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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

The intrinsic mechanical properties of hydromagnesite, Mg 5 (CO 3 ) 4 (OH) 2 ·4H 2 O, a key phase of reactive MgO carbonate cement

To potentially enable CO 2 sequestration, reactive MgO carbonate cement is emerging as an alternative binder to Portland cement. Understanding the mechanical properties of its binding phase is critical for understanding the strength development and performing materials design for reactive MgO cement systems; however, the intrinsic mechanical properties of hydromagnesite (Mg 5 (CO 3 ) 4 (OH) 2 ·4H 2 O), a key binding phase, remain unexplored. Here the present study utilized synchrotron-based high-pressure X-ray diffraction to determine the unit cell-scale, intrinsic mechanical properties of hydromagnesite for the first time. Up to hydrostatic loading of 7.7 GPa, the bulk modulus of hydromagnesite was determined as 59 GPa or 71 GPa fitted using the second-order or third-order Birch-Murnaghan equation of state, which we contextualize with binding phases in various cement systems. The experiment results are applicable in materials design of low-carbon concrete and valuable for the validation and calibration of atomistic models.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Phase-field modeling of crack growth and mitigation in solid oxide cells

Fracture and crack growth is one of the main degradation mechanisms in solid oxide cells (SOCs). However, the modeling of crack growth in SOCs is challenging due to their complex microstructures and possible plasticity development within the Ni particles in Ni-based SOC electrodes. In this study, a phase-field fracture model is developed, which incorporates the SOC microstructures and phase-dependent material properties, including yield strength, fracture toughness in the bulk and at the interphase boundaries. The model is employed to study crack initiation and growth under thermal and redox cycling on the hydrogen electrode side of SOCs. The simulation results demonstrate that under thermal cycling, work-zone cracking dominates in electrolyte-supported SOCs with cracks initiated at the triple-phase boundaries, while only minor mechanical degradation occurs in hydrogen-electrode-supported SOCs after hundreds of thermal cycles. Under redox cycling, through-cracking of yttria-stabilized zirconia (YSZ) in the hydrogen electrode and electrolyte layers dominates. Finally, the simulation results suggest several crack-mitigation strategies, including decreasing the porosity in the hydrogen electrode support layer and synchronizing thermal strain to balance oxidation strain.

08 HYDROGEN↗
DOE OSTI2024

Microstructure and mechanical properties of ultrasonic spot welding of AA7075-T6 and A380 casting aluminum alloy

Ultrasonic spot welding (USW) was employed to join AA7075-T6 and casting Al alloy A380. Under a constant welding power, the influence of the welding time duration (from 1 s to 3 s) on peak temperature, microstructure, hardness, and mechanical strength of the joints were studied. It was found that the peak temperature increased with welding time. A sound solid-state metallurgical bonding was obtained at the joint interface. The cracks occurred at the edge of the joints were eventually eliminated as the welding time increased. A layer of refined grains formed in A380 adjacent to the bonding line. Further, hardness reduction occurred in AA7075 at the joint interface and the degree of hardness reduction and the volume increased with the peak temperature. By increasing welding time, lap shear tensile tests show that the peak load increased from 5.3 kN to 6.55 kN. The corresponding interfacial shear strength ranged from 96.29 MPa to 99.72 MPa, lower than the shear strength of both base materials (331 MPa for AA7075 and 185 MPa for A380). All joint samples exhibited interfacial fracture after lap shear tensile testing, with a thin layer of A380 remnant attached to AA7075 at the center of the fractured surface.

36 MATERIALS SCIENCE↗
DOE OSTI2022

High strain-rate compression behavior of polymeric rod and plate Kelvin lattice structures

