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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 OSTI2023

Effect of Mn on eutectic phase equilibria in Al-rich Al-Ce-Ni alloys

Microstructural analysis of additively manufactured (AM) Al-Ce-Ni-Mn alloys has identified phases not predicted from existing ternary liquidus projections in the Al-Ce-Ni system. Because the rapid cooling rate of AM is orders of magnitude above that of traditional casting, it is unclear if these additional phases arose from the non-equilibrium processing conditions of AM, a drastic shift in phase stability in the system due to the addition of 1 wt% Mn, or some combination of these two influences. The phases and microstructure of cast samples of Al-Ce-Ni and Al-Ce-Ni-Mn alloys were characterized for several annealing conditions which revealed the equilibrium phases at different temperatures. Phase analysis confirmed that minute levels of Mn substituted for Ni in the system drastically shifts the liquidus projection in the Al-rich corner of the ternary phase diagram such that the eutectic Al 3 Ni phase is suppressed in favor of the Al 23 Ni 6 (Ce,Mn) 4 phase. Further addition of Mn promotes the formation of Al 20 Mn 2 Ce and Al 10 Mn 2 Ce phases. The phase analysis data was then used to improve the CALPHAD modeling of the liquidus projection and isothermal sections for the Al-rich Al-Ce-Ni-Mn quaternary system. Thermodynamic modeling and experimental analysis on phases in the AM sample of Al-Ce-Ni with Mn confirmed that the phases present are consistent with Mn-containing Al-Ce-Ni cast samples. Here, this investigation demonstrates the potential for using secondary alloying elements to drastically alter phase stability and microstructure in alloy systems.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Wet Brush Homopolymers as “Smart Solvents” for Rapid, Large Period Block Copolymer Thin Film Self-Assembly

The spontaneous formation of periodic nanopatterns through the self-assembly of block copolymer (BCP) thin films offers an enticing path to engineer functional material properties over large areas, but the prohibitively slow ordering of ultrahigh molecular weight BCPs that generate large pattern periods (>100 nm) severely restricts the design space in which BCPs may be used. Here, we demonstrate that blending lamellae-forming polystyrene-block-poly(methyl methacrylate) diblock copolymers with very low molecular weight polystyrene and poly(methyl methacrylate) homopolymers can reduce by an order-of-magnitude the times required to form ordered large period patterns through solvent vapor annealing. Using in situ grazing-incidence small-angle X-ray scattering and ex situ electron microscopy, we show that the added homopolymer plasticizers act as a “smart solvent”: They increase the mobility of the long BCP chains by amplifying the dilution effect during solvent vapor annealing but segregate to like domains during subsequent thermal annealing to produce high-quality patterns with periods that may exceed 200 nm, which are readily transferred to other materials. The dramatic impact of homopolymer plasticizers may help extend the use of BCPs into new areas, particularly for visible light photonic applications that demand larger period nanopatterns.

36 MATERIALS SCIENCE↗
NASA NTRS1999

Long-Term Cyclic Oxidation Behavior of Uncoated and Coated Re-108 and In-939 at 980 and 870 C

Very long-term cyclic oxidation behavior of Re-108 and ln-939 with and without a protective coating was evaluated at 980 and 870 C, respectively. Re-108 and ln-939 without a protective coating began to show rapid weight loss at 3000 h due to scale spallation, indicating the need for an oxidation protective coating for longer than thousands of hours of oxidative life. NiAl-base coatings of a vapor phase aluminide (VPA), a pack aluminide (CODEP), and a slurry paint aluminide (SERMALOY J) were applied on Re-108 and ln-939. VPA and CODEP on Re-108 and all three coatings on ln-939 showed excellent cyclic oxidation resistance out to 10000 hr. Coated alloys were annealed in an inert atmosphere to determine the loss of Al from the coating into the alloy substrate through diffusion. The Al loss from the coating through diffusion was twice as great as the Al loss through oxidation after 10000 h of cyclic exposure. Oxidation life of VPA-coated Re-108 was estimated by calculating the amount of Al initially available for protective oxidation and the amount of Al lost through oxidation and diffusion.

