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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
NASA NTRS1995

The tribology of PS212 coatings and PM212 composites for the lubrication of titanium 6A1-4V components of a Stirling engine space power system

The Stirling space power machine incorporates a linear alternator to generate electrical power. The alternator is a reciprocating device that is driven by a solar or nuclear-powered Stirling engine. The power piston and cylinder are made of titanium 6A1-4V (Ti6-4) alloy, and are designed to be lubricated by a hydrodynamically-generated gas film. Rubbing occurs during starts and stops and there is a possibility of an occasional high speed rub. Since titanium is known to have a severe galling tendency in sliding contacts, a 'backup,' self-lubricating coating on the cylinder and/or the piston is needed. This report describes the results of a research program to study the lubrication of Ti6-4 with the following chromium carbide based materials: plasma-sprayed PS212 coatings and sintered PM212 counterfaces. Program objectives are to achieve adherent coatings on Ti6-4 and to measure the friction and wear characteristics of the following sliding combinations under conditions simulative of the Stirling-driven space power linear alternator: Ti6-4/Ti6-4 baseline, Ti6-4/PS212 coated Ti6-4, and Ps212 coated Ti6-4/PM212

Sliney, Harold E.↗
NASA NTRS1996

A Two Phase HfB2-SiB4 Material

A two phase HfB2-SiB4 material which is useful as a high temperature oxidation resistant coating. This invention relates to ceramic coatings and more particularly to ceramic coatings containing metal borides. Boride materials are known to have good oxidation resistance, with HfB2 considered to be the best pure boride for oxidation applications. It has been shown that the addition of 10 to 20 percent SiC to HfB2 increases the oxidation resistance. The HfB2-SiC materials are prepared by hot pressing powder mixtures. Hot pressing powder mixtures has limited ability to produce fine grained multiphase materials due to particle coarsening during the sintering process. Additionally, the purity of the final monolithic structure is limited to the purity of the starting powders. Chemical vapor deposition (CVD) offers a method of producing highly pure multiphase ceramics, with better control of microstructure. Researchers have tried to produce HfB2-SiC coatings by CVD but without success.

SILICON COMPOUNDS↗
NASA NTRS2010

Silicon Oxycarbide Aerogels for High-Temperature Thermal Insulation

This work has shown that the use of SOC-A35 leads to aerogel materials containing a significant concentration of carbidic species and limited amorphous free carbon. Substitution of the divalent oxide species in silica with tetravalent carbidic carbon has directly led to materials that exhibit increased network viscosity, reduced sintering, and limited densification. The SiOC aerogels produced in this work have the highest carbide content of any dense or porous SiOC glass reported in the literature at that time, and exhibit tremendous long-term thermal stability.

Evans, Owen↗
DOE OSTI2024

Compensating for Sintering Distortion in Additively Manufactured Shaped Charge Liners using Physics-Informed Machine Learning

Copper is a challenging material to process using laser-based additive manufacturing due to its high reflectivity and high thermal conductivity. Sintering-based processes can produce solid copper parts without the processing challenges and defects associated with laser melting; however, sintering can also cause distortion in copper parts, especially those with thin walls. In this study, we use physics-informed Gaussian process regression to predict and compensate for sintering distortion in thin-walled copper parts produced using a Markforged Metal X bound powder extrusion (BPE) additive manufacturing system. Through experimental characterization and computational simulation of copper’s viscoelastic sintering behavior, we can predict sintering deformation. We can then manufacture, simulate, and test parts with various compensation scaling factors to inform Gaussian process regression and predict a compensated as-printed (pre-sintered) part geometry that produces the desired final (post-sintered) part.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The onset of selective laser flash sintering in undoped and doped lanthanum chromite

Previous studies have shown that selective laser flash sintering (SLFS) can be initiated in dielectrics that exhibit ionic or electronic conduction at high temperature. These materials required high laser powers to reach the temperatures where electrical conduction is sufficient to initiate SLFS. In this study, SLFS in lanthanum chromite (LC), an intrinsic electronic conductor with high conductivity, and lanthanum strontium chromite (LSC), which is doped to further increase electronic conductivity, were investigated with a focus on understanding the initiation mechanisms. Results show that the initiation of SLFS in LC and LSC occurs when electronic charge carriers are activated and flow to the electrode where the current is measured. A combination of carriers produced at the electrode, temperature-activated intrinsic charge carriers, and extrinsic charge carriers present in LSC due to doping are responsible for the facile initiation of SLFS.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Development of Aluminum Feedstock for Additive Manufacturing

