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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 OSTI2021

Deformation behavior of CP-titanium under strain path changes: Experiment and crystal plasticity modeling

The deformation behavior of commercially pure rolled titanium subjected to strain path changes is studied using experiments and a crystal plasticity model. Four different loading combinations are performed at room temperature to study the activation of slip, twinning, de-twinning and double-twinning in hexagonal closed packed titanium. The strain paths considered are: rolling direction compression (RDC) followed by normal direction compression (NDC), RDC followed by transverse direction compression (TDC), NDC followed by RDC, and NDC followed by TDC. An EBSD-based analysis of the distribution of boundary misorientation angles before and after reload was developed to analyze the evolution of {$10\bar{1}2$} tensile and {$11\bar{2}2$} compression twins. This analysis supports the model results concerning the treatment of twin reorientation. A de-twinning and double-twinning model accounting for back stress effects, an important feature of strain path changes, is implemented within the framework of the visco-plastic self-consistent (VPSC) model along with a dislocation density (DD) based hardening scheme. In the model, plasticity is accommodated by prismatic $\langle$a$\rangle$, basal $\langle$a$\rangle$ and pyramidal $\langle$c+a$\rangle$ slip modes, and {$10\bar{1}2$} tensile and {$11\bar{2}2$} compression twinning modes. The VPSC model predicts the evolution of twinning, de-twinning and double-twinning processes for both tensile and compression twinning modes under strain path change. The model predicts macroscopic stress-strain response, texture evolution, and twin volume fraction that are in agreement with experimental observations. The evolution of texture is investigated in detail by separately analyzing the twinned domains, rather than the evolution of the global texture.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Copper carbon composite wire with a uniform carbon dispersion made by friction extrusion

Copper-carbon composites are a group of materials with excellent mechanical, electrical, thermal, and tribological properties. However, bulk size copper-carbon composites made by the traditional manufacturing processes, like rolling or extrusion, fall short of reaching some of these properties predicted by theory or demonstrated only by samples at centimeter scale or smaller. The two main challenges to the successful scaling-up are: 1) to uniformly disperse carbon in the metal matrix; 2) to avoid degradation due to oxidation or reaction from overheating. In this work, we first demonstrate friction extrusion as a new method to make bulk-size void-free copper-carbon composite wires with homogenized carbon dispersion. Three different carbon varieties, graphite powder, graphene nanopowder, and carbon nanotubes, were added to the copper matrix with the concentration ranging from 0.5 wt% to 15 wt%. Special tooling, processing parameters, and procedures were developed, especially for high carbon content samples. Ten-fold reductions of both copper grain size and carbon particle size were achieved and attributed to the high shear deformation. Energy dispersive X-ray spectrometry indicates the carbon powder was refined to a sub-micron level and uniformly dispersed in the copper matrix. Compared with that of pure copper, the thermal capacity of the composite wire increases by 30 % while density reduces by 29 %.

Friction extrusion, Metal matrix composite, Graphe↗
DOE OSTI2022

Behavior of helium cavities in ion-irradiated W-Ni-Fe ductile-phase toughened tungsten

This study reports on the distribution of helium (He) cavities in a hot-rolled W-Ni-Fe ductile-phase toughened tungsten (DPT W) composite irradiated to a dose and a helium concentration that are comparable to those in the material after 5-year irradiation in a conceptual fusion power plant. Here, the DPT W sample consists of W particles embedded in a ductile-phase NiFeW matrix with a nominal composition of 90W-7Ni-3Fe by weight. It was hot-rolled to a thickness reduction by 87% (87R DPT W). Sequential irradiation of the material with 1.2 MeV Ni + ions to a fluence of 2.15×10 16 Ni + /cm 2 and 90 keV He + ions to 6.5×10 15 He + /cm 2 was performed at 973 K. Larger He cavities with a lower number density are observed in NiFeW than W. Helium cavities are aggregated preferentially along the NiFeW/W interphase boundary. This behavior is not observed along the W/W grain boundary under the same irradiation conditions. A similar distribution of He cavities with comparable sizes is observed in 87R DPT W irradiated with He + ions only, suggesting that the He cavity distribution is not significantly affected by pre-irradiation of Ni + ions at 973 K. The data from this study does not provide any evidence for formation of visible voids or Ni precipitates in W phase irradiated with Ni + ions only. Diffusion and clustering of He atoms and mobile vacancies during ion irradiation at 973 K are responsible for the formation and growth of the He cavities.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Manufacturing Oxide Dispersion Strengthened (ODS) steel plate via cold spray and friction stir processing

