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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Methods and systems for fabricating high quality superconducting tapes

An MOCVD system fabricates high quality superconductor tapes with variable thicknesses. The MOCVD system can include a gas flow chamber between two parallel channels in a housing. A substrate tape is heated and then passed through the MOCVD housing such that the gas flow is perpendicular to the tape's surface. Precursors are injected into the gas flow for deposition on the substrate tape. In this way, superconductor tapes can be fabricated with variable thicknesses, uniform precursor deposition, and high critical current densities.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Design and fabrication of the waveguide Iris couplers for the Spallation Neutron Source drift tube linac

The Spallation Neutron Source (SNS) employs six cavities in the Drift Tube Linac (DTL) section to accelerate the H- ion beam to 87MeV. Each cavity is energized by a 2.5MW peak power klystron at 402.5MHz using rapid tapered waveguide iris couplers. All six original iris couplers have been in operation without replacement for over two decades. The increased RF power demands of the Proton Power Upgrade (PPU) project and operational problems, including arcing, temperature excursions, and vacuum bursts, have prompted the development of new iris coupler spares. The original iris couplers were made of GlidCop material, which is known to be mechanically strong and thermally stable, but is porous, expensive, and difficult to use in fabrication. To overcome these problems, the new spare couplers use Oxygen-Free Copper (OFC) and stainless steel (SS). This paper will discuss the mechanical, thermal and RF design, as well as challenges in the final coupler fabrication.

Lee, Sung-Woo↗
DOE OSTI2022

Ultra-high temperature carbide foams and methods of fabricating the same

Ultra-high temperature carbide (UHTC) foams and methods of fabricating and using the same are provided. The UHTC foams are produced in a three-step process, including UHTC slurry preparation, freeze-drying, and spark plasma sintering (SPS). The fabrication methods allow for the production of any kind of single- or multi-component UHTC foam, while also providing flexibility in the shape and size of the UHTC foams to produce near-net-shape components.

Agarwal, Arvind↗
DOE OSTI2023

Method for fabricating a hybrid carbon nanofiber product

Hybrid carbon nanofiber (Cnf) products (e.g., mats, yarns, webs, etc.) and methods of fabricating the same are provided. The hybrid Cnf products are flexible and lightweight and have high thermal conductivity. An electrospinning process can be used to fabricate the hybrid Cnf products and can include preparation of an electrospinning solution, electrospinning, and carbonization (e.g., under a vacuum condition).

Agarwal, Arvind↗
DOE OSTI2023

Small gap device system and method of fabrication

A small-gap device system, preferably including two or more electrodes and one or more spacers maintaining a gap between two or more of the electrodes. A spacer for a small-gap device system, preferably including a plurality of legs defining a mesh structure. A method of spacer and/or small-gap device fabrication, preferably including: defining lateral features, depositing spacer material, selectively removing spacer material, separating the spacer from a fabrication substrate, and/or assembling the small-gap device.

Schwede, Jared William↗
DOE OSTI2023

Ultra-high temperature carbide foams and methods of fabricating the same

Ultra-high temperature carbide (UHTC) foams and methods of fabricating and using the same are provided. The UHTC foams are produced in a three-step process, including UHTC slurry preparation, freeze-drying, and spark plasma sintering (SPS). The fabrication methods allow for the production of any kind of single- or multi-component UHTC foam, while also providing flexibility in the shape and size of the UHTC foams to produce near-net-shape components.

Agarwal, Arvind↗
DOE OSTI2020

Fabrication Lessons Learned of Transportation Packaging from the Perspective of a Design Authority - 20322

This paper presents lessons learned regarding fabricating packaging systems from the perspective of a design authority (DA). Capturing and implementing lessons learned is critical for an organization to reduce systematic project risk and thereby promote the likelihood of project success. This paper defines the design authority as the organization responsible for technical design, resolving technical design issues, quality assurance program, and maintenance of the packaging system license. A package system is defined as the packaging, its contents, and auxiliary equipment. Packages are certified by the NRC under 10 CFR 71[1] for transportation by ground. The following lessons learned subjects are presented in the paper: quality assurance, interpretation of drawing dimensional requirements, execution of manufacturing processes, hardware dimensional inspection, and leakage rate testing. All discrepancies presented in this paper have been resolved as described in the appropriate final data package. All described package systems are in compliance with their Safety Analysis Report (SAR) and certificate of conformance requirements. The intent of this paper is to identify opportunities for improving the outcome of future projects and to mitigate fabrication challenges proactively. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Fabrication status of production SSR1 jacketed cavities for PIP-II at Fermilab

This paper provides an overview of the current fabrication status of superconducting SSR1 spoke cavities intended for integration into the PIP-II SRF linac at Fermilab. It explores the ongoing development and fabrication processes of the jacketed SSR1 cavity, highlighting key modifications made in the mechanical design to enhance structural integrity.

