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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 OSTI2023

Prediction of Substrate Distortion in Powder DED Using Finite Element Model

Abstract Leveraging the capabilities of both additive and subtractive manufacturing to repair tooling and other high value items can result in significant cost and time saving opportunities. However, when dimensional accuracy of the repaired component must be held within a specified tolerance, distortion of the component induced during repair can lead to an out of specification final component. This work presents simulation of a novel method to mitigate part distortion using sacrificial support structures. A blown powder directed energy deposition system was utilized for deposition of sacrificial support structures and clad surface depositions. Sacrificial support structures were deposited on the underside of the substrate with varying geometries prior to clad surface depositions. A finite element model was developed and verified using experimental results. The simulation and experimental control results were found to match within 6%. It has been shown that simulation can be used to predict effects of sacrificial support structures on substrate distortion in a blown powder directed energy deposition process.

Burl, Alan G.↗
DOE OSTI2025

Friction surface layer deposition of triple-phase Al 10 Cr 12 Fe 35 Mn 23 Ni 20 high entropy alloy: Process optimization and microstructural evolution

A high-strength Co-free triple-phase Al 10 Cr 12 Fe 35 Mn 23 Ni 20 high-entropy alloy (HEA) was successfully fabricated using Friction Surface Layer Deposition (FSLD), a bulk manufacturing method. Multiple single-layer deposits were produced by varying forging force (F) and traverse speeds (T r ) to optimize the process parameters. The optimized conditions (F = 40 kN & T r = 200 mm/min) were then applied to manufacture a scaled-up multi-layer specimen. The initial microstructure of the HEA consisted of coarse grains of the soft FCC-phase, long columnar dendrites of the hard BCC-phase, and small precipitates of the harder B2-phase within the BCC-dendrites. During FSLD, the FCC-matrix underwent continuous dynamic recrystallization due to high-temperature severe plastic deformation, forming finer equiaxed grains. Simultaneously, the BCC-dendrites fractured into smaller fragments, some of which experienced partial growth and coarsening under applied stress, resulting in an hourglass morphology. In contrast, the small B2-precipitates within the BCC-fragments dissolved during the elevated temperatures of FSLD and reprecipitated as substantially finer precipitates during continuous cooling post-FSLD. Additionally, the orientation relationships between the FCC and BCC/B2 phases were completely destroyed by the severe thermoplastic deformation inherent to FSLD. The microstructural refinements led to a substantial improvement in hardness from 177 HV to 283 HV, driven by Hall-Petch strengthening. The increased number of interfaces, including coherent BCC-B2 interfaces, potentially enhances the sink strength and radiation tolerance of the HEA, making it a promising candidate for nuclear applications. In conclusion, this study also highlights FSLD as a versatile technique for achieving tunable properties in HEAs, with detailed schematics illustrating the complex mechanisms of phase transformations during processing.

Additive Manufacturing↗
DOE OSTI2021

Status Update for the Canister Deposition Field Demonstration

This report updates the high-level test plan for evaluating surface deposition on three commercial 32PTH2 spent nuclear fuel (SNF) canisters inside NUTECH Horizontal Modular Storage (NUHOMS) Advanced Horizontal Storage Modules (AHSM) from Orano (formerly Transnuclear Inc.) and provides a description of the surface characterization activities that have been conducted to date. The details contained in this report represent the best designs and approaches explored for testing as of this publication. Given the rapidly developing nature of this test program, some of these plans may change to accommodate new objectives or requirements. The goal of the testing is to collect highly defensible and detailed surface deposition measurements from the surface of dry storage canisters in a marine coastal environment to guide chloride-induced stress corrosion crack (CISCC) research. To facilitate surface sampling, the otherwise highly prototypic dry storage systems will not contain SNF but rather will be electrically heated to mimic the thermal-hydraulic-environment. Instrumentation throughout the canister, storage module, and environment will provide an extensive amount of information for the use of model validation. Manual sampling over a comprehensive portion of the canister surface at regular time intervals will offer a high-fidelity quantification of the conditions experienced in a harsh yet realistic environment.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Enhanced nucleation mechanism in ruthenium atomic layer deposition: Exploring surface termination and precursor ligand effects with RuCpEt(CO)2