Oxide dispersion strengthened (ODS) steels, traditionally fabricated by ball milling and conventional powder metallurgy techniques to achieve bulk form, followed by intricate rolling and thermal treatment steps to achieve plate or sheet form. Here, we present a novel processing route that combines cold spray (CS) with friction stir processing (FSP) to manufacture ODS steel plate directly from gas atomization reaction synthesis (GARS)-prepared powder, thus no rolling steps involved. Microstructural and mechanical characterizations were performed to assess the quality and properties of the resulting ODS steel plate. Our findings demonstrate that the slightly porous CS deposited layer was fully consolidated after FSP, yielding a fully dense ODS steel plate that exhibited a favorable tradeoff between strength and ductility upon extraction from the substrate. Furthermore, through microstructural analysis, we revealed the presence of an appreciable density (∼10 22 /m 3 ) of nano-sized oxide particles, with the majority being smaller than 5 nm via the combined CS + FSP fabrication route. This work serves as a first proof-of-concept demonstration of the manufacturing approach described herein, offering a possible alternative route for producing ODS steel plates.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Deformation band corrosion as a result of applied stress and cold-work in 304 stainless steel in simulated pressurized water reactor primary water conditions

Stainless steels like 304SS are commonly used in pressurized water reactor primary water environments due to their excellent resistance to stress corrosion cracking (SCC). However, SCC susceptibility has been observed in cold-worked 304SS. Cold-rolling introduces a high density of defects, such as deformation bands or dislocations, into the microstructure; applied stress, even if macroscopically below the yield stress, can result in regions with high localized stresses. Cold-worked and non-cold-worked samples were exposed to 360 °C simulated PWR primary water for 1500 h with and without active loading. Corrosion susceptibility of dislocations and deformation bands induced by cold-rolling and/or applied stress was studied using high-resolution (analytical) transmission electron microscopy. Deformation bands were generated in all specimens examined in the study. Penetrative oxidation was observed in some deformation bands in each specimen. The depth of penetrative deformation band oxidation frequently exceeded the depth of grain boundary oxidation in all specimens. However, deformation band oxides generally were narrowly confined to the deformation band plane. Highly Ni-rich regions were observed beyond all oxidation fronts. Surface oxides were thicker in the specimens exposed under active loading. In conclusion, the implications of these findings at surfaces for deformation bands intersecting stress corrosion crack paths are discussed.

EFTEM↗
DOE OSTI2021

Lithium substituted poly(amic acid) as a water-soluble anode binder for high-temperature pre-lithiation

Multifunctional binders hold great promise in advanced electrode designs for both fundamental research and practical utilization of lithium-ion batteries (LIBs). The reactions between Si/SiO x -dominated anodes with lithium are expected to be exothermic in principle, while the thermal tolerance along with the volume change makes high-temperature binders attractive for large scale roll-to-roll manufacturing. For instance, if a high temperature binder is also water soluble, it can be compatible with the current graphite-based anode manufacturing process. In this work, we present a water-soluble poly(amic acid)-based binder, which can withstand high temperature for industrial pre-lithiation process and effectively hold active materials together during repeated charge and discharge cycles. This lithium substituted poly(amic acid) binder (denoted as Li-Pa) can serve as a drop-in replacement for environmentally friendly electrode fabrication in large scale by providing aqueous solubility, exceptional thermal stability and mechanical flexibility.

25 ENERGY STORAGE↗
DOE OSTI2020

Highly permeable polyethersulfone substrates with bicontinuous structure for composite membranes in CO 2 /N 2 separation

Substrate morphology has a significant effect on the CO 2 transport performance of a thin-film composite (TFC) membrane. In this study, a new mixed solvent comprising 2-pyrrolidone (2-PD) and 2-methoxyethanol (2-ME) was used to prepare polyethersulfone (PES) substrates with bicontinuous structure by water vapor-induced phase separation, followed by immersion in water as nonsolvent. Here, compared with the commonly used solvent, N-methyl-2-pyrrolidone (NMP), the 2-PD/2-ME mixed solvent is more hydrophilic and can decrease the thermodynamic stability of the casting solution significantly. As a result, the phase separation was induced via the spinodal decomposition mechanism. The open morphology bestowed the optimized substrate with a very high CO 2 permeance of 133,226 ± 3,870 GPU (1 GPU = 10 –6 cm 3 (STP) s –1 cm –2 cmHg –1 = 3.3464 × 10 -9 kg-mol s –1 m –2 Pa –1 ), which was 5 times more permeable than the baseline substrate synthesized with NMP. By using this new substrate, the prepared TFC membrane containing amines showed an increased CO 2 permeance of 908 ± 8 GPU at 57°C, which was 48 GPU higher than that with the baseline substrate. Meanwhile, the CO 2 /N 2 selectivity was retained at 162 ± 4 at 57°C. In addition, the good scalability of the new PES substrate was demonstrated by roll-to-roll fabrication of a 50' long scale-up PES substrate with a width of 21".

