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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Destabilization of counter-propagating Alfvénic instabilities by tangential, co-current neutral beam injection

Injection of high-energy neutrals is a common tool to heat the plasma and drive current non-inductively in fusion devices. Once neutrals ionize, the resulting energetic particles can drive instabilities that are detrimental for the performance and the predictability of plasma discharges. A broad deposition profile of neutrals from neutral beam injection, e.g. by aiming the beam tangentially on the outboard midplane (i.e. off-axis), is often assumed to limit those undesired effects by reducing the radial gradient of the EP density, thus reducing the drive for instabilities. However, this paper presents new evidence that tangential neutral beam injection, including off-axis injection near the plasma mid-radius, can also lead to undesired effects such as the destabilization of Alfvénic instabilities. Time-dependent analysis with the TRANSP code indicates that instabilities are driven by a combination of radial and energy gradients in the distribution function of the energetic particles. Finally, the mechanisms for wave-particle interaction revealed by the energetic particle phase space resolved analysis are the basis to identify strategies to mitigate or suppress the observed instabilities.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2018

Results of the Aerosol Sampling Experiment on the International Space Station

The indoor air quality of the International Space Station (ISS), in terms of particulate matter, has been assessed through a sampling experiment that collected airborne debris for return to Earth. The Aerosol Sampling Experiment took place on ISS in December 2016 and January 2017, with sample return in February 2017. For redundancy, two different aerosol samplers collected particles in two size ranges spanning from 10 nm to hundreds of micrometers. Multiple analysis techniques have been used to characterize the particles, such as reflective light microscopy, manual scanning electron microscopy (SEM) analysis (secondary and backscattered imaging) with energy dispersive spectroscopy (EDS) x-ray analysis, computer controlled scanning electron microscopy (CCSEM) and Raman spectroscopy. Sampling took place in five locations on ISS, with the greatest deposition of particles in Node 3, followed by Node 1, the US Lab and Node 2. The PMM had very few airborne particles, as expected, owing to the lack of human presence. A large proportion of the sampled material consisted of fibers from clothing. Many particles had complex morphologies or contained multiple metals in a carbonaceous matrix. Metal particles were analyzed for each sampling location in terms of both weight and number percent, with 27 heavy metals detected. Fiberglass and TiO2 particles were present in every location. Quantitative analysis results are presented, and where possible, particle emission sources are identified with the intention to fuel discussions on mitigation.

Meyer, Marit E.↗
DOE OSTI2025

Mechanistic Insights into the Surface Instabilities of TiNb 2 O 7, a High‐Power Li‐Ion Anode

TiNb 2 O 7 (TNO) is a promising Li-ion battery anode for high-power applications, such as implantable medical devices and heavy-duty equipment. Hailed as being safe due to its elevated operating potential near 1.6 V, TNO has long been assumed to be highly stable in the carbonate-based electrolytes used in Li-ion batteries. Herein, all mechanisms occurring at the surface of both TNO and Nd-doped TNO are identified, and both materials in fact show significant gassing. CO 2 is even released at open circuit conditions, demonstrating the poor chemical stability of the material in the electrolyte even prior to battery operation. Such extreme instability is a critical safety concern. In addition, it was found that Ti dissolves from the surface of TNO particles at low voltage (below 1.4 V vs Li), and in fact deposits on the counter electrode. Ti further inside TNO particles then diffuses to the Ti-poor surface during discharge. Partial carbon-coating as a mitigating measure has also been tested and found to exacerbate these processes. The findings identify novel reactions occurring within TNO, and clearly highlight the need to stabilize the surfaces of TNO in order to prevent such aggressive deterioration at the surface of the particles.