The rapid evolution of materials science and manufacturing technologies in recent years has offered new pathways to manipulate materials for bespoke manufacturing. Here we aim to develop feedstocks for applications such as radiator panels, fuel tanks, and structural components for outfitting. As a strong, light weight and thermally conductive material aluminum is ideal for these applications. An often-overlooked source of aluminum waste is food packaging used on the International Space Station. Reusing this waste stream will reduce the cost and logistics of regular sparing. In Space Manufacturing (ISM) will utilize this technology is such areas as sparing and outfitting. However, processing aluminum can present challenges, especially in the context of additive manufacturing and sintering, due to its high reactivity and tendency to form a tenacious oxide layer. Identifying appropriate binders and sintering profiles can overcome these challenges. Herein we present our work on obtaining aluminum powder derived from food packaging, binder selection for aluminum feedstock, and a demonstration of bound metal deposition printing.

aluminum↗
DOE OSTI2020

Doping effect of Al in LLZO

Lithium ion batteries have become a common use in most electronic devices and transportation. However, the use of liquid electrolytes poses a serious safe hazard due to their high flammability. The narrow operating temperature and voltage windows also limit further improvement of the energy density.Solid-state lithium batteries with the use of more stable and safer solid electrolyte have garnered much attention and could be the future choice for battery technology. A promising potential candidate for the solid electrolyte component is the garnet type Li 7 La 3 Zr 2 O 12 (LLZO) ceramic material since it possesses high ionic conductivity at room temperature and enables the use of high capacity lithium anode and high voltage/capacity cathodes.However, to form the stable cubic phase of LLZO and high densification,high sintering temperatures above 1100°C is typically required, which causes Lithium loss of the system.Many studieshave been taken to dop LLZO with various precursors such as Ga, Ta, and Al to stabilize the cubic structure and reduce calcination temperature, while the doping effect on sintering densification is still unclear. In this study Al doping along with ball milling were explored to stabilize the cubic phase of LLZO and improve densification, while reducing the amount of impurity phases. Samples were synthesized from the precursors Li 2 CO 3 , Al 2 O 3 , La 2 O 3 , and ZrO 2 by ball milling followed by heat treatment for 12 hours at 1000°C. XRD with Rietveld fitting was used to determine the two phases of LLZO (cubic, tetragonal) and other possible secondary phases. Furthermore,SEM with top and cross sectional views was conducted to investigate the morphology and microstructure of sintered pellets.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Pelletization with Spark Plasma Sintering and Characterization of Metal Iodides: An Assessment of Long-Term Radioiodine Immobilization Options

Four promising iodine “getter” materials (Ag, Cu, Bi, and Sn) for radioiodine capture were assessed in their pure metal-iodide (MI x ) pelletized forms to compare relative chemical durabilities. To study chemical durability, commercial MI x compounds of AgI, BiI 3 , BiOI, CuI, and SnI 4 were converted to dense monolithic pellets using spark plasma sintering. Semidynamic leach testing in the form of modified ASTM C1308 tests was then performed on the pellets in two different forms including unmounted (as-pressed) specimens (i.e., “U”) and epoxy-mounted specimens (i.e., “M”) with polished surfaces. The chemical durability results and sample characterizations showed that three of the five MI x compounds tested (i.e., AgI, CuI, and BiOI) displayed moderate to high leach resistances. Further, the remaining two MI x compounds (i.e., BiI 3 and SnI 4 ), which are both desirable iodine waste forms due to their high iodine loading capacities, readily decomposed during leach testing, indicated by crystallographic changes in the specimens as well as large amounts of iodine detected in the leachate solutions. The instabilities of BiI 3 and SnI 4 raise uncertainties for using the base metals/cations (i.e., Bi 0 /Bi 3+ and Sn 0 /Sn 4+ , respectively) as viable getters for radioiodine capture due to likely poor waste form chemical durabilities after capture and consolidation into waste forms.

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

Multicycle flash sintering of cubic Y 2 O 3 -stabilized ZrO 2 : An in situ energy dispersive synchrotron x-ray diffraction study with high temporal resolution

The current induced unit cell volume changes, (111) Bragg peak full width at half maximum (FWHM) and its integrated intensity in 8 % Y 2 O 3 stabilized ZrO 2 (8 %YSZ) solid state electrolyte was monitored during a triple-flash sintering experiment by in situ energy dispersive x-ray diffraction using a polychromatic synchrotron probe (max, photon energy 200 keV) with 2 second temporal resolution. The first spontaneous singularity in the unit cell volume (+0.54 %) was observed at 899 °C under 15 V/mm applied field intensity, which was associated with 13 mA/mm 2 current draw and an increase in density to 97 %. Following anelastic relaxation of the unit cell volume under open circuit conditions, the same applied field was applied twice in a row which resulted in additional induced singularities at 925 °C (+0.48 %) and 944 °C (+0.42 %). A floating baseline, which was above the thermal expansion baseline, was observed from 833 to 969 °C and was attributed to Joule heating. In conclusion, the singularity at 899 °C is associated with a sharp change in (111) FWHM and a 34 % decrease in integrated peak area that was attributed to changes in the distribution of oxygen vacancies and the changes in their concentration as induced by the applied field in the spontaneous transient stage of flash sintering.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Development of High Temperature (>700°C) molten Salt Pump Technology for Gen3 Solar Power Tower Systems