Aiazzi, T.↗
DOE OSTI2024

Alkali semi-metal films and method and apparatus for fabricating them

Methods and systems for fabricating a film, such as, for example, a photocathode, having a tailored band structure and thin-film components that can be tailored for specific applications, such as, for example photocathode having a high quantum efficiency, and simple components fabricated by those methods.

Bhandari, Harish B.↗
DOE OSTI2024

Methods and systems for fabricating high quality superconducting tapes

An MOCVD system fabricates high quality superconductor tapes with variable thicknesses. The MOCVD system can include a gas flow chamber between two parallel channels in a housing. A substrate tape is heated and then passed through the MOCVD housing such that the gas flow is perpendicular to the tape's surface. Precursors are injected into the gas flow for deposition on the substrate tape. In this way, superconductor tapes can be fabricated with variable thicknesses, uniform precursor deposition, and high critical current densities.

Majkic, Goran↗
DOE OSTI2024

Methods of fabricating porous ceramic electrodes for solid state battery applications

Compositions and methods for the fabrication of electrode and porous lithium-garnet electrolyte scaffolds for use in solid state batteries and other devices are provided. The methods produce porous structures using phase inversion or high shear compaction processes to fabricate a solid-state battery electrode material from LLZO electrolytes. Engineered electrode structures with a porous scaffold of solid electrolyte material provide lower interfacial resistances and a mechanical support for a thin solid electrode layer improving performance.

Tucker, Michael↗
DOE OSTI2022

Fabrication and Characterization of Iron-Based Catalysts for the Dehydrogenation of Fossil Fuels

For a prosperous and sustainable future, hydrogen is an encouraging solution due to its simple transition for industrial decarbonization and synergy for economic development. Paradoxically, current hydrogen production pathways release substantial amount of greenhouse gases into the atmosphere contributing to climate change. To keep up with increasing demand, hydrogen could be produced through microwave-assisted thermocatalytic dehydrogenation of fossil fuels without emitting carbon dioxide. This requires specified catalysts to meet the requirements of hydrogen yield and selectivity. The objective of the present research is to fabricate, characterize, and compare iron-based alumina (FeAlxOy) catalysts produced via solution combustion synthesis and iron-based catalysts on silicon carbide support (Fe/SiC) produced via incipient wetness impregnation. Heat mode, fuel type, and oxidizer mole ratio were varied for FeAlxOy catalysts, and metal loading was varied for Fe/SiC catalysts. Each resultant product was characterized by X-ray diffraction analysis, scanning electron microscopy, laser diffraction particle size analysis, and Brunauer-Emmett-Teller (BET) surface area analysis. Characterization suggests that fabrication of iron-based alumina nanocomposites through solution combustion synthesis in a muffle furnace using citric acid as the fuel yields the most promising catalyst.

Reyes, Victoria Isabel↗
DOE OSTI2022

Spall damage mechanisms in laser powder bed fabricated stainless steel 316L

This paper reports on spall damage mechanisms in laser powder bed fusion (LPBF) fabricated stainless steel 316L (SS316L) subjected to uniaxial, strain plate-impact loading and explores failure evolution with increasing impact velocity and peak pressure. Analysis of velocimetry profiles reveals a heterogeneous failure response with several different failure mechanisms activated during impact and resulting spall. The analysis is supported by optical microscopy and electron backscattered diffraction (EBSD) observation of soft recovered impacted samples, which show evidence of localized nano-twinning, twin growth, severe grain rotation, and grain refinement along the spall plane, in addition to pore nucleation, coalescence, and growth. Furthermore, the observed failure mechanisms, including crack formation and propagation along high angle grain boundaries (HAGBs), are not consistently indicative of ductile fracture typical of wrought stainless steel.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fabrication of OMT-Coupled Kinetic Inductance Detector for CMB Detection

Future cosmic microwave background (CMB) experiments, including the large scale ground-based Stage Four CMB Experiment (CMB-S4), satellites, and balloons, aim to map the CMB to an unprecedented precision in order to answer several key questions in cosmology. However, to reach the target noise sensitivity, more than 100,000 detectors will be needed. Arrays of kinetic inductance detectors (KIDs) are a promising alternative for experiments that require large number of detectors due to the intrinsic multiplexing capabilities. We present the fabrication procedure for a prototype planar orthomode transducer (OMT)-coupled multi-color KID array optimized for 220/270 GHz frequency bands. These devices are made from silicon-on-insulator wafers to provide a low-loss substrate for the KIDs. The OMT couples the two polarizations of light from a wide-band feedhorn to separate Nb/SiN/Nb microstrip lines, which are then coupled to Al/Nb lumped-element KIDs (LEKIDs). The silicon on the backside of the OMT is etched away using deep reactive ion etch to release the OMT membrane to enable operation over a wide bandwidth. Finally, the buried oxide is removed underneath the KID capacitors in order to minimize two-level system noise and loss mitigation. We achieved a good yield (> 80%) on our prototype devices.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Fused filament fabrication of thermoplastic polyurethane composites with microencapsulated phase-change material

