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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Interdependence of Support Wettability - Electrodeposition Rate- Sodium Metal Anode and SEI Microstructure

Here, this study examines how current collector support chemistry (sodiophilic intermetallic Na 2 Te vs. sodiophobic baseline Cu) and electrodeposition rate affect microstructure of sodium metal and its solid electrolyte interphase (SEI). Capacity and current (6 mAh cm -2 , 0.5–3 mA cm -2 ) representative of commercially relevant mass loading in anode-free sodium metal battery (AF-SMBs) are analyzed. Synchrotron X-ray nanotomography and grazing-incidence wide-angle X-ray scattering (GIWAXS) are combined with cryogenic ion beam (cryo-FIB) microscopy. Highlighted are major differences in film morphology, internal porosity, and crystallographic preferred orientation e.g. (110) vs. (100) and (211) with support and deposition rate. Within the SEI, sodium fluoride (NaF) is more prevalent with Te-Cu versus sodium hydride (NaH) and sodium hydroxide (NaOH) with baseline Cu. Due to competitive grain growth the preferred orientation of sodium crystallites depends on film thickness. Mesoscale modeling delineates the role of SEI (ionic conductivity, morphology) on electrodeposit growth and onset of electrochemical instability.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Abnormal grain growth in ultrafine grained Ni under high-cycle loading

Abnormal grain growth can occur in polycrystalline materials with only a fraction of grains growing drastically to consume other grains. We report abnormal grain growth in ultrafine grained metal in a rarely explored high-cycle loading regime at ambient temperature. Abnormal grain growth is observed in electroplated Ni microbeams with average initial grain sizes less than 640 nm under a large number of loading cycles (up to 109) with low strain amplitudes (< 0.3%). Such abnormal grain growth occurs predominantly in the family of grains whose <100> orientation is along the tensile/compressive loading direction. Micromechanics analysis suggests that the elastic anisotropy of grains dictates the thermodynamic driving force of abnormal grain growth, such that the lowest strain energy density of the <100> oriented grain family dominates grain growth. This work unveils a unique type of abnormal grain growth that may be harnessed to tailor grain microstructures in materials.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Unraveling the implications of finite specimen size on the interpretation of dynamic experiments for polycrystalline aluminum through direct numerical simulations

Normal and Pressure-shear plate impact (NPI and PSPI) experiments are popular experimental techniques for studying the mean-field macroscopic behavior of polycrystalline metals under high-rate dynamic loading. However, since both configurations rely upon geometry for subjecting the specimen to high strain rates, these experiments often involve a limited specimen size. Moreover, because of the inherent heterogeneities present within polycrystalline metals, it is difficult to ascertain if the size of the specimen and/or regions where measurements are made are sufficiently large for making representative inferences about the mean-field macroscopic properties from single-point velocity measurements. In the present study, we quantify the expected measurement variability on observable point measurements in NPI and PSPI experiments by carrying out direct numerical simulations (DNS) of statistically representative polycrystalline microstructures subjected to dynamic compression and compression-shear loading. In particular, we consider the role of specific material heterogeneities (e.g. the grain-to-grain difference in size, crystallographic orientation) on dispersion in the normal and transverse particle velocity records and on local fluctuations in key state variables (e.g. velocity, accumulated plastic strain) by incorporating these effects directly into a representative synthetic microstructure geometry and crystalline description of pure polycrystalline aluminum. The form of the present study is a large parametric investigation, consisting of ten ensembles of one hundred simulations. Each of the thousand simulations reflects a randomly realized synthetic microstructure in one of five cases of decreasing average grain size for the two loading configurations. Our analysis of the DNS results demonstrates that for both of these experimental configurations, the grain size directly correlates with the coefficient of variation (CV) in simulated point measurements, showing a convergent decrease in CV to zero (i.e. particle velocity record approaches the mean-field value) with decreasing grain size. Remarkably, the magnitude of variations in the particle velocity record is shown to be largest where the deviatoric stresses are most significant. In the case of NPI, this occurs at the elastic and plastic wavefront, whereas, in the case of PSPI, the magnitude of fluctuations are approximately constant throughout the experimental window time. The reasoning for the scatter in particle velocity due to the heterogeneous microstructure is demonstrated to be dependent on the mechanisms for accommodating deformation and on the interaction of reflection waves generated at sites of heterogeneities occurring at the scale of grains. Lastly, we develop a power-law description for the magnitude of scattering versus characteristic length, which provides a statistical framework for assessing the required number of grains per characteristic specimen dimension for minimizing scatter within these two experimental configurations (NPI, PSPI).

