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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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Effects of high temperature treatment on microstructure and mechanical properties of laser-clad NiCrBSi/WC coatings on titanium alloy substrate

Laser-clad composite coatings on the Ti6Al4V substrate were heat-treated at 700, 800, and 900 °C for 1 h. The effects of post-heat treatment on the microstructure, microhardness, and fracture toughness of the coatings were investigated by scanning electron microscopy, X-ray diffractometry, energy dispersive spectroscopy, and optical microscopy. The wear resistance of the coatings was evaluated under dry reciprocating sliding friction at room temperature. The coatings mainly comprised some coarse gray blocky (W,Ti)C particles accompanied by the fine white WC particles, a large number of black TiC cellular/dendrites, and the matrix composed of NiTi and Ni{sub 3}Ti; some unknown rich Ni- and Ti-rich particles with sizes ranging from 10 nm to 50 nm were precipitated and uniformly distributed in the Ni{sub 3}Ti phase to form a thin granular layer after heat treatment at 700 °C. The granular layer spread from the edge toward the center of the Ni{sub 3}Ti phase with increasing temperature. A large number of fine equiaxed Cr{sub 23}C{sub 6} particles with 0.2–0.5 μm sizes were observed around the edges of the NiTi supersaturated solid solution when the temperature was further increased to 900 °C. The microhardness and fracture toughness of the coatings were improved with increased temperature due to the dispersion-strengthening effect of the precipitates. Dominant wear mechanisms for all the coatings included abrasive and delamination wear. The post-heat treatment not only reduced wear volume and friction coefficient, but also decreased cracking susceptibility during sliding friction. Comparatively speaking, the heat-treated coating at 900 °C presented the most excellent wear resistance. - Highlights: • TiC + WC reinforced intermetallic compound matrix composite coatings were produced. • The formation mechanism of the reinforcements was analyzed. • Two precipitates were generated at elevated temperature. • Cracking susceptibility and microhardness of the coatings were improved. • Post-heat treatment enhances wear resistance of the coatings.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Effect of small addition of Cr on stability of retained austenite in high carbon steel

High carbon steels with dual phase structures of martensite and austenite have considerable potential for industrial application in high abrasion environments due to their hardness, strength and relatively low cost. To design cost effective high carbon steels with superior properties, it is crucial to identify the effect of Chromium (Cr) on the stability of retained austenite (RA) and to fully understand its effect on solid-state phase transition. This study addresses this important knowledge gap. Using standard compression tests on bulk material, quantitative X-ray diffraction analysis, nano-indentation on individual austenitic grains, transmission electron microscopy and electron backscatter diffraction–based orientation microscopy techniques, the authors investigated the effect of Cr on the microstructure, transformation behaviour and mechanical stability of retained austenite in high carbon steel, with varying Cr contents. The results revealed that increasing the Cr %, altered the morphology of the RA and increased its stability, consequently, increasing the critical pressure for martensitic transformation. This study has critically addressed the elastoplastic behaviour of retained austenite – and provides a deep understanding of the effect of small additions of Cr on the metastable austenite of high carbon steel from the macro- to nano-level. Consequently, it paves the way for new applications for high carbon low alloy steels. - Highlights: • Effect of small addition of Cr on metastable austenite of high carbon steel from the macro- to nano-level • A multi-scale study of elastoplastic behaviour of retained austenite in high carbon steel • The mechanical stability of retained austenite during plastic deformation increased with increasing Cr content • Effect of grain boundary misorientation angle on hardness of individual retained austenite grains in high carbon steel.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Adhesion mechanisms on solar glass: Effects of relative humidity, surface roughness, and particle shape and size

To better understand and quantify soiling rates on solar panels, we are investigating the adhesion mechanisms between dust particles and solar glass. In this work, we report on two of the fundamental adhesion mechanisms: van der Waals and capillary adhesion forces. The adhesion was determined using force versus distance (F-z) measurements performed with an atomic force microscope (AFM). To emulate dust interacting with the front surface of a solar panel, we measured how oxidized AFM tips, SiO 2 glass spheres, and real dust particles adhered to actual solar glass. The van der Waals forces were evaluated by measurements performed with zero relative humidity in a glove box, and the capillary forces were measured in a stable environment created inside the AFM enclosure with relative humidity values ranging from 18% to 80%. To simulate topographic features of the solar panels caused by factors such as cleaning and abrasion, we induced different degrees of surface roughness in the solar glass. As a result, we were able to 1) identify and quantify both the van der Waals and capillary forces, 2) establish the effects of surface roughness, relative humidity, and particle size on the adhesion mechanisms, and 3) compare adhesion forces between well-controlled particles (AFM tips and glass spheres) and real dust particles.

