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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Laser-induced slip casting as an additive manufacturing approach for silicon carbide

Here, this work presents processing silicon carbide (SiC) with the laser-induced slip casting (LIS) additive manufacturing (AM). SiC was stabilized in water with polyethyleneimine (PEI) dispersant, and SiC slurries were made with rheology for LIS printing. High-density ceramic parts were printed, followed by single-step binder burnout and sintering. The printed parts achieved 93–95 % of theoretical density. X-ray computed tomography (XCT) revealed a small distribution of flaws exceeding 100 microns. The mechanical properties were measured in both parallel and perpendicular to the printing layers, and the orientation with layers perpendicular to the bending moment resulted in higher strength compared to the parallel direction. Porosity resulting from processing and large inclusions of boron carbide (B4C) were the root cause of failure in the measured samples. Despite these defects through this effort, this new approach demonstrates promise for green forming of SiC with densities greater than 95 % theoretical and tensile strengths above 250 MPa.

Additive Manufacturing↗
DOE OSTI2024

Probing the fatigue enhancement in a thermally aged cast duplex stainless steel by in situ neutron diffraction

After long-term thermal aging at 400 °C for 3000 h and 10,000 h, a cast duplex stainless steel exhibits promoted fatigue performance, including enhanced three-stage cyclic hardening and prolonged fatigue life. Utilizing in situ neutron diffraction, the phase-specific stresses are resolved, and their evolutions over entire fatigue cycling reveal the underlying mechanisms of the fatigue enhancement. It is found that the ferrite phase bears a much higher stress than the austenite matrix under both as-received and aged conditions. The enhanced cyclic hardening in Stage I is attributed to the strengthening of both phases due to thermal aging, while the enhancement in Stage III results from the martensitic transformation induced strengthening. The fatigue life is prolonged thanks to the cyclic hardening and the delay of martensitic transformation in the austenite phase after thermal aging.

Yu, Dunji↗
DOE OSTI2025

Daily modulations and broadband strategy in axion searches: An application with the CAST-CAPP detector

It has been previously advocated that the presence of the daily and annual modulations of the axion flux on the Earth’s surface may dramatically change the strategy of the axion searches. The arguments were based on the so-called Axion Quark Nugget (AQN) dark matter model which was originally put forward to explain the similarity of the dark and visible cosmological matter densities Ω dark ∼ Ω visible . In this framework, the population of galactic axions with mass 10 − 6 eV ≲ m a ≲ 10 − 3 eV and velocity ⟨ v a ⟩ ∼ 10 − 3 c will be accompanied by axions with typical velocities ⟨ v a ⟩ ∼ 0.6 c emitted by AQNs. Furthermore, in this framework, it has also been argued that the AQN-induced axion daily modulation (in contrast with the conventional weakly interactive massive particle paradigm) could be as large as (10–20)%, representing the main motivation for the present investigation. We argue that the daily modulations along with the broadband detection strategy can be very useful tools for the discovery of such relativistic axions. The data from the CAST-CAPP detector have been used following such arguments. Unfortunately, due to the dependence of the amplifier chain on temperature-dependent gain drifts and other factors, we could not conclusively show the presence or absence of a dark sector-originated daily modulation. However, this proof of principle analysis procedure can serve as a reference for future studies. Published by the American Physical Society 2025

Caspers, F.↗
DOE OSTI2025

LDR Inorganic Spiked Simulants in Pozzolan-Substituted Cast Stone for Hanford Pretreated Low-Activity Tank Waste

Pretreated Low Activity Waste (PTW/LAW) at the Hanford Site, is currently projected for disposition through a cementitious waste form. The current standard formulation, Cast Stone, uses Class F fly ash, blast furnace slag, and Portland cement. However, the future availability of Class F fly ash is uncertain, as many coal-fired power plants—the source of this byproduct—are being decommissioned or converted to natural gas. This issue has prompted research into identifying and evaluating suitable alternative materials to replace fly ash in the cementitious waste forms used by the Department of Energy (DOE). The Savannah River National Laboratory (SRNL) successfully identified four natural pozzolans for the replacement of Class F fly ash in the current Savannah River Site (SRS) low-level waste (LLW) form, Saltstone.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Macro-micro multiscale modeling to assist the design of HPDC Al castings microstructure and alloys for EV super-large body structures (Phase 1)

