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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 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

High-energy synchrotron x-ray study of deformation-induced martensitic transformation in a neutron-irradiated Type 316 stainless steel

An unusual tensile deformation behaviour in the form of a propagating band along the sample gauge was observed in two neutron-irradiated 316 stainless steel samples during room-temperature tests, leading to a combination of high strength and high ductility. These bands were not observed in an unirradiated counterpart. With the help of in situ high-energy synchrotron x-ray diffraction, the phase-specific crystal information was tracked at different deformation levels in each sample. Post-irradiation and post-deformation samples were examined using electron microscopy to characterize various microstructural features. All samples displayed a deformation-induced martensitic phase transformation, which was identified as a second strain-hardening mechanism accompanying the dislocation hardening. The deformation-induced martensitic transformation was rationalized by the effect of applied stress on the effective martensite start temperature. The results showed that the irradiation did not alter the dislocation hardening and the martensitic transformation mechanisms, but the increased yield strength in irradiated materials facilitated the localized phase transformation at the onset of plastic deformation, in contrast to the unirradiated material which required pre-straining. The hardening effect of the martensitic transformation reduced the tendency towards necking and mitigated the loss of ductility in the irradiated material by carrying the deformation in the form of a propagating band. Despite the beneficial effect from the martensitic transformation, this study indicates that this mechanism cannot not be activated at typical operating temperatures of nuclear reactors.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Recent advances in ink-based additive manufacturing for porous structures

The use of porous structures is an ancient wisdom, people found its importance ever since we began to understand nature. The evolution of porous structure gives rise to multi-scale (combined nano-, micro-, and macro-) porous networks. Traditional manufacturing technologies have challenges in creating shape-complex and conformable porous structures for real-world applications. Additive manufacturing (AM) with the capability of assembling various materials with complex and customized architectures is rapidly developing. With the advancement of material development, the integration of AM and porous structure offers unparalleled and emerging opportunities for concept-to-design-to-fabrication of multi-scale porous networks, enabling the multi-functionalities of the 3D printed specimen and broadening its applications. In this work, we provide a comprehensive review of the state-of-the-art ink-based AM techniques for 3D printing porous structures. The ink design principle, ink composition, and printability are thoroughly discussed. The methodologies of various AM technologies for porous structures are analyzed. Readers can find a clear experimental guidance toward 3D printing multi-scale porous structures. The synergistic and collective merits of additive manufacturing and porous structure are highlighted and systematically discussed in this review. The challenges and promises of this field for future research are also outlined.

36 MATERIALS SCIENCE↗
DOE OSTI2022

3D-printed electrically conductive silicon carbide

The development of electrically conductive ceramics could achieve robust mechanical strength as well as practically high conductivity, offering applications in structural electrodes, conductors, catalyst supports, etc. However, its operating temperature is limited due to the intrinsic dense structures inevitably hindering the thermal management capability, thus resulting in a temperature-dependent electrical behavior in high-temperature environments. In this work, we report an additive manufacturing protocol through vat photopolymerization 3D printing to fabricate the architectured conductive silicon carbide (SiC) ceramics that simultaneously possess high electrical conductivity as well as low thermal conductivity, and demonstrate electric reliability under high-temperature environments above 600°C. The percolation of graphene into the ceramic scaffold establishes a uniform conductive network, exhibiting its electrical conductivity up to 1000 S m –1 . The bulk density of the 3D-printed ceramic is measured from 0.366 g cm –3 to 0.897 g cm –3 , with thermal conductivity ranging from 62 mW m –1 K –1 to 88 mW m –1 K –1 . Furthermore, the mechanical performance of conductive ceramic can be effectively reinforced by densifying the microstructures via spark plasma sintering treatment. The proposed additive manufacturing strategy widens the potential of ceramics as a structural and functional material, offering a promising pathway toward high-temperature electronics applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

An ultrastable heterostructured oxide catalyst based on high-entropy materials: A new strategy toward catalyst stabilization via synergistic interfacial interaction

Designing high–performance catalysts that can stabilize catalytic active sites against sintering to deactivation at temperature higher than 900°C is significant but challenging. In this work, we report a new strategy to obtain a transition metal oxide catalyst with high temperature stability for CO oxidation. This is achieved through a synergistic interfacial interaction at the interface of a heterostructure between high– entropy oxides (HEO, high temperature stability) and CuCeO x (catalytic site). The catalytic site (CuCeO x ) for CO oxidation is realized by dissolving an amount of Cu species in HEO into CeO 2 via an entropy–driven mechanochemical process. In situ XRD and HAADF–STEM have confirmed the high temperature stability of the heterostructure CuCeO x –HEO, which can remain its CO oxidation catalytic activity at elevated temperatures. It should be expected that this innovative will offer the potential to the synthesis of catalysts with high temperature stability in industry.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Suppressing CO formation in low-temperature methanol steam reforming via Ce-modified CuZnGa layered oxide catalysts

