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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Fabrication of nanoporous doped metal oxide coatings via selective infiltration of a block copolymer template: The case of Al-doped zinc oxide

Conductive nanoporous conformal coatings are important for various applications including touchscreens, displays, and electrochromic windows, though design of such coating with controlled porosity and composition remains challenging. We propose a sequential infiltration synthesis (SIS) method for the fabrication of nanoporous conductive aluminum-doped zinc oxide (AZO) films by infiltrating block copolymer (BCP) templates, specifically polystyrene-block-polyvinyl pyridine (PS-b-P4VP), with diethyl zinc and trimethyl aluminum precursors. Tunability of both porosity and electrical conductivity is achieved by precisely controlling the swelling behavior of the polymer templates and adjusting the number of SIS cycles. Further, our results reveal that porosity levels can reach up to 80 %, with resistivity as low as ~7.83 Ωcm. Using conductive atomic force microscopy (C-AFM) and Hall effect measurements, we show that lower concentrations of aluminum doping relative to zinc (around 1: 17) results in higher conductivity of the AZO films. Additionally, AZO is based on zinc oxide (ZnO) which is cost-efficient, abundant and less toxic than commonly used transparent conductive oxides such as indium tin oxide (ITO) and fluorine-doped tin oxide (FTO). Therefore, this novel approach opens new possibilities for creating highly porous, conformal, conductive AZO coatings with customizable porosity and composition, making them ideal candidates for diverse optoelectronic applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Macroscopic modeling of gas permeability in hierarchical micro/nanoporous media: A unified characterization of rarefaction using Klinkenberg theory and equivalent diameter

Estimating gas transport through a hierarchical micro/nanoporous system is challenging due to non-equilibrium gas dynamics. The primary difficulty lies in determining the rarefaction level, because identifying a representative flow dimension in a complex porous system with multiple pore scales is not straightforward. Our study performed a pore-level analysis for gas permeability in dual-scale porous media with varying porosity, throat size, and secondary pore size under different rarefaction conditions. We found that secondary porosity negatively affects permeability due to increased friction forces, with this influence growing as the secondary pore size and porosity increase until the secondary pore becomes comparable to the throat. However, rarefaction reduces the effects of secondary pores due to boundary slip. Traditional Knudsen number (Kn) calculations based on Darcy-defined height failed to accurately describe the rarefaction effects on gas permeability. Instead, we introduced an equivalent diameter to calculate the Kn, which provided an accurate normalization of apparent gas permeability independent of pore geometry. Furthermore, the extended Kozeny–Carman–Klinkenberg model developed in our previous study successfully yielded a macroscopic model for apparent gas permeability in hierarchical micro/nanoporous systems as a function of the traditional Darcy height and porosity.

04 OIL SHALES AND TAR SANDS↗
DOE OSTI2024

Manufacturing Cathodes via Dry-Processing for Lithium-Ion Batteries

Conventional lithium-ion battery (LIB) electrodes are prepared through a wet slurry process with n-methyl pyrrolidone solvent, especially for cathodes. The wet slurry process encounters several disadvantages such as binder migration, electrode cracking in thick electrodes, energy intense heat-dry NMP solvent removal, and costly NMP recovery. The cost and energy consumption of coating and drying of electrode are about 11.5 % and > 46 % in LIB manufacturing, respectively. Thereby, it is essential to develop a facile roll-to-roll solvent-free LIB electrode processing for reducing the cost and energy consumption. Recently, the Maxwell-type dry processing (DP) shines new lights on LIB manufacturing, which mainly bases on dry mixing (DM) of electrode component powder followed by calendering into electrode films and laminating onto current collectors, realizing the rapid manufacturing of LIB electrodes in a powder-to-film manner for industries. This report shares some recent progress on the DP from our group. We aim to further advance the manufacturing science of DP by correlating the processing conditions with electrode properties and performance. Particularly, we investigate the effect of DM, and compression on the polytetrafluoroethylene (PTFE) binder fiberization, porosity, mechanical properties, electrical conductivity and electrochemical behaviors of electrodes. The DM study suggests that PTFE fiberization heavily relies on the degree of DM. Insufficient DM results in poor PTFE fiberization while outrageous DM damages the formed PTFE fibers. Both negatively affect the mechanical behaviors of the electrodes and their rate capability. However, moderate DM is highly beneficial. In addition, our study of the porosity impact reveals that LiNi0.8Mn0.1Co0.1O2 (NMC) secondary particles can be broken into primary particles due to compression, especially at low porosity. Those fractured NMC secondary particles exhibit lower modulus. We propose that a moderate porosity of around 32% favors the electronic conductivity, charge transfer impedance and rate capability. The study of the cathodic electrolyte interphase layer of PTFE-based DPed electrode confirms that side reactions of PTFE binder due to the formation of LiF in LiClO4-based electrolyte.