Implementation of High Pressure Die Casting (HPDC) Aluminum (Al) body structures for high volume electrified vehicles (EV) to improve electric efficiency remains a key strategy within many original equipment manufacturers (OEM)s. In addition to high strength for safety requirements, superior Self Piercing Riveting (SPR) performance is demanded for HPDC Al alloys to be compatible with high volume SPR joining. In this work, it is proposed to extend and validate an existing Contractor finite element multiscale macro-micro modeling approach to quantify the influence of the microstructure of HPDC alloys on the fracture strain/displacement under 3-point bend and clinch testing. The success of this work will allow to replace solution treatment stage with low energy consumption heat treatment (HT) processes, or to design new non heat treatable (NHT) HPDC Al alloys to eliminate HT requirements. Ultimately, this project will facilitate the application of HPDC Al alloys for super-large vehicle structures to significantly reduce vehicle weight and thus improving energy efficiency. The purpose of this project is to extend and validate an existing f

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

On the Corrosion Response of Novel Heat Exchangers Manufactured by Casting of Al-Ce-Mg Alloy

Developing low-cost and durable heat exchangers is critical for next-generation heating, ventilation, air conditioning, and refrigeration systems. The emerging requirement to minimize the total refrigerant charge inventory while ensuring a uniform distribution of refrigerant has led to the deployment of advanced manufacturing strategies. At the same time, corrosion is a longstanding issue for metal components, especially those used in heat exchanger (HX) applications. In this study, Al-Ce-Mg alloy-based HXs have been investigated. The corrosion resistance of HXs prototype manufactured by the casting process has been examined and the potential of a new manufacturing approach has been explored to meet the requirements of emerging needs.

Brechtl, Jamieson↗
DOE OSTI2024

Effect of microalloying additions on microstructural evolution and thermal stability in cast Al-Ni alloys

Enhancement of thermal stability in Al-Ni alloys through microalloying with slow-diffusing elements, specifically Zr, has been previously reported which is attributed to Zr segregation at the Al/Al 3 Ni interface. In this study, we explore the influence of microalloying Al-Ni alloys with Zr, Ti, V, and Fe on microstructural evolution, hardness, and electrical and thermal conductivity across a range of heat-treatment temperatures from 300 to 450 °C. The distribution of microalloying elements and precipitates after heat treatment is characterized using atom probe tomography (APT). Our investigation confirms Zr segregation to the Al/Al 3 Ni interface, while similar interfacial segregation is absent with the addition of Ti, V, and Fe. Additionally, our analysis of the Al 3 Ni microfiber morphology reveals that their coarsening and spheroidization rates are similar with and without interfacial segregation; thus, retaining the fiber reinforcement through interfacial segregation of slow diffusing elements may not be an effective strategy. Precipitation of L1 2 nanoparticles was found to be the dominant mechanism affecting enhanced hardness and electrical conductivity in Al-Ni-Zr alloys, attributed to precipitation strengthening and solute depletion, respectively. Similar precipitation was not observed for additions of Ti, V, and Fe following heat treatment. We provide a thermodynamic explanation for this limitation. Furthermore, the findings of this study suggest that an effective approach for designing Al-Ni alloys should involve prioritizing microalloying elements to maximize L1 2 precipitation and minimize solute content in the FCC-Al matrix post heat treatment, rather than focusing on Al/Al3Ni interfacial segregation.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Phase-field model of freeze casting