14 SOLAR ENERGY↗
DOE OSTI2017

Transparent superhydrophobic surfaces using a spray coating process

One significant maintenance problem and cost associated with solar energy conversion systems is the soiling due to the accumulation of dust and other pollutants. Here in this work, we describe a scalable approach for applying antisoiling coatings based on superhydrophobic (SH) silica particles using a spray coating process. A large water contact angle (WCA) is one of the characteristics of excellent SH surfaces and because of the low surface energy and low adhesion forces the soiling rate is reduced. Our findings indicate that the WCA depends strongly on the ratio of the polymer binder and the nanoparticles. The nanoparticle surface coverage of the spray coated samples was substantially improved after rinsing with solvent. This process tended to remove large aggregates and excess polymer binder and further increased the WCA by allowing exposure of the functionalized nanoparticles. The durability of the SH coatings was enhanced when the substrate was pretreated with polymer binder and an optimal curing time between 30 and 60 min. The abrasion tests of the SH coatings we report in this study showed that the WCA decreased from ~ 166° to ~ 157° after exposure to 2.6 g of sand. Such coatings will help reduce costs of periodic cleaning of solar energy conversion systems (photovoltaic panels and concentrated solar mirrors).

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2018

Soiling and cleaning: Initial observations from 5-year photovoltaic glass coating durability study

The contamination of solar photovoltaic cover glass can significantly reduce the transmittance of light to the surface of the photovoltaic cell, reducing the module's power output. The solar industry has been developing antireflection (AR) and antisoiling (AS) surface coatings to enhance light transmittance and mitigate the impacts of soiling. Although uncoated glass has been field tested for decades, minimal data exist to demonstrate the durability of AR and AS coatings against abrasion and surface erosion, including from: natural weathering, airborne sand, and industry cleaning practices. Coupons 75 mm square of varying types have been field-deployed to gather long-term data on coating durability; the initial results are presented here after 1 year of outdoor exposure near Sacramento, California. Duplicate sets of coupons were cleaned monthly per four different cleaning practices. All coupons demonstrated inorganic soiling as well as microscale biological contamination, regardless of cleaning method. Additionally, full-sized, field-aged modules from other areas of the world presented with similar types of contamination as the field-aged coupons; micrographs and results from genomic sequencing of this contamination are included here. Optical microscopy, scanning electron microscopy, atomic force microscopy/energy-dispersive spectroscopy, surface roughness, transmittance, and surface energy analysis of representative specimens and cleaning practices are presented.

14 SOLAR ENERGY↗
DOE OSTI2018

Anti-soiling and highly transparent coatings with multi-scale features

We report that soiling of optical surfaces due to sand and dust accumulation is the main cause for decreased efficiency of concentrating solar power and photovoltaic installations in desert areas. Nanostructured coatings with tailored surface roughness can reduce the rate of soil accumulation and maintain the high optical performance of the solar mirrors and cover glass. Here, we investigate the correlation between the size and structure of the surface features of the coating and its anti-soiling and optical properties. To control the morphology of the surface features we developed two types of coating: (1) based on small size (30–50 nm) silica particles with nanostructured surface and (2) based on unstructured nanoparticles with bimodal size distribution (80 and 35 nm). We tailored the surface features of the coatings to achieve synergistic improvements over different length-scales and thus decrease the adhesion force between the soil particles and the surface. Adhesion force measurements were performed using atomic force microscopy. The adhesion force and energy required to separate a silica particle from the surface of coated solar glass was significantly lower than the respective values from the surface of uncoated solar glass. A falling sand abrasion test, modeled after the procedure in ASTM D968, was performed. The optical properties of coated and uncoated solar glass were measured before and after the soiling test. Coated solar mirror samples were tested in the field. The results of the field test provided evidence that the anti-soiling coating is effective at reducing soiling and improving the specular reflectances of the coated mirrors. Finally, the use of the developed anti-soiling coating can be extended to other power-grid applications where reducing the soil accumulation is valuable.

