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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Shear Assisted Processing and Extrusion (ShAPE) of Aluminum Alloy 7075, 2024, and Al-12.4TM

The most common aluminum alloys utilized in the aerospace industry are 7075 and 2024 due to their high strength-to-weight ratio compared to advanced high strength steels and other aluminum alloys. Despite excellent performance, these aluminum alloys have seen limited use outside of the aerospace industry due in part to high cost. If high-performance aluminum extrusions could be made more cost effectively by eliminating energy intensive process steps typical of conventional extrusion, then numerous opportunities exist for more widespread adoption. A key reason for the high cost of 7075 and 2024 extrusions (25-75% higher than 6061) is their slow extrusion speed. 7075 and 2024 are limited to 2 m/min and 3.5 m/min respectively, in contrast to 6061 which can be extruded at 20–80 m/min. In addition to slow speed, aluminum alloys require numerous thermal treatments throughout the extrusion process including homogenization and pre-heating prior to extrusion, and solution heat treating and artificial aging after extrusion. Each of these steps contribute to the total energy consumed during manufacturing of extruded components. This project investigates the use of ShAPE to improve extrusion speed and reduce, or even eliminate, the typical thermal treatments for high strength aluminum alloys, all while improving material performance. The overarching goal of this project was to demonstrate that Shear Assisted Processing and Extrusion (ShAPE) can manufacture high-performance aluminum alloy tubing with lower manufacturing energy and improved mechanical properties compared to conventional extrusion. Unlike conventional extrusion where the billet is rammed against a stationary die using a strictly linear motion, the ShAPE process superimposes a rotational shear force by spinning the die while the billet is plunged. Compared to conventional linear extrusion, the ShAPE process imparts significantly more strain into the feedstock material, which enables the formation of novel microstructures. These microstructures manifest an array of property and process improvements for extrusion of high-performance aluminum alloys. The following accomplishments were achieved for this project: Extrusion of 7075 at 12.2 meters/min compared to 2 meters/min for conventional extrusion; Elimination of 7075 billet homogenization (430 °C for 20 hours) which is required prior to conventional extrusion; Elimination of 7075 billet pre-heating (400 °C for 1 hour) in a separate furnace which is required prior to conventional extrusion; Achieved 7075-T6with yield strength = 595 MPa, ultimate tensile strength = 531MPa, and elongation = 17.4% for extrusions made from unhomogenized billets. Exceeds the ASTM and ASM standard, and typical industry values; Achieved 7075-T5 (i.e., no solution heat treatment) with yield strength = 588 MPa, ultimate tensile strength = 535 MPa, and elongation = 14.8% for extrusions made from homogenized billets; Extrusion of 2024 at 7.4 meters/min compared to 3.5 meters/min for conventional extrusion; Achieved 2024-T8510 yield strength = 522 MPa, ultimate strength = 510MPa, and elongation = 7.1% for extrusions made from wrought billets. Exceeds the ASTM and ASM standard, and typical industry values; Extrusion of Al-12.4TM high-performance aluminum powder directly into tubing, in a single step, which eliminates process steps typical of powder metallurgy extrusion.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Development and Evaluation of Embrittlement Resistant Alloys for Advanced LWR Cladding