The compressive high strain-rate behavior of polymeric Kelvin lattice structures with rod-based or plate-based unit cells was investigated through experimental techniques and finite element simulations. Polymeric lattice structures with 5x5x5 unit cell geometries were manufactured on the millimeter scale using vat polymerization additive manufacturing and tested at low (0.001/s) and high (1000/s) strain-rates. High strain-rate experiments were performed and validated for a viscoelastic split-Hopkinson (Kolsky) pressure bar system (SHPB) coupled with high-speed imaging and digital image correlation (DIC). Experimental results at both low and high strain-rates show the formation of a localized deformation band which was more prevalent in low relative density specimens and low strain-rate experiments. Strain-rate effects of lattice specimens strongly correlate with effects of the base polymer material; both bulk polymer and lattice specimen demonstrated strain-rate hardening, strain-rate stiffening, and decreased fracture strain under dynamic loading. Results show mechanical failure properties and energy absorption depended strongly on the relative density of the lattice specimen and exhibited distinct scaling between relative density and geometry type (rod, plate) and loading rate. High relative density plate-lattices demonstrated inferior mechanical properties to rod-lattices; however, there exists a critical relative density for a given mechanical property (17%- 28%) below which plate-lattices outperform rod-lattices of similar mass. As a result, high strain-rate explicit finite element simulations were performed and showed good agreement with the mechanical failure trends and deformation modes observed in the experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Wood template-supported phase change material composites for durable and form-stable thermal energy storage in buildings

Here, to reduce and shift peak energy loads in buildings, phase change materials (PCMs) with high transition enthalpies and transition temperatures near human thermal comfort are desirable for thermal energy storage (TES). Traditional solid/liquid PCMs suffer from leakage during thermal cycling, requiring encapsulation that lowers heat storage capacity. Wood templates (WTs), with porous and hierarchical structures, provide natural encapsulation scaffolds for PCM containment. Polyethylene glycol (PEG) is a compatible PCM with WTs, but when infiltrated alone, ~30 wt% of PEG binds to wood with no detectable phase change, limiting TES efficiency. To address this, we developed a method to (1) improve the form stability of balsa and pine-based composites (BWT + PCMs and PWT + PCMs) and (2) reduce inactive PCM within the composites to ~10 wt%. BWT + PCMs exhibit transition properties upwards of 114.2 J/g at 25.4 degrees C, with no degradation after 1000 thermal cycles, and similar stiffness compared to raw balsa. Meanwhile, PWT + PCMs exhibit 25 % higher storage efficiency with the addition of poly(ethylene glycol) diacrylate compared to solely PEG-infiltrated PWT. PWT + PCM retains 84 % of raw pine's mechanical stiffness, sufficient for light-duty construction. Our shape-stabilized WT + PCM composites enrich the functionality of wood materials as both ideal TES material candidates and light-duty building construction applications.

25 ENERGY STORAGE↗
DOE OSTI2025

Anion and Cation Size Effects on Viscoelasticity and Ion Transport of Imine Vitrimer Electrolytes

Vitrimers are a subclass of covalent adaptable networks where bond exchange occurs without breaking, thereby offering polymer materials with enhanced mechanical strength, thermal stability, and reprocessability compared to conventional electrolytes. Despite recent progress, we lack a complete understanding of the role of ions in controlling the physical and chemical properties of vitrimers. In this work, we study how different salts affect the viscoelasticity, morphology, and ionic conductivity of imine vitrimers. Our results show that addition of salt decreases relaxation times at elevated temperatures due to the catalytic effect of the cations, with smaller cations leading to faster relaxation. However, the activation energy for terminal relaxation increases with smaller cation size. This apparent discrepancy is attributed to the complex interplay among bond exchange kinetics, chain diffusion, and salt dissociation. Anions act as plasticizers by reducing the shear modulus, except lithium bromide. Ionic conductivity increases with larger anions due to smaller salt dissociation energies, whereas the cation type has a minor impact as polymer segmental dynamics dominate ionic transport. Imine-based vitrimers are reprocessable and recyclable, maintaining original mechanical properties and ionic conductivity after recovery. Mixed salt vitrimers exhibited tunable viscoelasticity and ionic conductivity intermediate to the analogous pure salt systems. Altogether, this work highlights the role of salt in the dynamic and conductive properties of imine vitrimers.

