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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Adhesive Bonding of Copper Prepared by Laser-Interference near the Interference Structuring Limits

Adhesive bonding requires adequate surface preparation for ensuring an appropriate joint quality. The interest in adhesive joining has recently expanded to thermal systems having a large number of joints employed for manufacturing and assembly. This study presents surface topology of copper 110 produced by a laser-interference setup that would theoretically yield a periodicity of 1.7 μm, which is near the 1.6–2 μm structuring limit that was estimated based on thermal diffusion length scale for an 8 ns laser pulse. The results show that although the expected periodic interference structuring was not attained, the melt-induced texturing was affected by the laser-interference profile. Single-lap shear tests were performed with specimen surfaces prepared by traditional abrasion and laser-interference structuring methods. Several laser processing parameters, such as the laser spot size, density, number of pulses, and raster speed, were studied. Scanning electron microscope and profilometry measurements were used to characterize the processed surface microstructures. Web-like structures, which indicate widespread melting, were shown to be formed at different processing conditions. Based on the surface topologies investigated, two laser raster speeds were selected to make single-lap-joint specimens. Baseline joints were prepared by abrading joining specimens. The shear-lap strength and displacement at maximum load were shown to be higher by 16.8% and 43.8% for the laser-structured specimens than those of the baseline specimens, respectively. Moreover, the load-displacement curves indicated that the laser-structured joints were more ductile than those without laser-structuring. The increased ductility for the laser-structured joints was found to yield an increase in the energy absorbed during shear-lap testing of approximately of 80–90% over those measured for baseline joints. It is another indicator that laser-interference structuring enhanced the bonding performance of single-lap shear joints.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Concurrent reaction-bonded joining and densification of additively manufactured silicon carbide by liquid silicon infiltration

Here, in this study, additive-manufactured silicon carbide preforms were joined and densified by reaction bonding via liquid silicon infiltration. The silicon carbide preforms were first printed by binder jetting additive manufacturing. To demonstrate concurrent joining and densification, two preforms with carbon or parchment papers at the interface were concurrently joined and infiltrated by liquid silicon. Results showed a robust interface with thicknesses ranging from 150 to 500 µm, depending on the paper type and the number of paper layers. High-energy synchrotron X-ray revealed that β-phase silicon carbide was formed inside the interface. Finally, two additively manufactured samples with complicated channel geometry were successfully joined. Energy dispersive spectroscopy of the interface of the channeled samples showed a consistent and robust joining. This concurrent approach of joining and densification enables efficiency improvement of fabricating silicon carbide parts with complicated geometries and widens geometry freedom for additive manufacturing of silicon carbide.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Three-dimensional microstructure of a friction stir welded magnesium/steel interface characterized via high-energy synchrotron X-rays

Here, the three-dimensional (3D) microstructure of a friction stir assisted scribe technique (FaST) weld interface consisting of AZ31 magnesium (Mg) alloy and zinc (Zn)-coated DP590 steel was analyzed via synchrotron micro-computed tomography (μ-CT), correlated to synchrotron x-ray diffraction, and electron microscopy. Diffraction assessment of the AZ31/Zn-coated DP590 steel interface revealed the presence of several complex Mg–Zn intermetallic phases and differences in crystalline orientation of the Mg phase at the weld interface. The 3D characterization of the synchrotron μ-CT images of the weld interface revealed: (1) the presence of AZ31 weld nugget material with iron (Fe)-rich particles; (2) the presence of a weld layer at the joining interface with Fe-rich particles; (3) the formation of a thin non-uniform layer between the weld layer and the interface of the scribed DP590 material; and (4) the presence of an Fe–Al-rich intermetallic layer and Fe-rich particles at the interface of the scribed DP590 material. This study also performed a detailed analysis of lump-like features seen in the Zn coating layer at the weld interface. A detailed 3D particle analysis of the Fe-rich particles in the AZ31 weld nugget and the weld layer at the weld interface revealed the presence of several types of particle morphologies (i.e., spherical and irregular).

