain sensors for instrumented surveillance test articles in molten salt reactors. In addition, sensor qualification methodologies are further developed for determining the reliability and robustness at the interface of the additively manufactured strain gauge materials.

36 - MATERIALS SCIENCE↗
DOE OSTI2026

Influence of Powder Characteristics and Processing Methods on Creep Performance of Powder Metallurgy Hot Isostatic Pressed SS316

The U.S. nuclear energy expansion goals are driving the demand for manufacturing routes that can rapidly produce large, complex, near net shape components. Powder metallurgy hot isostatic pressing (PM HIP) is an advanced manufacturing technique that can be economically scaled-up, while alleviating the supply chain challenges that forging and casting face in terms of cost and lead time constraints. This makes PM-HIP a viable technology to aid and accelerate large-scale part manufacturing for nuclear applications. However, large-scale qualification and deployment of this technology require a thorough understanding of the influence of powder feedstock quality, powder handling history, hot isostatic pressing (HIP) parameters, and subsequent heat treatment on microstructural evolution and elevated temperature mechanical performance. The present work focusses on 316 austenitic stainless steel (SS316) which is most commonly used in high temperature environments for nuclear applications Results from this study show that PM HIPed SS316 meets ASME tensile requirements at room temperature and at elevated temperature. However, creep performance of PM-HIPed SS316 remains inferior to its wrought counterpart, demonstrating that tensile performance alone is not a reliable metric for long duration high temperature integrity. Further, this report delineates powder derived microstructural features that govern creep damage, with key evidences pointing to “microstructural inheritance” from gas atomized powder feedstocks. Commercial SS316 powders of varying chemical compositions and recycling histories were studies, and the results showed large differences in elemental segregation, oxide surface layers and secondary phase distributions. Multi-scale characterization revealed segregation of chromium, molybdenum, manganese and silicon at the boundaries and the precipitation of manganese-, silicon-, and molybdenum-oxides. During HIP consolidation, these surface oxides transform into decorated prior particle boundaries (PPBs) and grain boundary inclusions that persist through conventional post-HIP solution annealing treatment. The retained oxides in post-HIP microstructures were found to influence grain growth, precipitation behavior, and ultimately creep cavitation and fracture. Such post-HIP heat treatments are therefore limited by a complex trade-off between grain growth, and oxide coarsening which aggravate creep damage by acting as nucleation sites for cavities. The objective of this work is to establish an integrated processing–structure–property framework for PM-HIP 316 stainless steel by investigating the influence of powder feedstock characteristics in pre- and post-HIP processing as well as to understand the significance of post-HIP heat treatment on microstructural evolution and creep properties. The results from this report emphasize the significance of powder feedstock integrity in improving creep performance of PM-HIPed SS316, by highlight the effect of rapid solidification, elemental segregation, oxide formation and powder recycling on microstructural defect inheritance following HIP consolidation. Rather than considering HIP processing, solution annealing, and mechanical performance independently, this report treats powder production, HIP consolidation, post-HIP thermal processing, and creep deformation as interconnected stages within a continuous metallurgical process. The resulting framework will provide a scientific basis for developing feedstock engineering strategies capable of improving long-term reliability of PM-HIP stainless steels and accelerating their qualification for advanced nuclear applications.

Ajjarapu, Pavan [Oak Ridge National Laboratory (OR↗
DOE OSTI2024

Manufacture and testing of biomass-derivable thermosets for wind blade recycling

Wind energy is helping to decarbonize the electrical grid, but wind blades are not recyclable, and current end-of-life management strategies are not sustainable. Here, to address the material recyclability challenges in sustainable energy infrastructure, we introduce scalable biomass-derivable polyester covalent adaptable networks and corresponding fiber-reinforced composites for recyclable wind blade fabrication. Through experimental and computational studies, including vacuum-assisted resin-transfer molding of a 9-meter wind blade prototype, we demonstrate drop-in technological readiness of this material with existing manufacture techniques, superior properties relative to incumbent materials, and practical end-of-life chemical recyclability. Most notable is the counterintuitive creep suppression, outperforming industry state-of-the-art thermosets despite the dynamic cross-link topology. Overall, this report details the many facets of wind blade manufacture, encompassing chemistry, engineering, safety, mechanical analyses, weathering, and chemical recyclability, enabling a realistic path toward biomass-derivable, recyclable wind blades.