14 SOLAR ENERGY↗
DOE OSTI2021

Tribological behavior of ceramic-alloy bearing contacts in molten salt lubrication for concentrating solar power

Molten salts are considered as candidate heat transfer fluids and thermal energy storage media for next generation concentrating solar power (CSP). A molten salt circulates inside the piping and heat exchanger and also functions as a lubricant for the sleeve bearings of the CSP pump. Furthermore, wear- and corrosion-resistant high-temperature bearing materials are critical for the pump efficiency and durability. This study evaluated the tribological performance of candidate bearing materials in lubrication of a molten chloride salt mixture (20% NaCl + 40% MgCl 2 + 40% KCl) at 750 °C in an inert argon gas (a simulative CSP pump environment). Six ceramic-alloy pairs were tested, zirconia and silicon nitride against Haynes 244, Hastelloy C276, and Tribaloy T900 alloy, and ranked by the friction coefficient and wear loss. Characterization of worn surfaces suggested the wear mechanism as a combination of abrasion, adhesion, and tribocorrosion. Results from this study provide fundamental insight for the development and selection of bearing materials for molten salt powered CSP pumps.

14 SOLAR ENERGY↗
DOE OSTI2021

Why does a phosphonium-phosphinate ionic liquid protect the contact surfaces from wear and micropitting but increase vibration when used as an additive in rolling-sliding lubrication?

A phosphonium-phosphinate ionic liquid (IL) was studied as a lubricant additive for rolling-sliding contacts. The bench-scale test was designed to simulate automotive rear axle operation during cold start, highway towing, and overload conditions. Adding such an IL (2%) into a base oil significantly reduced wear loss and rolling contact fatigue, e.g., microcracking and micropitting, but made the vibrational noise notably higher under a low (-1.5%) sliding roll ratio (SRR). Additionally, worn surface characterization revealed an interesting texture pattern with alternating smoother plateaus and rougher valleys, which is believed to cause the high vibration. No increased vibration was observed at a high (-30%) SRR, possibly because the more aggressive sliding abrasion prevented such a surface texture from forming.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Tribological behavior of spark plasma sintered Ti 3 SiC 2 MAX phase composites

Ti₃SiC₂ MAX phases are considered promising candidates for tribological applications; but, their low hardness (5-6 GPa) can lead to increased abrasive wear and higher wear rates. This study investigates the effect of incorporating hard SiC particles on microstructure, mechanical, and tribological behavior of Ti₃SiC₂-SiC-based MAX phase composites prepared using spark plasma sintering at 1400 °C, 40 MPa, 15-minute holding time. Phase and microstructural characterization of composites confirmed the formation of Ti₃SiC₂ MAX phase (90%) along with TiC as a minor phase (10%). For Ti₃SiC₂-SiC, homogeneous distribution of SiC grains within Ti₃SiC₂ matrix resulted in increased hardness from ~11.6 GPa to ~14.8 GPa; however, the flexural strength decreased from ~615 MPa to ~597 MPa due to coefficient of thermal expansion mismatch. Tribological behavior of Ti₃SiC₂-SiC MAX phase composites was assessed using unidirectional sliding ball-on-flat tests with a 52100 steel ball at different loads and a constant speed of 0.05 m/s. SiC reinforced composites exhibited a decreased friction coefficient from 0.39 to 0.29 and wear rates comparable to Ti₃SiC₂ (7-10×10⁻³ mm³/N·m). SEM and EDS analysis of the worn surfaces indicated material transfer from the steel ball counter body and its oxidation due to frictional heating, at lower loads (2N and 5N), whereas at higher load (10N), fracture of the transfer layer dominated, with the presence of microcracks, delamination, grain pull-outs, and wear debris. Improved mechanical properties and good adhesion of SiC with Ti₃SiC₂ matrix resulted in reduced microcracks and grain pull-outs, making Ti₃SiC₂-SiC/Steel tribo-pair more suitable for tribological applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Grid-to-rod fretting wear study of SiC/SiC composite accident-tolerant fuel claddings using an autoclave fretting bench test

Grid-to-rod-fretting (GTRF) in pressurized water reactors (PWRs) is known to cause wear and surface damage on the fuel claddings, potentially leading to radioactive leakage. One of the accident-tolerant fuel (ATF) concepts is to use advanced cladding materials that could withstand higher temperatures. Here, we investigated the wear behavior of candidate silicon carbide (SiC)-based composite claddings with different levels of surface finish in fretting against a commercial ZIRLO alloy grid using a unique bench-scale autoclave GTRF rig. The experiments mimicked the environment in an industrial full-assembly PWR simulator. Fretting tests were conducted with a realistic load (~0.5 N) in deionized water under a pressure of 20–23 bar at 204 °C for 100 h. While the SiC/SiC composite claddings showed significantly higher wear resistance than the commercial ZIRLO alloy cladding as expected, the smoother versions experienced surprisingly higher wear than the much softer counterface, ZIRLO grid. The wear mechanism of the SiC/SiC cladding was attributed to the SiC wear debris that was trapped at the fretting interface causing both 3-body and 2-body (embedded into the grid surface) abrasion of the cladding. Rougher SiC/SiC claddings had less material loss but caused more wear on the ZIRLO grid. Finally, pre-oxidized ZIRLO grid showed better compatibility with the SiC/SiC cladding to protect both the cladding and grid as a result of reduced wear debris trapping.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Carbon nanotube (CNT) reinforced 316L stainless steel composites made by laser powder bed fusion: Microstructure and wear response

