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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 OSTI2022

Quasi-isentropic compression of an additively manufactured aluminum alloy to 14.8 GPa

We uniaxially and shocklessly compressed an additively manufactured aluminum alloy, laser powder bed fusion (LPBF) AlSi10Mg, to peak stresses ranging from 4.4 to 14.8 GPa at peak strain rates on the order of [Formula: see text] via a series of magnetic loading experiments to measure the principal isentrope, yield strength, and shear modulus as a function of material orientation and applied stress. We did not observe significant anisotropy in any of the measured quantities. We found that the principal isentrope, within the uncertainty and up to our peak stress, overlaps the material’s Hugoniot. We measured yield strengths and shear moduli ranging from 0.28 to 0.81 GPa and 36 to 52 GPa, respectively. Our results indicate that LPBF AlSi10Mg behaves similarly to wrought Al alloys under quasi-isentropic compression.

Brown, Nathan P.↗
DOE OSTI2026

Creep in multi-principal element materials –– A review

The ongoing push towards enhanced energy efficiency and reduced emissions has necessitated the creation of materials with superior performance, especially under extreme conditions. Modern industries, such as aerospace, energy production, and nuclear power, rely heavily on materials that can withstand elevated temperatures without compromising structural integrity. At these heightened temperatures, materials, even when subjected to mechanical stresses well below their yield strength, may experience slow deformation leading to eventual rupture — a phenomenon known as creep. With the expansive design space that comes with the high entropy concept and their reported excellent high temperature strength, multi-principal element materials (MPEMs) have attracted interest in the scientific community for high-temperature applications. Here, this review offers a comprehensive examination of existing studies on creep in MPEMs, which includes multi-principal element−alloys, −bulk metallic glasses, −ceramics, and −superalloys, comparing published findings on MPEMs with pure elements, traditional alloys, bulk metallic glasses, and superalloys. The sub-topics covered include a comparison among different creep-testing methods, creep mechanisms, creep exponents, creep strain rates, activation volume, and creep-activation energy. Modeling efforts for predicting creep behavior of MPEMs are also reviewed. Methods for improving creep resistance by performing heat treatments and/or modifying microstructures are discussed. Overall, the current state of MPEMs has not yet surpassed the creep performance of commercial alloys. Finally, directions for future efforts are suggested, such as experimenting in various controlled environments, expanding the number of compositions tested, exploring advanced manufacturing techniques, and using machine-learning to predict creep properties based on compositions and microstructures.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Additive manufacturing of mullite ceramic by digital light processing

Mullite material was successfully additively manufactured using digital light processing (DLP). The printed geometry involves a one-step process of pyrolysis, de-binding, and sintering under a plain atmosphere to achieve an average of 76 % ceramic yield and linear shrinkage of 12 %. Furthermore, the thermal profile was carefully controlled to obtain consistent phases in which the XRD shows a mullite phase. Here, in addition, the Weibull analysis was conducted on the sintered flexural specimens, showing a Weibull modulus (m) of 13.05 with a characteristic strength (σ 0 ) of 94.96 MPa. Synchrotron microtomography was performed on the sintered specimens, which showed two distinct porosity distributions (small and large). Large porosity (non-spherical elongated) is the primary cause of decreased material strength, while small porosity (spherical) is the sintering product. The measured thermal conductivity of the specimens was in the range of 2.7–3.1 W/m∙k and decreased with an increase in temperature. Lastly, large-scale prototypes were printed concurrently with a fine resolution of 25 μm without any compromise on the predetermined design and structure.

Additive manufacturing↗
DOE OSTI2022

The formation and evolution of Ni 2 Cr precipitates in Ni–Cr model alloys as a function of stoichiometry characterized by synchrotron x-ray diffraction