Generation 3 Concentrating Solar Power (CSP) Systems require thermal energy storage that can efficiently receive solar heat and deliver it to a working fluid at temperatures greater than 700°C. For liquid systems, the thermal transfer fluid must be phase stable over large temperature ranges. High temperature molten salts meet this criteria, but are difficult liquids to handle. The high heat and salt content can be very corrosive to several different materials that are wetted by the liquid salt. For power tower collectors, the molten salt must be pumped under high pressure to the top of the collector tower. These pumps have impellers and shafts as part of their rotating elements, and under load, require bearings to control shaft movement while rotating. These high temperature pumps require submerged bearings, and thus bearing materials that can withstand the temperature and molten salt contact over long periods of time. This is essential for keeping pump maintenance costs low, and downtime to a minimum. Long running bearing materials is an enabling technology for integrated liquid systems in Generation 3 CSP Systems. Keeping costs low and systems reliable are critical for the broad adoption of Gen 3 CSP Systems. Hayward Tyler, Inc (HTI) proposed development of journal bearing materials for use in vertical pumps designed for pumping high temperature molten salt on both the hot and cold sides of the solar power tower. To complete this objective, HTI utilized the testing capabilities of Oak Ridge National Laboratory (ORNL) and High Temperature System Design (HTSD). Materials would first be selected for static corrosion testing, then downselected for tribological testing. Successful tribologically tested materials would then be downselected for use in additional test regimes. Ten samples were selected for static corrosion testing. Three passed the static testing regime. Two of these materials were downselected for ball material in tribological testing against three metallic alloys: Sintered Y2O3 Partially Stabilized Zirconia YTZP and Silicon Nitride, Grade 147-31N. HTI also proposed collecting data from a thorough bearing test regime using a test rig designed and built as part of this project, and also a conceptual design for a high temperature molten salt vertical pump. HTI withdrew from the project prior to completion of this work and this report reflects only the work completed prior to withdrawal. The completed work produced two papers, one manuscript submitted for publication, and one paper published in the journal Solar Energy Materials and Solar Cells. The papers are: “Tribological behavior of ceramic-alloy bearing contacts in molten salt lubrication for concentrating solar power” and “Material Selection and Corrosion Studies Of Candidate Bearing Materials For Use In Molten Chloride Salt."

14 SOLAR ENERGY↗
DOE OSTI2022

Power Electronics Materials and Bonded Interfaces - Reliability and Lifetime

Wide-bandgap devices have pushed the operational limit of semiconductor devices in automotive power electronics packages to higher temperatures (>200 C). While a higher efficiency can be achieved through the use of wide-bandgap devices, the entire package must be re-designed with components that can withstand the higher temperature limits. Sintered silver and transient liquid phase bonds are potential candidates as bonded materials for use in higher temperatures however, the underlying mechanics of deformation under thermal loads and the resulting failure mechanisms in these materials are not well understood. Accelerated experiments conducted at NREL reveal that high-lead solder joints have better reliability than sintered silver under extreme thermal cycling conditions. Furthermore, efforts to develop a crack propagation model for the high-temperature materials are described.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Development of a high-temperature Inconel 625 heat exchanger by model design and binder jetting additive manufacturing

A nickel-based Inconel 625 superalloy heat exchanger for high-temperature applications was developed via binder jetting additive manufacturing. The material properties were characterized first on printed and sintered parts. Two sintering temperatures were used to investigate the effects of the temperature on densification and microstructure. For channel geometry design, the heat transfer capabilities of the heat exchanger were optimized for the cross-section geometry of fluid flow channels in a counterflow configuration, and a stress analysis was conducted to investigate the effects of channel geometry. After headers were incorporated into the heat exchanger as a one-piece component, a prototype was printed. A complete depowdering was achieved via compressed air blowing, and sintering was performed with the developed profile. Ultimately, a one-piece heat exchanger with a nearly full density was obtained. Heat transfer tests were performed on this unit, and the results were compared with those from the simulations. In this study, systematic processes were developed for an additively manufactured Inconel-based heat exchanger for high-pressure, high-temperature heat transfer applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Modeling the performance and faradaic efficiency of solid oxide electrolysis cells using doped barium zirconate perovskite electrolytes