Lee, K. N.↗
NASA NTRS1996

The Ultrafine Mineralogy of a Molten Interplanetary Dust Particle as an Example of the Quench Regime of Atmospheric Entry Heating

Melting and degassing of interplanetary dust particle L2005B22 at approx. 1200 C was due to flash heating during atmospheric entry. Preservation of the porous particle texture supports rapid quenching from the peak heating temperature whereby olivine and pyroxene nanocrystals (3 nm-26 nm) show partial devitrification of the quenched melt at T approx. = 450 C - 740 C. The implied ultrahigh cooling rates are calculated at approx. 105 C/h-106 C/h, which is consistent with quench rates inferred from the temperature-time profiles based on atmospheric entry heating models. A vesicular rim on a nonstoichiometric relic forsterite grain in this particle represents either evaporative magnesium loss during flash heating or thermally annealed ion implantation texture.

Rietmeijer, Frans J. M.↗
NASA NTRS2000

Long-Term Cyclic Oxidation Behavior of Uncoated and Coated Re-108 and In-939 at 980 and 870 C

Very long-term cyclic oxidation behavior of Re108 and In939 with and without a protective coating was evaluated at 980 and 870 C, respectively. Re-108 and In-939 without a protective coating began to show a rapid weight loss at 3000 h due to scale spallation, indicating the need for an oxidation protective coating for longer than thousands of hours of oxidative life. NiAl-base coatings of a vapor phase aluminide (VPA), a pack aluminide (CODEP), and a slurry paint aluminide (SERMALOY J) were applied on Re-108 and In-939. The VPA and CODEP on Re-108 and all three coatings on In-939 showed excellent cyclic oxidation resistance out to 10,000 h. Coated alloys were annealed in an inert atmosphere to determine the loss of Al from the coating into the alloy substrate through diffusion. The Al loss from the coating through diffusion was twice as great as the Al loss through oxidation after 10,000 h of cyclic exposure. The oxidation life of VPA-coated Re-108 was estimated by calculating the amount of Al initially available for protective oxidation and the amount of Al lost through oxidation and diffusion.

Lee, K. N.↗
DOE OSTI2020

Zeolite Nanosheets Stabilize Catalyst Particles to Promote the Growth of Thermodynamically Unfavorable, Small–Diameter Carbon Nanotubes

A challenge in the synthesis of single–wall carbon nanotubes (SWCNTs) is the lack of control over the formation and evolution of catalyst nanoparticles and the lack of control over their size or chirality. Here, zeolite MFI nanosheets (MFI–Ns) are used to keep cobalt (Co) nanoparticles stable during prolonged annealing conditions. Environmental transmission electron microscopy (ETEM) shows that the MFI–Ns can influence the size and shape of nanoparticles via particle/support registry, which leads to the preferential docking of nanoparticles to four or fewer pores and to the regulation of the SWCNT synthesis products. The resulting SWCNT population exhibits a narrow diameter distribution and SWCNTs of nearly all chiral angles, including sub–nm zigzag (ZZ) and near–ZZ tubes. Theoretical simulations reveal that the growth of these unfavorable tubes from unsupported catalysts leads to the rapid encapsulation of catalyst nanoparticles bearing them; their presence in the growth products suggests that the MFI–Ns prevent nanoparticle encapsulation and prologue ZZ and near–ZZ SWCNT growth. Furthermore, these results thus present a path forward for controlling nanoparticle formation and evolution, for achieving size– and shape–selectivity at high temperature, and for controlling SWCNT synthesis.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Structure characterization and steam oxidation performance of U 3 Si 2 with Zr alloying additions