Cu-based layered double hydroxides (LDHs) are widely recognized as effective catalysts for low-temperature methanol steam reforming, yet achieving high hydrogen productivity together with near-complete suppression of CO formation remains challenging. Here, we report the synthesis and evaluation of a series of CuZnGa LDH-derived catalysts and Ce-modified analogues prepared via an aqueous miscible organic method, which enables high metal dispersion and precise structural control. The optimized CuZnGa catalyst exhibits a hydrogen production rate of 16.9 µmol H 2 ·g cat −1 ·s −1 at 180 °C with an H 2 /CO ratio exceeding 3500, outperforming many state-of-the-art low-temperature systems. Importantly, the incorporation of small amounts of Ce further suppresses CO formation while maintaining high hydrogen productivity. Combined spectroscopic characterization and density functional theory calculations reveal that Ce is incorporated into the LDH lattice by substituting Ga 3+ sites up to a critical threshold, beyond which highly dispersed CeO x species are formed. These species provide mobile lattice oxygen that participates in a Mars-van Krevelen-type pathway, selectively oxidizing CO and suppressing the reverse water-gas shift reaction. This study establishes a clear relationship between Ce speciation, oxygen mobility, and catalytic selectivity in LDH-derived systems. The resulting catalysts demonstrate the potential of interface-engineered Cu-based materials for efficient low-temperature hydrogen production with minimal CO contamination.

09 BIOMASS FUELS↗
DOE OSTI2020

Load altering attack-tolerant defense strategy for load frequency control system

Cyber attacks are emerging threats to every information-oriented energy management system. By violating the cyber systems, the hacker can disrupt the security and stability due to the strong coupling between the cyber and physical facilities. In this paper, one type of cyber attacks designated as the load altering attack is studied for the power system frequency control, and corresponding defense strategies are proposed to improve the frequency control performance. Considering the difficulty of the application of model-based controller into large-scale power systems, a novel model-free defense framework is for the first time presented. Under this framework, both active defense and passive defense strategies are designed. The former assumes that the defender has the initiative to learn different attack scenarios. Adaptive defense strategies are implemented using the online attack identification information and off-line trained strategy pool. The latter assumes that the defender passively tolerates various attack scenarios via the pre-trained off-line strategy. Both approaches prove to be effective through validation based on the IEEE benchmark systems. The proposed defense framework and defense strategies can be extended to other energy control systems to enhance their attack tolerance capability.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Tailoring biogenic straw insulation from additive manufacturing

In the pursuit of carbon-storing materials that could help accomplish high levels of building sustainability, wheat straw has emerged as a promising alternative to fossil fuel-based building materials. Straw is 100% biodegradable and abundant agricultural waste used in the construction 400 years ago, and it has been reported to have the lowest embodied carbon when measured against other typical insulating materials. Here, in this study, we report additive manufacturing of carbon-sequestration insulation panel materials by upcycling cellulose fibrils from wheat straw. Cellulose obtained from alkaline and 2,2,6,6-tetramethylpiperidine-1-oxyl radical-mediated oxidation shows thermal conductivity of 0.036 W m -1 K -1 , alongside elastic and flexural modulus of 900 MPa and 502 MPa, respectively. In addition, an in-situ hydrophobic treatment in the cellulose-based insulation panels is achieved with an average water contact angle of 133.7° Furthermore, the extrusion-based additive manufacturing of a 3D-printable ink obtained by mixing the cellulose and silica aerogel precursor is accomplished, with the printed material exhibiting structural integrity, thus showing great potential towards the development of state-of-the-art, sustainable materials for carbon-sequestration building applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effect of PVD-coated chromium on the subcooled flow boiling performance of nuclear reactor cladding materials

Here we elucidate the separate effect of a thin Cr coating deposited by physical vapor deposition (PVD) on the subcooled flow boiling performance of zircaloy-4. First, we run flow boiling experiments on prototypical zircaloy-4 surfaces mimicking the scratch pattern and surface roughness of nuclear reactor claddings. Then, we PVD-coat a 0.3 µm thick chromium layer on the same exact surface and repeat the same flow boiling investigations. All experiments are run using deionized water at atmospheric pressure, flowing on a 1 × 3 cm 2 rectangular cross section channel at a rate of 1000 kg/m 2 /s and a subcooling of 10 K. We measure the average temperature of the boiling surface at increasing surface heat fluxes, covering a wide range of heat transfer regimes, from single-phase forced convection to the boiling crisis. We also record high-speed videos of the boiling process, which we postprocess to measure bubble nucleation site density, growth time, departure diameter and frequency. The surface analysis reveals that, while the chromium coating does not seem change the surface roughness and morphology, it improves surface wettability. However, it decreases the critical heat flux. The chromium coating causes an increase of nucleation temperature, bubble departure diameter and growth time, and a reduction of the nucleation site density. The concurrence of these observations indicates that a size reduction of the nucleation sites, conformally covered by the chromium coating, may be the cause of the boiling performance deterioration. We confirm this hypothesis repeating the same analysis on a FeCrAl sample prepared and tested using the same protocol as the zircaloy-4 sample, but with a different initial surface texture.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

