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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
NASA NTRS1992

Permeability of rayon based polymer composites

Several types of anomalous rayon based phenolic behavior have been observed in post-fired nozzles and exit cones. Many of these events have been shown to be related to the development of internal gas pressure within the material. The development of internal gas pressure is a function of the amount of gas produced within the material and the rate at which that gas is allowed to escape. The latter property of the material is referred to as the material's permeability. The permeability of two dimensional carbonized rayon based phenolic composites is a function of material direction, temperature, and stress/strain state. Recently significant differences in the permeability of these materials has been uncovered which may explain their inconsistent performance. This paper summarizes what is known about the permeability of these materials to date and gives possible implications of these finding to the performance of these materials in an ablative environment.

Stokes, E. H.↗
DOE OSTI2020

Thermal and Electrical Properties of Isocyanate Derived Organic Aerogels for Cryogenic Insulation Applications

The use and storage of cryogens such as liquefied nitrogen, helium, hydrogen among others requires reliable and efficient thermal insulation systems. Passive insulation from high performance materials that are well-known for their inherent low thermal conductivity would reduce the overall costs involved in design, manufacture and maintenance of such systems. One such class of materials are referred to as aerogels. These materials are known for their low density, high mesoporosity, high surface areas, low thermal conductivity and high acoustic impedance. Aerogels were invented by S.S. Kistler in 1931 and the most common type are those made of silica. However, the inherent fragility of silica aerogels makes them hard to mass produce, and therefore applications have been limited. A major breakthrough was introduced by our team almost 20 years ago with the invention of polymer crosslinked silica aerogels. Those materials shifted attention to all-polymer aerogels that have overcome all fragility issues associated with their inorganic counterparts. This study focuses on such polymeric aerogels that can be mass produced as large monoliths while maintaining the low thermal conductivity of traditional silica aerogels over a wide temperature range. Manufacturing flexibility of polymeric aerogels allows fabrication of blocks and sheets that can be applied in various configurations to insulate cryogenic and superconducting devices. The thermal conductivity with 80 K and room temperature boundary are reported as well as other properties (electrical), that need to be considered when designing devices for cryogenic applications.

Churu, Gitogo↗
NASA NTRS1972

Reference data for thermocouple materials below the ice point.

Standard thermoelectric data have been determined for four thermocouple combinations used below the ice point: commercial types E, K, and T and the special combination of KP vs Au-0.07 at.% Fe. Power series coefficients necessary to generate E = f(T) data for these combinations are given. In addition, extensive tests were carried out to ascertain the variability between materials from different manufacturers. Typical wires processed for low-temperature usage often have slightly thermoelectric properties (up to 1%) from those, nominally identical, wires made for high-temperature applications. Generally, type E is the most satisfactory standardized commercial combination. The Au-0.07 at.% Fe material has been examined in particular detail, because it is not yet an ISA standard material. It has excellent sensitivity in the liquid helium/liquid hydrogen temperature range and a nearly linear thermovoltage at higher temperatures.

Sparks, L. L.↗
NASA NTRS1993

Properties of Extruded PS-212 Type Self-Lubricating Materials

Research has been underway at the NASA Lewis Research Center since the 1960's to develop high temperature, self-lubricating materials. The bulk of the research has been done in-house by a team of researchers from the Materials Division. A series of self-lubricating solid material systems has been developed over the years. One of the most promising is the composite material system referred to as PS-212 or PM-212. This material is a powder metallurgy product composed of metal bonded chromium carbide and two solid lubricating materials known to be self-lubricating over a wide temperature range. NASA feels this material has a wide potential in industrial applications. Simplified processing of this material would enhance its commercial potential. Processing changes have the potential to reduce processing costs, but tribological and physical properties must not be adversely affected. Extrusion processing has been employed in this investigation as a consolidation process for PM-212/PS-212. It has been successful in that high density bars of EX-212 (extruded PM-212) can readily be fabricated. Friction and strength data indicate these properties have been maintained or improved over the P.M. version. A range of extrusion temperatures have been investigated and tensile, friction, wear, and microstructural data have been obtained. Results indicate extrusion temperatures are not critical from a densification standpoint, but other properties are temperature dependent.