17 WIND ENERGY↗
NASA NTRS1966

Design of thick honeycomb core structures

The demand for weight reduction in flight vehicles suggests the use of lightweight sandwich structures. Several factors must be considered to obtain minimum-weight sandwich constructions. High-strength thin facings combined with lightweight thick core can offer a highly efficient structure when careful consideration is given to practical proportions between facings and core, edge design details, and manufacturing techniques. This paper discusses design approaches to relatively thick-core sandwich constructions. 'A large cylindrical structure subjected to axial compression loading and panel-type structures requiring low deflection under transverse loads are briefly analyzed. The selection of structural adhesives for thick-core structures and manufacturing considerations also are discussed.

SANDWICH CONSTRUCTION↗
NASA NTRS2018

Characterization of Titanium Alloys Produced by Electron Beam Directed Energy Deposition

Functionally graded materials offer the potential to improve structural efficiency by allowing the material composition and/or microstructural features to spatially vary within a component. Additive manufacturing techniques enable the fabrication of such graded materials and structures. While examining several titanium alloys, this paper focuses on Ti-8Al-1Er as it has a unique microstructure that is only feasible when produced by rapid solidification methods like electron beam directed energy deposition, an additive manufacturing process. The results show that, when mixed, Ti-8Al-1Er and commercially-pure titanium uniformly mix at various ratios and the resultant static tensile properties of the mixed alloys behave according to rule-of-mixtures. At discontinuous interfaces between Ti-8Al-1Er and commercially-pure titanium, the crack growth behavior progresses smoothly across the discontinuity as the crack transitions from one crack growth regime into another. Studies on monolithic samples shows the mechanisms of damage in the Ti-8Al-1Er; specifically, that strain localization occurs near grain boundaries of high mis-orientation on the microscale and that twinning and dislocation density is concentrated near erbia-strengthening particles (Er2O3) on the nanoscale.

Newman, John A.↗
DOE OSTI2022

Developing an Ultra-Compact, Topology-Optimized Heat Exchanger using Additive Manufacturing

Traditional heat exchanger designs have relied on a plate-fin architecture, assembled in a crossflow configuration. These HX designs are limited in their maximum allowable temperature and, therefore, efficiency. More advanced designs, such as those containing counter-flow, microtube cores, can yield higher efficiencies, but generally require complex headers. The design of such headers is usually determined based on user experience rather than on rigorous design tools, which can lead to lossy architectures; conventional headers can generate up to 50% of the total pressure loss through the HX. Furthermore, the consequences of manufacturing techniques are rarely considered during the design phase. Our team has developed an ultra-compact, topology-optimized heat exchanger capable of operating in environments with temperatures and pressures up to 800°C (1472°F) and 250 bar (3626 psi), respectively. Throughout the program, the team leveraged extensive additive manufacturing research and experience in supercritical carbon dioxide (sCO 2 ) power generation experience to develop and commercialize the technology. The final power density numbers for the subscale and full-scale heat exchangers are >15 kW/kg and >50 kW/L, which includes the core and the headers. The team has involved the RTX business units, notably Collins Aerospace, in discussions for commercializing the technology.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Crystal plasticity model of residual stress in additive manufacturing using the element elimination and reactivation method

Selective laser melting is receiving increasing interest as an additive manufacturing technique. Residual stresses induced by the large temperature gradients and inhomogeneous cooling process can favour the generation of cracks. In this work, a crystal plasticity finite element model is developed to simulate the formation of residual stresses and to understand the correlation between plastic deformation, grain orientation and residual stresses in the additive manufacturing process. The temperature profile and grain structure from thermal-fluid flow and grain growth simulations are implemented into the crystal plasticity model. An element elimination and reactivation method is proposed to model the melting and solidification and to reinitialize state variables, such as the plastic deformation, in the reactivated elements. The accuracy of this method is judged against previous method based on the stiffness degradation of liquid regions by comparing the plastic deformation as a function of time induced by thermal stresses. The method is used to investigate residual stresses parallel and perpendicular to the laser scan direction, and the correlation with the maximum Schmid factor of the grains along those directions. The magnitude of the residual stress can be predicted as a function of the depth, grain orientation and position with respect to the molten pool. The simulation results are directly comparable to X-ray diffraction experiments and stress–strain curves.

