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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 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Friction Stir Scribe Joining of Carbon Fiber Reinforced Polymer (CFRP) to Aluminum

The purpose of this project was to develop the critical process technology, models, and tools necessary to advance the Friction Stir Scribe, FSS, joining method through experimentation, validation at the laboratory scale, and integration into a production-like robotic environment. Implementation of FSS technology for joining polymer composites to metals will enable greater use of lightweight materials by providing technology capable of joining linear configurations without the use of adhesives or other third-body fasteners by creating an in-situ joint from the parent materials. As FSS technology provides the capability to join multi-material structures on robotic platforms using linear configurations, the development of this technology for use on the BIW will impact a great diversity of CFRP joints within the vehicle; thus, allowing a greater reduction in vehicle mass through more specifically designed structures. The FSS process has been developed to include integration of the FSS tool with a stationary shoulder, which has been shown to be required to achieve the desired surface quality (i.e., crown flash level). However, the targeted joint strength has not been achieved because the resulting stirred CFRP microstructure does not provide similar performance as the as-molded composite leading to low fracture strengths despite our efforts investigating various unique alternative approaches. In support of the experimental work, a process-structure model was developed and validated for the FSS joining (FSSJ) process using surrogate materials (steel and Al). The cyclic corrosion testing of the FSS joints and self-piercing riveted (SPR) joints revealed different modes of galvanic corrosion in the two types of joints. The SPR samples exhibited a greater amount of corrosion on the external surfaces. The presence of steel rivets in these joints exacerbated the situation, with the rivets getting preferentially corroded. The FSSJ samples despite exhibiting less surface corrosion, exhibited severe corrosion under the joint overlap area.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Insights into the Effect of Heat Treatment and Carbon Coating on the Electrochemical Behaviors of SiO Anodes for Li-Ion Batteries

The use of SiO as an anode material has attracted significant interest due to its high capacity and long cycling life. Many promising approaches, including structural design and carbon coating at high temperatures, effectively improve its intrinsic low electrical conductivity and poor Coulombic efficiency. However, the “heat treatment process-composition and microstructure-electrochemical properties” relationship of the SiO anode is not fundamentally understood. Here the structure and composition evolution in amorphous SiO and graphene-coated SiO is investigated using different heat-treatment conditions. X-ray absorption near-edge structure techniques are also employed to analyze the surface and bulk composition change during the initial lithiation process, supplemented by physical or chemical characterization and electrochemical testing. Here results reveal the structural transition of SiO during heat treatment, from amorphous to disproportionated hierarchical structure, where the as-formed dielectric exterior SiO 2 shell and interior SiO 2 matrix severely polarizes electrodes, hindering the lithiation process. Carbon coating on SiO effectively restricts the growth of the SiO 2 shell and facilitates charge transfer, leading to improved electrochemical performance. A schematic model is proposed to reveal the relationship between the treatments, the resultant structural evolutions, and corresponding electrochemical behaviors.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Design and simulation of an all optical full-adder based on photonic crystals

In this paper, we have designed and investigated a new all optical full-adder based on two-dimensional photonic crystal, using interaction between incident signals in optical waveguides. The designed structure is simple and it is only consisted of 15 × 22 dielectric rods with a radius of 109 nm in a square cell and lattice constant of 409 nm, which incorporates of five optical waveguides. Two types of defects have been used to control the light behavior. The surface of the proposed structure is equal to 72 μm{sup 2}, hence it is very compact. The operating wavelength of the proposed device is 1550 nm which is appropriate for telecommunication systems. The average delay time of the device is less than 2 ps, which indicates a data rate of more than 0.5 THz. This structure has a smaller size, faster response, and larger separation, between logic level 0 and 1, compared to two previously reported structures (the average constant ratio of device is 11 dB).