Miniaturization of microelectronic devices necessitates atomic precision in manufacturing techniques, particularly in the deposition of thin films. Atomic layer deposition (ALD) is recognized for its precision in controlling film thickness and composition on intricate three-dimensional structures. This study focuses on the ALD nucleation and growth mechanisms of ruthenium (Ru), a metal that has significant future implications for microelectronics. Despite its advantages, the deposition of a high surface-free energy material like Ru on a low surface-free energy material such as an oxide often faces challenges of large nucleation delays and non-uniform growth. To address these challenges, we explored the effectiveness of organometallic surface pretreatments using trimethylaluminum (TMA) or diethylzinc (DEZ) to enhance Ru film nucleation and growth. Our study employed a less-studied Ru precursor, cyclopentadienylethyl(dicarbonyl)ruthenium [RuCpEt(CO)2], which demonstrated promising results in terms of reduced nucleation delay and increased film continuity. Ru ALD was performed on silicon substrates with native oxide, using RuCpEt(CO)2 and O2 as coreactants. Our findings reveal that surface pretreatment significantly improves nucleation density and film thickness within the initial 60 ALD cycles, achieving up to a 3.2-fold increase in Ru surface coverage compared to nonpretreated substrates. Supported by density functional theory calculations, we propose that the enhanced nucleation observed with RuCpEt(CO)2 compared to previously-studied Ru(Cp)2 is due to two key mechanisms: the facilitated removal of CO ligands during deposition, which enhances the reactivity of the precursor, and a hydrogen-abstraction reaction involving the ethyl ligand of RuCpEt(CO)2 and the metal-alkyl groups on the surface. This study not only advances our understanding of Ru ALD processes but also highlights the significant impact of precursor chemistry and surface treatments in optimizing ALD for advanced microelectronic applications.

Materials Science↗
DOE OSTI2020

Multimodal Imaging of Autofluorescent Sites Reveals Varied Chemical Speciation in SSZ-13 Crystals

In this report a multimodal imaging study of chabazite is used to analyse emissive deposits. A notable difference is seen in the morphology of agglomerated surface deposits and larger subsurface deposits. Comparison of the distribution of organic residue throughout the crystal volume and XRF mapping is demonstrating that a fluorescence-based technique can also be used to indirectly comment on the compositional chemistry of the inorganic framework. A multimodal imaging study of chabazite is used to show the distribution of and discriminate between different emissive deposits arising as a result of the detemplation process. Confocal imaging, 3D fluorescence lifetime imaging, 3D multispectral fluorescence imaging, and Raman mapping are used to show three different types of emissive behaviours each characterised by different spatial distributions, trends in lifetime, spectral signals, and Raman signatures. A notable difference is seen in the morphology of agglomerated surface deposits and larger subsurface deposits, which experience lifetime augmentation due to spatial confinement. The distribution of organic residue throughout the crystal volume is comparable to XRF mapping that shows Si enrichment on the outer edges and higher Al content through the centre, demonstrating that a fluorescence-based technique can also be used to indirectly comment on the compositional chemistry of the inorganic framework.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1988

Contamination of grazing incidence EUV mirrors - An assessment

Contamination assessment for space optical systems requires an understanding of the sensitivity of component performance, e.g. mirror reflectance, to materials deposited on the mirror surface. In a previous study, the sensitivity of typical normal incidence mirror coatings to surface deposits of generic hydrocarbons was reported. Recent activity in the development of grazing incidence telescopes for extreme ultraviolet space astronomy has stimulated the need for a similar assessment in the spectral region extending from approximately 100 A to 1000 A. The model used for analysis treats the contamination layer as a continuous thin film deposited on the mirror surface. The mirror surfaces selected for this study are opaque vacuum deposited gold and the uncoated and polished Zerodur. Scatter caused by film irregularities or particulates are not included in this assessment. Parametric evaluations at 100, 500, and 1000 A determine the sensitivity of mirror reflectance to a range of optical constants selected for the generic contaminants. This sensitivity analysis combined with the limited amount of optical data in the EUV for hydrocarbons, is used to select representative optical constants for the three wavelength regions. Reflectance versus contamination layer thickness curves are then calculated and used to determine critical thickness limits based on allowable reflectance change. Initial observations indicate that thickness limits will be highly dependent on the real part of the complex index of refraction of the contaminant film being less than 1.0. Preliminary laboratory measurements of samples contaminated with some commonly encountered hydrocarbons confirm trends indicated in the analytical studies.

Osantowski, John F.↗
NASA NTRS2006

Vacuum Ultraviolet Radiation Desorption of Molecular Contaminants Deposited on Quartz Crystal Microbalances

Recent quartz crystal microbalance measurements made in the Marshall Space Flight Center, Photo-Deposition Facility, for several materials, recorded a significant loss of deposited contaminants when the deposition surface of the microbalance was illuminated by a deuterium lamp. These measurements differ from observations made by other investigators in which the rate of deposition increased significantly when the deposition surface was illuminated with vacuum ultraviolet radiation. These observations suggest that the accelerated deposition of molecular contaminants on optically sensitive surfaces is dependant upon the contaminant being deposited and must be addressed during the materials selection process by common material screening techniques.

