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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Influence of Surface Pretreatment on the Corrosion Resistance of Cold-Sprayed Nickel Coatings in Acidic Chloride Solution

Corrosion resistance of the cold-sprayed nickel coatings deposited on the Ni surface (substrate) without and with abrasive grit-blasting treatment of the substrate was investigated. The corundum powder with different grain sizes was used. The corrosive environment contained an acidic chloride solution. The mechanism of the corrosion of nickel was suggested and discussed. Corrosion electrochemical parameters were determined by electrochemical methods. The corrosion effect of a nickel coating depends on the grain size used to prepare the substrate. The nickel coating after the medium grit-blasting treatment of the substrate was found to be the most corrosion resistant. However, the smallest resistance on the corrosion effect should be attributed to the nickel coating on the substrate after the coarse grit-blasting treatment.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The Effect of Grain Refinement on Solid Particle Erosion of Grade 5 Ti Alloy

In this work, the results on solid particle erosion of an ultrafine-grained Grade 5 titanium alloy, which was produced using high-pressure torsion (HPT) technique, are presented. In order to assess influence of the HPT treatment on material’s behavior in erosive conditions, special experimental procedures were developed. The ultrafine-grained (UFG) alloy was tested alongside with a conventional coarse-grained (CG) Grade 5 titanium alloy in equal conditions. The experiments were conducted in a small-scale wind tunnel with corundum particles as an abrasive material. Both particle dimensions and particle velocities were varied in course of the experiments. Erosion resistance of the samples was evaluated in two ways—mass reduction measurements with subsequent gravimetric erosion rate calculations and investigation of samples’ surface roughness after erosion tests. The UFG titanium alloy demonstrated considerable improvement of static mechanical properties (ultimate tensile strength, microhardness), whereas its CG counterpart appeared to be slightly more resistant to solid particle erosion, which might indicate the drop of dynamic strength properties for the HPT-processed material.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure and Wear Resistance of FeCrBSi Plasma-Sprayed Coating Remelted by Gas Tungsten Arc Welding Process

Herein, an FeCrBSi coating was fabricated via plasma spray on AISI1045 steel, and subsequently, a gas tungsten arc welding (GTA) process was employed to remelt the coating. The microstructure, microhardness, fracture toughness and surface roughness of the coating before and after remelting were investigated, as well as the wear resistance was tested by a UMT-3-type sliding wear apparatus. The results showed that, upon remelting, most defects in the as-sprayed coating were effectively eliminated, the surface roughness decreased by 43%, and the coating–substrate interface bonding changed from mechanical to metallurgical. The phase composition of the as-sprayed coating was primarily α-Fe and a small amount of hard Fe{sub 3}B phase, while the remelted coating consisted of α-Fe and (Fe,Cr){sub 23}C{sub 6} and a small quantity of CrB. In addition, remelting the coating was found to induce a 287.6% increase in the fracture toughness, a 33.4% increase in the average microhardness, and a 47.5% decrease in the wear volume, while the failure mechanism changed from abrasive wear to fatigue wear upon remelting. Therefore, GTA remelting of plasma-sprayed coating was found to be a feasible method to obtain a coating with good wear resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2016

The microstructure of the surface layer of magnesium laser alloyed with aluminum and silicon

The surface layer under analysis was formed as a result of diffusion bonding of a thin AlSi20 plate to a magnesium substrate followed by laser melting. Depending on the process parameters, the laser beam melted the AlSi20 plate only or the AlSi20 plate and a layer of the magnesium surface adjacent to it. Two types of microstructure of the remelted layer were thus analyzed. If the melting zone was limited to the AlSi20 plate, the microstructure of the surface layer was typical of a rapidly solidified hypereutectic Al–Si alloy. Since, however, the liquid AlSi20 reacted with the magnesium substrate, the following intermetallic phases formed: Al{sub 3}Mg{sub 2}, Mg{sub 17}Al{sub 12} and Mg{sub 2}Si. The microstructure of the modified surface layer of magnesium was examined using optical, scanning electron and transmission electron microscopy. The analysis of the surface properties of the laser modified magnesium revealed that the thin layer has a microstructure of a rapidly solidified Al–Si alloy offering good protection against corrosion. By contrast, the surface layer containing particles of intermetallic phases was more resistant to abrasion but had lower corrosion resistance than the silumin type layer. - Highlights: •A CO{sub 2} laser was used for surface alloying of Mg with AlSi20. •Before alloying, an AlSi20 plate was diffusion bonded with the Mg substrate. •The process parameters affected the alloyed layer microstructure and properties. •With melting limited to AlSi20, the layer had a structure of rapidly solidified AlSi20. •Mg–Al and Mg–Si phases were present when both the substrate and the plate were melted.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Electrocatalytic oxidation of 2-mercaptoethanol using modified glassy carbon electrode by MWCNT in combination with unsymmetrical manganese (II) Schiff base complexes