2-Pyrrolidone↗
DOE OSTI2025

Surface engineering of polymeric membranes with metal oxides for improved fouling resistance and superior oil-water separation

Rapid industrial growth has increased the need for efficient membranes to separate oil-water emulsions. Polyvinylidene fluoride (PVDF) membranes, although widely used due to their chemical inertness and favorable mechanical properties, suffer from fouling due to their intrinsic hydrophobicity. Modifying these membranes after fabrication offers a practical solution as it easily fits into existing large-scale manufacturing processes. Atomic layer deposition (ALD), an atomically-precise vapor phase surface modification technique, can create ultrathin metal oxide layers that greatly improve membrane hydrophilicity without significantly affecting the original pore size. However, PVDF's lack of reactive chemical moieties makes ALD challenging. Here, in this study, we present a simple alkali treatment that greatly enhances ALD nucleation and growth on PVDF membranes. This treatment imparts exceptional oil-water emulsion separation capabilities and antifouling behavior in PVDF membranes after just a few ALD cycles, surpassing the performance of PVDF membranes coated with hundreds of ALD cycles. This dramatic reduction in the number of ALD cycles required could enable cost-effective modification of commercial PVDF membranes at scale using spatial, roll-to-roll ALD. These modified membranes outperform reported modified PVDF membranes, with >99 % permeance recovery and <1 % irreversible loss of permeance and >98 % oil rejection from oil-water emulsions over 100 h continuous operation, making them promising for advanced water purification technologies.

Atomic layer deposition↗
DOE OSTI2021

On the exceptionally high ductility of Mg–2Zn-0.3Ca-0.2Ce-0.1Mn alloy

A newly developed Mg–2Zn-0.3Ca-0.2Ce-0.1Mn (in weight %, ZXEM2000) wrought alloy exhibits an exceptionally high tensile ductility (29% ± 1.4% tensile elongation) along the rolling direction at room temperature. In this work, we investigated the fundamental plastic deformation mechanisms that can contribute to the high ductility of ZXEM2000. Scanning electron microscopy and transmission electron microscopy were carried out at selected strain levels to characterize the microstructural evolution. Compared with the deformed microstructures from the hot-rolled pure Mg and Mg–3Al–1Zn alloy at similar conditions, our results revealed that the high ductility of ZXEM2000 could be attributed to four key factors: weaker texture, fine grain size, reduced twinning, and increased cross-slip frequency of < c +a > dislocation. Furthermore, these direct observations offer a key insight into improving ductility of magnesium alloys for future alloy design and development.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Macroscale property assessment and indentation characteristics of thick section friction stir welded AA 5083

The spatial gradients in microstructure have been proven to be effective in optimizing the performance of components, and several techniques have been developed to achieve this microstructure. Nevertheless, the local microstructural modification methods inevitably result in the formation of gradient microstructure leading to a variation in the property. Herein this work systematically investigates the effect of gradient microstructure formed during thick section friction stir weld Al5083 alloy on its mechanical properties. A novel macro-indentation technique, profilometer-based indentation plastometry (PIP), is utilized to capture the variation in the mechanical properties in the feedstock (rolled plate) and weld region. The feedstock exhibited a gradient microstructure owing to different stress states during rolling. Additionally, the stirring of the tool resulted in a complex material flow pattern producing a microstructure gradient in the weld region. The aspect ratio of the grains was identified as the primary factor causing variation in indentation response in the feedstock. In contrast, variation in the grain size in the weld region resulted in property variation. Overall, the stir zone has a lower yield strength (158±4MPa) than the base material (173±3MPa). In addition, microstructure heterogeneity in the stir zone resulted in lower elongation than the base material.

36 MATERIALS SCIENCE↗
DOE OSTI2024

In-situ ionothermal synthesis of nanoporous carbon/oxide composites: A new key to functional separators for stable lithium-sulfur batteries

Lithium-sulfur batteries (LSBs) with high energy density are promising for energy storage. However, conventional polypropylene-based separator cannot avoid polysulfides shuttling which impedes the practical application of LSBs. Herein, an in-situ ionothermal synthesis strategy that concurrently applies ionic liquid as the solvent, template and high-yield carbon source is proposed for the facile preparation of nanoporous carbon/oxide composite separator modifiers. The composites exhibit features of high polarity, self doping, oxygen vacancy, heteroatom doping, abundant defects and high electronic conductivity. Theoretical and experimental studies suggest that the composites can efficiently trap and convert polysulfides for high-performance LSBs. Indeed, in the composite-modified LSBs with next-generation roll-to-roll dry-processed high-loading sulfur cathodes, enhanced performance is achieved, revealing the effectiveness of the composites as functional materials towards separator modification. Therefore, the proposed strategy and its delivered nanoporous composites exhibit excellent versatility and practicality for high-performance LSBs.