Y-doped BaZrO 3 (BaZr 1 x Y x O 3 δ , or “BZY”), a proton-conducting ceramic featuring high bulk conductivity and good chemical stability, is a promising electrolyte material for solid oxide electrolysis cells. Further doping with Ce and/or Yb (creating materials “BCZY” and “BCZYYb”) can improve conductivity and sintering properties, but at significant penalty to cells’ faradaic efficiency (FE). Studies have proposed that reduction of lattice Ce can occur in the hydrogen electrode, which consumes some hydrogen produced by the hydrogen evolution reaction, leading to decreased FE. Despite studies suggesting this phenomenon, the mechanism is largely unknown. In this work, we developed a multiphysics model to study the transport of multiple defect species and the performance of BZY, BCZY, and BCZYYb, capturing the tradeoff between enhanced performance at the cost of FE for BCZY and BCZYYb electrolytes compared to BZY. We also found that increasing the water content of the anode gas supply lowers the current output of the cell but results in better FE. The model, which uses several parameters previously unavailable in the literature, was validated to experiments varying temperature, steam water content, and electrolyte material, as well as two performance metrics (performance curves and FE). Results verify and explain observed trends, informing future work on Ce-doped BZY electrolytes.

08 HYDROGEN↗
NASA NTRS1993

Lightweight nickel electrodes for nickel/hydrogen cells

Thick nickel electrodes with lightweight substrate material have been prepared and tested in Ni/H2 boilerplate cells containing 26 percent KOH electrolyte. Lightweight substrates used were either 85 or 90 percent in porosity and either 0.8 or 2 mm in thickness, respectively, compared with 80 to 82 percent porosity and 0.75 to 0.8 mm thickness of the state-of-the-art sintered plaque substrate. All of these thick electrodes had substantially improved theoretical (or chemical) capacity over that of state-of-the-art sintered nickel plaque electrodes. However, utilization of the active material was low (65 to 80 percent) compared with that of the state-of-the-art electrodes (approximately 90 percent) in 26 percent KOH. Due to this low utilization, the electrodes using 85 percent porous substrates did not show any advantage over the state-of-the-art ones. The electrodes using a 90 percent porous substrate, however, showed 17 percent higher usable specific capacity (about 0.13 Ah/g in 26 percent KOH) than that of the state-of-the-art nickel electrodes despite the low utilization. These electrodes achieved up to 4860 cycles at 40 percent depth-of-discharge with neither capacity loss nor any significant changes of rate capability and charging efficiency with cycling.

Lim, Hong S.↗
NASA NTRS1991

Physical and chemical analysis of a Ni/H2 cell

A cycled aerospace nickel hydrogen (Ni/H2) cell was subjected to destructive physical analysis to determine the reason for a capacity loss after 5,967 cycles at 60 percent depth of discharge. The positive plates in the cell were analyzed in terms of chemical composition, active material utilization, charge efficiency, and thickness increase. The microstructure of a cross section of the positive plate was determined by backscattered electron image analysis. The results suggest that the capacity loss in the cell is caused by low charge acceptance and low active material utilization at the positive plate. The oxidized nickel species content of the positive plate increased due to corrosion of the nickel sintered skeleton. This appears to circumvent the orderly reaction of the active material. Microstructural analysis has indicated that a new phase of active material is formed with cycling.

H Vaidyanathan↗
NASA NTRS1973

Controlled porosity and pore size substrates for nickel-cadmium cells

A novel process for the preparation of improved cadmium electrode plaques with precisely controlled pore size and porosity is described. The requirements for these plaques include far better uniformity, reproducibility, and life than is currently available with conventional materials. The key features of the work were preparation of plaques via a powder metallurgical technique which consisted of isostatically compacting a blend of a nickel powder with a fugitive pore-former and subsequently sintering the 'green' compact. Cadmium electrodes were prepared from these materials and were cycle tested in negative-limited cells using an accelerated, torturous test regime. Results were obtained which showed the new structures yielded electrodes that were superior to the conventional structures in mechanical properties and performance.

Gordy, D. J.↗
DOE OSTI2024

Extraordinary Thermal Stability and Sinter Resistance of Sub-2 nm Platinum Nanoparticles Anchored to a Carbon Support by Selenium

Nanoparticle sintering has long been a major challenge in developing catalytic systems for use at elevated temperatures. Here we report an in situ electron microscopy study of the extraordinary sinter resistance of a catalytic system comprised of sub-2 nm Pt nanoparticles on a Se-decorated carbon support. When heated to 700 °C, the average size of the Pt nanoparticles only increased from 1.6 to 2.2 nm, while the crystal structure, together with the {111} and {100} facets, of the Pt nanoparticles was well retained. Our electron microscopy analyses suggested that the superior resistance against sintering originated from the Pt–Se interaction. Confirmed by energy-dispersive X-ray elemental mapping and electron energy loss spectra, the Se atoms surrounding the Pt nanoparticles could survive the heating. This work not only offers an understanding of the physics behind the thermal behavior of this catalytic material but also sheds light on the future development of sinter-resistant catalytic systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