Ni-based alloys containing significant amounts of Cr, may precipitate new phases during long-term service at elevated temperatures. In Ni–Cr model alloys, the formation of Ni 2 Cr has been found to impact the material properties, including the strength and ductility after isothermal aging below the critical temperature of 590°C. In this work, we quantify the formation and evolution of long-range ordering in four Ni–Cr binary model alloys (Ni/Cr = 1.8, 2.0, 2.2, 2.4) after isothermal aging up to 10,000h at temperatures between 373 and 475°C. The alloys were characterized by hardness testing and synchrotron-based x-ray diffraction to quantify the impact of Ni 2 Cr phase fraction and precipitate size on mechanical properties. After 500h of isothermal aging, the formation of Ni 2 Cr was detected in all four alloys at 475°C. In the stochiometric alloy samples (Ni/Cr = 2.0), the formation of Ni 2 Cr was found after 500 and 3000h aging at 418 and 373°C, respectively. We found that the matrix lattice contraction and Ni 2 Cr phase fraction both saturate after early aging times. This is in stark contrast to the hardness and Ni 2 Cr precipitate size that both continue to increase with increasing aging time. Our results highlight that changes in hardness correlate linearly with Ni 2 Cr precipitate size rather than phase fraction. This important structure-property relationship can potentially help define Ni–Cr-based component lifetimes directly through an understanding of how Ni 2 Cr formation impacts strength and ductility. Here, we find that a precipitation hardening model for critical resolved shear stress with weakly coupled dislocations shows good agreement with the material property changes quantified from experimental measurements.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Microstructure, Texture, and Strength Development during High-Pressure Torsion of CrMnFeCoNi High-Entropy Alloy

The equiatomic face-centered cubic high-entropy alloy CrMnFeCoNi was severely deformed at room and liquid nitrogen temperature by high-pressure torsion up to shear strains of about 170. Its microstructure was analyzed by X-ray line profile analysis and transmission electron microscopy and its texture by X-ray microdiffraction. Microhardness measurements, after severe plastic deformation, were done at room temperature. It is shown that at a shear strain of about 20, a steady state grain size of 24 nm, and a dislocation density of the order of 1016 m−2 is reached. The dislocations are mainly screw-type with low dipole character. Mechanical twinning at room temperature is replaced by a martensitic phase transformation at 77 K. The texture developed at room temperature is typical for sheared face-centered cubic nanocrystalline metals, but it is extremely weak and becomes almost random after high-pressure torsion at 77 K. The strength of the nanocrystalline material produced by high-pressure torsion at 77 K is lower than that produced at room temperature. The results are discussed in terms of different mechanisms of deformation, including dislocation generation and propagation, twinning, grain boundary sliding, and phase transformation.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Dual Phase Soft Magnetic Laminates for Low-cost, Non/Reduced-Rare-Earth Containing Electrical Machines

To accelerate the mass market adoption of electric drive vehicles, the key technology barriers in electric motors are (1) magnet cost and rare-earth element price volatility; (2) non-rare-earth electric motor performance; and (3) materials property optimization. The goal of this project was to address these barriers by advancing a unique and innovative dual phase soft magnetic material technology and demonstrating the material in a 30-kW synchronous reluctance motor without using any permanent magnet for electric vehicles. Dual phase magnetic materials offer the electric motor designer the ability to locally control the magnetic saturation level in a motor laminate, while at the same time enhancing the mechanical strength of the laminate material, resulting in an enhancement in motor performance and efficiency. Scalable dual phase soft magnetic laminates manufacturing technologies were developed in collaboration with multiple US manufacturers. 1000 lbs of alloy sheet with a thickness of 0.25mm and width of 280 mm was manufactured within the specifications. Batch sizes of up to 240 laminates per run were produced from the alloy sheet. Two prototype motors with dual phase soft magnetic laminates were designed, built, and tested. The major goal of building the subscale prototype as a pathway to develop scalable manufacturing technologies for the dual phase soft magnetic laminates was met. The additional goal of building and testing the subscale prototype in order to validate the calculated performance with the tested motor performance was also met. For the full-scale 30kW continuous power synchronous reluctance motor prototype, the tested performance met the targets in terms of continuous power at the operating speeds up to 8000 rpm. Post-test studies were conducted and the root causes for the discrepancy between the predicted and tested peak power, continuous power at high speed range, and efficiency were identified. Further modeling study showed that the dual phase rotor machine has a 27% higher torque to active weight ratio than an equivalent performance silicon steel rotor machine. Application space and multiple discussions with traction motor and electric vehicle manufacturers for commercialization of the dual phase soft magnetic material technology were identified and conducted. An initial cost model was established based on the developed manufacturing technologies with the US manufacturers. Future paths for further cost reduction were identified, including increasing the market volume by broadening the applications of the dual phase soft magnetic laminate technology for electric machines in other energy sections such as oil & gas, heating, ventilation, and air conditioning (HVAC), and power generation.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Biodegradable Biocomposite Development for Large Scale Additive Manufacturing