Carbon nanotube (CNT) reinforced 316L stainless steel (SS) composites were fabricated by laser powder bed fusion (LPBF) additive manufacturing (AM). This study focuses on microstructure evolution, hardness, and wear behavior. The wear behavior for AM 316L SS and 1 wt% CNT/316L SS was studied by a dry sliding test under normal loads of 10, 15, and 25 N. The addition of CNT to 316L SS led to the change of solidification mode from cellular/columnar to dendritic growth, producing grain refinement. Nanoscale dendrites were observed. Although TEM characterization confirmed the existence of CNT in cell interior, most CNT were damaged, resulting in carbon material segregation along cellular/dendritic boundaries. The wear rate was found dramatically decreased due to the improved hardness. Compared to the adhesive and abrasive wear in AM 316L SS, the wear mechanism of CNT/316L composite was adhesion and oxidative wear. Furthermore, enhanced cellular/dendritic boundary strengthening by carbon segregation was the main strengthening mechanism of CNT/316L composite.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Improving knife milling performance for biomass preprocessing by using advanced blade materials

Mechanical preprocessing of biomass, including size reduction, is a crucial step in converting biomass into biofuel. However, feedstock inevitably contains abrasive intrinsic and extrinsic inorganics that may cause excessive tool wear in preprocessing. Here, this work demonstrates that performance of a knife mill can be significantly improved by applying a more wear-resistant blade material. A series of full-scale knife mill tests were performed for size reduction of forest residue using blades of tungsten carbide (WC–Co), iron-borided tool steel, and diamond-like carbon (DLC) coated tool steel. Blade material loss was quantified in correlation to the amount of feedstock processed and wear mechanisms were investigated via worn surface characterization. While the thin DLC coating was removed quickly, the WC-Co and iron-borided blades improved the tool life by 8X and 3X compared with the M2 tool steel blades (baseline), respectively. The in-situ throughput and power consumption measurements provided additional insights. The WC-Co and iron-borided blades had ~3X higher throughput than the baseline blades by the end of the test with lower normalized power consumption. The experimental results were then used as input for a techno-economic analysis, which suggested that the more wear resistant blades could cut the knife milling cost by $2–3 per ton of biomass processed with downtime reduced by 65–85%.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Tribological behavior of hybrid Aluminum-TiB 2 metal matrix composites for brake rotor applications

Here, this research investigates the feasibility of hybrid aluminum metal matrix composites (MMC) incorporating TiB 2 particles for brake rotor applications. The composites were produced by incorporating both in-situ, submicron-sized TiB 2 particles and regular micron-sized TiB 2 powders via stir and squeeze casting techniques into A206 aluminum alloy matrix. Systematic adjustments in the fractions of in-situ and ex-situ TiB 2 particles were conducted to evaluate their impact on wear behavior and mechanisms. Combination of both particle types allowed composites with up to 10 vol% of reinforcements. Composites with higher proportions of ex-situ particles demonstrated increased wear resistance compared to those solely composed of in-situ particles, control specimens without TiB 2 , and conventional cast iron counterparts. The lowest wear rate for the hybrid composites sliding against phenolic brake pads was 1.1 × 10 -5 mm 3 /Nm, signifying a 3-fold reduction relative to cast iron sliding against the same pads. Wear analysis elucidated distinctive mechanisms within the hybrid composites, characterized by mild fragmented abrasive wear, adhesive wear, and plastic deformation, accompanied by the formation of an intermixed tribo-oxide layer.

