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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 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Design, fabrication, simulation, and testing of additively manufactured lattice-based copper heat sinks

Here, this study investigates the potential advantages of lattice structure-based bound metal material extrusion (MEX) 3D printing for fabricating high-performance copper heat sinks. Copper powder-filled polymer filaments, with a copper content of > 90 wt.%, were developed specifically for the bound metal MEX 3D printing process. Three types of structures—planar, strut, and surface lattices—were 3D printed to facilitate efficient heat transfer pathways within the heat sinks. Subsequent post-processing steps, including polymer removal and sintering, were performed to achieve dense copper parts. Hot isostatic pressing was further employed to enhance the sintered density from 93 to 98%. Finite element analysis (FEA) simulations were conducted to assess the heat transfer efficiency of the designs, and heat transfer experiments were performed using a custom setup to validate the simulation results. Additionally, this research explores the use of extended hold times during pre-sintering and a reduced atmosphere to enhance the %IACS values (electrical conductivity) and thermal performance of the bound metal MEX 3D printed copper heat sinks. The investigation combines experimental analysis, including simulations and heat transfer experiments, to gain insights into the structure-material property relationships and optimize the thermal performance of the printed heat sinks.

Ajjarapu, Kameswara Pavan Kumar [Oak Ridge Nationa↗
NASA NTRS1972

Mass spectra stimulated by O+ and Ar+ interacting with a surface.

Beams of O(+) and Ar(+) in the energy range from 100 to 300 eV were directed into an aperture in one face of a copper box. The mass spectrum from a similar aperture in an adjacent face was observed with the aid of a commercial RF quadrupole spectrometer. On the basis of the results obtained it is reported that O(+) beams at about 200 eV may be essentially lost after a few collisions with a surface, in agreement with similar conclusions about atomic oxygen at thermal energies.

Siegel, M. W.↗
DOE OSTI2026

Reformulating a Gurson-based dynamic damage model and demonstrating improved predictive power and numerical robustness

The original Tepla (TEnsile PLAsticity) ductile damage model, based on the Gurson yield surface, has long been used to model damage evolution and material failure under dynamic loading. Unfortunately, Tepla suffered from mesh sensitivity, numerical instability, and limited predictive capability. Here, we theoretically reformulate Tepla to address these issues. We especially focus on the prediction of porosity, which is the key state variable used for modeling ductile damage, as compared to more easily measured surface velocities, which are at best an indirect measure of damage. Key model changes include separating the viscosity during volumetric void growth from underlying shear strength behavior and switching to an iterative bisection solver. The new Tepla is then calibrated on incipient spall experiments on half-hard copper and tantalum, which demonstrate its ability to simultaneously fit the model to recovered porosity distributions and measured surface velocities, a stringent test. Improved numerical behavior, such as greatly reduced mesh sensitivity, is also shown in those simulations. Finally, the new Tepla model is applied to several high-explosive loaded, sweeping wave experiments, showing the ability of the model to predict behavior on tests with significantly different loading conditions and histories than the calibration data.

36 MATERIALS SCIENCE↗
DOE OSTI2020

3D Morphology of Bimodal Porous Copper with Nano-Sized and Micron-Sized Pores to Enhance Transport Properties for Functional Applications

Multiscale porous metals with multiscale porosity from nanometer to micrometer have a high specific surface area and high effective diffusivity for ion transport, thereby enhancing functionalities and extending the applications of porous metals. Herein, the Cu–Fe–Al ternary system was selected as the precursor alloy to construct multiscale, bimodal porous copper by the chemical dealloying method. The effect of the phase composition and initial microstructure of precursor alloys (Al x Fe 75– x Cu 25 , x = 10–60) on the three-dimensional (3D) morphology of multiscale porous metals was systematically investigated, with a goal to precisely control the multiscale porous structure. The four crystal structure phases (body-centered cubic (BCC), face-centered cubic (FCC), CsCl type (B2), and monoclinic) in precursor alloys were analyzed by synchrotron X-ray diffraction refinement. The 3D morphology, feature size distribution, and tortuosity of four representative porous Cu after dealloying Al x Fe 75– x Cu 25 ( x = 10, 30, 50, and 60) precursor alloys were directly visualized and quantified via advanced synchrotron X-ray nanotomography. The relationship between the phases/crystal structures of precursor alloys and their corresponding porous morphology was established: the micron-sized pores in bimodal porous Cu are formed by dissolving the CuFeAl phase with BCC and monoclinic crystal structures, and the nano-sized pores are formed by dealloying the CuFeAl phase with FCC and B2 crystal structures. The size of the nanoporous structure depends on the ratio between the more noble and more active components in the precursor alloy, while the size of the microporous structure depends on the corresponding phase size in the precursor alloy. The tortuosity results showed that the multiscale porous structure with both nanoporosity and microporosity exhibits lower tortuosity, which will enhance transport properties for functional applications.