Oak Ridge National Laboratory (ORNL) worked with Mitsubishi Chemical America, Inc. to develop a highly biodegradable ~100% biobased feedstock for large format additive manufacturing (AM). Together, they developed a AM feedstock based on the biobased polyester, polybutylene succinate (PBS), that is typically used in agriculture and packaging projects. The motivation for this work was to leverage the high degradability of this polymer in AM to create a new avenue for end-of-life disposal of the product. A composite feedstock was developed from PBS, polylactic acid (PLA), and wood flour (WF). While WF improves printability, reduces feedstock cost, and can improve stiffness, it also often results in a loss in tensile strength which can inhibit/limit application of the material. To recover the loss in tensile strength suffered by including large quantities, up to 30 wt%, WF in the composite a chain extender was used to compatibilze the different composite constituents with each other. The feedstock was used to 3D-print demonstration mold for precast concrete catch basins and was tested by casting 750 lbs of concrete. The mold survived the demonstration. Aerobic degradation testing of the composite feedstock showed that it was highly degradable, 40% biodegradation after 90 days, compared to other incumbent biobased feedstocks.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Biodegradable Biocomposite Development for Large Scale Additive Manufacturing

Oak Ridge National Laboratory (ORNL) worked with Mitsubishi Chemical America, Inc. to develop a highly biodegradable ~100% biobased feedstock for large format additive manufacturing (AM). Together, they developed an AM feedstock based on the biobased polyester, polybutylene succinate (PBS), that is typically used in agriculture and packaging projects. The motivation for this work was to leverage the high degradability of this polymer in AM to create a new avenue for end-of-life disposal of the product. A composite feedstock was developed from PBS, polylactic acid (PLA), and wood flour (WF). While WF improves printability, reduces feedstock cost, and can improve stiffness, it also often results in a loss in tensile strength which can inhibit/limit applications of the material. To recover the loss in tensile strength suffered by including large quantities, up to 30 wt.% WF in the composite, a chain extender was used to compatibilize the different composite constituents with each other. The feedstock was used to 3D-print a demonstration mold for precast concrete catch basins and was tested by casting 750 lbs of concrete. The mold survived the demonstration. Aerobic degradation testing of the composite feedstock showed that it was highly degradable, 40% biodegradation after 90 days, compared to other incumbent biobased feedstocks.

100% biobased feedstock for large format additive ↗
DOE OSTI2025

Hygrothermal Aging and Thermomechanical Characterization of As-Manufactured Tidal Turbine Blade Composites

This study investigates the hygrothermal aging behavior and thermomechanical properties of as-manufactured glass fiber-reinforced epoxy and thermoplastic composite tidal turbine blades. The blades were previously deployed in a marine environment and subsequently analyzed through a comprehensive suite of material characterization techniques, including hygrothermal aging, dynamic mechanical analysis (DMA), tensile testing and X-ray computed tomography (XCT). Hygrothermal aging experiments revealed that while thermoplastic composites exhibited lower overall water absorption (0.78% vs. 0.47%), they had significantly higher diffusion coefficients than epoxy (2.1 vs. 12.1 × 10 −13 m 2 s −1 ), suggesting faster saturation in operational environments. DMA results demonstrated that water ingress caused plasticization in epoxy matrices, reducing the glass transition temperature and increasing damping (112 °C to 104 °C), while thermoplastic composites showed more stable thermal behavior (87 °C glass transition temperature). Tensile testing revealed substantial reductions in ultimate strength (>40%) for both materials after prolonged water exposure, with minimal change in elastic modulus, highlighting the role of matrix degradation over fiber reinforcement. XCT image analysis showed that both composites were manufactured with high quality: no large voids or cracks were present, and the degree of misalignment was low. These findings inform future marine renewable energy composite designs by emphasizing the critical influence of moisture on long-term structural integrity and the need for optimized material systems in harsh marine environments. This work provides a rare real-world comparison of epoxy and recyclable thermoplastic tidal turbine blades, showing how laboratory aging tests and advanced imaging reveal the influence of material and manufacturing choices on long-term marine durability.