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2019

Boosting Superior Lithium Storage Performance of Alloy-Based Anode Materials via Ultraconformal Sb Coating–Derived Favorable Solid-Electrolyte Interphase

Alloy materials such as Si and Ge are attractive as high-capacity anodes for rechargeable batteries, but such anodes undergo severe capacity degradation during discharge-charge processes. Compared to the over-emphasized efforts on the electrode structure design to mitigate the volume changes, understanding and engineering of the solid-electrolyte interphase (SEI) are significantly lacking. This work demonstrates that modifying the surface of alloy-based anode materials by building an ultraconformal layer of Sb can significantly enhance their structural and interfacial stability during cycling. Combined experimental and theoretical studies consistently reveal that the ultraconformal Sb layer is dynamically converted to Li 3 Sb during cycling, which can selectively adsorb and catalytically decompose electrolyte additives to form a robust, thin, and dense LiF-dominated SEI, and simultaneously restrain the decomposition of electrolyte solvents. Hence, the Sb-coated porous Ge electrode delivers much higher initial Coulombic efficiency of 85% and higher reversible capacity of 1046 mAh g -1 after 200 cycles at 500 mA g -1 , compared to only 72% and 170 mAh g -1 for bare porous Ge. The present finding has indicated that tailoring surface structures of electrode materials is an appealing approach to construct a robust SEI and achieve long-term cycling stability for alloy-based anode materials.

25 ENERGY STORAGE↗
DOE OSTI2018

Thermodynamic and kinetic hydricities of metal-free hydrides

Metal-free hydrides are of increasing research interest due to their roles in recent scientific advances in catalysis, such as hydrogen activation with frustrated Lewis pairs and electrocatalytic CO 2 reduction with pyridinium and other aromatic cations. The structural design of hydrides for specific applications necessitates the correct description of their thermodynamic and kinetic prowess using reliable parameters – thermodynamic hydricity (ΔG H – ) and nucleophilicity ( N ). This review summarizes reported experimental and calculated hydricity values for more than 200 metal-free hydride donors, including carbon-, boron-, nitrogen- and silicon-based hydrides. We describe different experimental and computational methods used to obtain these thermodynamic and kinetic parameters. Furthermore, tabulated data on metal-free hydrides are discussed in terms of structure–property relationships, relevance to catalysis and contemporary limitations for replacing transition-metal hydride catalysts. Lastly, several selected applications of metal-free hydrides in catalysis are described, including photosynthetic CO 2 reduction and hydrogen activation with frustrated Lewis pairs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Identification of Selective Dual ROCK1 and ROCK2 Inhibitors Using Structure-Based Drug Design

A HTS campaign identified compound 1, an excellent hit-like molecule to initiate medicinal chemistry efforts to optimize a dual ROCK1 and ROCK2 inhibitor. Substitution (2-Cl, 2-NH 2 , 2-F, 3-F) of the pyridine hinge binding motif or replacement with pyrimidine afforded compounds with a clean CYP inhibition profile. Cocrystal structures of an early lead compound were obtained in PKA, ROCK1, and ROCK2. This provided critical structural information for medicinal chemistry to drive compound design. The structural data indicated the preferred configuration at the central benzylic carbon would be $(R)$, and application of this information to compound design resulted in compound 16. This compound was shown to be a potent and selective dual ROCK inhibitor in both enzyme and cell assays and efficacious in the retinal nerve fiber layer model after oral dosing. This tool compound has been made available through the AbbVie Compound Toolbox. Finally, the cocrystal structures also identified that aspartic acid residues 176 and 218 in ROCK2, which are glutamic acids in PKA, could be targeted as residues to drive both potency and kinome selectivity. Introduction of a piperidin-3-ylmethanamine group to the compound series resulted in compound 58, a potent and selective dual ROCK inhibitor with excellent predicted drug-like properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2014

Telluride Misfit Layer Compounds: [(PbTe) 1.17 ] m (TiTe 2 ) n

Telluride misfit layer compounds are reported for the first time. These compounds were synthesized using a novel approach of structurally designing a precursor that would form the desired product upon low-temperature annealing, which allows the synthesis of kinetically stable products that do not appear on the equilibrium phase diagram. Four new compounds of the [(PbTe)1.17]m(TiTe2)n family are reported, and their structures were examined by a variety of X-ray diffraction techniques.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2014

Telluride Misfit Layer Compounds: [(PbTe) 1.17 ] m (TiTe 2 ) n

Telluride misfit layer compounds are reported for the first time. These compounds were synthesized using a novel approach of structurally designing a precursor that would form the desired product upon low-temperature annealing, which allows the synthesis of kinetically stable products that do not appear on the equilibrium phase diagram. Four new compounds of the [(PbTe)1.17]m(TiTe2)n family are reported, and their structures were examined by a variety of X-ray diffraction techniques.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