Directional solidification of water-based solutions has emerged as a versatile technique for templating hierarchical porous materials. However, the underlying mechanisms of pattern formation remain incompletely understood. In this work, we present a detailed derivation and analysis of a quantitative phase-field model for simulating this nonequilibrium process. The phase-field model extends the thin-interface formulation of dilute binary alloy solidification with antitrapping to incorporate the highly anisotropic energetic and kinetic properties of the partially faceted ice-water interface. This interface is faceted in the basal plane normal to the ⟨0001⟩ directions and atomically rough in other directions within the basal plane. On the basal plane, the model reproduces a linear or nonlinear relationship between the interface growth rate and the kinetic undercooling that can be linked to experimental measurements. In both cases, spontaneous parity breaking of the solidification front is observed when the preferred growth direction is aligned with the temperature gradient. This phenomenon leads to the formation of partially faceted ice lamellae that drift laterally in one of the ⟨0001⟩ directions. Here, we demonstrate that the drifting velocity of the ice lamellae is controlled by the kinetics on the basal plane and converges as the thickness of the diffuse solid-liquid interface decreases. Furthermore, we examine the effect of the form of the kinetic anisotropy, which is chosen here such that the inverse of the kinetic coefficient varies linearly from a finite value in the ⟨0001⟩ directions to zero in all other directions within the basal plane, consistent with the assumption that the interface grows in local thermodynamic equilibrium in this plane. Our results indicate that the drifting velocity of ice lamellae is not affected by the slope of this linear relation, and the radius and undercooling at the tip of an ice lamella converge at relatively small slope values. Consequently, the phase-field simulations remain quantitative with computationally tractable choices of both the interface thickness and the slope assumed in the form of the kinetic anisotropy.

Materials science↗
DOE OSTI2024

Facilitating Implementation of High-Volume Fly Ash Use in Pre-cast Concrete Construction to Increase Beneficial Utilization

The main goal of this project was to increase the beneficial use of fly ash as a supplementary cementitious material for precast concrete applications. A major focus was to develop balanced concrete mix design strategies which collectively satisfy the follow objectives: 1) increase fly ash beneficial use by at least 15% in the precast concrete industry, 2) maintain or exceed stringent structural property requirements (e.g., compressive strength at initial prestress, modulus of rupture, etc.), 3) exhibit little or no additional cost relative to conventional mixtures, and 4) mitigate detrimental environmental consequences inadvertently caused by increased beneficial use. Outcomes from this project include recommendations for design guidelines and code provisions for sustainable concrete mix designs, facilitating diversion and harvesting of large quantities of fly ash from landfills or impoundments, and multiple frameworks for incorporating discarded fly ash materials (i.e., landfilled or ponded fly ash after separating the impurities) in concrete construction.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

CAST Technical Bulletin #004: Network Time Protocol Introduction

Network Time Protocol (NTP), as it traditionally generated and widely consumed, is a legacy system with known security vulnerabilities. The vulnerabilities can be mitigated by modern implementations of NTP that use internal and external redundancy for better accuracy and fault tolerance. Precision Time Protocol (PTP) is an alternative that uses master clocks inside secure networks to eliminate the known vulnerabilities of NTP.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

CAST Technical Bulletin #008: Two-Way Satellite Time and Frequency Transfer (TWSTFT) Setup and Lessons learned

Two-way satellite time and frequency transfer (TWSTFT) has been a trusted time transfer and synchronization method for a long time. It provides good timing accuracy, usually 100 ns or less. The setup of two-way satellite time and frequency transfer (TWSTFT) coordination and communication are crucial to having a system that runs and works as it should, especially when the setup involves traveling and working at a third-party facility. Even with perfect planning, some problems will arise; this document describes TWSTFT setup and lessons learned.

42 ENGINEERING↗
DOE OSTI2025

Center for Alternative Synchronization and Timing (CAST) Technical Bulletin #007: Holdover Experiment #1

Stable and accurate timing forms the foundation of many modern essential services. While Global Navigation Satellite Systems (GNSS) provide a cheap way to achieve extremely accurate timing, these systems are vulnerable to interference and complete outages, forcing systems that rely on them into a state of holdover. Testing and characterizing holdover performance is therefore essential for ensuring that these modern services do not go down when GNSS-based timing is unavailable.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Center for Alternative Synchronization and Timing (CAST) Technical Bulletin #006: Holdover Experimental Summary

Stable and accurate timing forms the foundation of many modern essential services. While Global Navigation Satellite Systems (GNSS) provide a cheap way to achieve extremely accurate timing, these systems are vulnerable to interference and complete outages, forcing systems that rely on them into a state of holdover. Testing and characterizing holdover performance is therefore essential for ensuring that these modern services do not go down when GNSS-based timing is unavailable.

24 POWER TRANSMISSION AND DISTRIBUTION↗