Highlights: • High electocatalytic efficiency and stability of modified hybrid electrode GC/MWCNTs/MnSaloph. • Direct reflection of catalytic activity of manganese complexes on electrocatalytic oxidation of 2-ME. • Decreasing overpotential and increasing catalytic peak current toward oxidation of 2-ME. • Deposition of range of novel substituted N{sub 2}O{sub 2} Saloph complexes of manganese(II) on GCE/MWCNT. • Enhancement of electrocatalytic oxidation activity upon electron donating substitutions on the Saloph. - Abstract: The performance of modified hybrid glassy carbon electrode with composite of carbon nanotubes and manganese complexes for the electrocatalytic oxidation of 2-mercaptoethanol is developed. GC electrode was modified using MWCNT and new N{sub 2}O{sub 2} unsymmetrical tetradentate Schiff base complexes of manganese namely Manganese Saloph complexes 1-5, with general formula Mn[(5-x-4-y-Sal)(5-x′-4-y′-Sal) Ph], where x, x′ = H, Br, NO{sub 2} and y, y′ = H, MeO. Direct immobilization of CNT on the surface of GCE is performed by abrasive immobilization, and then modified by manganese(II) complexes via direct deposition method. These novel modified electrodes clearly demonstrate the necessity of modifying bare carbon electrodes to endow them with the desired behavior and were identified by HRTEM. Also complexes were characterized by elemental analyses, MS, UV–vis and IR spectroscopy. Modified hybrid GC/MWCNT/MnSaloph electrode exhibits strong and stable electrocatalytic activity towards the electrooxidation of 2-mercaptoethanol molecules in comparison with bare glassy carbon electrode with advantages of very low over potential and high catalytic current. Such ability promotes the thiol’s electron transfer reaction. Also, electron withdrawing substituent on the Saloph was enhanced electrocatalytic oxidation activity.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2018

Electrochemically reduced graphene oxide nanosheet coatings as solid lubricants in humid air

Highlights: • A facile, low cost and green approach to fabricate ERGO coatings is reported. • The feasibility of using ERGO coatings as solid lubricants is demonstrated. • ERGO coatings reduce copper’s COF to 1/6 and wear rate to more than 1/260. - Abstract: A facile, low cost and green approach to fabricating graphene nanosheet coatings is reported. It is composed of spraying graphene oxide (GO) suspension to form GO nanosheet coatings followed by a low voltage electrochemical reduction process. The tribological performance of the as-prepared electrochemically reduced graphene oxide (ERGO) nanosheet coatings on copper disk are evaluated by sliding against steel ball in humid air. The friction coefficient of copper is reduced to 1/6 its value, and its specific wear rate is reduced more than two orders of magnitude when copper disk is coated with ERGO nanosheet coatings. These improved tribological performance are attributed to the presence of ERGO nanosheets in the sliding interface of steel vs. copper friction pair. They not only provide easy shearing, reducing the friction coefficient, but also effectively suppress abrasive wear and adhesive wear, decreasing the wear rate of copper disk.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2021

Wear Mechanism Analysis of a New Rotary Shear Biomass Comminution System

A new biomass comminution system, Crumbler rotary shear, was developed to process fuel-grade biomass. The rotary shear is more efficient than the traditional hammer mill in comminuting high-moisture biomass and producing more uniform particles with minimal fines. However, the milling unit experiences significant wear in processing dirty woodchips. This study investigated the wear mechanisms of the rotary shear system based on analysis of the minerals carried by woodchips and characterization of actual worn components. Abrasive wear was found to be the dominant effect, and localized adhesive wear (material transfer), microfracture (chipping), and plastic deformation were additional effects. Connections have been made between the wear progression of key cutting components and the particle size change of biomass extrinsic minerals. On the basis of the wear mechanism understanding, mitigations based on advanced tool materials and optimized tool geometric designs are being developed for improving the tool life and cutting efficiency.

09 BIOMASS FUELS↗
DOE OSTI2020

Material Characterization-Based Wear Mechanism Investigation for Biomass Hammer Mills

Biomass, as harvested, is composed of inorganic compounds both intrinsically and extrinsically and can be abrasive. The present study investigates the wear modes and mechanisms of two types of blades of hammer mills used in biomass size reduction (impacting the particle size and distribution) and densification (impacting the size, shape, and density). The dominant wear modes for the stage 1 steel blades are determined to be erosive and polishing wear. For the stage 2 blades with a carbide weld overlay, the main wear mechanisms are erosion and fracture. Partial replacement of Co by Fe in the outer layer of the carbide grits, likely induced by diffusion during high-temperature welding, has been correlated to the observed microcracking. Finally, the microcracking is believed to weaken the grit strength and fracture toughness to make the overlay prone to fracture and erosion due to repetitive contact with the inorganic contents in chopping biomass.