Research and development of high uranium density fuels supports the on-going effort to enhance reactor technology, safety, performance, and economics. Among high uranium density fuels, U 3 Si 2 is a favored fuel candidate due to its higher uranium density and improved thermal conductivity when compared to traditional UO 2 . While U 3 Si 2 demonstrates an improved fuel economy, it suffers from rapid degradation when exposed to water at T > 300°C. In order for U 3 Si 2 to be implemented in water cooled reactors, the water reaction must be understood and mitigated. Reported here is the performance of Zr alloying additions to U 3 Si 2 exposed to high temperature steam oxidation environments. Here, the investigation shows that homogenization heat treatment contributes to a delayed onset of oxidation and an improved homogeneity throughout the arc-melt fabricated alloyed compositions. Of the pre- and post-annealed samples, the post-annealed 7 vol% Zr addition exhibited the highest onset temperature of oxidation. A preliminary computational investigation to complement the experimental analysis assesses the solubility of Zr in U 3 Si 2 and its incorporation in the crystal lattice.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2011

Crystalline Silicates in Comets: Modeling Irregularly-Shaped Forsterite Crystals and Its Implications on Condensation Conditions

Crystalline silicates in comets are a product of the condensation in the hot inner regions (T > or approx. equals 1400 K [1]) of our proto-planetary disk or annealing at somewhat lower temperatures (T > or approx. equals 1000-1200 K) [2, 3, 4] in shocks coupled with disk evolutionary processes that include radial transport of crystals from their formation locations out to the cold outer regions where comet nuclei formed. The grain shape of forsterite (crystals) could be indicative of their formation pathways at high temperatures through vapor-solid condensation or at lower temperatures through vapor-liquid-solid formation and growth [5, 6, 7]. Experiments demonstrate that crystals that formed from a rapidly cooled highly supersaturated silicate vapor are characterized by bulky, platy, columnar/needle and droplet shapes for values of temperature and supersaturation, T and sigma, of 1000-1450 C and < 97, 700-1000 C and 97-161, 580-820 C and 131-230, and <500 C and > 230, respectively [7]. The experimental columnar/needle shapes, which form by vapor-liquid-solid at lower temperatures (<820 C), are extended stacks of plates, where the extension is not correlated with an axial direction: columnar/needles may be extended in the c-axis or a-axis direction, can change directions, and/or are off-kilter or a bit askew extending in a combination of the a- and c-axis direction.

Wooden, Diane H.↗
DOE OSTI2020

Thermal conductivity of (Ge 2 Sb 2 Te 5 ) 1–x Cx phase change films

Germanium–antimony–telluride has emerged as a nonvolatile phase change memory material due to the large resistivity contrast between amorphous and crystalline states, rapid crystallization, and cyclic endurance. Improving thermal phase stability, however, has necessitated further alloying with optional addition of a quaternary species (e.g., C). In this work, the thermal transport implications of this additional species are investigated using frequency-domain thermoreflectance in combination with structural characterization derived from x-ray diffraction and Raman spectroscopy. Specifically, the room temperature thermal conductivity and heat capacity of (Ge 2 Sb 2 Te 5 ) 1–x C x are reported as a function of carbon concentration (x ≤ 0:12) and anneal temperature (T ≤ 350 °C) with results assessed in reference to the measured phase, structure, and electronic resistivity. Phase stability imparted by the carbon comes with comparatively low thermal penalty as materials exhibiting similar levels of crystallinity have comparable thermal conductivity despite the addition of carbon. The additional thermal stability provided by the carbon does, however, necessitate higher anneal temperatures to achieve similar levels of structural order.

42 ENGINEERING↗
DOE OSTI2020

UO 2 + 5 vol% ZrB 2 nano composite nuclear fuels with full boron retention and enhanced oxidation resistance