Waters, W. J.↗
DOE OSTI2026

Degradation of Magnetic Materials for High-Temperature Active Magnetic Bearing Applications in CO₂-Based Environments

High-temperature Active Magnetic Bearings (AMBs) are a promising alternative to conventional bearings in hermetically sealed turbomachinery for supercritical CO₂ (sCO₂) systems. They offer reduced CO₂ leakage, lower windage losses, enhanced misalignment tolerance, reduced wear, and built-in diagnostic capabilities. A critical challenge, however, is ensuring long-term material stability in harsh CO₂-rich environments. This study investigated the degradation behavior of permanent and soft magnetic materials (Alnico 9C, Alnico 5-7C, SmCo 18-T550, Hiperco-50, and coated variants) after up to 6,000 hours of exposure in gaseous CO₂, sCO₂, or air at 450 °C and 550 °C. The evaluation included post-exposure mass change measurements, scanning electron microscopy (SEM) analysis, and magnetic property assessments. The results demonstrate oxidation rates, microstructural evolution, and retention of magnetic performance across conditions. The findings offer essential insights into the thermal corrosion behavior of magnetic materials under CO₂ rich environments and serve as a reference for material selection in AMB system designs.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Compendium of Material Composition Data for Radiation Transport Modeling

In 2011, Pacific Northwest National Laboratory (PNNL) produced a document known as the Materials Compendium, or Compendium of Material Composition Data for Radiation Transport Modeling, PNNL 15870, Rev. 1, that contains material information useable for modeling purposes for properties of 372 materials. This information is used in several modeling programs used by the radiological/nuclear community, though it is primarily tailored for the Monte-Carlo-N-Particle code produced by Los Alamos National Laboratory. This new document Revision 2 includes a complete review and update of all materials data and references, addressing discrepancies and changes in materials data or references that have occurred since the first revision, an additional 40 materials have been added, primarily newer detector materials developed since the last revision, and isotopic specificity.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2025

Mechanical properties, strain hardening, and fracture behavior of ultrasonic additively manufactured Zircaloy-4 after low-temperature neutron irradiation

Ultrasonic additive manufacturing (UAM) is a solid-state, layer-by-layer advanced manufacturing process that has the potential to create custom spatially controlled composites with embedded wires and sensors for nuclear component manufacture. For this work, to assess the feasibility of using UAM for nuclear-relevant materials research, the technique was used to produce a 3.5-mm-thick Zircaloy-4 plate for irradiation testing. The UAM Zircaloy-4 specimens were irradiated in the High Flux Isotope Reactor at a target irradiation temperature of 117 °C to 2.9 displacements per atom (dpa) to assess differences in irradiation-hardening behavior as a function of alloy processing path. The UAM and reference baseplate (BP) materials increased in yield strength by 372±27 MPa and 346±21 MPa, respectively, and both suffered significant reductions in uniform and total elongation attributed to irradiation hardening at low-temperature. Although the materials had similar nanoscale defect structures, including nanoscale black dot/loop features and strain-induced dislocation channels, the UAM material’s processing-related defects resulted in accelerated strain localization and failure as demonstrated by lower post-irradiation uniform elongation of UAM specimens (0.5 %) compared to BP (1.5 %) material. The UAM material also showed considerable anisotropy in mechanical response due to crack propagation along weld boundaries, resulting in differences in strength & ductility when tested parallel and perpendicular to the prior UAM build orientation. Therefore, although the fundamental irradiation response of UAM-processed Zircaloy-4 was phenomenologically comparable to that of BP reference material, additional optimization of the UAM processing is needed to produce irradiation-resistant and nuclear-relevant materials.