36 MATERIALS SCIENCE↗
DOE OSTI2026

Computational Design of Interlayers for Thermally Stable Compositionally Graded Coatings on Nickel Alloys

To extend the service life of Ni-based superalloys, refractory metal coatings are often used. However, direct bonding between metals with dissimilar crystal structure promotes brittle intermetallic phase formation. This work presents a computational thermodynamic framework for high throughput design of functionally graded interlayers to suppress deleterious phases that may form at the interlayer. The Thermo-Calc software package was used to screen candidate metallic interlayer elements based on stability of solid-solution phases. Vanadium was identified as a promising interlayer due to its consistent suppression of intermetallic phases. Temperature-dependent phase diagram mapping between 600 and 1000 °C guided selection of a compositional pathway that significantly reduced intermetallic formation compared to directly joining the Ni-based and Nb refractory alloys. Time–temperature–transformation analysis was performed to assess whether equilibrium-predicted phases are kinetically accessible along regions of the graded path where non-solid-solution phases are not fully suppressed. The methodology was further applied to additional Ni-based alloy and coating systems, illustrating its transferability as an approach for rapid computational design of graded interlayers in dissimilar high-temperature materials.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Multiple‐Repeated Plasma Surface Treatments for Significantly Improving Bonding Performance of Metal‐Carbon‐Fiber‐Reinforced Thermoplastic Polymer Dissimilar Adhesive Joints

This work investigates how multiple‐repeated plasma surface treatments can significantly enhance adhesively bonded metal‐carbon‐fiber‐reinforced thermoplastic polymer (CFRTP) dissimilar joints, a topic that has been rarely investigated compared to other parameters during the plasma treatment process. By conducting double cantilever beam tests on adhesively bonded AA6061‐carbon‐fiber‐reinforced polyphthalamide (CFRPPA) dissimilar joints, it is shown that the average Mode I specific fracture energy after 20 repetitions of the same plasma treatment, using processing parameters without noticeably changing surface roughness, can be improved and saturated up to almost 2000% compared to non‐treated joints and almost 240% compared to a single plasma treatment commonly used in the literature. The improvement can be attributed to the enhanced chemical bonding at the CFRPPA‐adhesive interface. This study is important for achieving strong bonding performance of CFRTP‐related structural joints using multiple plasma treatments, a simple and effective method.

36 MATERIALS SCIENCE↗
DOE OSTI2021

APS: High-Energy X-rays Expediting Applied and Fundamental Research

The Advanced Photon Source (APS) at Argonne National Laboratory (ANL) was designed and built as one of the first large 3rd generation synchrotrons operated at 7 GeV. The United States Department of Energy (DOE) Office of Science funded the construction and continues to fund the operation of this national facility. Furthermore, the beamlines were originally operated by Collaborative Access Teams (CAT), which allowed a strong involvement of research institutes, universities, and industry. Today 43 of 68 beamlines are operated by the X-ray Science Division (XSD) and 35 beamlines are directly funded by the DOE Office of Science. The APS became operational in 1995, and was planned right from the beginning with 4 beamlines dedicated to high-energy x-rays above 40 keV: 1-ID designed to study engineering materials science, 6-ID-D for magnetism and condensed matter research, 11-ID-B dedicated to magnetic Compton scattering using an Elliptical Multipole Wiggler, and 11-ID-C for materials science and condensed matter physics. These stations were later joined by the bending magnet beamlines 6-BM for white beam studies and 17-BM for rapid powder diffraction. CAT operated beamlines such as 15-ID for crystallography or 16-ID for high-pressure studies also use the high-energy x-ray regime frequently. The program in Compton scattering ended in 2004 and the wiggler was replaced by an undulator. 11-ID-B became the first dedicated station for Pair Distribution Function (PDF) Analysis.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
NASA NTRS1973

Materials data handbook on titanium 6Al-4V

Handbook has been prepared which describes latest property information on titanium 6Al-4V. Scope of information presented includes physical- and mechanical-property data at cryogenic, ambient, and elevated temperatures, supplemented with useful information in such areas as material procurement,metallurgy of alloy, corrosion, environmental effects, fabrication, and joining technology.

Muraca, R. F.↗
NASA NTRS1973

Materials data handbook on Inconel Alloy 718

Handbook is divided into twelve chapters. Scope of information presented includes physical- and mechanical-property data at cryogenic, ambient, and elevated temperatures. This is supplemented with useful information in such areas as material procurement, metallurgy of alloy, corrosion, environmental effect, fabrication, and joining techniques. Design data are presented, as available.