A novel 3-D pulsating heat pipe module for high heat-flux applications

This study proposed a novel pulsating heat pipes (PHP) for high-flux thermal module. According to the open literature, the maximum value of the heat flux is 23.7 W∙cm –2 handled by PHP, which is far behind industry requirements. Therefore, the present study proposes a novel 3D PHP suitable for high heat-flux applications. The PHP were experimentally tested for different working fluids, including methanol and water. Furthermore, the experiments were performed to analyze the influence of various operating parameters, such as filling ratio (25–60%), heat load (100–800 W), and air flow rate 100–250 cubic feet per minute (CFM). In this work, the results showed that this PHP can sustain a heat flux up to 70 W∙cm –2 with the maximum case temperature under 80 °C, which is approximately three times higher than the available literature. Furthermore, the performance of the PHP module was compared against the commercial module with wicked heat pipe. The PHP exhibited about 7% higher heat dissipation compared to the commercial module. Since the proposed module uses simple copper tubes in its construction over the wicked structure used in commercial module, the novel 3D PHP module provides additional economic and mass production capability.

3D pulsating heat pipe↗
DOE OSTI2024

Universal correlation for falling film evaporation heat transfer coefficients of water and seawater

Horizontal falling film evaporators are widely utilized in desalination industries to increase fresh water supply. However, universal correlations for seawater falling film evaporation under varied operational and geometrical conditions are simply unavailable in open literature. Thus, this study aims to develop such a universal correlation for both plain and enhanced tubes. The detailed heat transfer mechanisms are reviewed, and rational parameters are incorporated to develop the universal correlation. A dataset of 994 data points from 9 sources covering a wide range of conditions was compiled. These conditions include Reynolds numbers from 10 to 7235, heat fluxes from 7.7 to 208 kW/m -2 , saturation temperatures from 278 to 401 K, salinities from 0 to 60 gsalt kg -1 water, tube diameters from 15.8 to 50.8 mm, and liquid feeder height to diameter ratios from 1 to 2.25. Upon analysis, it was found that most of the recommended existing correlations exhibited poor predictive accuracy, as evidenced by larger MADs. The developed correlation in this study demonstrated the best predictive accuracy for the entire dataset, yielding a MAD of 16.8 % and an R 2 of 0.82. Furthermore, the performance of the new correlation was individually assessed across a broader spectrum of operational and design conditions, reflecting the individual conditions’ influences with an overall MAD of 20 %.

42 ENGINEERING↗
DOE OSTI2020

Inverse design of two-dimensional graphene/h-BN hybrids by a regressional and conditional GAN

Design of materials with desired properties is currently laborious and heavily relies on intuition of researchers through a trial-and-error process. To tackle this challenge, in this work we propose a novel regressional and conditional generative adversarial network (RCGAN) for inverse design of representative two-dimensional materials, the graphene and boron-nitride (BN) hybrids. RCGAN incorporates a supervised regressor network, thus overcoming the common technical barrier in the traditional unsupervised GANs, which cannot generate data when fed with continuous and quantitative labels. RCGAN can autonomously generate graphene/BN hybrids given any target bandgap values. These structures are distinguished from the ones used for training and exhibit high diversity for a given bandgap. Moreover, they exhibit high fidelity, yielding bandgaps within ~10% MAE F of the desired bandgaps as validated by density functional theory (DFT) calculations. Analysis by the principle component analysis (PCA) and modified locally linear embedding (MLLE) reveals that the generator has successfully generated structures following the statistical distribution of the real structures. It implies the possibility of the RCGAN in recognizing physical rules hidden in the high-dimensional data. The novel strategy for designing regressional GAN architecture together with the successful application to inverse design of materials would inspire further exploration in research fields beyond materials.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Molten salt electrochemical upcycling of CO 2 to graphite for high performance battery anodes