Digital image correlation↗
NASA NTRS2019

Stress Corrosion Evaluation of Elgiloy Alloy for the ISS ECLSS — Universal Waste Management System

Elgiloy® alloy (UNS R30003)—a spring material per AMS 5876D (reference 1)—is one among several alloys recently evaluated for stress corrosion cracking resistance in support of the International Space Station (ISS) Environmental Control and Life Support System (ECLSS). Elgiloy was evaluated particularly for its expected use in the Universal Waste Management System (described in references 2 and 3). Data for other alloys previously evaluated were reported in references 4 and 5. Materials included in reference 4 are Inconel 625, Hastelloy® C276, commercially pure titanium, titanium with 6% aluminum and 4% vanadium (Ti6Al4V), extra-low interstitial Ti6Al4V, and Cronidur 30. The results for Nitinol 60 are in reference 5. During the water recovery process, the metallic components fabricated from these materials are exposed to acidic solutions used for waste treatment. The purpose of the current and previous stress corrosion evaluations is to determine if these materials have adequate stress corrosion resistance.

Torres, Pablo D.↗
NASA NTRS1993

Post-impact alteration of the Manson impact structure

Core materials from the Manson impact site (Manson, Iowa) are examined in order to evaluate post-impact alteration processes. Diagenetic interpretation of post-impact events is based on petrologic, mineralogic, and geochemical investigation of core materials including the following: target strata, disturbed and disrupted strata, ejecta, breccias, microbreccias, and impact melt. The diagenetic study utilizes research cores obtained by the continental scientific drilling project (CSDP) at the Manson structure, as well as core and cuttings of related materials. Samples include impactites (breccias, microbreccias, and melt material), crater fill material (sedimentary clast breccias), disturbed and disrupted target rocks, and reference target material (Amoco Eisheid No. 1 materials). The study of multiple cores will permit development of a regional picture of post-impact thermal history. The specific objectives are as follows: (1) provide a detailed description of authigenic and alteration mineralogy from diverse lithologies encountered in research drill cores at the Manson impact structure, and (2) identify and relate significant post-impact mineral alteration to post-impact thermal regime (extent and duration). Results will provide mineralogical and geochemical constraints on models for post-impact processes including the following: infilling of the crater depression; cooling and hydrothermal alteration of melt rocks; and subsequent long-term, low-temperature alteration of target rocks, breccias, and melt rocks. Preliminary petrologic and x-ray diffraction examination of fracture linings and void fillings from research core M1 indicate the presence of quartz, chlorite, mixed-layer clays, gypsum/anhydrite, calcite, and minor pyrite.

Crossey, L. J.↗
DOE OSTI2021

Compaction of crushed salt for safe containment – overview of the KOMPASS project

Abstract. In Germany, rock salt formations are possible host rock candidates for a repository for heat-emitting radioactive waste. The safety concept of a repository in salt bases on a multibarrier system consisting mainly of the geological barrier salt and geotechnical seals ensuring safe containment. Crushed salt will be used for backfilling of cavities and sealing measures in drifts and shafts due to its favourable properties and its easy availability (mined-off material). The creep of the rock salt leads to crushed salt compaction with time. Thereby, the crushed salts' porosity is reduced from the initial porosity of 30 %–40 % to a value comparable to the porosity of undisturbed rock salt (≤1 %). In such low porosity ranges, technical impermeability is assumed. The compaction behaviour of crushed salt is rather complex and involves several coupled THM processes (Kröhn et al., 2017; Hansen et al., 2014). It is influenced by internal properties like humidity and grain size distribution, as well as boundary conditions such as temperature, compaction rate or stress state. However, the current process understanding has some important gaps referring to the material behaviour, experimental database and numerical modelling. It needs to be extended and validated, especially in the low porosity range. The objective of the KOMPASS project was development of methods and strategies for the reduction of deficits in the prediction of crushed salt compaction leading to an improvement of the prognosis quality. Key results are as follows (KOMPASS Phase 1, 2020): selection of an easily available and permanently producible synthetic crushed salt mixture, acting as a reference material for generic investigations; development and proof of different techniques for producing pre-compacted samples for further investigations; establishment of a tool of microstructure investigation methods to demonstrate the comparability of grain structures of pre-compacted samples with in-situ compacted material for future investigations; execution of various laboratory experiments using pre-compacted samples, e.g. long-term creep tests which deliver reliable information about time- and stress-dependent compaction behaviour; development of a complex experimental investigation strategy to derive necessary model parameters considering individual functional dependencies. Its technical feasibility was successfully verified; benchmarking with various existing numerical models using datasets from three different triaxial long-term tests. The result was not entirely satisfactory; however, the number of influencing factors is small and further validation work has to be done. Overall, the KOMPASS project has made significant progress in the approaches to solving the outstanding question, building the basis for further investigations.