25 ENERGY STORAGE↗
DOE OSTI2020

Si-based materials for lithium-ion batteries VII. 70% surface-modified Si/C-carbon black/lithiated polyacrylic acid electrode

X-ray photoelectron spectroscopy (XPS) was used to analyze a 70% Si/C-carbon black/lithiated polyacrylic acid electrode fabricated at the Cell Analysis, Modeling, and Prototyping Facility (CAMP), Argonne National Laboratory. The spectra were obtained using incident monochromatic Al K α radiation at 1486.6 eV (0.834 01 nm). An initial survey spectrum together with O 1s, C 1s, and Si 2p are presented. A final survey spectrum was collected to ascertain the amount of beam-induced damage, which appears to be minimal. Finally, the spectra indicate the principal core level photoelectron and Auger electron signals with only minor copper, nitrogen, calcium, and lithium signals and show the expected silicon-carbon species related to the surface modification process in addition to oxidized carbon and silicon due to atmospheric exposure as well contributions related to the binder material.

25 ENERGY STORAGE↗
DOE OSTI2020

The Role of Helium on Ejecta Production in Copper

The effect of helium (He) concentration on ejecta production in OFHC-Copper was investigated using Richtmyer–Meshkov Instability (RMI) experiments. The experiments involved complex samples with periodic surface perturbations machined onto the surface. Each of the four target was implanted with a unique helium concentration that varied from 0 to 4000 appm. The perturbation’s wavelengths were λ ≈ 65 μ m, and their amplitudes h 0 were varied to determine the wavenumber ( 2 π / λ ) amplitude product k h 0 at which ejecta production beganfor Cu with and without He. The velocity and mass of the ejecta produced was quantified using Photon Doppler Velocimetry (PDV) and Lithium-Niobate (LN) pins, respectively. Our results show that there was an increase of 30% in the velocity at which the ejecta cloud was traveling in Copper with 4000 appm as compared to its unimplanted counterpart. Our work also shows that there was a finer cloud of ejecta particles that was not detected by the PDV probes but was detected by the early arrival of a “signal” at the LN pins. While the LN pins were not able to successfully quantify the mass produced due to it being in the solid state, they did provide information on timing. Our results show that ejecta was produced for a longer time in the 4000 appm copper.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Design and Implementation of Surface Eroding Thermocouples for Stage-One Modular Divertor Integration at the DIII-D Tokamak

The DIII-D has upgraded its upper divertor to a modular system using copper alloy pedestals to alter the divertor geometry without changing the vessel structure. Six new graphite tiles were designed for the shape and volume rise (SVR) divertor. Here, these new SVR tiles facilitated the formation of a poloidal array of 27 surface eroding thermocouples (SETCs) in the upper divertor region. At one location, a specialized recessed SETC, paired with a standard flush SETC, was installed in one of the ceiling tiles to provide comprehensive heat flux measurements, distinguishing between charged and noncharged particle contributions. Upgrades were made to the SETC system in the small-angle slot (SAS) divertor to improve overall performance. These upgrades included optimizing the feedthrough system to double the thermocouple cable capacity and reallocating cables from the SAS area to the SVR divertor. A compact isolation amplifier system with a fixed gain of 41 was employed to improve the signal level and minimize interference. Additionally, two analog-to-analog fiber systems were implemented for transmitting thermocouple signals over a single fiber, significantly reducing both noise levels and costs. The newly installed SETCs in the SVR divertor successfully completed initial commissioning testing. The SETCs captured the in-out asymmetry in the power distribution between the inner and outer strike points and demonstrated the dependency of the heat flux profile on the outer strike point location. During divertor detachment, heat flux mitigation was noted at the outer strike point location, while significant heat flux contributions from neutral particles were measured in the SVR divertor.

Divertor↗
NASA NTRS2005

A Materials Compatibility and Thermal Stability Analysis of Common Hydrocarbon Fuels