42 ENGINEERING↗
DOE OSTI2025

Annual and sub-seasonal dynamics of a rapidly eroding permafrost coastline along the Beaufort Sea in northern Alaska

Drew Point, an unlithified ice-rich permafrost coastline along the Alaskan Beaufort Sea, is among the most rapidly eroding Arctic coastlines, with an average erosion rate of 19 m/yr from 2007 to 2019. We use 16 high-resolution remote sensing datasets (satellite, airborne, and UAV imagery) to analyze erosion mechanisms (thermal abrasion and denudation) in relation to environmental forcings along a 1.5 km stretch of coastline during the 2018 and 2019 open water seasons. In a striking contrast, 2019 exhibited the highest mean erosion rate (34.5 m) within the 2007–2019 record, while 2018 had the second lowest (11.2 m). Block failure contributed to sub-seasonal erosion rates 6 to 21 times higher than thermal denudation, with staggered block fall timing, lag responses post-storm, and non-storm block collapse influencing overall erosion magnitude and timing. To quantify wind effects, we developed wind sums, a metric combining cumulative wind speed and directional data that can be used as a proxy for integrated storm intensity capable of incorporating lagged responses that correlated strongly with erosion at sub-seasonal and annual scales. Our findings emphasize the dominant role of wind during periods of open water and air temperature during the thaw season in driving permafrost coastline erosion dynamics, while highlighting the importance of spatiotemporally high-resolution datasets for understanding Arctic coastal change dynamics.

Alaska Beaufort Sea Coast↗
DOE OSTI2015

Investigation of the structure and properties of boron-containing coatings obtained by electron-beam treatment

An investigation of surface-hardened materials obtained by cladding with an electron beam injected into the air atmosphere was carried out. Structural investigations of coatings revealed that an increase in boron carbide concentration in a saturating mixture contributed to a rise of a volume fraction of iron borides in coatings. The maximum hardened depth reached 2 mm. Hardened layers were characterized by the formation of heterogeneous structure which consisted of iron borides and titanium carbides distributed uniformly in the eutectic matrix. Areas of titanium boride conglomerations were detected. It was found that an increase in the boron carbide content led to an enhancement in hardness of the investigated materials. Friction testing against loosely fixed abrasive particles showed that electron-beam cladding of powder mixtures containing boron carbides, titanium, and iron in air atmosphere allowed enhancing a resistance of materials hardened in two times.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Superhard sp{sup 2}–sp{sup 3} hybrid carbon allotropes with tunable electronic properties

Four sp{sup 2}–sp{sup 3} hybrid carbon allotropes are proposed on the basis of first principles calculations. These four carbon allotropes are energetically more favorable than graphite under suitable pressure conditions. They can be assembled from graphite through intralayer wrinkling and interlayer buckling, which is similar to the formation of diamond from graphite. For one of the sp{sup 2}–sp{sup 3} hybrid carbon allotropes, mC24, the electron diffraction patterns match these of i-carbon, which is synthesized from shock-compressed graphite (H. Hirai and K. Kondo, Science, 1991, 253, 772). The allotropes exhibit tunable electronic characteristics from metallic to semiconductive with band gaps comparable to those of silicon allotropes. They are all superhard materials with Vickers hardness values comparable to that of cubic BN. The sp{sup 2}–sp{sup 3} hybrid carbon allotroes are promising materials for photovoltaic electronic devices, and abrasive and grinding tools.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

The mechanical properties of austenite stainless steel 304 after structural deformation through cold work

The 304 stainless steel (SS) type is widely used in oil and gas operations due to its excellent corrosion resistance. However, the presence of the fine sand particles and H{sub 2}S gas contained in crude oil could lead the erosion and abrasion in steel. In this study, cold rolled treatments were conducted to the 304 SS in order to increase the wear resistance of the steel. The cold work has resulted in thickness reduction to 20%, 40% and 60% of the original. Various microstructural characterizations were used to analyze the effect of deformation. The hardness characterization showed that the initial hardness value increased from 145 HVC to 395 HVC as the level of deformation increase. Further, the wear resistance increased with the deformation rate from 0% to 40% and subsequently decreased from 40% to 60% deformation rate. Microstructural characterization shows that the boundary change to coincide by 56 µm, 49 µm, 45 µm, and 43 µm width and the grain go to flatten and being folded like needles. The effect of deformation on the grain morphology and structure was also studied by optical metallography and X-Ray Diffraction. It is shown that the deformation by means of a cold rolled process has transformed the austenite structure into martensitic structure.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

Experimental study and effect of particulate interference on the microhardness, wear and microstructural properties of ternary doped coating