Friedenberg, Larissa↗
NASA NTRS1996

NASA-UVa Light Aerospace Alloy and Structures Technology Program: Aluminum-Based Materials for High Speed Aircraft

This report is concerned with 'Aluminum-Based Materials for High Speed Aircraft' which was initiated to identify the technology needs associated with advanced, low-cost aluminum base materials for use as primary structural materials. Using a reference baseline aircraft, these materials concept will be further developed and evaluated both technically and economically to determine the most attractive combinations of designs, materials, and manufacturing techniques for major structural sections of an HSCT. Once this has been accomplished, the baseline aircraft will be resized, if applicable, and performance objectives and economic evaluations made to determine aircraft operating costs. The two primary objectives of this study are: (1) to identify the most promising aluminum-based materials with respect to major structural use on the HSCT and to further develop those materials, and (2) to assess these materials through detailed trade and evaluation studies with respect to their structural efficiency on the HSCT.

Starke, E. A., Jr.↗
DOE OSTI2023

Precursor recommendation for inorganic synthesis by machine learning materials similarity from scientific literature

Synthesis prediction is a key accelerator for the rapid design of advanced materials. However, determining synthesis variables such as the choice of precursor materials is challenging for inorganic materials because the sequence of reactions during heating is not well understood. In this work, we use a knowledge base of 29,900 solid-state synthesis recipes, text-mined from the scientific literature, to automatically learn which precursors to recommend for the synthesis of a novel target material. The data-driven approach learns chemical similarity of materials and refers the synthesis of a new target to precedent synthesis procedures of similar materials, mimicking human synthesis design. When proposing five precursor sets for each of 2654 unseen test target materials, the recommendation strategy achieves a success rate of at least 82%. Our approach captures decades of heuristic synthesis data in a mathematical form, making it accessible for use in recommendation engines and autonomous laboratories.

36 MATERIALS SCIENCE↗
DOE OSTI2022

High-entropy materials

We report that primarily over the last decade, the concept of multiple-principal-element metallic materials, commonly referred to as high-entropy alloys, or more generally, high-entropy materials, has taken the field of materials science, particularly structural metallurgy, by storm, at least as measured by the plethora of publications that are focused on this topic. In this article and the following six articles, we attempt to distill what all this is about, with a description of why these materials may be important, why they may differ from traditional materials and how theoretical, computational, and experimental studies can shed light on the science underlying their behavior and potential application.

36 MATERIALS SCIENCE↗
NASA NTRS2011

Methods and instruments for materials testing

Methods and instruments for characterizing a material, such as the properties of bone in a living human subject, using a test probe constructed for insertion into the material and a reference probe aligned with the test probe in a housing. The housing is hand held or placed so that the reference probe contacts the surface of the material under pressure applied either by hand or by the weight of the housing. The test probe is inserted into the material to indent the material while maintaining the reference probe substantially under the hand pressure or weight of the housing allowing evaluation of a property of the material related to indentation of the material by the probe. Force can be generated by a voice coil in a magnet structure to the end of which the test probe is connected and supported in the magnet structure by a flexure, opposing flexures, a linear translation stage, or a linear bearing. Optionally, a measurement unit containing the test probe and reference probe is connected to a base unit with a wireless connection, allowing in the field material testing.