25 ENERGY STORAGE↗
DOE OSTI2020

Ion irradiation effects on Cr-coated zircaloy-4 surface wettability and pool boiling critical heat flux.

The concept of coating the currently used nuclear fuel cladding (zirconium-based alloy, typically Zircaloy-4 or Zirc-4) with an oxidation preventive layer is a progressing Accident tolerant Fuel (ATF) candidate alloys. The coated Zirc-4-based alloys could be a solution to suppress undesirable fast reaction kinetics with high-temperature steam. Zirc-4 has been the most preferred cladding material in pressurized water reactors (PWRs). Chromium (Cr) based alloys as a coating material provides excellent corrosion protection and good strength and wear resistance. In this paper, we present the surface wettability measurements and pool boiling Critical Heat Flux (CHF) for Cr-coated Zirc-4 claddings pre- and post-exposure to an ion irradiation environment. The wettability measurements, including static contact angle (contact angle, θ) and average surface roughness (surface roughness, Ra), are introduced for samples of different coating thicknesses (5–30 μm thick). The coatings fabricated by the cold spray of Cr-Al particles to 10 mm × 10 mm × 1.95 mm Zirc-4 substrates. Post fabrication, a Pilgering (cold rolling) process, was applied to finalize the coating thickness and resulted in a significant reduction in surface roughness of initially fabricated rough surfaces. The process produced three distinguished samples 5-μm unpolished (as machined), 5-μm, and 30-μm polished (cold rolled). The measurements are presented for the three surfaces and bare Zirc-4 as a baseline surface. The contact angle analyses were implemented in theoretical models from the literature to predict pool boiling CHF. Pool boiling experiments were conducted to measure the pool boiling CHF values and compare them to the predicted values. Scanning Electron Microscope (SEM) images and Energy Dispersive X-ray Spectroscopy (EDS) analysis was performed to characterize the surfaces for better understanding and interpreting the results. The SEM images showed localized surface damage due to ion irradiation. No recognized change in the measured surface roughness due to ion irradiation. The contact angles of irradiated Cr-coated surfaces are consistently higher (10°) than pre-irradiated surfaces. Decreasing the Cr-coating layer thickness resulted in lower contact angle pre- and post- ion irradiation. The predicted pool boiling CHF using the Kandlikar model is in good agreement with the experimentally measured CHF values within ±12% for all samples.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Laser-interference pulse number dependence of surface chemistry and sub-surface microstructure of AA2024-T3 alloy

The laser-based treatment of a metal surface is an intrinsically non-chemical technique that can alter both the topology and chemistry of surfaces. A laser-based treatment for coating and joining applications can offer alternative surface preparations to the chemically-based surface preparation techniques, which are subject to severe environmental protection and hazardous-waste management considerations. In this study, the surface chemistry and sub-surface microstructural changes are investigated for a novel surface processing method using laser interferometry produced by two beams of a pulsed Nd:YAG laser. The two-beam laser-interference allowed the structuring of the surface at length scales much less than that of the laser beam spot. Surface chemistry changes in the oxide layer of AA 2024-T3 aluminum alloy rolled sheet due to laser processing were investigated using x-ray photoelectron spectroscopy (XPS). Near surface microstructural changes have been investigated with scanning electron microscopy and energy dispersive x-ray spectroscopy (SEM/EDS), and scanning transmission electron microscopy (STEM) as a function of number of interfering laser shots. SEM microstructure pictures of the top surface shows the minimization of surface defects, as all of the sharp features from a rolled sheet surface were smoothed by laser-structuring. STEM images indicate that the laser-interference processing reduced the formation of CuMn-rich precipitates over a 500–800 nm depth from the top surface. XPS data indicated that the Al oxide layer is modified compared to that of the baseline specimen and that the oxide thickness increases with the number of shots per spot. Finally, the additional thicker oxide on Al alloys is expected to increase the corrosion resistance of the coated Al 2024.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The effect of annealing on kink band formation in Ag/Fe nanolaminates