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Carbonation, strength development, and characterization of calcined limestone as a potential construction material

The emergence of the modern Portland cement has led to the downfall of lime as a construction material. Consequentially, its use has been limited to repair and restoration of historical buildings. Yet, its lower calcination temperature (~950 °C) and the ability to gain strength through carbonation implies its potential as a sustainable alternative to cement. In this study, calcined limestone was studied concerning its carbonation and strength development. Superplasticizer, raw limestone, and different carbonation regimes were explored as techniques to improve the composite strength development, a shortfall that hinders its re-adoption. The results indicated that the raw limestone as a partial replacement of the calcined limestone significantly improved the carbonation degree and mechanical properties. The average compressive strength reached 20 MPa under 20% CO{sub 2} due to the formation of an interconnected network of calcite as the dominant carbonation product. Supercritical CO{sub 2}, in contrast, formed disjoint particles or agglomerates of carbonates.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Solutionization via Severe Plastic Deformation: Effect on Natural Aging in an Al-Mg-Si-(Mn) Alloy

Shear Assisted Processing and Extrusion (ShAPE), a severe plastic deformation technique that is fast and scalable, was used to produce thin-wall tubing from alloy 6082 (Al-0.8Mg-0.9Si-0.7Mn) with in-situ solutionization during processing quickly followed by quenching. Quench medium and input material heat treatment were varied and natural aging behavior (T1 heat treatment) was evaluated using tensile testing. As-cast input material was found to have higher strength early in post-ShAPE natural aging and homogenized input material was found to have strengthening during natural aging. Compared to air quenching, water quenching gave greater strength both early in and after natural aging. These observations along with microscopy suggest that: 1. air quenching was too slow; 2. as-cast material was not fully solutionized but plastic deformation broke up the coarse intermetallic particles, which provided strengthening; and 3. homogenized material was solutionized well, which led to good natural aging behavior.

Milligan, Brian K.↗
DOE OSTI2023

Engineered Wood: Sustainable Technologies and Applications

Natural wood has been used for construction, fuel, and furniture for thousands of years because of its versatility, renewability, and aesthetic appeal. However, new opportunities for wood are arising as researchers have developed ways to tune the material's optical, thermal, mechanical, and ionic transport properties by chemically and physically modifying wood's naturally porous structure and chemical composition. Such modifications can be used to produce sustainable, functional materials for various emerging applications such as automobiles, construction, energy storage, and environmental remediation. In this review, we highlight recent advancements in engineered wood for sustainable technologies, including thermal and light management, environmental remediation, nanofluidics, batteries, and structural materials with high strength-to-weight ratios. Additionally, the current challenges, opportunities, and future of wood research are discussed, providing a guideline for the further development of next-generation, sustainable wood-based materials.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Liquid-free covalent reinforcement of carbon nanotube dry-spun yarns and free-standing sheets

Carbon nanotubes (CNTs) possess exceptional mechanical properties, surpassing stiffness and strength metrics of common materials such as steel alloys by 100× at the nanoscale. However, when myriads of individual CNTs are bundled together into macroscopic ensembles like fibers or sheets, the result is a 100-fold drop in strength compared to its individual components. Here we present a general strategy aimed to close this gap in property scaling. By using vapor-phase polymerization of a crosslinkable polymer, we reinforced the weak interlinkages among individual CNTs within both yarns and sheets to promote a better transference of mechanical load across the structure. Furthermore, after the treatment, dry-spun, low-density 2.3 μm thin yarns increased their elastic moduli by at least 300%, and free-standing CNT sheets exhibited a 10× boost. In-situ synchrotron small-angle X-ray scattering revealed that polymer-reinforced yarns undergo limited CNT bundle rearrangement when subjected to tensile loads compared to pristine yarns. This evidence supports the hypothesis that the polymer hinders CNTs slippage, the root cause of the poor scaling of mechanical properties in these materials. While we demonstrated this reinforcement method for CNT structures, it is not specific to CNTs and could be used in a wide variety of other hierarchical nanostructured ensembles.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A Brief Review of Sylgard 184