Hansma, Paul↗
DOE OSTI2022

Simple Approximation for the Ideal Reference State of Gases Adsorbed on Solid-State Surfaces

Reference states are useful as models for facilitating calculations of equilibrium constants, and they may also serve as standard states that are convenient for organizing and tabulating thermodynamic data; however, standard state conventions and appropriate reference states for adsorbed species have received less attention than those for pure substances and solutes. Here, we compare seven choices of reference states for calculations of equilibrium constants and transition state theory rate constants for flat surfaces, in particular (1) an ideal 2D harmonic oscillator, (2) an ideal rigid-molecule harmonic oscillator, (3) an ideal 2D harmonic oscillator with separable surface modes, (4) a 2D ideal gas, (5) an ideal 2D hindered translator, (6) an ideal 2D hindered translator with lowest-order barriers, and (7) a simple ideal 2D hindered translator proposed in this work. The advantage of models 5–7 is that they can treat both mobile and localized adsorbates in a consistent way, whereas models 1–3 are only appropriate for localized adsorbates, and model 4 is only appropriate for a freely translating adsorbate. Furthermore, models 6 and 7 reduce the computational cost without the user having to calculate barrier heights for diffusion. An advantage of the simple ideal 2D hindered translator is that it has a physical high-temperature limit. We also propose a reference state for nonflat surfaces. Here, the user is encouraged to choose a reference state based on the appropriateness of the model and the practicality of the calculations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Upcycling of Mixed Aluminum Alloy Shredder Scrap using Shear Processing

Conservation of critical materials is an increasing area of focus in the Unites States. In 2023, aluminum was added to the US Department of Energy Final Critical Materials List which has spurred public and private research into sustainable management of these resources. Additionally, efficiency in manufacturing and conservation of natural resources are growing concerns with targets to lower global carbon emissions, as primary aluminum alloy production is energy intensive, requiring 14 MWh of electricity plus 0.4 tonnes of CO2 per tonne of Al. Due to these factors, is essential that more sustainable manufacturing methods for aluminum alloys are developed going forward. To this end, much research is ongoing on the topic of more efficient utilization and recovery. However, most of this research still requires primary aluminum in the production process. Here, it will be attempted to bypass the use of primary aluminum and produce useful material recycled from 100% post-consumer scrap. Even considering recent developments in recycling of Al scrap, there is still a large amount of post-consumer scrap that is underutilized due to high impurity content, and that amount will increase significantly as more and more aluminum alloys are utilized in vehicles. This “scrap wave” is expected to cover 80% of the demand for automotive aluminum alloys by 2050 . A challenge to be addressed before the coming scrap wave can be fully utilized is that the tolerance of manufacturing techniques to impurities or off-spec alloy compositions must be increased. Particularly, in 5000-and 6000-series alloys (the most common wrought alloys in durable products), excess iron, copper, and silicon create brittle intermetallics during casting that remain in the extruded microstructure which limit the formability, ductility, and corrosion resistance of the alloy. Concerningly, many of the highest-volume post-consumer aluminum scrap streams such as automotive shredder scrap contain a mix of alloys including both wrought and cast alloys. Their compositions can vary widely depending on geography and the time of year. Because they are mixed, they often contain high content of multiple alloying elements such as Si and Cu in higher concentrations than are found in typical wrought alloys. They may also be contaminated with non-Al alloys from fasteners that get mixed in and often have high content of unwanted elements such as Fe. As a method for utilizing these underused scrap streams that are high in tramp elements, an emerging extrusion technology is being developed at the Pacific Northwest National Laboratory (PNNL) that aims to upcycle 100% post-consumer aluminum scrap directly into extruded components without the addition of primary aluminum . This new technology, called Shear Assisted Processing and Extrusion (ShAPE), is enabling a shift away from today’s recycling paradigm by reaching deeper into lower-value scrap streams, using shredder scrap as the extrusion billet material. Sometimes referred to as Twitch or Tweak, these scrap streams result from shredding and sorting of automobiles, building materials, appliances, and consumer goods. ShAPE combines the linear axis of conventional extrusion with a rotating extrusion die. This rotating die applies large strain to the material during extrusion, which breaks up large impurity-containing intermetallic particles, reducing their deleterious effects. This has been demonstrated for 6063 machining scrap spiked with excess Fe, and Twitch scrap high in Fe, Si and Cu where strength and ductility were retained for both feedstock compositions. Additionally, the extreme plastic deformation during ShAPE enables extrusion of billets with high Si that are too brittle for processing by conventional extrusion. By using 100% post-consumer shedder scrap as feedstock, ShAPE has the potential to slash embodied energy and carbon in extruded components by >80% compared to conventional extrusion of primary aluminum alloys.