25 ENERGY STORAGE↗
DOE OSTI2016

Operation of a high-gradient superconducting radio-frequency cavity with a non-evaporable getter pump

The use of non-evaporable getter (NEG) pumps in particle accelerators has increased significantly over the past few years because of their large pumping speed, particularly for hydrogen, compared to the size of the pump. A concern about using such pumps in superconducting radio-frequency (SRF) accelerators is the possibility of shedding particulates which could then migrate into the SRF cavities and produce field emission, therefore degrading the cavity performance. One option to mitigate such issue is to use sintered getter materials which intrinsically offer superior mechanical and particle retention properties. In this article we present the results from cryogenic RF tests of a high-gradient SRF cavity after being evacuated several times with an NEG pump equipped with sintered getter disks and placed in close proximity to the cavity. Here, the results showed that the cavity performance was not affected by the pump up to the quench gradient of 34 MV/m. As a result of this study, two such NEG pumps have been installed next to a cryomodule in the CEBAF accelerator to maintain ultra-high vacuum in the SRF cryomodule and two adjacent warm girder sections.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

COUPLING SMOOTHED PARTICLE HYDRODYNAMICS WITH FINITE ELEMENT METHOD TO SIMULATE RESIDUAL STRESSES FROM FRICTION STIR PROCESSING

Friction stir processing (FSP) is a solid-state material processing technique that locally modifies the microstructure but also induces undesirable residual stresses. A robust numerical model for the FSP can help in mitigating these residual stresses. Heat source models within a finite element method (FEM) framework suffer from inaccuracies. In contrast, smoothed particle hydrodynamics (SPH) model that explicitly captures the material flow near the tool and the associated heat generation are accurate. However, the computational expense of SPH simulations can be prohibitive. In this work, we propose a coupled SPH-FEM framework. SPH is used to model the heat generation accurately near the tool and which is then inserted into to the FEM model as a heat source. To verify this proposed coupling approach, a test case is set up with typical FSP conditions and it is modeled in both SPH and SPH-FEM. The temperatures profiles were compared after the simulations have reached steady-state temperatures. The similarity of the temperature profiles from SPH-FEA and SPH validated the proposed coupling approach. This proposed approach achieves the accuracy of the SPH method while potentially retaining the low computational expense of FEM.

smoothed particle hydrodynamics, Finite Element Me↗
NASA NTRS1993

Near-surface temperature gradients and their effects on thermal-infrared emission spectra of particulate planetary surfaces

The infrared energy emitted from a planetary surface is generated within a finite depth determined by the material's absorption skin depth. This parameter varies significantly with wavelength in the infrared but has an average value of around 50 microns for most geologic materials. In solid rock, heat transfer is efficient enough so that this 50 micron zone of the near surface from which the radiation emanates will be more or less isothermal. In particulate materials, however, heat transfer is more complicated and occurs via a combination of mechanisms, including solid conduction within grains and across grain contacts, conduction through the interstitial gas, and thermal radiation within individual particles and across the void spaces in between grains. On planets with substantial atmospheres, the gas component dominates the heat transfer and tends to mitigate near-surface thermal gradients. However, on airless bodies, the gas component is absent and heat transfer occurs via solid conductions and radiation. If the particles are small relative to the average absorption skin depth, then the top 50-100 microns or so of the surface will be cooled by radiation to space allowing the creation of significant near-surface thermal gradients. In those regions of the spectrum where the absorption coefficient is low, the emission will come from the deeper, warmer parts of the medium, whereas in regions of high absorption, the emission will emanate from shallower, cooler parts of the medium. The resulting emission spectrum will show non-compositional features as a result of the thermal structure in the material. We have modeled the heat transfer in a particulate medium in order to determine the magnitude of near-surface thermal gradients for surfaces on airless bodies and on Mars. We use the calculated thermal structure to determine the effects it has on the infrared emission spectrum of the surface.