The boron isotope ( 10 B) can be used as a neutron absorber in UO 2 to control the reactivity of nuclear fuel pellets, however, the boron source can react with oxygen source in UO 2 to form B 2 O 3 that vaporize readily at temperatures above 1200 °C. Unfortunately, the sintering of UO 2 fuel requires hours holding at high temperature (>1700 °C), resulting in an inevitable B loss during sintering and unpredictable B concentration in final product. It is challenging to incorporate boron through a conventional sintering method. In this work, we demonstrated that spark plasma sintering (SPS), a field assisted sintering technology, can effectively densify UO 2 + 5 vol% ZrB 2 composite fuel pellets by rapid consolidation at 1600 °C for a short duration of 5 min under an applied pressure of 40 MPa. Further, thermogravimetric analysis (TGA) measurements confirm that ZrB 2 is fully retained inside the composite fuel pellets. Inside the composite fuel pellets, nano sized ZrB 2 particles are uniformly distributed along the grain boundaries of the UO 2 matrix. The ZrB 2 particle transforms to a glassy B 2 O 3 phase covering the sample surface and grain boundaries of UO 2 matrix after a simple post-sintering annealing at 1000 °C in flowing Argon gas for 4 h. The formed glassy B 2 O 3 slows down the diffusion of oxygen ions and postpones the onset temperature for oxidation of UO 2 from 400 °C to 550 °C. This study demonstrates the capability of SPS, an advanced fuel manufacturing technique, to achieve a full retention of ZrB 2 in UO 2 oxide fuel and increase oxidation resistance through a simple post-sintering annealing. The reported work holds great engineering potential for development of advanced oxide fuel for nuclear application.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2010

Modeling Nucleation and Grain Growth in the Solar Nebula: Initial Progress Report

The primitive solar nebula was a violent and chaotic environment where high energy collisions, lightning, shocks and magnetic re-connection events rapidly vaporized some fraction of nebular dust, melted larger particles while leaving the largest grains virtually undisturbed. At the same time, some tiny grains containing very easily disturbed noble gas signatures (e.g., small, pre-solar graphite or SiC particles) never experienced this violence, yet can be found directly adjacent to much larger meteoritic components (chondrules or CAIs) that did. Additional components in the matrix of the most primitive carbonaceous chondrites and in some chondritic porous interplanetary dust particles include tiny nebular condensates, aggregates of condensates and partially annealed aggregates. Grains formed in violent transient events in the solar nebula did not come to equilibrium with their surroundings. To understand the formation and textures of these materials as well as their nebular abundances we must rely on Nucleation Theory and kinetic models of grain growth, coagulation and annealing. Such models have been very uncertain in the past: we will discuss the steps we are taking to increase their reliability.

Nuth, Joseph A.↗
DOE OSTI2026

Domain Knowledge Guided Bayesian Optimization For Autonomous Alignment Of Complex Scientific Instruments

Bayesian Optimization (BO) is a powerful tool for optimizing complex non-linear systems. However, its performance degrades in high-dimensional problems with tightly coupled parameters and highly asymmetric objective landscapes, where rewards are sparse. In such needle-in-a-haystack scenarios, even advanced methods like trust-region BO (TurBO) often lead to unsatisfactory results. We propose a domain knowledge guided Bayesian Optimization approach, which leverages physical insight to fundamentally simplify the search problem by transforming coordinates to decouple input features and align the active subspaces with the primary search axes. We demonstrate this approach's efficacy on a challenging 12-dimensional, 6-crystal Split-and-Delay optical system, where conventional approaches, including standard BO, TuRBO and multi-objective BO, consistently led to unsatisfactory results. When combined with an reverse annealing exploration strategy, this approach reliably converges to the global optimum. The coordinate transformation itself is the key to this success, significantly accelerating the search by aligning input co-ordinate axes with the problem's active subspaces. As increasingly complex scientific instruments, from large telescopes to new spectrometers at X-ray Free Electron Lasers are deployed, the demand for robust high-dimensional optimization grows. Our results demonstrate a generalizable paradigm: leveraging physical insight to transform high-dimensional, coupled optimization problems into simpler representations can enable rapid and robust automated tuning for consistent high performance while still retaining current optimization algorithms.