Kink banding is a common, though not well understood, failure mechanism in anisotropic materials such as nano metallic laminates (NMLs). In this work, we investigate the effect of annealing on kink band (KB) formation in Ag/Fe NMLs prepared by accumulative roll bonding (ARB) using in situ micropillar compression, scanning/transmission electron microscopy (S/TEM), and transmission Kikuchi diffraction (TKD) analyses. Our results show that annealing increases the KB initiation strain, decreases the probability of KB formation, and decreases the load drop magnitude accompanying kink banding in Ag/Fe NMLs. Post-compression analyses reveal that annealing facilitates more uniform deformation of pillars and affects the formation of geometrically necessary grain boundaries (GNBs) near the kink band boundary (KBB). Compared to its as-rolled counterpart, annealed Ag/Fe has wider KBs with blunter KBBs.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Scalable slot-die coating of phyllosilicate membranes for selective ion separations

Abstract Two-dimensional (2D) materials have recently drawn attention as candidate materials for molecular-scale membrane separations due to their tunable nanoscale interlayer properties. Phyllosilicates, a broad class of naturally abundant 2D clay minerals, offer significant advantages over synthetic 2D materials, including low cost, stability, and environmental compatibility. While these properties make phyllosilicates attractive for industrial-scale nanofiltration applications, phyllosilicate-based membranes have, to date, only been fabricated at the lab scale via vacuum filtration. Scalable fabrication methods are essential to advance the technical maturity of phyllosilicate membranes and bring these promising materials closer to large-scale adoption. Herein, we have successfully scaled up phyllosilicate (vermiculite) membrane fabrication via slot-die coating and roll-to-roll coating of an ethylenediamine–vermiculite (EDAVM) mixture onto nylon. The coated membranes are 1–2 μm $ \unicode{x03BC} \mathrm{m} $ mu m in thickness and exhibit similar structure and performance to vacuum-filtered EDAVM membranes. The membranes also show selectivity for monovalent ions over multivalent ions in binary salt mixtures. This work represents a major step toward scaling up phyllosilicate membranes for industrial ion separation applications such as resource recovery from water.

Booth, Austin [Princeton University]↗
DOE OSTI2020

Ferroelastic Hysteresis in Thin Films of Methylammonium Lead Iodide

Mechanical strain can modify the structural and electronic properties of methylammonium lead iodide MAPbI 3 . The consequences of ferroelastic hysteresis, which involves the retention of structural memory upon cycles of deformation, are reported for polycrystalline thin films of MAPbI 3 . Repeatedly bent films were examined using grazing incidence wide-angle X-ray scattering (GIWAXS) to quantitatively characterize the strains and proportions of twin domains. Approximate locations for the coercive stress and saturation on the ferroelastic stress–strain curve are identified, and changes to the stress–strain curve with cyclic strain are characterized. Notably, an external stress source, such as thermal stress from the substrate or a roll-to-roll printing setup, must apply at least |50| MPa to modify the proportions of different twins. The presence of specific twin domains is found to correlate to previously reported strain and defect heterogeneity in MAPbI 3 films. Domains from differently strained twin sets interact with each other. Long-term stability testing reveals that the domain walls are highly immobile over extended periods. Nucleation of new domain walls occurs for specific mechanical strains and correlates closely with degradation. Furthermore, these results help to explain the behavior of ion migration, degradation rate, and photoluminescence in thin films under compressive and tensile strain.

Defects↗
DOE OSTI2021

Controlling Polymer Morphology in Blade-Coated All-Polymer Solar Cells

In this report translating all-polymer solar cells from spin-coating to scalable roll-to-roll-compatible fabrication techniques is a critical step toward the application of organic photovoltaics at a scale. Techniques to control polymer crystallization and phase separation during solution printing are essential to obtain high-performance printed organic solar cells. Here, we demonstrate a novel solvent additive approach employing trace amounts of phthalates as additives to control polymer crystallinity and suppress unfavorable phase separation in a representative PTB7-Th/P(NDI2OD-2T) all-polymer solar cell. The best-performing additive increased the blade-coated device performance from 2.09 to 4.50% power conversion efficiency, an over twofold improvement, mitigating the loss in performance that is typically observed during process transfer from spin-coating to blade-coating. It is suggested that the improved device performance stems from a finer polymer phase-separation size and overall improved active layer morphology, evidenced by device characterization data and indirectly supported by grazing incidence wide-angle X-ray scattering analyses. Real-time X-ray diffraction measurements during blade-coating provide mechanistic insights and suggest that the dioctyl phthalate additive may act as a compatibilizer, reducing the demixing of the donor and acceptor polymer during film formation, enabling a smaller phase separation and improved performance. The structural diversity of the class of phthalate additives makes this simple yet effective concept promising for translating other all-polymer material systems to blade-coating and other scalable printing techniques.

14 SOLAR ENERGY↗