Henderson, B. G.↗
NASA NTRS2008

Addition of Electrostatic Forces to EDEM with Applications to Triboelectrically Charged Particles

Tribocharging of particles is common in many processes including fine powder handling and mixing, printer toner transport and dust extraction. In a lunar environment with its high vacuum and lack of water, electrostatic forces are an important factor to consider when designing and operating equipment. Dust mitigation and management is critical to safe and predictable performance of people and equipment. The extreme nature of lunar conditions makes it difficult and costly to carryout experiments on earth which are necessary to better understand how particles gather and transfer charge between each other and with equipment surfaces. DEM (Discrete Element Modeling) provides an excellent virtual laboratory for studying tribocharging of particles as well as for design of devices for dust mitigation and for other purposes related to handling and processing of lunar regolith. Theoretical and experimental work has been performed pursuant to incorporating screened Coulombic electrostatic forces into EDEM Tm, a commercial DEM software package. The DEM software is used to model the trajectories of large numbers of particles for industrial particulate handling and processing applications and can be coupled with other solvers and numerical models to calculate particle interaction with surrounding media and force fields. In this paper we will present overview of the theoretical calculations and experimental data and their comparison to the results of the DEM simulations. We will also discuss current plans to revise the DEM software with advanced electrodynamic and mechanical algorithms.

Hogue, Michael D.↗
DOE OSTI2018

Mitigation of stimulated Raman scattering in the kinetic regime by external magnetic fields

Here, we show via particle-in-cell simulations that small normalized magnetic fields (ω c /ω p << 1) can significantly modify the evolution of backward stimulated Raman scattering (SRS) in the kinetic regime due to the enhanced dissipation of nonlinear electron plasma waves propagating perpendicular to magnetic fields. A magnetic field applied perpendicularly to the electron plasma wave (and driving light wave) increases the SRS threshold for kinetic inflation and decreases the amount of reflectivity when SRS is driven significantly above threshold. Analysis indicates that this arises because trapped electrons are accelerated as they surf across the wave, leading to the continual dissipation of the electron plasma waves over a wider range of wave amplitudes. The reduction in SRS reflectivity is most significant for a purely perpendicular field, although reduction also occurs for other angles; a parallel field can slightly increase single-speckle SRS but decreases multispeckle SRS. These simulations demonstrate the significance of magnetic-field contributions to nonlinear electron plasma wave damping with respect to nonlinear parametric decay instabilities; the simulation parameters are directly relevant for SRS in inertial confinement fusion devices and indicate that approximately 30 tesla magnetic fields might significantly reduce SRS backscatter.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2008

Discrete Element Modeling of Triboelectrically Charged Particles

Tribocharging of particles is common in many processes including fine powder handling and mixing, printer toner transport and dust extraction. In a lunar environment with its high vacuum and lack of water, electrostatic forces are an important factor to consider when designing and operating equipment. Dust mitigation and management is critical to safe and predictable performance of people and equipment. The extreme nature of lunar conditions makes it difficult and costly to carry out experiments on earth which are necessary to better understand how particles gather and transfer charge between each other and with equipment surfaces. DEM (Discrete Element Modeling) provides an excellent virtual laboratory for studying tribocharging of particles as well as for design of devices for dust mitigation and for other purposes related to handling and processing of lunar regolith. Theoretical and experimental work has been performed pursuant to incorporating screened Coulombic electrostatic forces into EDEM, a commercial DEM software package. The DEM software is used to model the trajectories of large numbers of particles for industrial particulate handling and processing applications and can be coupled with other solvers and numerical models to calculate particle interaction with surrounding media and force fields. While simple Coulombic force between two particles is well understood, its operation in an ensemble of particles is more complex. When the tribocharging of particles and surfaces due to frictional contact is also considered, it is necessary to consider longer range of interaction of particles in response to electrostatic charging. The standard DEM algorithm accounts for particle mechanical properties and inertia as a function of particle shape and mass. If fluid drag is neglected, then particle dynamics are governed by contact between particles, between particles and equipment surfaces and gravity forces. Consideration of particle charge and any tribocharging and electric field effects requires calculation of the forces due to these effects.