A materials compatibility and thermal stability investigation was conducted using five common liquid hydrocarbon fuels and two structural materials. The tests were performed at the NASA Glenn Research Center Heated Tube Facility under environmental conditions similar to those encountered in regeneratively cooled rocket engines. Scanning-electron microscopic analysis in conjunction with energy dispersive spectroscopy (EDS) was utilized to characterize the condition of the tube inner wall surface and any carbon deposition or corrosion that was formed during selected runs. Results show that the carbon deposition process in stainless steel tubes was relatively insensitive to fuel type or test condition. The deposition rates were comparable for all fuels and none of the stainless steel test pieces showed any signs of corrosion. For tests conducted with copper tubing, the sulfur content of the fuel had a significant impact on both the condition of the tube wall and carbon deposition rates. Carbon deposition rates for the lowest sulfur fuels (2 ppm) were slightly higher than those recorded in the stainless steel tubes with no corrosion observed on the inner wall surface. For slightly higher sulfur content (25 ppm) fuels, nodules that intruded into the flow area were observed to form on the inner wall surface. These nodules induced moderate tube pressure drop increases. The highest sulfur content fuels (400 ppm) produced extensive wall pitting and dendritic copper sulfide growth that was continuous along the entire tube wall surface. The result of this tube degradation was the inability to maintain flow rate due to rapidly increasing test section pressure drops. Accompanying this corrosion were carbon deposition rates an order of magnitude greater than those observed in comparable stainless steel tests. The results of this investigation indicate that trace impurities in fuels (i.e. sulfur) can significantly impact the carbon deposition process and produce unacceptable corrosion levels in copper based structural materials.

Meyer, M. L.↗
NASA NTRS1972

Process for the Production of Star Tracklng [Tracking] Reticles

A method for the production of reticles, particularly those for use in outer space, wherein the product is a quartz base coated with highly adherent layers of chromium, chromium-silver, and silver vacuum deposited through a mask, and then coated with an electrodeposit of copper from a copper sulfate solution followed by an electrodeposit of black chromium. The masks are produced by coating a beryllium-copper alloy substrate with a positive working photoresist, developing the photoresist according to a pattern to leave a positive mask, plating uncoated areas with gold, removing the photoresist, coating the substrate with a negative working photoresist, developing the negative working photoresist to expose the base metal of the pattern, and chemically etching the unplated side of the pattern to produce the mask. The mask produced is then used in the vacuum deposition of: (1) chromium metal on the surface of a quartz base to obtain a highly adherent quartz-chromium interface; (2) silver on the chromium deposit, during the final stage of chromium deposit, to produce a silver chromium alloy layer; and (3) silver onto the surface of the alloy layer. The coated quartz base is then coated by electroplating utilizing an acid copper deposit followed by a black chromium electrodeposit to produce the product of the present invention.

Smith, Wade O.↗
DOE OSTI2019

Dendrite–Free Potassium Metal Anodes in a Carbonate Electrolyte

Potassium (K) metal anodes suffer from a challenging problem of dendrite growth. In this study, it is demonstrated that a tailored current collector will stabilize the metal plating–stripping behavior even with a conventional KPF 6 –carbonate electrolyte. A 3D copper current collector is functionalized with partially reduced graphene oxide to create a potassiophilic surface, the electrode being denoted as rGO@3D–Cu. Potassiophilic versus potassiophobic experiments demonstrate that molten K fully wets rGO@3D–Cu after 6 s, but does not wet unfunctionalized 3D–Cu. Electrochemically, a unique synergy is achieved that is driven by interfacial tension and geometry: the adherent rGO underlayer promotes 2D layer–by–layer (Frank–van der Merwe) metal film growth at early stages of plating, while the tortuous 3D–Cu electrode reduces the current density and geometrically frustrates dendrites. The rGO@3D–Cu symmetric cells and half–cells achieve state–of–the–art plating and stripping performance. Here, the symmetric rGO@3D–Cu cells exhibit stable cycling at 0.1–2 mA cm –2 , while baseline Cu prematurely fails when the current reaches 0.5 mA cm –2 . The half–cells cells of rGO@3D–Cu (no K reservoir) are stable at 0.5 mA cm –2 for 10 000 min (100 cycles), and at 1 mA cm –2 for 5000 min. The baseline 3D–Cu, planar rGO@Cu, and planar Cu foil fails after 5110, 3012, and 1410 min, respectively.

25 ENERGY STORAGE↗
DOE OSTI2020

HEX 2-piece ID Absorber: Steady and Transient Thermal FEA

Radiation fans from Insertion Devices and Bending Magnets are “trimmed” by various water-cooled absorbers located strategically downstream of those sources. Mostly, the absorber surfaces onto which power is deposited are constructed from Glidcop Al-15 (rarely OFHC copper). On the basis of Tech Note 327 a re-design for improved thermal performance has evolved to a two-piece ID Absorber configuration; one between dipole chamber and quadrupole, another after the sextupole, each with reduced incident angle. The ring’s Active Interlock (AI) system protects against overheating by disabling mis-steered beam within an allotted time. SRP (Synchrotron Radiation Protection) protocol has a limiting maximum allowable temperature of 100*C at any point when subject to mis-steered beam for a fixed period before AI activation. After 0.2 msec, radiation exceeding +/- 0.5mm offset and +/- 0.25 mrad angular error from the HEX SCW will trip in fault. AI specification allows 1.0 msec to fully dump the electron beam.