Anions↗
DOE OSTI2024

Elucidating Polymer Binder Entanglement in Freestanding Sulfide Solid-State Electrolyte Membranes

This study advances the development of flexible, sheet-type sulfide solid-state electrolytes (SSEs) for use in all-solid-state batteries, emphasizing the important and previously insufficiently investigated role of polymer binder entanglement. Here, the molecular weight of polymer binders is pivotal in crafting robust, freestanding SSE films. Our research uncovers a dual impact: higher molecular weight binders bolster the structural integrity of SSE films but elevate grain boundary resistance and diminish critical current density, whereas lower molecular weight poly(isobutylene) films, despite their more uniform distribution, lack the essential strain hardening or strength for sustained active material contact. Crucially, full cells employing higher molecular weight binders demonstrate improved discharge capacity retention, contrasting sharply with the notable capacity degradation in lower molecular weight cells. Our findings not only deepen the comprehension of binder influences in solid-state batteries but also chart a course for refining all-solid-state battery technologies, a key stride for the future of energy storage solutions.

25 ENERGY STORAGE↗
DOE OSTI2023

Luminescent Bimetallic Two-Coordinate Gold(I) Complexes Utilizing Janus Carbenes

A series of bimetallic carbene-metal-amide (cMa) complexes have been prepared with bridging biscarbene ligands to serve as a model for the design of luminescent materials with large oscillator strengths and small energy differences between the singlet and triplet states (ΔE ST ). The complexes have a general structure (R 2 N)Au(:carbene—carbene:)Au(NR 2 ). The bimetallic complexes show solvation-dependent absorption and emission that is analyzed in detail. It is found that the molar absorptivity of the bimetallic complexes is correlated with the energy barrier to rotation of the metal–ligand bond. The bimetallic cMa complexes also exhibit short emission lifetimes (τ = 200–300 ns) with high photoluminescence efficiencies (Φ PL > 95%). The radiative rates of bimetallic cMa complexes are 3–4 times faster than that of the corresponding monometallic complexes. Analysis of temperature-dependent luminescence data indicates that the lifetime for the singlet state (τS 1 ) of bimetallic cMa complexes is near 12 ns with a ΔE ST of 40–50 meV. Here the presented compounds provide a general design for cMa complexes to achieve small values for ΔE ST while retaining high radiative rates. Solution-processed organic light-emitting devices (OLEDs) made using two of the complexes as luminescent dopants show high efficiency and low roll-off at high luminance.

14 SOLAR ENERGY↗
DOE OSTI2023

Simultaneous determination of electrical conductivity and thickness of nonmagnetic metallic foils using two-sided multifrequency eddy current techniques

Here, in this paper, we describe a simple method for performing multifrequency eddy current characterization of free-standing uniform-thickness metallic foils using a forked inductive coil arrangement. The method involves measuring the mutual inductance between two coils when a foil is present between the coils, and when it is not present; the ratio of these mutual inductances is compared with an analytical solution, and foil conductivity, thickness, and sheet resistance are simultaneously estimated using numerical inversion and least-squares fitting. This method was used to characterize 34 non-ferrous metallic samples with thicknesses between 50 and 640 μm and with conductivities between 0.8 × 10 7 and 5.8 × 10 7 S/m. The estimated thicknesses from eddy current characterization agreed well with those measured using confocal optical techniques; the two approaches agreed to within 1 μm for samples that were thinner than 200 μm, and to within 0.5% for samples that had a thickness of 200 μm or greater. The estimated conductivities from eddy current characterization were in close agreement with expected values, given knowledge of the materials used. A particular strength of this approach is that the instrumentation needed is broadly available in research and development laboratories and the associated fixturing is easy to manufacture and assemble. A calibration procedure is described that can be used to reduce errors from geometric uncertainties. This calibration requires a sample that has only a known conductivity or thickness; both do not need to be known. The method described herein is likely extensible to conductivities and thickness well outside the ranges measured as part of this work.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Design of an Additively Manufactured Recuperator With 800 °C Inlet Temperature for sCO2 Power Cycle Application