Here, the present study examines the thermal energy storage (TES) effectiveness and printability of microencapsulated phase-change material (MEPCM) combined with thermoplastic polyurethane (TPU) for fused filament fabrication (FFF). Two formulations were assessed: 24D MEPCM, which changes phase at 24 ° C, compounded with TPU pellets and 43D MEPCM, which changes phase at 43 ° C, integrated with TPU powder. These combinations are designed to evaluate the effectiveness of the form of the TPU (pellets versus powder) in the FFF process. The investigation includes a comprehensive analysis of thermal characteristics, encompassing phase-change temperature, latent heat of fusion, thermal conductivity, and thermal decomposition, which are assessed through differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). Additionally, mechanical properties, including stress-strain behavior, are examined to evaluate material suitability for TES applications, while microstructural visualization is used to provide deeper insights into material performance, structural integrity, and the quality of printed components. The 24D MEPCM and TPU pellets formulation experienced a significant loss of approximately 39.6% of PCM during filament extrusion and printing, resulting in a reduced effective latent heat. Therefore, further characterization of the pellet formulation was discontinued due to excessive leakage. In contrast, the 43D MEPCM and TPU powder formulation demonstrated minimal PCM loss, with the 60 wt.% composition achieving an effective latent heat of 132 J/g. This value represents the highest effective latent heat currently documented in the literature for PCM-polymer-composite materials produced using an FFF-based additive manufacturing process.

25 ENERGY STORAGE↗
DOE OSTI2020

Printing polymer blends through in situ active mixing during fused filament fabrication

Fused filament fabrication (FFF) enables production of 3D objects over a range of material compositions at low-cost relative to traditional manufacturing approaches. To date, a limited but growing number of materials are able to be used with FFF, however many applications exist where specific mechanical, thermal, or chemical properties are needed that cannot currently be met with the available feedstock selection. Therefore, a need exists to tune these materials for specific chemical or mechanical properties. One common formulation strategy to address these demanding design parameters is to develop composites or polymer blend filaments. Typically, this is a time-consuming and costly optimization process. Here, we have developed hardware for reproducibly mixing two filaments of similar or dissimilar compositions at the time of printing within individual printed layers. This mixing occurs via software-controlled rotating hardware in the chamber of an extruder’s hot-end. The efficiency of mixing within the printed layers has been characterized in detail as a function of the rotational speed and geometry of the blending hardware. These parameters were exploited to program the ratio and distribution of thermoplastic-based filaments blended within printed extrudate. Example printed specimens were produced with thermoplastic polyurethane (TPU) elastomer blended with rigid polylactic acid (PLA) and Nylon blended with PLA. In addition, a conductive carbon nanotube (CNT)-PLA composite was blended as a function of mixer geometry and input feed ratios with non-conductive PLA and resistance values were measured across the resulting printed specimens.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Fused filament fabrication of novel phase-change material functional composites

Additively manufactured polymer heat exchangers are of recent interest in the thermal sciences due to their lightweight and intricate heat-transfer-enhancing geometrical features. The goal of the present research is to directly encapsulate phase-change material (PCM) into polymer filament for the purpose of 3D printing polymer heat exchangers capable of latent heat thermal energy storage and management. PCMs have the ability to absorb large amounts of latent heat while undergoing a solid-to-liquid phase change at a nearly constant temperature. Encapsulation or containment of PCMs is necessary to prevent leaking since the material continuously cycles between a liquid and a solid state. An organic-based PCM and high-density polyethylene (HDPE) were combined and extruded into a functional composite filament. For the first time, with the aid of a heated enclosure and HDPE build plates, it was demonstrated that these functional composite materials can be printed using fused filament fabrication (FFF). Printing HDPE is known to be difficult; however, based on what was observed in the current study, the PCM and HDPE composite was easier to print than pure HDPE. Thermal properties, such as latent heat of fusion, phase-change temperature, and thermal conductivity, of the composite filament and 3D printed samples were investigated and compared with compression-molded bulk material. Finally, the microstructures of the composite filament and 3D printed samples were visualized, and the basic structures of the HDPE and PCM within both the filament and 3D printed parts were clearly delineated.

36 MATERIALS SCIENCE↗