Tao, Runming↗
NASA NTRS1971

Thermal conductivity and electrical resistivity of porous material

Thermal conductivity and electrical resistivity of porous materials, including 304L stainless steel Rigimesh, 304L stainless steel sintered spherical powders, and OFHC sintered spherical powders at different porosities and temperatures are reported and correlated. It was found that the thermal conductivity and electrical resistivity can be related to the solid material properties and the porosity of the porous matrix regardless of the matrix structure. It was also found that the Wiedermann-Franz-Lorenz relationship is valid for the porous materials under consideration. For high conductivity materials, the Lorenz constant and the lattice component of conductivity depend on the material and are independent of the porosity. For low conductivity, the lattice component depends on the porosity as well.

Koh, J. C. Y.↗
NASA NTRS1986

Petrographic survey of lunar regolith breccias

Regolith breccias from the Moon and from parent bodies of some meteorites may provide samples of ancient regoliths which have been frozen in time. If these rocks were essentially closed at some earlier time and that time can be determined, then these rocks provide a record of conditions in the solar system at that point in time. A survey of regolith breccias in the Apollo collection was conducted concentrating initially on Apollo 15 and 16. All available thin sections for 32 regolith breccias from Apollo 15 and 19 breccias from Apollo 16 were surveyed. These are most of the returned regolith breccias larger than 1 cm from these two mission. For comparison several fragmental matrix breccias which do not strictly qualify as regolith breccias were investigated. The criteria for classification as a regolith breccia is the presence of identifiable soil components such as glass spheres or agglutinates. The breccias are classified according to their intergranular porosity. In addition the fracture porosity is noted, and the relative abundance of agglutinates and spheres. Several petrographic trends are also noted. Identifiable regolith material decreases with decreasing intergranular porosity while fracture porosity increases. This relative lack of maturity of regolith breccias mayreflect their generally earlier formation age an the maturity of the regolith at that earlier time.

Mckay, D. S.↗
NASA NTRS1994

Microstructural analysis of cracks generated during welding of 2195 aluminum-lithium alloy

This research summarizes a series of studies conducted at Marshall Space Flight Center to characterize the properties of 2195 Al-Li alloy. 2195 Al-Li alloy, developed by Martin Marietta laboratories, is designated as a replacement of 2219 Al-Cu alloy for the External Tank (E.T.) of the space shuttle. 2195 Al-Li alloy with its advantage of increased strength per weight over its predecessor, 2219 Al-Cu alloy, also challenges current technology. 2195 Al-Li has a greater tendency to crack than its predecessor. The present study began with the observation of pore formation in 2195 Al-Li alloy in a thermal aging process. In preliminary studies, Talia and Nunes found that most of the two pass welds studied exhibited round and crack-like porosity at the weld roots. Furthermore, the porosity observed was associated with the grain boundaries. The porosity level can be increased by thermal treatment in the air. A solid state reaction proceeding from dendritic boundaries in the weld fusion zone was observed to correlate with the generation of the porosity.

Talia, George E.↗
NASA NTRS1995

Surface Textural Properties of Icy Satellites: A Comparison between Europa and Rhea

Solar phase curves for Rhea are presented using new telescopic opposition data along with Voyager imaging observations. Two viable solutions were found to Hapke's model which was used to describe this phase curve. The porosity derived from the model's opposition parameters show that the optically active portion of Rhea's regolith has a porosity between 80 and 95 percent, which is slightly lower than the porosity seen on Europa and higher than the porosity measured for the Moon using similar methods. The macroscopic roughness is comparable to that measured by Vebiscer and Veverka for Rhea. The single particle scattering functions found in this study are predominantly forward scattering, which contradicts the results of Vebiscer and Veverka.