Abstract Recuperators with design temperatures at and above 800 °C can further increase the thermal efficiency of supercritical CO2 power cycles by enabling higher turbine exhaust temperatures. Mar-M247 is a well-suited nickel-based superalloy for high temperature service due to its high creep strength that prevents excessive material thickness being required for pressure containment. Additive manufacturing using a high-speed laser-directed energy deposition (L-DED) process presents a promising solution, with build trials demonstrating the ability to produce nonconventional flow channels for enhanced heat transfer. A design process is presented that includes aerothermal and mechanical evaluation to maximize performance within the constraints of the manufacturing process. A 2-D heat transfer network and pressure drop code allows prediction of flow distribution and its effect on overall thermal performance. Established literature correlations, along with CFD simulation, inform the prediction of heat transfer coefficients and friction factors for the flowpaths and enhancement features in the heat exchanger core. Mechanical evaluation using finite element analysis (FEA) modeling with the intent of the ASME Boiler & Pressure Vessel Code (BPVC) Section VIII, Div. 2 assesses the operational safety of the design. The detailed design features annular finned passages that take advantage of helical flow paths to distribute the flow from separated headers to shared heat transfer surfaces. Performance predictions for the recuperator at a 50 kW scale provide insights into the feasibility of the additively manufactured (AM) process to produce recuperators on a commercial scale that extend existing operating envelopes.

Engineering↗
DOE OSTI2024

Evaluating Model Robustness for Defect Identification and Classification in a Composite Aerostructure Material

Aircraft structures are required to have a high level of quality to satisfy their need for light weight, efficient flight, and withstanding high loads over their lifespan. These aerostructures are typically made from a composite material due to their good tensile strength and resistance to compression. To ensure their structural integrity, the composite material requires inspection for common flaws such as porosity, delaminations, voids, foreign object debris, and other defects. Ultrasonic testing (UT) is a popular non-destructive inspection (NDI) technique used for effectively evaluating the composite material. Current inspection methods rely heavily on human experience and are extremely time consuming. Therefore, there is a need for the development of techniques to reduce the manual inspection time. This work compares the performance of different deep learning-based methods in the identification and classification of defects. Deep learning has shown great promise in numerous fields, and we show its effectiveness in the evaluation of the composite aerostructure material. The methods developed here are both highly reliable with a top recall value of 98.64% as well as extremely efficient requiring an average of 4 s during the inferencing stage to evaluate new composites. Lastly, we investigate model robustness to concept drift by measuring its performance over time.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Comparative Study on Deep Learning Methods for Defect Identification and Classification in Composite Aerostructure Material

Aircraft structures are required to have a high level of quality to satisfy their need for light weight, efficient flight, and withstanding high loads over their lifespan. These aerostructures are typically made from composite material due to their good tensile strength and resistance to compression. To ensure their structural integrity, the composite material requires inspection for common flaws such as porosity, delaminations, voids, foreign object debris, and other defects. Ultrasonic testing (UT) is a popular non-destructive inspection (NDI) technique used for effectively evaluating composite material. Current inspection methods rely heavily on human experience and are extremely time consuming. Therefore, there is a need for the development of techniques to reduce the manual inspection time. This work compares the performance of different deep learning-based methods in the identification and classification of defects. Deep learning has shown great promise in numerous fields, and we show its effectiveness in the evaluation of composite aerostructure material. Furthermore, the methods developed here are both highly reliable with a top recall value of 98.63% as well as extremely efficient requiring an average of 4 seconds during the inferencing stage to evaluate new composites.

composites↗
DOE OSTI2026

Molecular origin of anisotropic shear elastoplasticity in chitin

Chitin nano- and mesoscale structures present in the exoskeleton of crustaceans exhibit exceptional longitudinal stiffness and toughness, rivaling or even exceeding that of many synthetic polymer architectures. Here, we reveal the origin of the asymmetric shear response in chitin multiscale architectures, marked by pronounced anisotropy in deformation. Under shear aligned with the molecular axis, chitin accommodates strain through coherent atomic rearrangements that enable elastic recovery. In contrast, shear applied perpendicular to this axis induces liquid-like plasticity via localized sliding. These results demonstrate the intrinsic mechanical anisotropy of chitin, underpinning a dual function in resisting repetitive loading while dissipating internal stress during high-strain events. Our findings establish the molecular basis of shear elastoplasticity in multiscale chitin structures, wherein axial elasticity supports energy storage in load-bearing regions, whereas transverse plasticity enables controlled energy dissipation. These atomic-scale insights lay a foundation for the predictive design of chitin-based materials with tunable strength-toughness profiles.