36 MATERIALS SCIENCE↗
NASA NTRS1966

Copper-acrylic enamel serves as lubricant for cold drawing of refractory metals

Acrylic enamel spray containing metallic copper pigment lubricates refractory metal tubing during cold drawing operations so that the tubing surface remains free from scratches and nicks and does not seize in the die. Zirconium alloys, zirconium, tantalum alloys, niobium alloys, vanandium alloys and titanium alloys have been drawn using this lubricant.

Beane, C.↗
NASA NTRS1974

Preparation of thick molybdenum targets

Thick natural molybdenum deposits on nickel plated copper substrates were prepared by thermal decomposition of molybdenum hexacarbonyl vapors on a heated surface in an inert gas atmosphere. The molybdenum metal atoms are firmly bonded to the substrate atoms, thus providing an excellent thermal contact across the junction. Molybdenum targets thus prepared should be useful for internal bombardment in a cyclotron where thermal energy inputs can exceed 10 kW.

Singh, J. J.↗
NASA NTRS1975

Flat-plate /vapor-chamber/ heat pipes

This paper discusses the design, fabrication and testing of heat pipes constructed in the form of flat-plate panels. The test panels were constructed of copper with methyl alcohol as the working fluid. Capillary grooves etched on the internal surfaces provided evaporation and condensation heat-transfer coefficients on the order of 1600 Btu/hr-sq ft-deg F. Two panels were launched on board a sounding rocket; the payload reached an altitude of 140 miles, and zero gravity was achieved for almost six minutes. The panel with working fluid inside demonstrated a heat input flux of 2.5 watts/sq cm, with only a 3 to 5 C temperature difference throughout the entire panel.

Fleischman, G. L.↗
NASA NTRS1992

Charged particle activation studies on the surface of LDEF spacecraft

High energy proton induced nuclear reaction products are examined using seven elements, namely: aluminum, silicon, nickel, copper, zirconium, tantalum, and tungsten. We detected activities due to Na-22 from Al, Co-56 and Co-57 from Ni, Co-58 from Cu, and Y-88 from Zr targets. No induced activity was observed in Si, Ta, and W, most probably due to the long cooling times. Only the Zr sample contained a weak Be-7 peak, although Ta and W were also located at the leading edge of the spacecraft. Gamma-rays of individual isotopes were measured using a high-resolution Ge(Li) solid state detector coupled to a 4096-multichannel analyzer. Activities were calculated for Co-56 (846 keV) and Co-57 (122 and 136 keV's) at the time of the entry of the spacecraft and found to be 0.014 +/- 0.005 c/s-g, 0.018 +/- 0.002 c/s-g, and 0.0024 +/- 0.0007 c/s-g, respectively.

Olmez, Ilhan↗
NASA NTRS1993

Ultrasonic Polishing

The ultrasonic polishing process makes use of the high-frequency (ultrasonic) vibrations of an abradable tool which automatically conforms to the work piece and an abrasive slurry to finish surfaces and edges on complex, highly detailed, close tolerance cavities in materials from beryllium copper to carbide. Applications range from critical deburring of guidance system components to removing EDM recast layers from aircraft engine components to polishing molds for forming carbide cutting tool inserts or injection molding plastics. A variety of materials including tool steels, carbides, and even ceramics can be successfully processed. Since the abradable tool automatically conforms to the work piece geometry, the ultrasonic finishing method described offers a number of important benefits in finishing components with complex geometries.

Gilmore, Randy↗
NASA NTRS1993

Charged particle activation studies on the surface of LDEF spacecraft

High energy proton induced nuclear reaction products are examined using seven elements, namely, Aluminum, Silicon, Nickel, Copper, Zirconium, Tantalum, and Tungsten. The samples were in the form of plates, 2 x 2 x 1/8 inches. Activities due to Na-22 from Al, Co-56 and Co-57 from Ni, Co-58 from Cu, and Y-88 from Zr targets were detected. No induced activity was observed in Si, Ta, and W, most probably due to the long cooling times. Only the Zr sample contained a weak Be-7 peak, although Ta and W were also located at the leading edge of the spacecraft. Gamma-rays of individual isotopes were measured using high-resolution Ge(Li) solid state detector coupled to 4096-multichannel analyzer. Activities were calculated for Co-56 (846 keV) and Co-57 (122 and 136 keV's) at the time of the entry of the spacecraft and found to be 0.014 plus or minus 0.005 c/sec. g, 0.018 plus or minus 0.002 c/sec. g, and 0.0024 plus or minus 0.0007 c/sec. g, respectively.

Olmez, Ilhan↗