36 MATERIALS SCIENCE↗
DOE OSTI2021

Optimization of Magnesium-Doped Lithium Metal Anode for High Performance Lithium Metal Batteries through Modeling and Experiment

Lithium (Li)-magnesium (Mg) alloy with limited Mg amount, which can also be called Mg-doped Li (Li-Mg), has been considered as a potential alternative anode for high energy density rechargeable Li metal batteries. However, the optimum doping-content of Mg in Li-Mg anode and the mechanism of the improved performance are not well understood. In this study, density functional theory (DFT) calculations are used to investigate the effect of Mg amount in Li-Mg anode. The Li-Mg with about 5 wt. % Mg (abbreviated as Li-Mg5) has the lowest absorption energy of Li, thus all the surface area can be “controlled” by Mg atoms, leading to the smooth and continuous deposition of Li on the surface around the Mg center. A localized high concentration electrolyte enables Li-Mg5 to exhibit the best cycling stability in Li metal batteries with high-loading cathode and lean electrolyte under 4.4 V high-voltage, which is approaching the demand of practical application. This electrolyte also helps generate an inorganic-rich solid electrolyte interphase, which leads to smooth, compact and less corrosion layer on the Li-Mg5 surface. Both theoretical simulations and experimental results prove that Li-Mg5 has optimum Mg content and gives best battery cycling performance.

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

An In-Depth Exploration of the Electrochemical Oxygen Reduction Reaction (ORR) Phenomenon on Carbon-Based Catalysts in Alkaline and Acidic Mediums

Detailed studies of the electrochemical oxygen reduction reaction (ORR) on catalyst materials are crucial to improving the performance of different electrochemical energy conversion and storage systems (e.g., fuel cells and batteries), as well as numerous chemical synthesis processes. In the effort to reduce the loading of expensive platinum group metal (PGM)-based catalysts for ORR in the electrochemical systems, many carbon-based catalysts have already shown promising results and numerous investigations on those catalysts are in progress. Most of these studies show the catalyst materials’ ORR performance as current density data obtained through the rotating disk electrode (RDE), rotating ring-disk electrode (RRDE) experiments taking cyclic voltammograms (CV) or linear sweep voltammograms (LSV) approaches. However, the provided descriptions or interpretations of those data curves are often ambiguous and recondite which can lead to an erroneous understanding of the ORR phenomenon in those specific systems and inaccurate characterization of the catalyst materials. In this paper, we presented a study of ORR on a newly developed carbon-based catalyst, the nitrogen-doped graphene/metal-organic framework (N-G/MOF), through RDE and RRDE experiments in both alkaline and acidic mediums, taking the LSV approach. The functions and crucial considerations for the different parts of the RDE/RRDE experiment such as the working electrode, reference electrode, counter electrode, electrolyte, and overall RDE/RRDE process are delineated which can serve as guidelines for the new researchers in this field. Experimentally obtained LSV curves’ shapes and their correlations with the possible ORR reaction pathways within the applied potential range are discussed in depth. We also demonstrated how the presence of hydrogen peroxide (H2O2), a possible intermediate of ORR, in the alkaline electrolyte and the concentration of acid in the acidic electrolyte can maneuver the ORR current density output in compliance with the possible ORR pathways.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1986

Factors influencing design and selection of GTAW robotic welding machines for the Space Shuttle main engine

Proposed hardware and software for microprocessor-controlled power supplies and welding machines are described. The application of the automatic seven-axis welding machine, which is to be preprogrammed to allow minimum intervention by the welding operator during the actual process, to the welding of the Space Shuttle main engine is discussed. The production requirements for the gas tungsten arc welds for the Space Shuttle main engine are examined. Consideration is given to positioner design, welding variables, inert shielding gas management, filler metal wire control, the up loading and down loading of data from off-line computers, process improvements, tooling, the welding variable library, and adaptive sensor control.

Flanigan, L.↗
NASA NTRS1991

Superelement methods in high temperature metal matrix composites

A study into fiber fracture and debonding in metal matrix composites is conducted using the finite element method. The superelement finite element technique was used to model a metal matrix composite under various loading condition and with varying degrees of fiber debonding. The use of superelement saved many man hours by allowing for alteration of only the primary superelement to manipulate partial bonding for the entire model. The composite's material properties were calculated and the effects of fiber debonding on these properties were noted. The internal stress state of the composite while under various loads was also studied. Special interest was devoted to the change in stress state as a result of increasing fiber debonding.