CLIC Drive Beam Gun

The Compact Linear Collider (CLIC) is a proposed future electron-positron collider, designed to perform collisions at energies from 0.5 to 5 TeV, with a nominal design optimized for 3 TeV (Dannheim, 2012). CLIC generates three beams: the drive beam, the main electron beam and the positron beam. The drive beam is a high current electron beam that is accelerated in an S-band linac and then decelerated in 12 GHz structures to generate the RF for accelerating the colliding main electron and positron beams. The drive beam employs a high current thermionic DC electron gun. This report explores the optimal anode – cathode geometry as well as analyzes the mechanical and electrical integrity of the gun structure designed by CERN.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

6.26 Low Cost Basalt Fiber for Automotive Applications

Vehicle lightweighting is an essential component to the automotive industry to improve fuel economy of internal combustion engine (ICE) vehicles to meet ever improving emission standards and to improve the range of electric vehicles (EV). Composite materials offer high specific modulus and specific strength, which makes them appealing for these light weighting efforts. Sheet molding compounds (SMC) are particularly interesting from an automotive perspective because of the relatively low cost and high volume of producing SMC parts. Traditionally, composite materials for automotive application are glass fiber reinforced because of the attractive price - performance ratio, but basalt fibers are a cost and recycling competitive reinforcement alternative in this market. The aim of this project was to examine the feasibility of utilizing basalt fiber for automotive applications. More specifically, an effort was made to examine different fiber sizings on basalt fiber combined with vinyl-ester (VE) resin, and their performance as part of an SMC process. In addition to offering vehicle lightweighting with fiber reinforced polymer composites, basalt fiber is a fully recyclable material and thus supports the IACMI technical goal of: Demonstrate that the technology is capable at a sufficient scale for >80% recyclability or reuse of fiber reinforced polymer composites in five years into useful components with projected cost and quality at commercial scale competitive with virgin materials on a pathway to 95% recyclability or reuse starting in ten years. Three different fiber sizings were applied to a continuous roving of basalt fiber and compared to a traditional Electrical/Chemical Resistance (E-CR) glass fiber that is typically used in these types of applications. Fiber tows were examined for Loss on Ignition percentage (LOI%), Tex, and tow strength. Some sizings clearly outperformed others, and the ability to process these fibers on a pilot scale SMC line was demonstrated. A test plan for the manufacturing and mechanical testing of SMC panels was developed. This work continues outside the time frame allocated for this project. When this work is completed, it will be added to this report and posted as Appendix C. Glass fiber reinforced SMC materials have already proven feasible as a light weighting method for traditionally steel parts like the Volkswagen (VW) Atlas lift-gate (Figure 1); this project team is seeking the feasibility of basalt fiber as a drop-in replacement for glass fiber reinforced SMC. Sizing development for basalt fibers has proven that the mechanical properties are better than E-glass and closer to S-glass, which makes it an interesting material for SMC applications. Better mechanical properties translate to less material needed to achieve load case requirement for target applications. The business case has already been demonstrated for 100,000 parts per year of glass fiber reinforced SMC Atlas lift-gates compared to traditional steel manufacturing processes. Reduced overhead and assembly costs are offset by glass fiber SMC higher cost per kg beyond 100,000 parts per year, which is still a relatively low volume for the automotive industry. For basalt fiber reinforced SMC to become feasible for automotive applications, the price-performance ratio has to be precisely determined. Based on the mechanical performance it is possible to establish a range of applications and technical solutions in which the potential of basalt SMC can be utilized, while the price of the material can be used to compile the business case for such applications. Based on these business cases and the sustainability indicators, glass fiber reinforcement (or other) materials can be directly substituted. Volkswagen’s commitment to reducing carbon emissions cannot be understated. Basalt fiber shows promise of reducing the carbon footprint in SMC materials, especially if sizing optimizations can be made with thermoplastic based SMC. To fully realize the value of basalt fiber reinforced materials, a lifecycle cost analysis should be performed on basalt’s production and recycling, and then compared against E-glass. From this assessment, a true judgement can be made on the commercialization potential of this material. Figure 1. Example of Fiber Reinforced Polymer Composite Liftgate As a conclusion, we can state that Mafic basalt fiber is not a direct replacement for E-glass or E-CR glass based on price, but should be considered a technical solution when E-glass does not provide adequate performance in a composite design and S-glass, aramid and carbon fibers are too costly. Mafic basalt fiber can be placed on the high-performance fiber spectrum next to S-glass for performance but at one third the price. It should be considered for more technically challenging structural designs wherein the performance can demonstrate 20-25% performance enhancement over E-glass to elicit more strength or a weight reduction. Both Michelman and Mafic produce thermoplastic sizings which, in combination with Nylon and polypropylene resin and fibers, can further advance high speed composite implementations while maintaining an eco-friendly manufacturing process.