Hogue, Michael D.↗
DOE OSTI2011

LHeC ERL Design and Beam-dynamics Issues

We discuss machine and beam parameter choices for a Linac-Ring option of the Large Hadron electron Collider (LHeC) based on the LHC. With the total wall-plug power limited to 100 MW and a target current of about 6 mA the desired luminosity of 1033 cm-2 s-1 can be reached, providing one exploits unique features of the Energy Recovery Linac (ERL). Here, we describe the overall layout of such ERL complex located on the LHC site. We present an optimized multi-pass linac optics enabling operation of the proposed 3-pass Recirculating Linear Accelerator (RLA) in the Energy Recovery mode. We also describe emittance preserving return arc optics architecture; including layout and optics of the arc switch-yard. Furthermore, we discuss importance of collective effects such as: beam breakup in the RLA, as well as ion accumulation, with design-integrated mitigation measures, and the electron-beam disruption in collision. Finally, a few open questions are highlighted.

43 PARTICLE ACCELERATORS↗
NASA NTRS2023

Lunar Dust Mitigation: A Guide and Reference: First Edition (2021)

On the surface of the Moon, lunar dust specifically presents unique challenges to operations long-term due to regolith particles’ ubiquitous presence in the lunar environment, potential to electrostatically charge and possible chemical reactivity. Whether to avoid exposure, try to remove or simply to tolerate lunar dust infiltrating a system becomes a complex question involving length of required service life, dust effects and critical risks, mass and complexity trades for the entire system. This publication provides a snapshot of advice from topical experts for specific areas of concern to systems targeted for deployment on the lunar surface. Following introductory overview commentary, dust mitigation approaches appropriate to the lunar surface are first addressed for typically static structures such as optical surfaces, radiators, and other thermal control surfaces, followed by regolith exposure concerns for communications equipment and non-optical sensors. The broad topic of mechanisms and mechanical assemblies is broken down to address relevant component level concerns, such as for bearings and for seals. “Soft goods” components of space suits (fabric) specific concerns are discussed, followed finally by brief coverage of human health issues and concerns, though the emphasis of this publication remains with components directly exposed to the harsh lunar surface environment. A description of some lunar surface hazard details, in particular characteristics of lunar surface dust, follows in Appendix A, and more detailed explanations of quantification issues for particulates are in Appendix B. The simple inertial removal of particles from a surface is discussed in Appendix C, followed by a summary of terrestrial best practices for dust mitigation recommended within select industries in Appendix D. The aggregated bibliography of references, while extensive and very useful, should not be construed to be exhaustive and can serve as a constructive start.