This paper studies effects of the composite particle infringement of ZnO/Cr{sub 2}O{sub 3} on zinc rich ternary based coating. The corrosion-degradation property in 3.5% NaCl was investigatedusing polarization technique. The structural characteristics of the multilayer produce coatings were evaluated by scanning electron microscope (SEM) equipped with an energy dispersive spectrometer (EDS). The mechanical response of the coated samples was studied using a diamond base Dura –Scan) micro-hardness tester and a MTR-300 dry abrasive wear tester. The combined effect of the coatings gave highly-improved performance on microhardness, corrosion and wear damage. This also implies that protection of wind-energy structures in marine environments can be achieved by composite strengthening capacity.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Identification of Critical Process Parameters for Knife Milling and Alternative Communication Strategies

An assessment of knife milling operations was performed to identify parameters that require consideration to model wear and degradation of knife blades. A quality-by-design (QbD) paradigm was followed to identify material and feedstock attributes, and processing parameters that impact the quality attributes of the blades used in the comminution of biomass into forms compatible with downstream operations. Based on analytical and experimental observations of knife and tool wear, a QbD model is proposed that considers three wear mechanisms (erosion, abrasion, and gouging) to predict volumetric wear of knife blades and sharpness. These factors, if properly applied, provide a science-based approach to predict the mechanical efficiency of the mill as a function of feedstock properties, knife blade material properties, and processing parameters (feed rate, speed, and design parameters).

09 BIOMASS FUELS↗
DOE OSTI2022

Epoxy / Silicone Potting Material Removal for Greater Recovery of Circuit Boards

This report documents an exploratory research project, “Epoxy/Silicone Potting Material Removal for Greater Recovery of Circuit Boards,” that investigated micro abrasion and laser ablation as potential cost effective methods for removal of epoxy and silicone potting material from printed circuit boards (PCBs) to expose components for testing and repair. The ability to cost effectively remove such PCB potting materials will improve PCB repair, remanufacture, and reuse opportunities with potential for sizable reductions in material use, E-waste, and energy. Laser ablation was identified as a method potentially warranting further investigation, in particular for epoxy based potting materials.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

R&D to Ensure a Scientific Basis for Qualification Tests and Standards (Final Report)

Project return on investment in a photovoltaic (PV) system depends increasingly on maintaining high energy yields, and the system lifetime is a major factor in levelized cost of electricity (LCOE). Thus, the rate of PV deployment and the success of these assets depends upon reliable long-term power generation. The overarching objective of this program is to improve photovoltaic (PV) module reliability via development of tests and standards. Where reliability problems or risk are discovered, we can design tests to ensure that these liabilities don't affect future generations of products. Customers can use these tests to understand which products are susceptible to certain degradation mechanisms, and manufacturers can use the tests to design unwanted characteristics out of their products. The work under this program identifies PV reliability needs, performs characterization that provides scientific understanding of targeted degradation mechanisms, and translates those data into practical and predictive test protocols and standards. Major accomplishments include: A model for polarization-type potential induced degradation (PID-p) was developed and validated against experimental data. NREL is currently leading a new edition of IEC 62804-1 for PID detection. PID-p can cause large losses in current and voltage for some module designs on cloudy days. Finite element modeling (FEM) and experiment was used to determine when cells crack in a module. It was shown that cells in landscape orientation are much more likely to crack than those on portrait orientation. Shortly thereafter, the first products with portrait-oriented cells were introduced. Studies of how to test for light and elevated temperature degradation (LeTID) culminated with the publication of IEC TS 63342. Software to predict the progression of LeTID was developed, validated, and made publicly available. Field validated tests and international standards for durability of PV module coatings abrasion, backsheets, and encapsulants were developed. Examples are IEC 62788-1-1, IEC 62788-2 ED2, IEC TS 62788-7-2, IEC 62788-7-3 ED1, IEC 63209-2. NREL led the development a high-temperature testing technical specification, and published guidelines that enable installers to determine whether higher-temperature testing is needed, simply based on location and mounting configuration. In a number of our case studies, variations in the bills of materials or workmanship have been associated with variations in reliability. These observations emphasize the importance of quality assurance to reliability. A framework for criticality (i.e. Pareto) analysis was developed and published. The framework helps us and other researchers determine what problems should be addressed for reliability research to have the biggest industry impact. NREL continues to participate actively in international standards development and stakeholder engagement activities, including organizing an annual PV Reliability Workshop. These activities are important for ensuring we address issues that are relevant and timely, and that we convey our results to those who may benefit.

14 SOLAR ENERGY↗
DOE OSTI2017

More efficient grinding of hard-to-cut materials

The use of an impregnated abrasive tool in grinding stainless steel (12X18H10T) is investigated. The roughness of the machined surface and the grinding ratio are considerably better than when a traditional tool is employed.

42 ENGINEERING↗