The primary challenge preventing the deployment of reactor designs that leverage wrought FeCrAl as an advanced light-water reactor (LWR) cladding is irradiation hardening and embrittlement. Wrought FeCrAl alloys experience a loss of post-irradiation ductility and fracture toughness under low-temperature neutron irradiation (< 350°C) resulting from the combined effects of dislocation loop formation and the irradiation-enhanced precipitation of Cr-rich alpha-prime precipitates throughout the microstructure. Over the past decade, significant improvements in our understanding regarding the effect of Cr and Al content have been enabled through neutron irradiations, but even optimized wrought alloys such as C26M remain vulnerable to brittle failure during storage, transportation, and handling following irradiation. This report summarizes multiple irradiation campaigns initiated over the past 7 years and provides recent insights into the effect of (1) minor alloying composition, (2) alloy processing strategy, (3) crystal structure, and (4) the use of advanced oxide dispersion strengthened (ODS) alloys. The first irradiation campaign irradiated body-centered cubic FeCrAl alloy C26M with and without elements such as Mo and Y. It also included face-centered cubic alumina-forming austenitic (AFA) alloys that have a steeper neutronic penalty but that have far superior high-temperature strength than wrought FeCrAl. Finally, this campaign compared conventional wrought C26M with the same material produced using modern powder metallurgical hotisostatic pressing (PM-HIP). The second irradiation campaign, initiated in 2018, irradiated wrought and FeCrAl-ODS materials up to 50 dpa to assess their irradiation resistance to high-doses. The results of this work indicate that wrought C26M suffers significant degradation following neutron irradiation at LWR-relevant temperatures regardless of Mo and Y content. The PM-HIP variant appears to be more resilient to irradiation-induced ductility loss in comparison with wrought variants but still loses almost all ductility by 8 dpa. Notably, the AFAs retained at least 5% total elongation after irradiation at the same dose and temperature condition, although additional deterioration may be expected at higher fluence levels. FeCrAl-ODS materials show the greatest promise as a transformative longer-term accident-tolerant fuel (LT-ATF) cladding material. The extruded 106ZY10C alloy retained 10% total elongation after 16 dpa irradiation and retained 8% total elongation after 50 dpa. Additional challenges with FeCrAl-ODS alloys also remain, including optimization of end cap joining methodologies, enhancement of fracture toughness, scaling production to prove economic viability, and optimizing post-pilger heat treatments to maximize ductility and irradiation resistance. This series of irradiations demonstrates the efficacy of the LWR testbed available within the United States for the rapid irradiation and down-selection of LT-ATF candidates. As the country rapidly accelerates its timeline for the deployment of advanced reactor concepts, the effective utilization of the High Flux Isotope Reactor for separate-effects style irradiations should continue to be prioritized to answer the final questions pertaining to LT-ATF candidates necessary for the deployment of advanced boiling water reactors and small modular reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Epicuticular wax accumulation and regulation of wax pathway gene expression during bioenergy Sorghum stem development

Bioenergy sorghum is a drought-tolerant high-biomass C4 grass targeted for production on annual cropland marginal for food crops due primarily to abiotic constraints. To better understand the overall contribution of stem wax to bioenergy sorghum’s resilience, the current study characterized sorghum stem cuticular wax loads, composition, morphometrics, wax pathway gene expression and regulation using vegetative phase Wray, R07020, and TX08001 genotypes. Wax loads on sorghum stems (~103-215 µg/cm 2 ) were much higher than Arabidopsis stem and leaf wax loads. Wax on developing sorghum stem internodes was enriched in C28/30 primary alcohols (~65%) while stem wax on fully developed stems was enriched in C28/30 aldehydes (~80%). Scanning Electron Microscopy showed minimal wax on internodes prior to the onset of elongation and that wax tubules first appear associated with cork-silica cell complexes when internode cell elongation is complete. Sorghum homologs of genes involved in wax biosynthesis/transport were differentially expressed in the stem epidermis. Expression of many wax pathway genes (i.e., SbKCS6, SbCER3-1, SbWSD1, SbABCG12, SbABCG11 ) is low in immature apical internodes then increases at the onset of stem wax accumulation. SbCER4 is expressed relatively early in stem development consistent with accumulation of C28/30 primary alcohols on developing apical internodes. High expression of two SbCER3 homologs in fully elongated internodes is consistent with a role in production of C28/30 aldehydes. Gene regulatory network analysis aided the identification of sorghum homologs of transcription factors that regulate wax biosynthesis (i.e., SbSHN1, SbWRI1/3, SbMYB94/96/30/60, MYS1 ) and other transcription factors that could regulate and specify expression of the wax pathway in epidermal cells during cuticle development.

09 BIOMASS FUELS↗
DOE OSTI2024

Investigation of Microstructures and Tensile Properties of 316L Stainless Steel Fabricated via Laser Powder Bed Fusion

In this study, a thorough investigation of the microstructures and tensile properties of 316L stainless steel fabricated via laser powder bed fusion (L-PBF) was done. 316L stainless steel specimens with two different thicknesses of 1.5 mm and 4.0 mm fabricated under similar conditions were utilized. Microstructural characterization was performed using optical microscopy (OM) and scanning electron microscopy (SEM) equipped with electron backscatter diffraction (EBSD). Melt pools and cellular structures were observed using OM, whereas EBSD was utilized to obtain the grain size, grain boundary characteristics, and crystallographic texture. The 1.5 mm thick sample demonstrated a yield strength (YS) of 538.42 MPa, ultimate tensile strength (UTS) of 606.47 MPa, and elongation to failure of 69.88%, whereas the 4.0 mm thick sample had a YS of 551.21 MPa, UTS of 619.58 MPa, and elongation to failure of 73.66%. These results demonstrated a slight decrease in mechanical properties with decreasing thickness, with a 2.4% reduction in YS, 2.1% reduction in UTS, and 5.8% reduction in elongation to failure. In addition to other microstructural features, the cellular structures were observed to be the major contributors to the high mechanical properties. Using the inverse pole figure (IPF) maps, both thicknesses depicted a crystallographic texture of {001} <101> in their as-built state. However, when subjected to tensile loads, texture transitions to {111} <001> and {111} <011> were observed for the 1.5 mm and 4.0 mm samples, respectively. Additionally, EBSD analysis revealed the pre-existence of high-density dislocation networks and a high fraction of low-angle grain boundaries. Interestingly, twinning was observed, suggesting that the plastic deformation occurred through dislocation gliding and deformation twinning.