Trowbridge, Daniel↗
NASA NTRS1993

An analytical/numerical correlation study of the multiple concentric cylinder model for the thermoplastic response of metal matrix composites

The utility of a recently developed analytical micromechanics model for the response of metal matrix composites under thermal loading is illustrated by comparison with the results generated using the finite-element approach. The model is based on the concentric cylinder assemblage consisting of an arbitrary number of elastic or elastoplastic sublayers with isotropic or orthotropic, temperature-dependent properties. The elastoplastic boundary-value problem of an arbitrarily layered concentric cylinder is solved using the local/global stiffness matrix formulation (originally developed for elastic layered media) and Mendelson's iterative technique of successive elastic solutions. These features of the model facilitate efficient investigation of the effects of various microstructural details, such as functionally graded architectures of interfacial layers, on the evolution of residual stresses during cool down. The available closed-form expressions for the field variables can readily be incorporated into an optimization algorithm in order to efficiently identify optimal configurations of graded interfaces for given applications. Comparison of residual stress distributions after cool down generated using finite-element analysis and the present micromechanics model for four composite systems with substantially different temperature-dependent elastic, plastic, and thermal properties illustrates the efficacy of the developed analytical scheme.

Pindera, Marek-Jerzy↗
NASA NTRS1992

Design, analysis, and testing of a metal matrix composite web/flange intersection

An experimental and analytical program to study the local design details of a typical T-shaped web/flange intersection made from a metal matrix composite is described. Loads creating flange bending were applied to specimens having different designs and boundary conditions. Finite element analyses were conducted on models of the test specimens to predict the structural response. The analyses correctly predict failure load, mode, and location in the fillet material in the intersection region of the web and the flange when specimen quality is good. The test program shows the importance of fabrication quality in the intersection region. The full-scale test program that led to the investigation of this local detail is also described.

Biggers, S. B.↗
NASA NTRS1995

In-phase thermomechanical fatigue mechanisms in an unidirectional SCS-6/Ti 15-3 MMC

The objective of this investigation was to identify the inelastic deformation and damage mechanisms under in-phase (IP) thermomechanical fatigue (TMF) in a unidirectional SCS-6/Ti 15-3 metal matrix composite (MMC). Load-controlled IP TMF tests were conducted at 300-538 C at various stress ranges in high-purity argon. A major emphasis of this work was to identify damage mechanism well before final fracture of specimens, rather than to generate life diagrams, to aid development of a realistic deformation/damage and life model.

Newaz, Golam M.↗
NASA NTRS2001

Microgravity Production of Nanoparticles of Novel Materials Using Plasma Synthesis

The research goal is to study the formation in reduced gravity of high quality nanoparticulate of novel materials using plasma synthesis. Particular emphasis will be placed on the production of powders of non-oxide materials like diamond, SiC, SiN, c-BN, etc. The objective of the study is to investigate the effect of gravity on plasma synthesis of these materials, and to determine how the microgravity synthesis can improve the quality and yield of the nanoparticles. It is expected that the reduced gravity will aid in the understanding of the controlling mechanisms of plasma synthesis, and will increase the yield, and quality of the synthesized powder. These materials have properties of interest in several industrial applications, such as high temperature load bearings or high speed metal machining. Furthermore, because of the nano-meter size of the particulate produced in this process, they have specific application in the fabrication of MEMS based combustion systems, and in the development and growth of nano-systems and nano-structures of these materials. These are rapidly advancing research areas, and there is a great need for high quality nanoparticles of different materials. One of the primary systems of interest in the project will be gas-phase synthesis of nanopowder of non-oxide materials.

Frenklach, Michael↗
NASA NTRS2001

Evaluation of Ti-48Al-2Cr-2Nb Under Fretting Conditions

The fretting behavior of Ti-48Al-2Cr-2Nb (y-TiAl) in contact with the nickel-base superalloy 718 was examined in air at temperatures from 296 to 823 K (23 to 550 C). The interfacial adhesive bonds between Ti-48Al-2Cr-2Nb and superalloy 718 were generally stronger than the cohesive bonds within Ti-48Al-2Cr-2Nb. The failed Ti-48Al-2Cr-2Nb debris subsequently transferred to the superalloy 718. In reference experiments conducted with Ti-6Al-4V against superalloy 718 under identical fretting conditions, the degree of transfer was greater for Ti-6A1-4V than for Ti-48Al-2Cr-2Nb. Wear of Ti-48Al-2Cr-2Nb generally decreased with increasing fretting frequency. The increasing rate of oxidation at elevated temperatures led to a drop in wear at 473 K. However, fretting wear increased as the temperature was increased from 473 to 823 K. At 723 and 823 K, oxide film disruption generated cracks, loose wear debris, and pits on the Ti-48Al-2Cr-2Nb wear surface. Both increasing slip amplitude and increasing load tended to produce more metallic wear debris, causing severe abrasive wear in the contacting metals.