Domingue, D. L.↗
NASA NTRS2000

Long Life Nickel Electrodes for Nickel-Hydrogen Cells: Fiber Substrates Nickel Electrodes

Samples of nickel fiber mat electrodes were investigated over a wide range of fiber diameters, electrode thickness, porosity and active material loading levels. Thickness' were 0.040, 0.060 and 0.080 inches for the plaque: fiber diameters were primarily 2, 4, and 8 micron and porosity was 85, 90, and 95%. Capacities of 3.5 in. diameter electrodes were determined in the flooded condition with both 26 and 31% potassium hydroxide solution. These capacity tests indicated that the highest capacities per unit weight were obtained at the 90% porosity level with a 4 micron diameter fiber plaque. It appeared that the thinner electrodes had somewhat better performance, consistent with sintered electrode history. Limited testing with two-positive-electrode boiler plate cells was also carried out. Considerable difficulty with constructing the cells was encountered with short circuits the major problem. Nevertheless, four cells were tested. The cell with 95% porosity electrodes failed during conditioning cycling due to high voltage during charge. Discharge showed that this cell had lost nearly all of its capacity. The other three cells after 20 conditioning cycles showed capacities consistent with the flooded capacities of the electrodes. Positive electrodes made from fiber substrates may well show a weight advantage of standard sintered electrodes, but need considerably more work to prove this statement. A major problem to be investigated is the lower strength of the substrate compared to standard sintered electrodes. Problems with welding of leads were significant and implications that the electrodes would expand more than sintered electrodes need to be investigated. Loading levels were lower than had been expected based on sintered electrode experiences and the lower loading led to lower capacity values. However, lower loading causes less expansion and contraction during cycling so that stress on the substrate is reduced.

Rogers, Howard H.↗
NASA NTRS2001

Toward Understanding Pore Formation and Mobility During Controlled Directional Solidification in a Microgravity Environment Investigation (PFMI)

Porosity in the form of "bubbles and pipes" can occur during controlled directional solidification processing of metal alloys. It is detrimental to material properties and precludes obtaining meaningful scientific results. On Earth, density differences allow an initiated bubble can rise through the liquid and "pop" at the surface resulting in a sound casting. This is not likely to occur in a microgravity environment and, unfortunately, a number of experiments conducted in microgravity have suffered from porosity effects. The current investigation is a systematic effort towards understanding porosity formation and mobility during controlled directional solidification in a microgravity environment. This will be investigated by utilizing a transparent material, succinonitrile (SCN), in conjunction with a translating temperature gradient stage so that direct observation and recording of pore generation and mobility can be made. The talk will cover the porosity problem, the details of the proposed experiments and the experimental hardware, and the expectations from the microgravity experiments.

Grugel, R. N.↗
NASA NTRS2001

A Boundary Condition for Simulation of Flow Over Porous Surfaces

A new boundary condition is presented.for simulating the flow over passively porous surfaces. The model builds on the prior work of R.H. Bush to eliminate the need for constructing grid within an underlying plenum, thereby simplifying the numerical modeling of passively porous flow control systems and reducing computation cost. Code experts.for two structured-grid.flow solvers, TLNS3D and CFL3D. and one unstructured solver, USM3Dns, collaborated with an experimental porosity expert to develop the model and implement it into their respective codes. Results presented,for the three codes on a slender forebody with circumferential porosity and a wing with leading-edge porosity demonstrate a good agreement with experimental data and a remarkable ability to predict the aggregate aerodynamic effects of surface porosity with a simple boundary condition.

Frink, Neal T.↗
NASA NTRS2002

Pore Formation and Mobility (PFMI): An International Space Station Glovebox Investigation

Porosity in the form of "bubbles and pipes" can occur during controlled directional solidification processing of metal alloys. It is detrimental to material properties and precludes obtaining meaningful scientific results. On Earth, density differences allow an initiated bubble can rise through the liquid and "pop" at the surface resulting in a sound casting. This is not likely to occur in a microgravity environment and, unfortunately, a number of experiments conducted in microgravity have suffered from porosity effects. The current investigation is a systematic effort towards understanding porosity formation and mobility during controlled directional solidification in a microgravity environment. This will be investigated by utilizing a transparent material, succinonitrile (SCN), in conjunction with a translating temperature gradient stage so that direct observation and recording of pore generation and mobility can be made. The talk will cover the porosity problem, the details of the proposed experiments and the experimental hardware, and the expectations from the microgravity experiments.

Grugel, R. N.↗
NASA NTRS2006

Experimental Investigation of Solder Joint Defect Formation and Mitigation in Reduced-Gravity Environments

This paper documents a research effort on reduced gravity soldering of plated through hole joints which was conducted jointly by the National Center for Space Exploration Research, NASA Glenn Research Center, and NASA Johnson Space Center. Significant increases in joint porosity and changes in external geometry were observed in joints produced in reduced gravity as compared to normal gravity. Multiple techniques for mitigating the observed increase in porosity were tried, including several combinations of flux and solder application techniques, and demoisturizing the circuit board prior to soldering. Results were consistent with the hypothesis that the source of the porosity is a combination of both trapped moisture in the circuit board itself, as well as vaporized flux that is trapped in the molten solder. Other topics investigated include correlation of visual inspection results with joint porosity, pore size measurements, limited pressure effects (0.08 MPa - 0.1 MPa) on the size and number of pores, and joint cooling rate.