316L stainless steel↗
DOE OSTI2021

Mechanical Behavior Assessment of Ti-6Al-4V ELI Alloy Produced by Laser Powder Bed Fusion

The present work correlates the quasi-static, tensile mechanical properties of additively manufactured Ti-6Al-4V extra low interstitial (ELI, Grade 23) alloy to the phase constituents, microstructure, and fracture surface characteristics that changed with post-heat treatment of stress relief (670 °C for 5 h) and hot isostatic pressing (HIP with 100 MPa at 920 °C for 2 h under an Ar atmosphere). Ti-6Al-4V ELI alloy tensile specimens in both the horizontal (i.e., X and Y) and vertical (Z) directions were produced by the laser powder bed fusion (LPBF) technique. Higher yield strength (1141 MPa), higher tensile strength (1190 MPa), but lower elongation at fracture (6.9%), along with mechanical anisotropy were observed for as-stress-relieved (ASR) samples. However, after HIP, consistent and isotropic mechanical behaviors were observed with a slight reduction in yield strength (928 MPa) and tensile strength (1003 MPa), but with a significant improvement in elongation at fracture (16.1%). Phase constituents of acicular α' phase in ASR and lamellar α + β phases in HIP samples were observed and quantified to corroborate the reduction in strength and increase in ductility. The anisotropic variation in elongation at fracture observed for the ASR samples, particularly built in the build (Z) direction, was related to the presence of “keyhole” porosity.

42 ENGINEERING↗
NASA NTRS1972

Solar corona photography, part B

Photographic observations of the solar corona by the Apollo 16 command module pilot while in lunar orbit are reported. These were designed to provide data on outer coronal forms and intensities to elongation angles of 25 deg. The results of Apollo 15 solar corona photography verified the procedures and provided the first photographs of identifiable coronal streamers curving at elongation angles of some 10 deg. By using the Apollo 15 data, exposure settings were optimized for Apollo 16, and the results show a significant improvement in photometric quality over the large range of brightness to be photographed. Ground observations of the inner solar corona (to approximately 2 solar radii from Sun center) indicate a general lack of coronal structure, and results of data reduction thus far show no streamer structure at large elongation angles.

Macqueen, R. M.↗
NASA NTRS1978

Molded composite pyrogen igniter for rocket motors

A lightweight pyrogen igniter assembly including an elongated molded plastic tube adapted to contain a pyrogen charge was designed for insertion into a rocket motor casing for ignition of the rocket motor charge. A molded plastic closure cap provided for the elongated tube includes an ignition charge for igniting the pyrogen charge and an electrically actuated ignition squib for igniting the ignition charge. The ignition charge is contained within a portion of the closure cap, and it is retained therein by a noncorrosive ignition pellet retainer or screen which is adapted to rest on a shoulder of the elongated tube when the closure cap and tube are assembled together. A circumferentially disposed metal ring is provided along the external circumference of the closure cap and is molded or captured within the plastic cap in the molding process to provide, along with O-ring seals, a leakproof rotary joint.

Heier, W. C.↗
NASA NTRS1977

On the photometric axis of the zodiacal light

A model of the zodiacal cloud is used to predict the position of the photometric axis (the locus of points of maximum brightness) of the zodiacal light at any elongation angle from the sun for any time of the year for various symmetry planes: the orbital planes of Venus, Mars, and Jupiter, the invariable plane, and the solar equatorial plane. Using a scattering function which combines isotropic scattering and Fresnel reflection, the geocentric distance of the dust that contributes most of the brightness at each elongation angle is determined by computing the brightness contribution along the line of sight. A comparison of the predicted and observed positions shows that at elongation angles of 15 to 60 deg, the axis of symmetry appears to be close to the orbital plane of Venus. At angles of less than 10 deg, it is difficult to distinguish among the proposed planes of symmetry. Observations of the photometric axis at angles of 60 to 180 deg are scarce and do not permit precise determination of the axis of symmetry in that region.