36 MATERIALS SCIENCE↗
DOE OSTI2015

A biopolymer-like metal enabled hybrid material with exceptional mechanical prowess

The design principles for naturally occurring biological materials have inspired us to develop next-generation engineering materials with remarkable performance. Nacre, commonly referred to as nature’s armor, is renowned for its unusual combination of strength and toughness. Nature’s wisdom in nacre resides in its elaborate structural design and the judicious placement of a unique organic biopolymer with intelligent deformation features. However, up to now, it is still a challenge to transcribe the biopolymer’s deformation attributes into a stronger substitute in the design of new materials. In this study, we propose a new design strategy that employs shape memory alloy to transcribe the ‘‘J-curve’’ mechanical response and uniform molecular/atomic level deformation of the organic biopolymer in the design of high-performance hybrid materials. This design strategy is verified in a TiNi-Ti₃Sn model material system. The model material demonstrates an exceptional combination of mechanical properties that are superior to other high-performance metal-based lamellar composites known to date. Our design strategy creates new opportunities for the development of high-performance bio-inspired materials.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Failure Assessments for MQXF Magnet Support Structure with a Graded Approach

The High-Luminosity Large Hadron Collider (HLLHC) upgrade requires new quadrupoles, MQXF, to replace the present LHC inner triplets. The MQXFA magnet is the first prototype that has a 150 mm aperture and uses Nb 3 Sn superconducting technology in a 4.2 m magnetic length structure. The support structure design of the MQXFA magnet is based on the bladder-and-key technology, where a relatively low pre-stress at room temperature is increased to the final preload targets during the cool-down by the differential thermal contraction of the various components. The magnet support structure components experience different load levels from pre-load to cool-down and excitation. Consequently, a few parts experience high stresses that may cause localized plastic deformations or internal fracture development. The concept presented in this paper for the failure assessment of support structures integrates nonlinear finite element analysis with detailed sub-models and fracture mechanics into an advanced engineering tool. The nonlinear FE solutions enable estimations of the structural response to the given loads, and the advanced fracture analysis with failure assessment diagram (FAD) assesses the structure safety index of results obtained from the FE model. The study describes how the MQXFA shell end segments are being optimized based on the failure analyses.

43 PARTICLE ACCELERATORS↗
DOE OSTI2011

Fish-Friendly Hydropower Turbine Development & Deployment: Alden Turbine Preliminary Engineering and Model Testing

The Alden turbine was developed through the U.S. Department of Energy's (DOE's) former Advanced Hydro Turbine Systems Program (1994-2006) and, more recently, through the Electric Power Research Institute (EPRI) and the DOE's Wind & Water Power Program. The primary goal of the engineering study described here was to provide a commercially competitive turbine design that would yield fish passage survival rates comparable to or better than the survival rates of bypassing or spilling flow. Although the turbine design was performed for site conditions corresponding to 92 ft (28 m) net head and a discharge of 1500 cfs (42.5 cms), the design can be modified for additional sites with differing operating conditions. During the turbine development, design modifications were identified for the spiral case, distributor (stay vanes and wicket gates), runner, and draft tube to improve turbine performance while maintaining features for high fish passage survival. Computational results for pressure change rates and shear within the runner passage were similar in the original and final turbine geometries, while predicted minimum pressures were higher for the final turbine. The final turbine geometry and resulting flow environments are expected to further enhance the fish passage characteristics of the turbine. Computational results for the final design were shown to improve turbine efficiencies by over 6% at the selected operating condition when compared to the original concept. Prior to the release of the hydraulic components for model fabrication, finite element analysis calculations were conducted for the stay vanes, wicket gates, and runner to verify that structural design criteria for stress and deflections were met. A physical model of the turbine was manufactured and tested with data collected for power and efficiency, cavitation limits, runaway speed, axial and radial thrust, pressure pulsations, and wicket gate torque. All parameters were observed to fall within ranges expected for conventional radial flow machines. Based on these measurements, the expected efficiency peak for prototype application is 93.64%. These data were used in the final sizing of the supporting mechanical and balance of plant equipment. The preliminary equipment cost for the design specification is $1450/kW with a total supply schedule of 28 months. This equipment supply includes turbine, generator, unit controls, limited balance of plant equipment, field installation, and commissioning. Based on the selected head and flow design conditions, fish passage survival through the final turbine is estimated to be approximately 98% for 7.9-inch (200-mm) fish, and the predicted survival reaches 100% for fish 3.9 inches (100 mm) and less in length. Note that fish up to 7.9- inches (200 mm) in length make up more than 90% of fish entrained at hydro projects in the United States. Completion of these efforts provides a mechanical and electrical design that can be readily adapted to site-specific conditions with additional engineering development comparable to costs associated with conventional turbine designs.