dust↗
NASA NTRSDate not supplied

Advancing Dust Tolerant Mechanisms for a Sustained Exploration of the Moon

Introduction: “I think dust is probably one of our greatest inhibitors to a nominal operation on the Moon. I think we can overcome other physio-logical or physical or mechanical problems except dust.”– Gene Cernan, Apollo 17 Technical Debrief The Apollo missions revealed the impact of lu-nar dust on mechanisms. Lunar dust particles are jagged and electrostatically charged, giving them the ability to bind or damage mechanisms and alter thermal properties. Reports documented clogged equipment and jammed mechanisms in every mission, regardless of surface duration, as well as clogged mechanisms in the Extravehicular Mobility Suit (EMS), including zippers, wrist and hose locks, faceplates, and sunshades [1-2]. Several astronauts remarked they could not have sustained surface activity much longer because clogged joints would have frozen up completely [2]. Effective dust mitigation strategies are need-ed to support longer duration stays on the lunar surface [3-4]. State of the Art: Technology for mechanisms able to operate in dusty enviroments is advancing rapidly due to the needs of both Mars rovers and the Artemis program. Vacuum-tight connectors are essential for spacesuits and habitats, and their performance can be dependent on cleaning technologies, which have proven difficult on the lunar surface. Several TRL 3-5 technologies are undergoing tests with the expectation to reach TRL 6 within 1-2 years. Some mechanisms will be infused and tested on the VIPER (Volatiles Inves-tigating Polar Exploration Rover) mission planned for mid-2020s. NASA Funded Efforts: NASA has recognized the need for dust tolerant mechanisms, and has partnered with industry to advance the state-of-the-art. At NASA GRC, KSC, and JSC, the Dust Tolerant Mechanisms Project is working to devel-op advanced actuator seals for rotary joints and rotary bearing technologies for long-term sus-tained operation in lunar dust environments. An-other NASA project at NASA GRC, partnered with GSFC, JPL, and KSC is Motors for Dusty & Ex-treme Cold Environments (MDECE). MDECE is developing an unheated magnetically-geared mo-tor that can operate continuously for a long dura-tion at an ambient temperature of -243 ºC (33 K). NASA GRC has the capability to characterize the effects of dust on seals, mechanisms, and other mating surfaces and components under lunar conditions [5]. Through the SBIR/STTR program, NASA has funded several companies to advance dust toler-ant mechanisms via the Dust Tolerant Mecha-nisms sub-topic with applications in surface mobil-ity, spacesuits, connectors, joints, and more. LSIC and Community Efforts: The Lunar Surface Innovation Consortium (LSIC) Dust Miti-gation focus group has fostered collaborations across NASA, industry, and academia to develop solutions that minimizes the impact of lunar dust on robotic and human systems. Community ef-forts have included topical meetings on dust tol-erant mechanisms, featured technology presenta-tions, and feedback to NASA on potential gaps and needs. Testing: In 2021, NASA released NASA-STD-1008 [6]. This NASA Technical Standard estab-lishes minimum requirements and provides guid-ance for testing systems and hardware to be ex-posed to dust in planetary environments. The standard has specific sections dedicated to Mechanisms Testing (e.g. bearings, gears) as well as Seals and Mating Surfaces Testing (e.g. hatches, docking systems). Gaps and Needs: NASA is tracking dust tol-erant mechanisms as a gap in a cross-directorate analysis of capability areas needed to enable fu-ture human space-flight architectures. Two high-priority gap areas include additional facilities for testing mechanisms in lunar-surface conditions, and a better understanding of vulnerabilities to the smallest, nanometer-scale dust particles. Conclusion: Understanding and mitigating lu-nar dust is critical to successful, sustained opera-tions on the lunar surface – whether autonomous or otherwise. This presentation will discuss both the state-of-the-art and open needs in lunar dust tolerant mechanisms, technology impacts, mitiga-tion approaches, testing, LSIC community efforts, and more. References: [1] Gaier, J. R. (2020). The Im-pact of Dust on Lunar Surface Equipment During Apollo. Lunar Dust 2020. [2] GRC, & Gaier, J. R. (2005). The Effects of Lunar Dust on EVA Sys-tems During the Apollo Missions. [3] Johansen, M. R. (2020). An Update on NASA’s Lunar Dust Mitigation Strategy. Lunar Dust 2020. [4] ASI, CSA, ESA, JAXA, & NASA. (2016). Dust Mitiga-tion Gap Assessment Report. [5] Jimenez, N. et al (2022), LPSC Abstract 2572. [6] NASA-STD-1008, 2021.

J I Nunez↗
DOE OSTI2023

Reversible solid oxide cells: Early performance and microstructural evolution during electrolysis and switched mode operation

Incorporating more renewables into our energy mix will require a diversity of technological solutions. Reversible solid oxide cell systems (RSOCs) operating reversibly between fuel cell and electrolysis modes with high round-trip efficiencies offer one such solution. However, questions remain about the stability of the oxygen and fuel electrodes under reversible operation. Here, in this study, single cells with the configuration Ni-YSZ|YSZ|GDC10|NNO-NDC50|NNO are operated by reversible cycling under potentiostatic conditions. Test conditions are chosen to be representative of average stack conditions that are likely to be encountered during operation of a stack constructed of such cells. The results of reversible cycling over 500 h (21 cycles) are compared with operating the cells under potentiostatic conditions in the electrolysis-only mode (i.e., without cycling). Voltage-current density (DC), AC complex impedance spectroscopy, distribution of relaxation times (DRT) analysis, and scanning electron microscopy (SEM) indicate excellent reversibility and stability of the neodymium nickelate-based oxygen electrodes in both electrolysis and reversible cycling modes. Degradation behavior is attributed to the loss and coarsening of connected Ni particles in the fuel electrode, particularly in the active layer. However, reversible operation mitigates this degradation compared to operation in the electrolysis-only (SOEC-only) mode.