Misconi, N. Y.↗
NASA NTRS1982

Gravity perception and asymmetric growth in plants - A model derived from the grass pulvinus

It is pointed out that gravitropic responses in plants involve asymmetric growth. On the basis of the geometry of growth response in grass leaf sheath pulvinus, a general model is proposed for gravitropism in multicellular plant organs. The negative gravitropic response of a pulvinus is a result of cell elongation involving all but the uppermost region of a horizontally placed organ. Whereas the uppermost region does not grow, the lowermost region elongates maximally. The regions between elongate to intermediate extents. An expression is given relating the angle of curvature of the organ to the diameter and initial and final lengths of the organ. It is shown that the response of the individual cells can be expressed as inherent sensitivity to gravitational stimulus according to a particular equation.

Dayanandan, P.↗
NASA NTRS1984

Calcium elicited asymmetric auxin transport in gravity influenced root segments

Auxin is a prime candidate for regulating and modulating the differential growth response of primary corn roots to gravity. Auxin, indole-3-acetic acid (IAA), both promotes and inhibits root elongation rapidly within a narrow concentration range. Thus growth regulation would require only small changes in the short lag period for initiation of gravitropism. Since auxin is transported to/through the zone of elongation toward the meristem, it may serve as a direct communication link between the zone of elongation, site of gravitropic response, and the root cap (RC), site of gravity perception. When auxin transport is inhibited, gravitropism is also inhibited. Napthylpthalamic acid (NPA) is one such inhibitor. It inhibits gravitropism only when applied to the apical growing and dividing region of the root. Application at the basal end of the root does not influence gravitropic NPA causes upward curvature when applied to the upper surface of horizontal, two day-old, intact corn roots. This effect is countered by application of IAA to the opposite side.

Edwards, K. L.↗
NASA NTRS1984

An atomistic model of slip formation

The results of an atomistic model for the simulation of the early stages of crack initiation in a two-dimensional triangular lattice are presented. In the current model, each particle in the system is treated discretely and assumed to be interacting with the surrounding particles via Lennard-Jones potentials. A uniaxial load (in incremental elongations) is applied to the rectangular two-dimensional slab in either the x or the y direction. After each incremental elongation the system is equilibrated using a static method. Initially, elastic behavior in the x and y directions is observed. Continued elongation results in plastic deformation. In lattices with point defects, the defects first move to the surface, creating vacancies which trigger plastic deformation.

Halicioglu, T.↗
NASA NTRS1988

Arcs from gravitational lensing

The proposal made by Paczynski (1987) that the arcs of blue light found recently in two cluster cores are gravitationally lensed elongated images of background galaxies is investigated. It is shown that lenses that are circularly symmetric in projection produce pairs of arcs, in conflict with the observations. However, more realistic asymmetric lenses produce single arcs, which can become as elongated as the observed ones whenever the background galaxy is located on or close to a cusp caustic. Detailed computer simulations of lensing by clusters using a reasonable model of the mass distribution are presented. Elongated and curved lensed images longer than 10 arcsec occur in 12 percent of the simulated clusters. It is concluded that the lensing hypothesis must be taken seriously.

Grossman, Scott A.↗
NASA NTRS1989

Comments on comet shapes and aggregation processes

An important question for a comet mission is whether comet nuclei preserve information clarifying aggregation processes of planetary matter. New observational evidence shows that Trojan asteroids, as a group, display a higher fraction of highly-elongated objects than the belt. More recently evidence has accumulated that comet nuclei, as a group, also display highly-elongated shapes at macro-scale. This evidence comes from the several comets whose nuclear lightcurves or shapes have been well studied. Trojans and comet nuclei share other properties. Both groups have extremely low albedos and reddish-to neutral-black colors typical of asteroids of spectral class D, P, and C. Both groups may have had relatively low collision frequencies. An important problem to resolve with spacecraft imaging is whether these elongated shapes are primordial, or due to evolution of the objects. Two hypotheses that might be tested by a combination of global-scale and close-up imaging from various directions are: (1) The irregular shapes are primordial and related to the fact that these bodies have had lower collision frequencies than belt asteroids; or (2) The irregular shapes may be due to volatile loss.