Watson, J. Kevin↗
NASA NTRS2008

Friction Stir Weld Restart+Reweld Repair Allowables

A friction stir weld (FSW) repair method has been developed and successfully implemented on Al 2195 plate material for the Space Shuttle External Fuel Tank (ET). The method includes restarting the friction stir weld in the termination hole of the original weld followed by two reweld passes. Room temperature and cryogenic temperature mechanical properties exceeded minimum FSW design strength and compared well with the development data. Simulated service test results also compared closely to historical data for initial FSW, confirming no change to the critical flaw size or inspection requirements for the repaired weld. Testing of VPPA fusion/FSW intersection weld specimens exhibited acceptable strength and exceeded the minimum design value. Porosity, when present at the intersection was on the root side toe of the fusion weld, the "worst case" being 0.7 inch long. While such porosity may be removed by sanding, this "worst case" porosity condition was tested "as is" and demonstrated that porosity did not negatively affect the strength of the intersection weld. Large, 15-inch "wide panels" FSW repair welds were tested to demonstrate strength and evaluate residual stresses using photo stress analysis. All results exceeded design minimums, and photo stress analysis showed no significant stress gradients due to the presence of the restart and multi-pass FSW repair weld.

Clifton, Andrew↗
NASA NTRS2002

Experimental Study of Characteristics of Micro-Hole Porous Skins for Turbulent Skin Friction Reduction

Characteristics of micro-hole porous skins for the turbulent skin friction reduction technology called the micro-blowing technique (MBT) were assessed experimentally at Mach 0.4 and blowing fractions from zero to 0.005. The objective of this study was to provide guidelines for the selection of porous plates for MBT. The hole angle, pattern, diameter, aspect ratio, and porosity were the parameters considered for this study. The additional effort to angle and stagger the holes was experimentally determined to be unwarranted in terms of skin friction benefit; therefore, these parameters were systematically eliminated from the parametric study. The impact of the remaining three parameters was evaluated by fixing two parameters at the reference values while varying the third parameter. The best hole-diameter Reynolds number was found to be around 400, with an optimum aspect ratio of about 6. The optimum porosity was not conclusively discerned because the range of porosities in the test plates considered was not great enough. However, the porosity was estimated to be about 15 percent or less.

Hwang, Danny P.↗
NASA NTRS2015

Detection of CFRP Composite Manufacturing Defects Using a Guided Wave Approach

NASA Langley Research Center is investigating a guided-wave based defect detection technique for as-fabricated carbon fiber reinforced polymer (CFRP) composites. This technique will be extended to perform in-process cure monitoring, defect detection and size determination, and ultimately a closed-loop process control to maximize composite part quality and consistency. The overall objective of this work is to determine the capability and limitations of the proposed defect detection technique, as well as the number and types of sensors needed to identify the size, type, and location of the predominant types of manufacturing defects associated with laminate layup and cure. This includes, porosity, gaps, overlaps, through-the-thickness fiber waviness, and in-plane fiber waviness. The present study focuses on detection of the porosity formed from variations in the matrix curing process, and on local overlaps intentionally introduced during layup of the prepreg. By terminating the cycle prematurely, three 24-ply unidirectional composite panels were manufactured such that each subsequent panel had a higher final degree of cure, and lower level of porosity. It was demonstrated that the group velocity, normal to the fiber direction, of a guided wave mode increased by 5.52 percent from the first panel to the second panel and 1.26 percent from the second panel to the third panel. Therefore, group velocity was utilized as a metric for degree of cure and porosity measurements. A fully non-contact guided wave hybrid system composed of an air-coupled transducer and a laser Doppler vibrometer (LDV) was used for the detection and size determination of an overlap By transforming the plate response from the time-space domain to the frequency-wavenumber domain, the total wavefield was then separated into the incident and backscatter waves. The overlap region was accurately imaged by using a zero-lag cross-correlation (ZLCC) imaging condition, implying the incident and backscattered waves are in phase over the overlap boundaries.