13 HYDRO ENERGY↗
DOE OSTI2023

Electrothermally Driven Reconfiguration of Microrobotic Beam Structures for the ChipSail System

Solar sailing enables efficient propellant-free attitude adjustment and orbital maneuvers of solar sail spacecraft with high area-to-mass ratios. However, the heavy supporting mass for large solar sails inevitably leads to low area-to-mass ratios. Inspired by chip-scale satellites, a chip-scale solar sail system named ChipSail, consisting of microrobotic solar sails and a chip-scale satellite, was proposed in this work. The structural design and reconfigurable mechanisms of an electrothermally driven microrobotic solar sail made of Al\Ni 50 Ti 50 bilayer beams were introduced, and the theoretical model of its electro-thermo-mechanical behaviors was established. The analytical solutions to the out-of-plane deformation of the solar sail structure appeared to be in good agreement with the finite element analysis (FEA) results. A representative prototype of such solar sail structures was fabricated on silicon wafers using surface and bulk microfabrication, followed by an in-situ experiment of its reconfigurable property under controlled electrothermal actuation. The experimental results demonstrated significant electro-thermo-mechanical deformation of such microrobotic bilayer solar sails, showing great potential in the development of the ChipSail system. Analytical solutions to the electro-thermo-mechanical model, as well as the fabrication process and characterization techniques, provided a rapid performance evaluation and optimization of such microrobotic bilayer solar sails for the ChipSail.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2017

Wind Load and Heat Transfer Analysis of a New Linear Fresnel Assembly

An innovative design of linear Fresnel secondary receiver assembly is presented here. It includes an evacuated absorber tube and a secondary reflector. The secondary reflector is based on NREL’s new adaptive method. In this paper, a detailed wind load analysis and heat transfer analysis were conducted to assist the ongoing structural design.

Parikh, Abhishek↗
DOE OSTI2017

Wind load and heat transfer analysis of a new linear Fresnel assembly

An innovative design of linear Fresnel secondary receiver assembly is presented here. It includes an evacuated absorber tube and a secondary reflector. The secondary reflector is based on NREL’s new adaptive method. In this paper, a detailed wind load analysis and heat transfer analysis were conducted to assist the ongoing structural design.

Parikh, Abhishek↗
DOE OSTI2024

The Toughness of Interlocking Metasurfaces

Interlocking metasurfaces (ILMs) are arrays of autogenous latching unit cells patterned across a surface. These create structural joints similar to bioinspired suture joints but patterned over a 2D surface rather than a 1D seam. This enables ILMs to be an alternative to conventional joining technologies such as bolts, welds, and adhesives. However, compared to conventional joining methods, relatively little is known of the engineering considerations for designing structural ILMs. Herein, the interfacial toughness of an archetypal ILM is examined for the first time. Under the conditions studied here, the ILM is substantially tougher than the material from which it is made, in this case, exhibiting up to a 50% increase in interfacial crack initiation energy over the solid base material, a photocured 3D‐printed polymer. Through experimental tests using in‐situ digital image correlation along with complementary computational analyses, the mechanism of toughening in the ILM structure and the origins of toughness anisotropy are revealed. The increase in toughness is associated with cross‐cell interactions, that is, load‐sharing across unit cells, which give rise to a finite process zone length with different effective material properties. In this way, ILM toughening is analogous to crack blunting in ductile materials or fiber bridging in composites; yet here, the ILM is composed of a single‐phase base material and so the architected toughening is geometric in nature and hence amenable to future topological optimization.

fracture↗