316 stainless steel↗
NASA NTRS2019

Utilization of Unsupervised Anomalies Detector as a Tool for Managing the TDRS Constellation at GSFC

NASA’s Goddard Space Flight Center (GSFC) operates a constellation of ten geosynchronous Tracking and Data Relay Satellites (TDRS). The mission of the TDRS constellation is to provide relay communications from low-earth orbiting spacecraft to the primary ground station at the White Sands Complex in Las Cruces, New Mexico. Major customers include the International Space Station and Hubble Space Telescope. The NASA Space Network project office at GSFC manages the constellation of spacecraft. The constellation is over 30 years old, and a wide range of technologies and manufacturing techniques are represented on-orbit. Since 1983, the TDRS constellation has recorded thousands of gigabytes of telemetry data. Spacecraft telemetry data has changed throughout the three generations of TDRS spacecraft, however each spacecraft has the same basic functions with some generational enhancements. The constellation includes several spacecraft that have significantly outlived the manufacturer's projected lifetime. This has provided NASA with a significant benefit in terms of return on investment, however it places a burden on efficient management of the assets for maximum life without permitting a TDRS spacecraft to become stranded in its geosynchronous orbital slot. Consequently, the highest level of attention is paid to systems whose failure could strand a TDRS spacecraft in orbit. In this paper, we proposed two stages of analyzing spacecraft anomalies using data mining (DM) to enhance on-going predictions of spacecraft life, subsystem performance, and analysis of subsystem anomalies. The first stage conducts the unsupervised anomaly detector to detect potential anomalies in real-time telemetry data. The second stage introduced telemetry weight (TW) to each telemetry parameter to determine which parameter caused the strongest anomaly. We will present case studies of some of these analyses and how the data can impact decisions on the management of the constellation.

Ma, Kenneth Y.↗
DOE OSTI2022

3D printing of void-free glass monoliths: rheological and geometric considerations

Direct ink writing (DIW) is a versatile additive manufacturing technique capable of printing 3D architectures from a broad range of materials. The key advantage of DIW is the ability to spatially control both the architecture and the composition of the printed part, which enables the production of components with previously unachievable combinations of functionalities. One emergent application space for DIW has been in additively manufactured glass optics, where a “green body” is patterned layer-by-layer by extruding a silica-based slurry through a microfluidic nozzle and then thermally consolidated to transparent glass. A critical aspect of the process is ensuring that the printed part is completely free of voids that can occur in the interstitial spaces between the extruded filaments. This outcome is governed by the interplay between ink rheology and strains imposed by the printing process and geometric packing of the filaments. Here, we explore the strain- and rate-dependent deformation events in the DIW process to determine conditions that enable the printing of void-free monoliths without sacrificing shape fidelity. We focus on yield stress fluids consisting of fumed silica nanoparticles dispersed in organic solvents at varied volume fractions to control the rheological properties. We investigate the printability of these ink materials as a function of print process variables and devise the appropriate dimensionless parameters that capture the geometry-dependent and rate-dependent effects on the deformation of the extruded ink. Lastly, we use these scaling arguments to construct a phase diagram for void-free monolith printability.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Quality Procedures for TCR Metal Core Structure Advanced Manufacturing Processes

The Transformational Challenge Reactor (TCR) Manufacturing WBS# 3.02.04.02 organization is responsible for the advanced manufacturing process, research, development, and implementation that supports the TCR program under the TCR Additive Manufacturing (AM) Thrust. Advanced manufacturing at Oak Ridge National Laboratory (ORNL) includes the development and capabilities to use modern advanced manufacturing techniques, such as AM (e.g., 3D printing) and other novel methods, to rapidly design, develop, produce, finish, and characterize parts, samples, and components to support the nuclear and other high-quality standards industries. Deliverable # M2TC-20OR04020110 involved the development of TCR quality procedures for the TCR metal core structure by using the advanced manufacturing processes being developed at ORNL’s Manufacturing Demonstration Facility (MDF) and other ORNL locations. This report discusses the details of these procedures.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1978