Miyoshi, Kazuhisa↗
NASA NTRS2003

METAShield: Hot Metallic Aeroshell Concept for RLV/SOV

An innovative fuselage design approach that combines many desirable operational features with a simple and efficient structural approach is being developed by NASA. The approach, named METAShield for MEtallic TransAtmospheric Shield, utilizes lightly loaded, hot aeroshell structures surrounding integral propellant tanks that carry the primary structural loads. The aeroshells are designed to withstand the local pressure loads, transmitting them to the tanks with minimal restraint of thermal growth. No additional thermal protection system protects the METAShield, and a fibrous or multilayer insulation blanket, located in the space between the aeroshell and the tanks, serves as both high temperature and cryogenic insulation for the tanks. The concept is described in detail, and the performance and operational features are highlighted. Initial design results and analyses of the structural, thermal, and thermal-structural performance are described. Computational results evaluating resistance to hypervelocity impact damage, as well as some supporting aerothermal wind tunnel results. are also presented. Future development needs are summarized.

Scotti, Stephen J.↗
NASA NTRS2001

Friction pull plug welding: dual chamfered plate hole

Friction Pull Plug Welding (FPPW) is a solid state repair process for defects up to one inch in length, only requiring single sided tooling (OSL) for usage on flight hardware. Early attempts with FPPW followed the matching plug/plate geometry precedence of the successful Friction Push Plug Welding program, however no defect free welds were achieved due to substantial plug necking and plug rotational stalling. The dual chamfered hole has eliminated plug rotational stalling, both upon initial plug/plate contact and during welding. Also, the necking of the heated plug metal under a tensile heating/forging load has been eliminated through the usage of the dual chamfered plate hole.

Coletta, Edmond R.↗
NASA NTRS2018

Restore-L Satellite Servicing Internship Final Report

An experiment was conducted to determine whether a sample of shorter flexible metal hoses could sustain tensile loads of up to 200 lbf and continue to meet the minimum mission requirements. The purpose of this experiment was to determine if tension loads during the processing of the hoses compromise performance. With this information, it will be decided whether the flight flex-hose manufacturer should proceed with the testing of the full-scale flex-hoses. To reduce the time and funding required for this test, a test fixture was designed and assembled in the Engineering Development & Operations (EDO) test facility. In this test fixture, two Engineering Development Unit (EDU) flex-hoses were loaded with free floating weights up to 350 lbf. A load of 200 lbf equates to the maximum expected loading with a margin of safety, thus all data recorded after 200 lbf was purely for reference. Measurements were taken using a tape measure and a custom datum measurement system to record the loaded and unloaded length of each flex-hose at various loads. Any permanent stretching beyond a 1/8th of an inch was indicative of inelastic yielding. The loading of each flex-hose was done with an initial weight 80 lbf and was increased to 100 lbf. Additional loading up to 350 lbf was done by 50 lbf increments thereafter. During the performance of the test, slippage occurred in the mounting of the flex-hoses in the test fixture. The first slippage occurred during the testing of the first flex-hose due to the collar of the flex-hose slipping within the collet of the top Kellem. As a result, the first flex-hose test was terminated early to modify the fixture. Due to the flex-hose not inelastically yielding, the test was repeated on the first flex hose. This test resulted in another instance of slippage in the upper collar of the Kellem due to tape interfering with the securing of a collet around the collar of the flex-hose. The test was then continued with one more slippage of the flex-hose within the collet of the bottom Kellem. Preventive measures were taken for future slippage, and the second hose remained secure during testing.Once the tests were concluded, the elongation of each hose was analyzed for inelastic yielding. Both flex-hoses stretched a measurable and repeatable amount under loading, however, this stretching was recovered once each hose was unloaded. As a result, both EDU flex-hoses did not experience any inelastic yielding during the tension testing. Once received, one additional flex-hose will be tested for yielding, but at the time of this paper, the recommendation is to proceed with testing of the full-scale flex-hoses at the flex-hose manufacturer.

Dziekan, Joseph↗