Hartmann, William K.↗
NASA NTRS1990

Comet nuclei and Trojan asteroids - A new link and a possible mechanism for comet splittings

Relatively elongated shapes, implied by recent evidence of a greater incidence of high amplitude lightcurves for comet nuclei and Trojan asteroids than for similarly scaled main belt asteroids, are suggested to have evolved among comet nuclei and Trojans due to volatile loss. It is further suggested that such an evolutionary course may account for observed comet splitting; rotational splitting may specifically occur as a result of evolution in the direction of an elongated shape through sublimation. Supporting these hypotheses, the few m/sec separation velocities projected for rotationally splitting elongated nuclei are precisely in the observed range.

Hartmann, William K.↗
NASA NTRS1991

Mechanical properties of 2D and 3D braided textile composites

The purpose of this research was to determine the mechanical properties of 2D and 3D braided textile composite materials. Specifically, those designed for tension or shear loading were tested under static loading to failure to investigate the effects of braiding. The overall goal of the work was to provide a structural designer with an idea of how textile composites perform under typical loading conditions. From test results for unnotched tension, it was determined that the 2D is stronger, stiffer, and has higher elongation to failure than the 3D. It was also found that the polyetherether ketone (PEEK) resin system was stronger, stiffer, and had higher elongation at failure than the resin transfer molding (RTM) epoxy. Open hole tension tests showed that PEEK resin is more notch sensitive than RTM epoxy. Of greater significance, it was found that the 3D is less notch sensitive than the 2D. Unnotched compression tests indicated, as did the tension tests, that the 2D is stronger, stiffer, and has higher elongation at failure than the RTM epoxy. The most encouraging results were from compression after impact. The 3D braided composite showed a compression after impact failure stress equal to 92 percent of the unimpacted specimen. The 2D braided composite failed at about 67 percent of the unimpacted specimen. Higher damage tolerance is observed in textiles over conventional composite materials. This is observed in the results, especially in the 3D braided materials.

Norman, Timothy L.↗
NASA NTRS1992

Electrorepulsive actuator

The invention is a linear actuator that operates under the principle that like charges repel and opposite charges attract. The linear actuator consists of first and second pairs of spaced opposed conductors where one member of each pair of conductors is attached to a fixed member, and where the other member of each pair of conductors is attached to a movable member such as an elongated rod. The two pairs of spaced conductors may be provided in the form of two spacedly interwound helical vanes where the conductors are located on the opposite sides of the two helical vanes. One helical vane extends inwardly from a housing and the other helical vane extends outwardly from an elongated rod. The elongated rod may be caused to move linearly with respect to the housing by applying appropriate charges of like or opposite polarity to the electrical conductors on the helical vanes.

Collins, Earl R., Jr.↗
NASA NTRS1991

A constitutive relation for the viscous flow of an oriented fiber assembly

A constitutive relation for an equivalent, homogeneous fluid is developed for the anisotropic viscous flow of an oriented assembly of discontinuous fibers suspended in a viscous fluid. The anisotropic viscous compliance matrix can be expressed in terms of three constants by assuming the equivalent fluid to be incompressible and the microstructure to have axial symmetry (transversely isotropic). By means of a micromechanics analysis, the three terms of the constitutive relation are expressed in terms of the viscosity of the matrix fluid, the fiber aspect ratio, and the fiber volume fraction. A comparison of the viscosity terms reveals that the elongational viscosity in the fiber direction varies as the square of the fiber aspect ratio and a complex function of the fiber volume fraction. Furthermore, the ratio of the axial elongational viscosity to the transverse elongational viscosity and both axial and transverse shear viscosities was shown to be 10 exp 4 - 10 exp 6 for fiber aspect ratio of 100-1000, except at extreme values of the fiber volume fraction.

Pipes, R. B.↗
NASA NTRS1993

Statistics of highly magnified gravitational images in clusters of galaxies. I - Implications for the clusters. II - Implications for the sources

A study is presently conducted of the probability distribution of observing images of background galaxies that are gravitationally lensed in the form of elongated arcs by clusters of galaxies, as a function of arc width, curvature radius, and the elongation's orientation. An upper limit is obtained on the size of the cores which is smaller than cluster core radii obtained for the gas from the X-ray surface brightness. It is argued that lensing clusters tend to be elongated along the line of sight; projection effects will enhance surface density. In the second part of this work, it is shown that the number of arcs expected in lensing clusters is primarily dependent on the angular size of the sources, since lower magnification is required to generate an arc of fixed length for a larger source.

Miralda-Escude, Jordi↗