Application of Laminar Flow Control Technology to Long-Range Transport Design

The impact of laminar flow control (LFC) technology on aircraft structural design concepts and systems was discussed and the corresponding benefits were shown in terms of performance and fuel economy. Specific topics discussed include: (1) recent advances in laminar boundary layer development and stability analysis techniques in terms of suction requirements and wing suction surface design; (2) validation of theory and realistic simulation of disturbances and off-design conditions by wind tunnel testing; (3) compatibility of aerodynamic design of airfoils and wings with LFC requirements; (4) structural alternatives involving advanced alloys or composites in combinations made possible by advanced materials processing and manufacturing techniques; (5) addition of suction compressor and drive units and their location on the aircraft; and (6) problems associated with operation of LFC aircraft, including accumulation of insects at low altitudes and environmental considerations.

Gratzer, L. B.↗
DOE OSTI2023

Fast-, Light-Cured Scintillating Plastic for 3D-Printing Applications

Additive manufacturing techniques enable a wide range of possibilities for novel radiation detectors spanning simple to highly complex geometries, multi-material composites, and metamaterials that are either impossible or cost prohibitive to produce using conventional methods. The present work identifies a set of promising formulations of photocurable scintillator resins capable of neutron-gamma pulse shape discrimination (PSD) to support the additive manufacturing of fast neutron detectors. The development of these resins utilizes a step-by-step, trial-and-error approach to identify different monomer and cross-linker combinations that meet the requirements for 3D printing followed by a 2-level factorial parameter study to optimize the radiation detection performance, including light yield, PSD, optical clarity, and hardness. The formulations resulted in hard, clear, PSD-capable plastic scintillators that were cured solid within 10 s using 405 nm light. The best-performing scintillator produced a light yield 83% of EJ-276 and a PSD figure of merit equaling 1.28 at 450–550 keVee.

Frandsen, Brian G. (ORCID:0000000319964320)↗
DOE OSTI2021

Coupling of Spark Plasma Sintering with Advanced Modeling to Enable Process Scale-Up: LDRD Final Project Poster

Electric-field assisted sintering (EFAS) manufacturing techniques reduce energy usage requirements, fabricate near-net-shape parts, and produce bulk nanostructured materials through rapid heating and cooling rates achievable through Joule heating. Process parameters of pulsed DC voltage and constant pressure are applied through stainless steel rams and graphite tooling to the ceramic yttrium oxide powder to be sintered. Our high-fidelity modeling code application advances manufacturing for extreme environments by enabling process-informed design and improving microstructure consistency through multiphysics multiscale process-structure-property-performance correlation simulations.

36 MATERIALS SCIENCE↗
NASA NTRS1966

Sculpturing, forming, and spinning of large components for launch vehicles

At .the beginning of the S-IC booster contract, it was evident that certain manufacturing techniques would have to be developed before the proposed design could be put into full production. Much of the development activity that has been accomplished was initiated because the size of booster components was greater than the capacities of available equipment. This paper describes some of the more significant methods that have evolved from this development activity, and which demonstrate how the capability to manufacture S-IC components such as bulkhead gore segments, tank skins, Y-rings, and lox tunnels, has been acquired. The fabrication methods used to transform 2219 aluminum alloy plate into the large, sculptured, and contoured parts that make up the structural surfaces of the booster include hydraulic bulge forming, age forming, and adaptations of conventional skin milling and chemical milling processes. The importance of fixturing and the machining sequence related to fabrication of the Y-ring are pointed out. The shear-spinning process that is used to produce a seamless, one-piece lox tunnel 40 feet long from a cylindrical blank only 62 inches long is described. The presentation is concluded with a synopsis of the current design changes that are being implemented to improve strength-to-weight ratios. A brief statement of possible future activity is included.