Muraca, R. F.↗
NASA NTRS1987

Space research - At a crossroads

Efforts which must be expended if U.S. space research is to regain vitality in the next few years are discussed. Small-scale programs are the cornerstone for big science projects, giving both researchers and students a chance to practice the development of space missions and hardware and identify promising goals for larger projects. Small projects can be carried aloft by balloons, sounding rockets, the Shuttle and ELVs. It is recommended that NASA continue the development of remote sensing systems, and join with other government agencies to fund space-based materials science, space biology and medical research. Increased international cooperation in space projects is necessary for affording moderate to large scale missions, for political reasons, and to maximize available space resources. Finally, the establishment and funding of long-range goals in space, particularly the development of the infrastructure and technologies for the exploration and colonization of the planets, must be viewed as the normal outgrowth of the capabilities being developed for LEO operations.

Mcdonald, Frank B.↗
NASA NTRS1936

Experimental Studies of the Effective Width of Buckled Sheets

The object of the present experiments is a more exact determination of the effective width for the case of pure compression and of the sheet clamped at the angle section. From the experimental data of the effective width the calculation of the buckling load of an angle joined to a thin sheet is then deduced. The test material consisted of spring-hardened brass sheet.

Lahde, R↗
NASA NTRS1994

Collection and curation of interplanetary dust particles recovered from the stratosphere

Since May 1981, the National Aeronautics and Space Administration (NASA) has used aircraft to collect interplanetary dust particles (IDP's) from Earth's stratosphere. Specially designed dust collectors are prepared for flight and processed after flight in an ultraclean (Class-100) laboratory constructed for this purpose at the Lyndon B. Johnson Space Center (JSC) in Houston, Texas. Particles are individually retrieved from the collectors, examined, and cataloged, and then made available to the scientific community for research. Interplanetary dust thereby joins lunar samples and Antarctic meteorites as a critical extraterrestrial material being curated at JSC.

Zolensky, Michael E.↗
NASA NTRS2019

Electrochemical, Polarization, and Crevice Corrosion Testing of Inconel X750: A Supplement to the Environmental Control and Life Support System Sustaining Metal Materials Compatibility Study

In previous studies, electrochemical test results were experimentally acquired and then presented for several noble alloys in two specific solutions representative of waste liquids generated or present within the Environmental Control and Life Support System (ECLSS) aboard the International Space Station (ISS). Subsequently, another metal candidate, Inconel X750, has been submitted and was subjected to the same test routines in the same solutions and evaluated with the same statistical/analytical methodologies as those utilized in the earlier studies. Previous studies included three titanium grades, (Commercially Pure, 6Al-4V alloy, and 6Al-4V Low Interstitial alloy), two nickel-chromium alloys (Inconel® 625 and Hastelloy® C276), one high tier stainless steel (Cronidur® 30), and a nickel-titanium alloy (Nitinol 60). Thus far, all candidate alloys have exhibited excellent corrosion protection and galvanic compatibility attributes and have been deemed qualified materials for application within the ECLSS facility. Inconel X750 now joins that group. The titanium alloys gave the best results of all the metal candidates by demonstrating superior nobility and galvanic protection properties. It is worth noting that the corrosion performance properties for the three titanium alloys were essentially indistinguishable. As such and for expediency, this study and all future evaluations will refer only to the comparative properties already documented for Titanium 6Al-4V as this alloy is representative of all three alloys and considered to be more mainstream. Now the measured corrosion properties for Inconel X750 were very similar to those determined previously for Inconel 625 and Hastelloy C276 which were also determined to be very high performers. For the current effort, the results have clearly shown that Inconel X750 possesses exceptional anti-corrosion attributes comparable to metals in the highest tier of the galvanic series. Overall, one can conclude that Inconel X750 is quite noble, highly corrosion resistant and galvanically compatible with the other metal groups from both an electrochemical perspective and a long-term exposure scenario. This was clearly demonstrated after utilizing the same techniques as those applied in previous studies which included linear, Tafel and cyclic polarization, galvanic coupling with each of the other metal candidates, and pitting/crevicing assessments after one full year of immersion in the subject test solutions. Attributes defining the nobility and anti-corrosion capabilities for X750 appear to be on par with all the other candidates thus far and this alloy can now be classified as ‘excellent’ exhibiting very high resistance toward general, localized, and galvanic corrosion in the subject test media.