25 ENERGY STORAGE↗
DOE OSTI2019

Engineering Scale Simulation of Nonequilibrium Network Phases for Battery Electrolytes

According to the article, Diblock copolymers play an important role in the fabrication of battery materials and fuel cells. For these applications, one block provides mechanical stability, whereas the other is conducting. The application characteristics of the material critically depend on the morphology of the multicomponent material, and three-dimensional, percolating domains of the conducting domains are preferred. In this work, we investigate the nonequilibrium morphology of diblock copolymers after a quench from the disordered phase. After the spinodal self-assembly, we observe three-dimensionally percolating network structures for volume fractions, f ≥ 8/32, of the conducting component even if the equilibrium phases exhibit different percolation properties. We quantify the conductivity and tortuosity of these structures via a simple random-walk model and observe that the conductivity of the nonequilibrium structures is significantly smaller than that of the equilibrium phases. We also find large but finite-sized, fractal-like structures inside the morphology, which influence the transport properties. To explore the morphology on different scales and mitigate finite-size effects, we employ very large simulations with billions of particles. Our work demonstrates that for the prediction of bulk transport properties in these nonequilibrium morphologies it is necessary to study such large system sizes.

Polymer Science↗
DOE OSTI2019

Performance of missing transverse momentum reconstruction in proton-proton collisions at √ s = 13 TeV using the CMS detector

The performance of missing transverse momentum (p → T miss ) reconstruction algorithms for the CMS experiment is presented, using proton-proton collisions at a center-of-mass energy of 13 TeV, collected at the CERN LHC in 2016. The data sample corresponds to an integrated luminosity of 35.9 fb -1 . The results include measurements of the scale and resolution of p → T miss , and detailed studies of events identified with anomalous p → T miss . The performance is presented of a p → T miss reconstruction algorithm that mitigates the effects of multiple proton-proton interactions, using the "pileup per particle identification" method. The performance is shown of an algorithm used to estimate the compatibility of the reconstructed p → T miss with the hypothesis that it originates from resolution effects.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRSDate not supplied

An Overview of Spacecraft Aerosols: Sources, Dynamics, and Knowledge Gaps

NASA has prioritized development of airborne particulate monitoring systems and mitigation strategies for future Lunar, Martian, and deep-space exploration missions. Airborne particles, also called aerosols, can cause human health problems ranging from mild respiratory discomfort to more severe disease. NASA’s suspended cabin particle and Lunar dust concentration requirements are motivated by protecting crew health and comfort during spaceflight, especially as mission durations lengthen and become increasingly ground-independent. Spacecraft cabin aerosols can originate from a variety of sources, including skin flakes, fibers from clothes and other materials, mechanical wear from equipment, and personal care products (e.g., antiperspirant). As NASA plans future expeditions to the Moon and Mars, Lunar and planetary dust compose an additional, under-characterized source for airborne particles. In addition to these known sources, recent studies on ISS cabin aerosols also revealed particles with unknown origins and poorly understood formation mechanisms, including some that may be formed by oxidative and/or heterogeneous chemical processes. The aerosol monitors payload, to be launched February 2025, will focus on understanding these unknown sources and processes, as well as demonstrating novel technologies for particulate monitoring to be infused in future space flight programs. In this presentation, we will present our knowledge of spacecraft cabin aerosols to date, summarizing aerosol measurement experiments from Shuttle through ISS. Cabin aerosol sources, known and unknown, will be summarized, and knowledge gaps for future long-duration space exploration missions will be discussed.