Albyn, Keith↗
DOE OSTI2024

Utilizing HYSPLIT for Emergency Response Modeling at SRS

The threat of a disaster happening at the Savannah River Site (SRS) is low, but not zero. When an emergency arises, emergency responders utilize a variety of tools to detect, track, and mitigate the disaster. HYSPLIT is a community atmospheric dispersion model that is highly configurable and has been used operationally to simulate particle, chemical, and radionuclide releases. We have developed a preliminary user interface (UI) that configures HYSPLIT to run for a variety of Emergency Action Level (EAL) scenarios at SRS. Using a hypothetical EAL scenario of an accidental release of Pu-238 in H-area and K-area onsite, an analysis was done to show how a preliminary UI framework allows HYSPLIT to be run on a terminal without the need form an active network connection. The study was successful in multiple aspects. For the preliminary UI, users were able to input certain characteristics of the hypothetical EAL such as hours of emission (how long was Pu-238 being released), curies of release, release start time (when does the model run start), and type of radionuclide directly into the terminal. For HYSPLIT, the model was successful in being able to take the UI input, calculate the results from the inputs and output multiple figures of both total volumetric airborne concentrations and surface deposition. We used the Pu-238 Derived Intervention Level (DIL) deposition thresholds for produce, dairy, and beef for visualization of the surface deposition, showing how a release would impact ingestion pathways.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
NASA NTRS1981

Analysis of condensates formed at the Viking 2 lander site - The first winter

Relative surface albedo, spectral reflectance estimates and a limited photometric function are reduced from Viking 2 lander data obtained during a 249 Mars day period, in the lander's first year, when a light ground covering appeared on the surface. During the deposition, surface broadband albedo more than doubled and blue reflectance increased by a factor of 4.0. Comparison of lander data with earlier laboratory measurements of CO2 and H2O frosts and snows shows that reflectance estimates do not resemble either of those solids. The condensate reflectance resembles that of the surface after the covering disappeared. The covering may have been colored by dust which fell before it, by dust mixed with it, or by dust on top of it; but the data strongly support a mixture of dust with H2O and CO2 solids. The covering thickness is estimated to be between 0.5 and a few millimeters.

Wall, S. D.↗
NASA NTRS1982

Plasma deposition and surface modification techniques for wear resistance

The ion-assisted or plasma coating technology is discussed as it applies to the deposition of hard, wear resistant refractory compound films. Of the many sputtering and ion plating modes and configurations the reactive magnetron sputtering and the reactive triode ion plating techniques are the preferred ones to deposit wear resistant coatings for tribological applications. Both of these techniques incorporate additional means to enhance the ionization efficiency and chemical reaction to precision tailor desirable tribological characteristics. Interrelationships between film formation, structure, and ribological properties are strictly controlled by the deposition parameters and the substrate condition. The enhanced ionization contributes to the excellent adherence and coherence, reduced internal stresses and improved structural growth to form dense, cohesive, equiaxed grain structure for improved wear resistance and control.

Spalvins, T.↗
NASA NTRS1975

Dopant gas effect on silicon chemical vapor depositions: A surface potential model

A surface potential model is proposed to consistently explain the known dopant gas effects on silicon chemical vapor deposition. This model predicts that the effects of the same dopant gases on the diamond deposition rate using methane and carbon tetrachloride should be opposite and similar to those of silane, respectively. Available data are in agreement with this prediction.

Chang, C. A.↗
NASA NTRS1974

Auger electron spectroscopy of lunar samples

Auger spectroscopy has been employed to study the surface composition of a number of grains from the submillimeter lunar fines. Some of the problems associated with using this technique for lunar sample analyses are discussed in terms of relevant physical principles. The use of inert gas sputtering to obtain thickness profiles of surface films is shown to be important in this type of investigation. Four anorthite grains from the Apollo 17 fines have been examined for evidence of vapor-deposited surface coatings of micrometeorite impact origin. The results indicate that the thickness of surface deposits, if they exist at all, are orders of magnitude less than expected. Auger analysis of orange glass balls form the 74220,107 fines have established sulfur-rich surface coatings on the order of 30 A in thickness.

Grant, R. W.↗
NASA NTRS1978

Vapor phase growth technique of III-V compounds utilizing a preheating step

In the vapor phase epitaxy fabrication of semiconductor devices and in particular semiconductor lasers, the deposition body on which a particular layer of the laser is to be grown is preheated to a temperature about 40.degree. to 60.degree. C. lower than the temperature at which deposition occurs. It has been discovered that by preheating at this lower temperature there is reduced thermal decomposition at the deposition surface, especially for semiconductor materials such as indium gallium phosphide and gallium arsenide phosphide. A reduction in thermal decomposition reduces imperfections in the deposition body in the vicinity of the deposition surface, thereby providing a device with higher efficiency and longer lifetime.

Olsen, Gregory Hammond↗
DOE OSTI2021

Polymer exhaust for eliminating extruder transients

An additive manufacturing method that includes an extruder providing a supply of working material and a nozzle connected with respect to the extruder, the nozzle directing the working material to a deposit surface. A diverter valve is positioned between the extruder and the nozzle to direct the working material to an exhaust port away from the deposit surface under certain conditions.