Lee, R. E.↗
NASA NTRS2001

Challenges and Opportunities in Design, Fabrication, and Testing of High Temperature Joints in Ceramics and Ceramic Composites

Ceramic joining has been recognized as an enabling technology for successful utilization of advanced ceramics and composite materials. A number of joint design and testing issues have been discussed for ceramic joints in silicon carbide-based ceramics and fiber-reinforced composites. These joints have been fabricated using an affordable, robust ceramic joining technology (ARCJoinT). The microstructure and good high temperature mechanical capability (compressive and flexural strengths) of ceramic joints in silicon carbide-based ceramics and composite materials are reported.

Singh, M.↗
DOE OSTI2025

Formation of Composite SiC/SiC Joints by Embedded Wire Chemical Vapor Deposition

The joining of ceramic monoliths or composites to date has primarily been limited to the formation of brittle monolithic joints using heterogeneous (dissimilar) materials, similar to brazing in metals. The development of a damage-tolerant joint layer by SiC fiber reinforcements is demonstrated here. Tube workpieces made of SiC fiber-SiC matrix composite are joined using a nonwoven SiC fiber mat densified by embedded wire chemical vapor deposition (EWCVD), creating a fiber-reinforced weld-like joint by homogeneous joining. EWCVD uses a localized heating method to target deposition and growth to the joint region specifically, while minimizing thermal damage to the surrounding composite tube material. X-ray computed tomography (XCT) is used to nondestructively characterize as-made joints for relative density, adhesion, and composition. In situ XCT analysis during mechanical testing revealed crack deflections in the bonding layer, which indicates a toughening mechanism typical of ceramic matrix composite phase. Gas permeation testing of these proof-of-concept composite joints identified relatively high leak rates in comparison to fully coated SiC/SiC composite tube workpieces. In conclusion, the novelty of the composite joining method and current technology challenges, including gas permeability, are discussed in comparison with traditional ceramic joints and materials.

SiC↗
DOE OSTI2021

Simulated Adhesive Response to Aging (CRADA 453 Final Report)

The goal of this project was to develop a suite of molecular models to investigate adhesive performance as a result of the presence of different levels of moisture. These different levels of moisture are accepted in the adhesives community to represent different states of aging. First, our team modeled the adhesive’s crosslinked structure. Next, we modeled adding water to the crosslinked structure and used high performance computing resources to simulate water diffusion through the bulk adhesive and possible sites for chain scission. Finally, we modeled the response of the simulated adhesive to tensile loads at various levels of moisture content. These simulations were validated by experimental characterization by the industry partner. We found that the Young’s modulus of the adhesive decreased by about 30% when the water content increased to 3 wt.%. Our simulations also identified the likely site where the polymer chain could break. Our integration of molecular level simulations and mechanical property predictions using high performance computing with experimental studies of a hydrated epoxy system has yielded fundamental insights that will help industry advance lightweight joining technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Brazing methods using porous interlayers and related articles

The disclosure relates to a brazing method for joining substrates, in particular where one of the substrates is difficult to wet with molten braze material. The method includes formation of a porous metal layer on a first substrate to assist wetting of the first substrate with a molten braze metal, which in turn permits joining of the first substrate with a second substrate via a braze metal later in an assembled brazed joint. Ceramic substrates can be particularly difficult to wet with molten braze metals, and the disclosed method can be used to join a ceramic substrate to another substrate. The brazed joint can be incorporated into a solid-oxide fuel cell, for example as a stack component thereof, in particular when the first substrate is a ceramic substrate and the joined substrate is a metallic substrate.

Nicholas, Jason Dale↗
DOE OSTI2023

Brazing methods using porous interlayers and related articles

The disclosure relates to a brazing method for joining substrates, in particular where one of the substrates is difficult to wet with molten braze material. The method includes formation of a porous metal layer on a first substrate to assist wetting of the first substrate with a molten braze metal, which in turn permits joining of the first substrate with a second substrate via a braze metal later in an assembled brazed joint. Ceramic substrates can be particularly difficult to wet with molten braze metals, and the disclosed method can be used to join a ceramic substrate to another substrate. The brazed joint can be incorporated into a solid-oxide fuel cell, for example as a stack component thereof, in particular when the first substrate is a ceramic substrate and the joined substrate is a metallic substrate.

Nicholas, Jason Dale↗