The efficient transformation of CO 2 into a value-added material is a potential strategy to help mitigate climate effects caused by CO 2 emissions. One potential CO 2 conversion product is graphite which is an important and versatile material extensively used in many applications including as an anode for lithium-ion batteries (LIBs). Commercial graphite, however, is traditionally synthesized via the energy intensive Acheson process (>3000 °C) and the performance of such graphite can be limited under fast charging conditions which is important for vehicle electrification. We report the electrochemical transformation of CO 2 to highly crystalline nano-graphite with a controlled microstructure in a carbonate molten salt at 780 °C. The use of a nickel foam electrode and controlled electrochemical parameters during the molten salt conversion process yielded pure graphite at a lower temperature compared to the Acheson process. Moreover, when investigated as an anode material for LIBs, the CO 2 -converted graphite exhibited high reversible capacity, long cycle life, and excellent rate capability even under fast charging conditions. This process provides a way to potentially reduce carbon emissions through the utilization of waste CO 2 by converting it into value-added graphite suitable for fast charging, high-energy-density batteries for vehicle electrification.

25 ENERGY STORAGE↗
DOE OSTI2023

Inferring colloidal interaction from scattering by machine learning

A machine learning solution for the potential inversion problem in elastic scattering is outlined. The inversion scheme consists of two major components, a generative network featuring a variational autoencoder which extracts the targeted static two-point correlation functions from experimentally measured scattering cross sections, and a Gaussian process framework which probabilistically infers the relevant structural parameters from the inverted correlation functions. Via a case study of charged colloidal suspensions, the feasibility of this approach for quantitative study of molecular interaction is critically benchmarked and its merit over existing deterministic approaches, in terms of numerical accuracy and computationally efficiency, is demonstrated.

36 MATERIALS SCIENCE↗
DOE OSTI2022

New bipolar host materials for high power efficiency green thermally activated delayed fluorescence $\mathrm{OLEDs}$

We report four bipolar molecules, namely m-CzPym, p-CzPym, m-CzTrz, and p-CzTrz, with carbazole (Cz) donor and a benzonitrile-substituted pyrimidine (Pym) or triazine (Trz) acceptor core were synthesized and characterized. The electron deficiency of heteroaryl cores together with the substitution pattern of benzonitrile were employed to tune the energy levels as well as the thermally activated delayed fluorescence (TADF) characteristics. The four molecules exhibited TADF behavior with inferior photoluminescent quantum yields (PLQYs) that limit their applications as emitters. These bipolar molecules were employed as TADF host materials for the benchmark TADF emitter 4CzIPN to achieve high-performing green TADF organic light-emitting diodes (OLEDs). Among the molecules, m-CzPym-hosted TADF-OLEDs achieved a maximum external quantum efficiency (EQE max ) of 31.5%, maximum power efficiency (PE max ) of 95.6 lm/W, and maximum current efficiency (CE max ) of 100.2 cd/A. Notably, p-CzPym-hosted TADF-OLEDs also achieved a PE max of 116.5 lm/W, turn-on voltage of 2.5 V, and impressive low efficiency roll-off performance (>89% of EQE max at 5000 cd/m 2 ), representing one of the highest efficiencies ever reported in 4CzIPN-doped devices. The high device efficiency can be ascribed to the balanced ambipolar carrier-transporting character of the host materials and high PLQY as well as the outstanding light outcoupling efficiency of the emitting layer.

42 ENGINEERING↗
DOE OSTI2022

CH 4 combustion over a commercial Pd/CeO 2 -ZrO 2 three-way catalyst: Impact of thermal aging and sulfur exposure

Thermal aging and sulfur poisoning are major problems influencing the efficiency and lifetime of natural gas three-way catalysts (TWCs) during real-world operation. In the present study, thermal aging and sulfur-induced deactivations on CH 4 combustion were investigated over commercial monolithic honeycombs, i.e., Pd/CexZr 1-x O 2 (CZ)-based TWCs that are thermally aged in the bench (HTA), followed by being operated behind the stoichiometric natural gas engine in high sulfur fuel (HTA + S). In this work, both HTA and HTA + S samples show degraded performance in CH 4 combustion relative to the fresh one, which are caused by the reconstruction of Pd species induced by thermal aging and the decreased reducibility of the support. The 18 O 2 labelling experiments show that in all cases CH 4 combustion proceeds via a MvK mechanism in which lattice O (OL) plays a key role. The sulfation aging (HTA + S sample) promotes the activation of CH 4 and O 2 by forming Pd δ+ -(SO$_4^{2-}$) δ- and Ce 3+ -VO couples at the interface as compared to HTA sample. However, such a promotion effect could be compromised by the blocking effect of sulfate on the exchange of O L from the bulk to the surface and across the surface. The fundamental understanding of thermal and S deactivation mechanisms from this study could help to predict a real-world lifetime use curve of natural gas TWCs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