Chesser, Phillip C.↗
DOE OSTI2023

Atomic layer deposition for surface area determination of solid oxide electrodes

Surface area measurements are important for characterizing porous solids, but commonly used methods such as Brunauer–Emmett–Teller (BET) gas adsorption and computed nanotomography are lacking for certain applications such as the development of solid oxide fuel cell electrodes, which often have absolute surface areas <1 m 2 and contain nanoscale features. Presented is a novel method for the surface area determination of samples with total measurable areas of 1–1000 cm 2 with a standard deviation ± 1 cm 2 , utilizing the atomic layer deposition (ALD) of Al 2 O 3 over microstructurally complex internal porosity. The volume of alumina is then quantified using plasma spectroscopy and converted to an area using the known ALD layer thickness. Under the modest ALD reactor soak times used (8.5 s), the precursor penetration depth is found to be ~50 μm, exceeding the requirement for uniformly coating SOFC functional layers. A model system, (La 0.8 Sr 0.2 ) 0.98 MnO 3–δ /Ce 0.9 Gd 0.1 O 1.95 (LSM/GDC) scaffolds of ~2.7 m 2 g –1 , was measured using the technique and compared against the BET method, and comparable results were obtained but with 1000 times less material needed. The technique is demonstrated for measurements in two example areas of active SOFC research: exsolved (Ni, Fe) nanoparticles on an Sr(Ti, Fe, Ni)O 3–δ electrode and PrO x catalyst nanoparticles infiltrated onto LSM/GDC scaffolds. Finally, the technique may be broadly useful wherever the accurate surface area determination of small absolute quantities of porous ceramic structures on the order of 0.1–50 m 2 g –1 is sought.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2004

Samples of Asteroid Surface Ponded Deposits in Chondritic Meteorites

One of the many unexpected observations of asteroid 433 Eros by the Near Earth Asteroid Rendezvous (NEAR) mission was the many ponds of fine-grained materials [1-3]. The ponds have smooth surfaces, and define equipotential surfaces up to 10's of meters in diameter [4]. The ponds have a uniformly sub-cm grain size and appear to be cohesive or indurated to some degree, as revealed by slumping. The ponds appear to be concentrated within 30 degrees of the equator of Eros, where gravity is lowest. There is some insight into the mineralogy and composition of the ponds surfaces from NEAR spectroscopy [2,4,5,6]. Compared to the bulk asteroid, ponds: (1) are distinctly bluer (high 550/760 nm ratio), (2) have a deeper 1um mafic band, (3) have reflectance elevated by 5%.

Zolensky, M. E.↗
NASA NTRS1978

Depositional and surface exposure history of the Shorty Crater core 74001/2 - FMR and magnetic studies

Surface exposure (maturity) indices and concentrations of FeO and metallic iron were determined at 0.5-cm intervals of the Apollo 17 core section, which sampled a pyroclastic deposit on the rim of Shorty Crater. The determinations showed that all of the soil in the core is extremely immature. An exposure history of the core is proposed: accumulation (about 3.6 billion years ago), shallow burial (during the first 20 million years), deep burial (till about 10-15 million years ago), followed by excavation (10-15 million years ago), and in situ reworking (till the present).

Morris, R. V.↗
DOE OSTI2022

Selective Removal of Barium and Hardness Ions from Brackish Water with Chemically Enhanced Electrodialysis

The use of a nonconventional water resource for energy and industrial applications often requires extraction of low-level undesirable ions from matrices of benign dominant ions. In this study, the selective extraction of Ba 2+ and Mg 2+ from synthetic brine solutions was evaluated using strong acid cation-exchange membranes modified with the surface deposition of macrocyclic molecules including crown ethers and calixarenes. Compared to the bare membrane, vinylbenzo-18-crown-6 (VB18C6) and calix[4]arene-amended membranes showed increased selectivity for Ba 2+ and Mg 2+ with respect to the dominant ion (Na + ) by up to fourfolds, with the calix[4]arene-modified membrane achieving more selective separation than VB18C6. Optimal selectivity was achieved at a moderate-to-high current density (3.1–6.3 mA/cm 2 ), which was attributed to the alleviation of transport limitation in the boundary layer by the surface modification. Amendment of a calix[4]arene derivative with a crown-6 “boot strap” and two carboxylic groups resulted in reduced selectivity due to the formation of strong complexes with divalent ions. Furthermore, these results show that surface deposition of ion sequestrants can be a versatile approach to improve the membrane’s selectivity; however, the performance is sensitive to feed water salinity, current loading, and the macrocycle-ion chemistry, where there is a trade-off between ion affinity and mobility.

36 MATERIALS SCIENCE↗