Hudson, Tyler B.↗
NASA NTRS2016

Permeability of Two Parachute Fabrics - Measurements, Modeling, and Application

Two parachute fabrics, described by Parachute Industry Specifications PIA-C-7020D Type I and PIA-C-44378D Type I, were tested to obtain their permeabilities in air (i.e., flow-through volume of air per area per time) over the range of differential pressures from 0.146 psf (7 Pa) to 25 psf (1197 Pa). Both fabrics met their specification permeabilities at the standard differential pressure of 0.5 inch of water (2.60 psf, 124 Pa). The permeability results were transformed into an effective porosity for use in calculations related to parachutes. Models were created that related the effective porosity to the unit Reynolds number for each of the fabrics. As an application example, these models were used to calculate the total porosities for two geometrically-equivalent subscale Disk-Gap-Band (DGB) parachutes fabricated from each of the two fabrics, and tested at the same operating conditions in a wind tunnel. Using the calculated total porosities and the results of the wind tunnel tests, the drag coefficient of a geometrically-equivalent full-scale DGB operating on Mars was estimated.

Cruz, Juan R.↗
NASA NTRS2017

Permeability of Two Parachute Fabrics: Measurements, Modeling, and Application

Two parachute fabrics, described by Parachute Industry Specifications PIA-C-7020D Type I and PIA-C-44378D Type I, were tested to obtain their permeabilities in air (i.e., flow-through volume of air per area per time) over the range of differential pressures from 0.146 psf (7 Pa) to 25 psf (1197 Pa). Both fabrics met their specification permeabilities at the standard differential pressure of 0.5 inch of water (2.60 psf, 124 Pa). The permeability results were transformed into an effective porosity for use in calculations related to parachutes. Models were created that related the effective porosity to the unit Reynolds number for each of the fabrics. As an application example, these models were used to calculate the total porosities for two geometrically-equivalent subscale Disk-Gap-Band (DGB) parachutes fabricated from each of the two fabrics, and tested at the same operating conditions in a wind tunnel. Using the calculated total porosities and the results of the wind tunnel tests, the drag coefficient of a geometrically-equivalent full-scale DGB operating on Mars was estimated.

Cruz, Juan R.↗
NASA NTRS2023

Phyllosilicate Decomposition on Bennu Due to Prolonged Surface Exposure

The Origins, Spectral Interpretation, Resource Identification, and Security–Regolith Explorer (OSIRIS-REx) mission to carbonaceous asteroid (101955) Bennu performed detailed mapping with a suite of instruments to characterize the composition and geology of its surface. Here we use data from the OSIRIS-REx Thermal Emission Spectrometer (OTES) instrument to investigate the relationship of OTES-derived spectral indices to other derived data products from OTES, the OSIRIS-REx Camera Suite (OCAMS), and the OSIRIS-REx Visible and InfraRed Spectrometer (OVIRS) at global and local scales. We quantitatively confirm that high values of the OTES silicate stretching slope (from ∼10 to ∼12 μm) in midday spectra that are indicative of thin and/or patchy dust cover are strongly associated with low thermal inertia (high porosity), low albedo boulders on Bennu. These high porosity boulders have brecciated textures with embedded clasts that likely originated on Bennu's parent body or during its disruption. The high porosity of these boulders is a key factor in the local production of the dust or its entrapment, as some large, brecciated boulders with a lower porosity have little evidence of dust. A second OTES spectral parameter, the silicate bending band depth near 22.7 μm applied to early evening spectra, is not correlated to thermal inertia, but is weakly to strongly correlated to albedo, OVIRS-derived 1.05 μm and 2.74 μm band depths, OVIRS-derived hydrogen abundance, and modeled nanophase troilite abundance. In several regions on Bennu there is a strong spatial relationship between these parameters, whereby areas with shallower silicate bending bands also have shallower 1.05 μm and 2.74 μm bands and lower albedo with higher nanophase troilite abundances. These correlations, combined with analysis of the silicate bending band in laboratory experiments of space weathered and mildly heated carbonaceous chondrites, suggests that decreased silicate bending band depths signify decomposition of phyllosilicates, likely Fe-bearing, due to space weathering or mild heating (<600 °C) via solar radiation during Bennu's time in near-Earth space. There is a strong association of larger silicate bending band depths in areas dominated by small rocks and unresolved material and in areas with small (≤ 25 m) craters identified as the spectrally reddest on Bennu, suggesting that this material has been more recently exposed due to impact and/or mass wasting processes. The shallowest silicate bending depths are associated with larger rocks and boulders that appear to have the longest surface exposure history, although there is band depth variation among them suggesting either initial composition variation that resulted in different responses to space weathering or heating, or varied exposure history of individual boulders themselves. We predict that any grains returned from Bennu with a significant surface exposure history will be characterized by shallower 22.7 μm, 1.05 μm and 2.7 μm band depths and increased sulfide (troilite) abundance, as well as textural and chemical evidence for phyllosilicate dehydration.

Asteroids, surfaces↗