42 ENGINEERING↗
DOE OSTI2021

A percolation theory for designing corrosion-resistant alloys

Iron-chromium and nickel-chromium binary alloys containing sufficient quantities of chromium serve as the prototypical corrosion-resistant metals owing to the presence of a nanometre-thick protective passive oxide film. Should this film be compromised by a scratch or abrasive wear, it reforms with little accompanying metal dissolution, a key criterion for good passive behaviour. This is a principal reason that stainless steels and other chromium-containing alloys are used in critical applications ranging from biomedical implants to nuclear reactor components. Unravelling the compositional dependence of this electrochemical behaviour is a long-standing unanswered question in corrosion science. Herein, we develop a percolation theory of alloy passivation based on two-dimensional to three-dimensional crossover effects that accounts for selective dissolution and the quantity of metal dissolved during the initial stage of passive film formation. We validate this theory both experimentally and by kinetic Monte Carlo simulation. Our results reveal a path forward for the design of corrosion-resistant metallic alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Monolithic graded-refractive-index glass-based antireflective coatings. Broadband/omnidirectional light harvesting and self-cleaning characteristics

The design of multifunctional coatings impact impact the performance of many optical systems and components. Such coatings should be mechanically robust, and combine user-defined optical and wetting functions with scalable fabrication formulations. By taking cues from the properties of some natural biological structures, we report here the formation of low-refractive index antireflective glass films that embody omni-directional optical properties over a wide range of wavelengths, while also possessing specific wetting capabilities. The coatings comprise an interconnected network of nanoscale pores surrounded by a nanostructured silica framework. These structures result from a novel fabrication method that utilizes metastable spinodal phase separation in glass-based materials. The approach not only enables design of surface microstructures with graded-index antireflection characteristics, where the surface reflection is suppressed through optical impedance matching between interfaces, but also facilitates self-cleaning ability through modification of the surface chemistry. Based on near complete elimination of Fresnel reflections (yielding >95% transmission through a single-side coated glass) and corresponding increase in broadband transmission, the fabricated nanostructured surfaces are found to promote a general and an invaluable ~3–7% relative increase in current output of multiple direct/indirect bandgap photovoltaic cells. Moreover, these antireflective surfaces also demonstrate superior resistance against mechanical wear and abrasion. Unlike conventional counterparts, the present antireflective coatings are essentially monolithic, enabling simultaneous realization of graded index anti-reflectivity, self-cleaning capability, and mechanical stability within the same surface. Moreover, the concept represents a fundamental basis for development of advanced coated optical quality products, especially where environmental exposure is required.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Investigation of aluminum surface cleaning using cavitating fluid flow

This paper investigates efficiency of specially designed atomizer used to spray water and cavitate microbubbles in water flow. Surface cleaning system was used to clean machined (grinded) aluminum surface from abrasive particles. It is established that cleaning efficiency depends on diameter of the diffuser, water pressure and distance between nozzle and metal surface. It is obtained that the best cleaning efficiency (100%) is achieved at pressure 36 bar, when diameter of diffuser is 0.4 mm and distance between nozzle and surface is 1 mm. It is also established that satisfactory cleaning efficiency (80%) is achieved not only when atomizer is placed closer to metal surface, but also at larger (120 mm) distances.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Microstructure and thermomechanical properties relationship of segmented thermoplastic polyurethane (TPU)

Thermoplastic polyurethanes (TPU) are important polymeric materials for seals. In competition with Acrylonitrile butadiene rubbers (NBR), TPU exhibits higher strength and a considerable better abrasion resistance. The advantage of NBR over TPU is a smaller compression set but however TPU excels in its much shorter processing cycle times. Generally a TPU is a block copolymer composed of hard and soft segments, which plays an important role in determining the material properties. TPU can be processed either to ready moulded parts or can be incorporated by multi component moulding, in both cases it shows decent mechanical properties. In the present work, the relationship between melt-process induced TPU morphology and resultant thermo mechanical properties were examined and determined by means of quasi-static tensile test, creep experiment, tension test and dynamical mechanical analysis (DMA). Scanning electron beam microscope (SEM) and differential scanning calorimeter (DSC) were used to study the morphology of the samples. A significant mathematical description of the stress-strain behaviour of TPU was found using a 3 term approach. Moreover it became evident that processing conditions such as processing temperature have crucial influence on morphology as well as short and long-term performance. To be more precise, samples processed at higher temperatures showed a lack of large hard segment agglomerates, a smaller strength for strains up to 250% and higher creep compliance.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Increasing the wear resistance of ultra-high molecular weight polyethylene by adding solid lubricating fillers

In order to compare effectiveness of adding solid lubricating fillers for polymeric composites based on ultra-high molecular weight polyethylene (UHMWPE) with graphite, molybdenum disulfide and polytetrafluoroethylene, their tribotechnical characteristics under dry friction, boundary lubrication and abrasive wearing were investigated. The optimal weight fractions of fillers in terms of improving wear resistance have been determined. The supramolecular structure and topography of wear track surfaces of UHMWPE-based composites with different content of fillers have been studied.

36 MATERIALS SCIENCE↗