Milligan, Brian K.↗
DOE OSTI2022

2,3-Diphenylthieno[3,4-b]pyrazines as Hole-Transporting Materials for Stable, High-Performance Perovskite Solar Cells

High-performance and durable perovskite solar cells (PSCs) have advanced rapidly, enabled in part by the development of superior interfacial hole-transporting layers (HTLs). Here, in this study, a new series of 2,3-diphenylthieno[3,4-b]pyrazine (DPTP)-based small molecules containing bis- and tetrakis-triphenyl amino donors (1–3) was synthesized from simple, low-cost, and readily available starting materials. The matched energy levels, ideal surface topographies, high hole mobilities of 8.57 × 10 –4 cm 2 V –1 S –1 , and stable chemical structures of DPTP-4D (3) make it an effective hole-transporting material, delivering a PCE of 20.18% with high environmental, thermal, and light-soaking stability when compared to the reference HTL materials, doped Spiro-OMeTAD and PTAA in PSC n-i-p planar devices. Overall, these DPTP-based molecules are promising HTM candidates for the fabrication of stable PSCs.

14 SOLAR ENERGY↗
DOE OSTI2020

Degradation of impact toughness in cast stainless steels during long-term thermal aging

Cast austenitic stainless steels (CASSs) have been extensively used for the large components of nuclear reactor primary coolant systems. Since the cast steels inevitably contain degradable metastable phases and replacement of the large coolant system components is impractical, the thermal embrittlement of CASS components has been a serious concern in the extended-term operation of nuclear power plants. This study aimed to systematically measure and analyze the effect of long-term thermal aging on the Charpy impact toughness to provide a comprehensive understanding of thermal degradation behavior and a practical aging model to predict the degree of thermal degradation in the cast stainless steels. Additionally, the materials tested in the research include eight CASS alloys (two CF3s, one CF3M, three CF8s, and two CF8Ms) and two reference wrought materials (304L and 316L), in which the nominal δ-ferrite content ranges from ~2% to 33%. These stainless steels have been thermally aged at two light water reactor (LWR) temperatures (290 and 330 °C) and at two accelerated-aging temperatures (360 and 400 °C) for up to 30,000 h; these include both under-aged and over-aged conditions relative to the extended service lifetime (80 years). Charpy impact testing was performed for aged and non-aged specimens, and the impact (absorbed) energy parameters were correlated with a new aging parameter (A). Both the reduction of impact fracture toughness and the shift of ductile-brittle transition temperature were strongly dependent on the δ-ferrite content and degree of thermal aging. A linear relationship was found between the increasing rate of the index transition temperature T 41J and aging parameter A; base on which an empirical model was proposed for prediction of the transition temperature as a simple function of the aging parameter (A) and δ-ferrite content (F). Finally, the critical aging parameter for embrittlement (AC) was evaluated and compared with the existing δ-ferrite content criteria.

36 MATERIALS SCIENCE↗