Milling↗
DOE OSTI2023

Recent advancements in high performance polymer electrolyte fuel cell electrode fabrication – Novel materials and manufacturing processes

The global effort to introduce polymer electrolyte fuel cells for clean and renewable energy to the market is increasing the demand for high performance, robust and affordable membrane electrode assemblies (MEAs). There is not yet a standard method for large scale production of MEAs, or the methods employed are generally unsatisfactory in terms of quality and performance. A large number of published data of newly developed catalyst and electrolyte materials, claim to improve the state of the art, but are often not fully comparable due to different experimental studies and experimental designs. This article summarizes the trends in material developments and emerging MEA-manufacturing techniques. The materials and techniques are systematically compared in terms of cell performance and scalability. Current and future scientific challenges are identified and analysed based on published findings over the past five years. Finally, the results of the cited papers have been quantitatively compared to each other and to the internal benchmarks used in each cited work to provide a complete picture of the state of the art in PEFC MEA manufacturing.

25 ENERGY STORAGE↗
NASA NTRS2009

Connecting Node

A paper describes the Octanode, a connecting node that facilitates the integration of multiple docking mechanisms, hatches, windows, and internal and external systems with the use of flat surfaces. The Octanode is a 26- faced Great Rhombicuboctahedron Archi medean solid with six octagonshaped panels, eight hexagon-shaped panels, and 12 square panels using three unique, simple, flat shapes to construct a spherical approximation. Each flat shape can be constructed with a variety of material and manufacturing techniques, such as honeycomb composite panels or a pocketed skinstringer configuration, using conventional means. The flat shapes can be connected together and sealed to create a pressurizable volume by the use of any conventional means including welding or fastening devices and sealant. The node can then be connected to other elements to allow transfer between those elements, or it could serve as an airlock. The Octanode can be manufactured on the ground and can be integrated with subsystems including hatches and ports. The node can then be transported to its intended location, whether on orbit or on surface. Any of the flat panels could be replaced by curved ones, turning the node into a copula. Windows may be placed on flat panes with optimal viewing angles that are not blocked by large connecting nodes. The advantage of using flat panels to represent a spherical approximation is that this allows for easier integration of subsystems and design features.

Johnson, Christopher J.↗
NASA NTRS2019

Technology Development for the Modification of High Aspect Ratio Geometries for Thermal and Environmental Control

A key technology development driver in environmental control systems and next generation optics are discussed utilizing thin film development borrowed from the semiconductor industry. The optical and physical properties of spacecraft radiator coatings are dictated by orbital environmental conditions. For example, coatings must adequately dissipate charge buildup when orbital conditions, such as polar, geostationary or gravity neutral, result in surface charging. Current dissipation techniques include depositing a layer of ITO (indium tin oxide) on the radiator surface in a high temperature process. The application of these enhanced coatings must be such that the properties in question are tailored to mission-specific requirements. The multi-billion-dollar semiconductor industry has adopted Atomic Layer Deposition (ALD) for self-assembly and atomic-scale placement. ALD is a cost-effective nanoadditive-manufacturing technique that allows for the conformal coating of substrates with atomic control in a benign temperature and pressure environment. By using ALD, modification of these coatings can be accomplished during coating application preprocessing. The preprocessing is rendered directly on the coating dry pigment before binding. Through the introduction of paired precursor gases, thin films can be deposited on a myriad of substrates ranging from glass, polymers, aerogels, metals, powders, and other high aspect-ratio micro- and nano- structures. By providing atomic-level control, where single layers of atoms can be deposited, the fabrication of metal transparent films, precise nano-laminates, and coatings of nano-channels and pores is achievable. A method has been demonstrated for the ALD of In2O3 and films on a variety of substrates from Si(100) wafers, glass slides, and on Z93P pigments resulting in a direct spaceflight application. Results will be presented that verify the chemical composition of ALD pigments and charge dissipation properties when the pigment goes through its binding and coating process and we present early results of ALD for carbon nanotube formation and encapsulation.

Dwivedi, Vivek H.↗