Claire Fortenberry↗
DOE OSTI2023

Biphasic Janus Particles Explain Self-Healing in Pt–Pd Diesel Oxidation Catalysts

The addition of Pd to Pt-based diesel oxidation catalysts is known to enhance performance and restrict the anomalous growth of Pt nanoparticles when subjected to aging at high temperatures in oxidative environments. To gain a mechanistic understanding, we studied the transport of the mobile Pt and Pd species to the vapor phase, since vapor phase transport is the primary route for sintering in these catalysts. The results are surprising: there is a 30-fold drop in the effective vapor pressure of Pt in the Pt-Pd catalysts compared to monometallic Pt. At the same time, there is a significant enhancement in the vapor pressure of Pd, compared to PdO, which otherwise has a negligible vapor pressure at the aging temperature. Such behavior cannot be explained simply by alloying Pt and Pd in the metallic phase, or a core-shell morphology where a PdO shell covers a Pt core. Transmission electron microscopic examination of catalysts aged up to 50 h in air at 800 °C shows that the particles exhibit a biphasic “Janus”-like structure. The metal and oxide phases are conjoined, exposing a metal and an oxide face to the gas phase. The high mobility of the Pt and Pd allows them to be partitioned into the metal and oxide phases, in apparent thermodynamic equilibrium. The PdO helps to trap mobile PtO2 and as a result contains high concentrations of Pt oxide, consistent with its role in mitigating the transport of Pt to the vapor phase and preventing the growth of anomalously large particles. In turn, Pt allows Pd to remain metallic, allowing the catalyst to retain both metal and oxide functionality for catalysis. The regeneration of deactivated catalysts typically requires an external input, such as a change in the working environment from reducing to oxidizing or vice-versa. Here, we show that the mobile species, which are primary contributors to catalyst sintering are effectively returned to the active site, hence our use of the term “selfhealing”. The detailed insights into the inner workings of the Pt-Pd diesel oxidation catalysts can help provide clues to the design of robust and durable heterogeneous catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Process control-enabled mitigation of microstructural and plastic heterogeneities in additively manufactured Grade 91 steel

Synergizing wire arc-directed energy deposition (WA-DED) additive manufacturing (AM) with particle-strengthened creep strength-enhanced ferritic (CSEF) steels enables fabrication and repair of critical power-plant components. Investigations focused on fusion-welded particle-strengthened CSEF steels, such as Grade 91 steel, have linked microstructurally heterogeneous regions—forming due to heat affected zones (HAZ)—with premature failure during elevated temperature service. Fusion-based AM, including WA-DED, likewise generates microstructurally and plastically heterogeneous regions due to spatiotemporally varying thermokinetics during deposition. However, works investigating such microstructural heterogeneities, their implications for mechanical behavior, and strategies to mitigate their formation remain scarce. This work identifies microstructurally and plastically heterogeneous regions within the WA-DED-processed Grade 91 steel. Spatial microhardness variations in the as-fabricated specimen correlate with the variation in the attributes of grain, martensitic microstructure, and precipitates across the fusion zone and HAZ. Digital image correlation-enabled tensile tests performed at 500 °C revealed pronounced deformation localization and a wave-like strain distribution, with wavelength close to the melt pool depth, indicating susceptibility of the as-fabricated components to premature creep failure. Such heterogeneity in microstructural and mechanical behavior was attributed to recurring solid-state phase transformations. Subsequently, an interlayer temperature control strategy was implemented, wherein maintaining interlayer temperature above the martensitic start temperature mitigated the heterogeneous microstructural and plastic response in the as-fabricated condition. Findings open pathways to achieving deformation-localization- and creep-resistant microstructures in WA-DED fabricated particle-strengthened CSEF steel components, reducing reliance on post-welding heat treatments—conventionally required to enhance creep resistance—and enabling on-demand, short lead-time fabrication of next-generation power-plant components.

Heat affected zones↗