FOS: Computer and information sciences↗
DOE OSTI2025

A high strength Al-2Ni-0.5Zr conductor alloy fabricated via laser powder bed fusion

There is a current need for new aluminum alloy design strategies to target applications requiring high strength and conductivity with reductions in mass. A new lightweight Al-2Ni-0.5Zr (wt. %) conductor alloy was fabricated using laser powder bed fusion. A design of experiments probed the alloy's solidification cracking susceptibility. It was observed that solidification cracking was generally reduced with fast scan speeds, above 1500 mm/s, and smaller hatch spacings. The different cooling rates throughout the melt pool produced a heterogeneous distribution of cellular and equiaxed Al 3 Ni precipitates in the as-printed alloy. Additionally, the rapid solidification characteristic of laser powder bed fusion created a super-saturated Zr solid solution. An aging heat treatment at 375 °C for 24 h imparted strengthening through the precipitation of L1 2 -Al 3 Zr nanoprecipitates, which counteracted the softening caused by the fragmentation and coarsening of Al 3 Ni precipitates. The yield strength increased from 138 MPa in the as-printed condition to 168 MPa after aging, while the ductility remained constant at ∼21%. The aging treatment simultaneously increased the electrical conductivity from 40.8% IACS (International Annealed Copper Standard) to 53.5% IACS. Modeling of the strengthening mechanisms and electrical conductivity contributions rationalized the simultaneous increase in strength and conductivity upon aging. Furthermore, the strengthening efficacy of the Al 3 Ni and L1 2 -Al 3 Zr precipitates, combined with the low Ni and Zr solubility in the FCC Al matrix, facilitated both high strength and electrical conductivity. Overall, the combination of strength and electrical conductivity positions this alloy as a suitable choice for additively manufactured lightweight conductors.

Additive manufacturing↗
NASA NTRS1986

Refractory grain processing in circumstellar shells Diagnostic infrared signatures

Recent advances in infrared speckle interferometry reported by Ridgway, et al. (1986) have made possible the determination of the temperatures at the inner radius of certain dusty outflows. When combined with recent data on the thermal annealing and hydrous alteration rates of amorphous magnesium silicate grains, this information allows one to predict that grains heated to high temperatures around stars such as NML Cygnus will be more crystalline than will cooler grains around stars like IRC +10420. In 1985, Jura and Morris (1985) showed that water vapor can condense on previously nucleated refractory grains in some stellar outflows. Stochastic heating events might provide sufficient energy to produce hydrated silicates from orginally amorphous grains provided that the loss of water from such materials does not occur too rapidly. Observable consequences of both types of grain processing are discussed.

Nuth, Joseph A., III↗
DOE OSTI2022

Microwave Heating of Nanocrystals for Rapid, Low-Aggregation Intermetallic Phase Transformations

The use of intermetallic Pt–Co nanocrystals (NCs) for the electrocatalytic oxygen reduction reaction is quickly gaining interest thanks to the higher electrochemical stability of the intermetallic L1 o phase compared to a random alloy A1 phase. However, the thermal treatment that enables the intermetallic phase transformation also causes considerable NC aggregation, resulting in a significant loss of electrochemically active surface area. Herein, we report the use of microwave radiation to induce the intermetallic phase transformation in Cu-doped Pt–Co NCs. We demonstrate that microwave radiation reduces NC aggregation while allowing for a complete phase transformation in only 30 s. Furthermore, these microwave-treated NCs demonstrate higher mass activity for the oxygen reduction reaction while maintaining electrochemical stability similar to the thermally annealed samples.

36 MATERIALS SCIENCE↗
DOE OSTI2022

High-surface-area corundum nanoparticles by resistive hotspot-induced phase transformation

Abstract High-surface-area α-Al 2 O 3 nanoparticles are used in high-strength ceramics and stable catalyst supports. The production of α-Al 2 O 3 by phase transformation from γ-Al 2 O 3 is hampered by a high activation energy barrier, which usually requires extended high-temperature annealing (~1500 K, > 10 h) and suffers from aggregation. Here, we report the synthesis of dehydrated α-Al 2 O 3 nanoparticles (phase purity ~100%, particle size ~23 nm, surface area ~65 m 2 g −1 ) by a pulsed direct current Joule heating of γ-Al 2 O 3 . The phase transformation is completed at a reduced bulk temperature and duration (~573 K, < 1 s) via an intermediate δʹ-Al 2 O 3 phase. Numerical simulations reveal the resistive hotspot-induced local heating in the pulsed current process enables the rapid transformation. Theoretical calculations show the topotactic transition (from γ- to δʹ- to α-Al 2 O 3 ) is driven by their surface energy differences. The α-Al 2 O 3 nanoparticles are sintered to nanograined ceramics with hardness superior to commercial alumina and approaching that of sapphire.