Wan, Zhangmin [University of British Columbia, Van↗
DOE OSTI2022

Raman gain control in optical fibers with orbital-angular-momentum-induced chirality of light

Stimulated Raman scattering is a particularly robust nonlinearity, occurring in virtually every material because its spectral linewidth and associated frequency shift do not typically depend on phases or directions (i.e. wavevectors) of the interacting light beams. In amorphous materials such as glass fibers, Raman bandwidths are large, enabling its use as a broadband gain element. This ubiquity makes it a versatile means for achieving optical amplification or realizing lasers over a large range of pulsewidths at user-defined colors. However, this ease of deploying the effect also presents itself as a stubborn source of noise in fiber-based quantum sources or parasitic emission in fiber lasers. Here, we show that orbital angular momentum carrying light beams experiencing spin-orbit interactions yield novel phase-matching criteria for Raman scattering. This enables tailoring its spectral shape (by over half the Raman shift in a given material) as well as strength (by ∼ 100×) simply by controlling light’s topological charge – a capability of utility across the multitude of applications where modulating Raman scattering is desired.

Liu, Xiao (ORCID:000000032239762X)↗
DOE OSTI2023

High-Performance Coal-Based Commercial Facade Panels and Architectural Components (Phase I Final Report)

Semplastics has developed, tested, and documented the viability for commercialization of a new class of composite architectural panel materials that use coal as the primary constituent. This project produced sample panels using these novel materials that comprise 55% coal by mass (71% carbon by mass) and are comparable in dimensions to commercially available materials, while displaying superior mechanical strength, significant weight savings, and better insulating ability at a competitive cost. Phase I moved this coal-based composite materials technology from a Technology Readiness Level (TRL) of 3 to TRL 5. Semplastics’ new coal-based composite materials display an array of high-performance characteristics, including light weight, mechanical durability, temperature stability, and water resistance. These new materials require less energy to produce than comparable commercial products and could be manufactured on existing conventional plastic resin processing equipment in commercial quantities. The coal particles are completely encapsulated in ceramic from a polymer-derived ceramic (PDC) precursor, then bonded together by another inorganic resin. The material can be molded and cured to produce fireproof components such as ceiling panels, facades, and extruded underlayment, blocking, and backer boards, as well as other architectural design components such as moldings. The project included the production of sample panels for proof of concept, testing of the panels to show their improved characteristics, and development of a scale-up strategy to demonstrate the viability of the coal-based panels as a commercial alternative to existing building materials.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Metal (Cu,Al)/CNT Composite Wires for Energy Efficient Motors

This report summarizes the main results of research project on Metal/CNT nanocomposites conducted at University of Central Florida (UCF). It should be noted that the project was budgeted for three years, but the budget period 3 was unfortunately not funded and conducted in COVID19 pandemic years due to many reasons. The demonstration plan on the small motors was also removed according to the discussion with the DOE program manager. All research activities were focused on the (Cu,Al)/CNT material development and wire extrusion. Existing methods to fabricate Metal/CNTs were usually suffering from agglomeration of CNTs due to their density and stiffness differences. A new method is studied by the UCF research team, where CNTs are surface treated firstly, then coated with pure metals (i.e., Al, Cu, and Nickle). The metal encapsulation on CNT is expected to significantly improve the interfacial bonding between CNTs and the intimated metal matrices. The coated CNT powders were used to make sample materials through sintering, then a customized wire extrusion process was employed to fabricate wires. Measurement of material property improvements in mechanical strength, thermal conductivity, and electrical conductivity were conducted on both cylinder samples and extruded wires. In addition to the sintering process, casting on metal coated CNT powder was also investigated. The best results we achieved are summarized as follows. (1) The measured thermal conductivity of Al/CNT composite made with Ni-encapsulated CNTs and pure Al powders is about 85% better than that of pure aluminum fabricated. The measured electrical conductivity of fabricated Al/CNT is about 14-20% better than that of pure aluminum. (2) The measured electrical conductivity of Cu/CNT is about 14.5% better than that of pure copper fabricated. (3) The mechanical strengths of both Cu/CNT and Al/CNT (with about 1% wt. CNTs) are 70% better than pure metals although losing some material ductility. (4) Two-stage wire extrusion at high temperatures were designed and successfully conducted to fabricate wires of Metal/CNTs.

36 MATERIALS SCIENCE↗