This paper will explore applications and functionality of the Dow material Sylgard 184. Pure Sylgard 184 is a “Two-part, clear, 10:1, RT and heat cure, good strength, UL and Mil Spec” material that has good dielectric properties. According to the Technical Data Sheet, Sylgard 184 has a base viscosity of 511 cP, mixed viscosity of 3500 cP, and a work time of 1.5 hours. The cured mate rial has a Shore A hardness of 43, a tensile strength of 980 PSI, and a dielectric strength of 500 volts/mil.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Single-photon superradiance in individual caesium lead halide quantum dots

The brightness of an emitter is ultimately described by Fermi’s golden rule, with a radiative rate proportional to its oscillator strength times the local density of photonic states. As the oscillator strength is an intrinsic material property, the quest for ever brighter emission has relied on the local density of photonic states engineering, using dielectric or plasmonic resonators. By contrast, a much less explored avenue is to boost the oscillator strength, and hence the emission rate, using a collective behaviour termed superradiance. Recently, it was proposed that the latter can be realized using the giant oscillator-strength transitions of a weakly confined exciton in a quantum well when its coherent motion extends over many unit cells. Here we demonstrate single-photon superradiance in perovskite quantum dots with a sub-100 picosecond radiative decay time, almost as short as the reported exciton coherence time. The characteristic dependence of radiative rates on the size, composition and temperature of the quantum dot suggests the formation of giant transition dipoles, as confirmed by effective-mass calculations. The results aid in the development of ultrabright, coherent quantum light sources and attest that quantum effects, for example, single-photon emission, persist in nanoparticles ten times larger than the exciton Bohr radius.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

High pressure phase transition and strength estimate in polycrystalline alumina during laser-driven shock compression

Alumina (Al 2 O 3 ) is an important ceramic material notable for its compressive strength and hardness. It represents one of the major oxide components of the Earth's mantle. Static compression experiments have reported evidence for phase transformations from the trigonal α-corundum phase to the orthorhombic Rh 2 O 3 (II)-type structure at ~90 GPa, and then to the post-perovskite structure at ~130 GPa, but these phases have yet to be directly observed under shock compression. In this work, we describe laser-driven shock compression experiments on polycrystalline alumina conducted at the Matter in Extreme Conditions endstation of the Linac Coherent Light Source. Ultrafast x-ray pulses (50 fs, 10 12 photons/pulse) were used to probe the atomic-level response at different times during shock propagation and subsequent pressure release. At 107 ± 8 GPa on the Hugoniot, we observe diffraction peaks that match the orthorhombic Rh 2 O 3 (II) phase with a density of 5.16 ± 0.03 g cm –3 . Upon unloading, the material transforms back to the α-corundum structure. Upon release to ambient pressure, densities are lower than predicted assuming isentropic release, indicating additional lattice expansion due to plastic work heating. Furthermore, using temperature values calculated from density measurements, we provide an estimate of alumina's strength on release from shock compression.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Integrated Multiphysics Modeling of Environmentally Assisted Brittle Fracture

Brittle materials, such as cement, compose major portions of built infrastructure and are vulnerable to degradation and fracture from chemo-mechanical effects. Currently, methods of modeling infrastructure do not account for the presence of a reactive environment, such as water, on the acceleration of failure. Here, we have developed methodologies and models of concrete and cement fracture that account for varying material properties, such as strength, shrinkage, and fracture toughness due to degradation or hydration. The models have been incorporated into peridynamics, non-local continuum mechanics methodology, that can model intersecting and branching brittle fracture that occurs in multicomponent brittle materials, such as concrete. Through development of new peridynamic capabilities, decalcification of cement and differential shrinkage in clay-cement composites have been evaluated, along with exemplar problems in nuclear waste cannisters and wellbores. We have developed methods to simulate multiphase phenomena in cement and cement-composite materials for energy and infrastructure applications.

36 MATERIALS SCIENCE↗