Deng, Bing (ORCID:0000000305308410)↗
DOE OSTI2022

Application of BISON to UO 2 MiniFuel fission gas release analysis

There has been a recent push to accelerate fuel qualification by developing revolutionary capabilities to reduce irradiation periods, and thereby, reduce the time required to qualify a new fuel system. One such capability is the MiniFuel irradiation capsule designed to miniaturize fuel samples and irradiate “mini” fuel samples under isothermal temperature conditions. MiniFuel allows steady-state irradiations to decouple the traditionally coupled fission rate (i.e., power) and temperature parameters to understand and generate microstructures observed in fuel operated in a commercial reactor. Furthermore, this process offers the possibility to gather in situ data as well as postirradiation or transient data such as thermal conductivity, specific heat, fission gas diffusion and release, etc. However, accelerating fuel qualification is not solely reliant on generating large amounts of data but also on developing an informed test matrix designed to rapidly generate impactful data. Additionally, this process is reliant on fuel performance codes, such as BISON, to evaluate MiniFuel irradiations using existing material models. This process pinpoints model/data gaps, identifies desired irradiation conditions, and subsequently supports model validation and development. This work describes the use of BISON to perform a number of sensitivity studies designed to understand conditions that lead to fission gas release (FGR) under steady-state isothermal irradiation conditions and temperature transient conditions. The model is applied to a UO 2 MiniFuel example and shows an overall good qualitative agreement with experimental FGR annealing tests under different temperature conditions. It also accounts well for microstructural effects on FGR. When quantitatively compared with FGR data from previously irradiated 103 MWd/kgU UO 2 discs under thermal annealing, the model shows a less satisfactory agreement with the experimental data. Finally, a UO 2 MiniFuel test matrix is proposed to help to extend the model's operational range and validate the new FGR model capabilities to higher burnups and transient conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1989

Superconducting Bi1.5Pb0.5Sr2Ca2Cu3O(x) ceramics by rapid melt quenching and glass crystallization

A glass of nominal Bi(1.5)Pb(0.5)Sr2Ca2Cu3O(x) composition, prepared by rapid quenching of the melt, showed a glass transition temperature of 383 C, crystallization temperature of 446 C, melting temperature of 855 C, and bulk density of 5.69 g/cu cm in air. The activation energy for crystallization of the glass was estimated to be 292kJ/mol from non-isothermal DSC. On heating in oxygen, the glass showed a slow and continuous weight gain starting at approximately 530 C which reached a plateau at approximately 820 C. The weight gained during heating was retained on cooling to ambient conditions indicating an irreversible oxidation step. The influence of annealing conditions on the formation of various phases in the glass has been investigated. The Bi(2)Sr(2)Ca(0)Cu(1)O(6) phase crystallized out first followed by formation of other phases at higher temperatures. The high-T(sub c) phase, isostructural with Bi(2)Sr(2)Ca(2)Cu(3)O(10) was not detected below 840 C, but its fraction increased with the annealing time at 840 C. A sample annealed at 840 C for 243h in air and furnace cooled showed the highest T(sub c)(R=0) of 107.2K and a narrow transition width, delta T(sub c)(10 to 90 percent), of approximately 2 K. The high T(sub c) phase does not seem to crystallize out directly from the glass but is rather produced at high temperature by reaction between the phases formed at lower temperatures. The kinetics of 110K phase formation was sluggish. It appears that the presence of lead helps in the formation and/or stabilization of the 110 K phase.

Bansal, Narottam P.↗