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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 559 records · Page 31
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

LiAlO 2 /LiAl 5 O 8 Membranes Derived from Flame-Synthesized Nanopowders as a Potential Electrolyte and Coating Material for All-Solid-State Batteries

Recently, γ-LiAlO 2 has attracted considerable attention as a coating in Li-ion battery electrodes. However, its potential as a Li + ceramic electrolyte is limited due to its poor ionic conductivity (<10 –10 S cm –1 ). Here, we demonstrate an effective method of processing LiAlO 2 membranes (<50 μm) using nanopowders (NPs) produced via liquid-feed flame spray pyrolysis (LF-FSP). Here, membranes consisting of selected mixtures of lithium aluminate polymorphs and Li contents were processed by conventional tape casting of NPs followed by thermocompression of the green films (100 °C/10 kpsi/10 min). The sintered green films (1100 °C/2 h/air) present a mixture of LiAlO 2 (~72 wt %) and LiAl 5 O 8 (~27 wt %) phases, offering ionic conductivities (>10 –6 S cm –1 ) at ambient with an activation energy of 0.5 eV. This greatly increases their potential utility as ceramic electrolytes for all-solid-state batteries, which could simplify battery designs, significantly reduce costs, and increase their safety. Furthermore, a solid-state Li/Li 3.1 AlO 2 /Li symmetric cell was assembled and galvanostatically cycled at 0.375 mA cm –2 current density, exhibiting a transference number ≈ 1.

25 ENERGY STORAGE↗
DOE OSTI2024

Reliability of Materials and Components for Solid Oxide Fuel Cells

Planar stack solid-oxide fuel cells (SOFCs) require seals that must operate reliably under demanding conditions for lifetimes of 40000 hours. This includes temperature fluctuations between 800°C and RT during on and off cycles, thermal stresses, oxidizing environments and chemical degradation to name a few. This comprehensive report provides results from long term testing of two commercially available multicomponent barium alkali silicate glasses: SCN and G6, chosen as sealing candidates. In this scope, the glass seals were deposited on YSZ and Al 2 O 3 substrates simulating electrolytes (Zrbased) and coatings (both zirconia and Al 2 O 3 ). The seal-substrate couples were subjected to 800°C under air and steam+H 2 +N 2 environments up to 40000 hours to test their integrity under real operating conditions. Extensive studies on the effects of exposure have been conducted over the span of testing at various time intervals. Within the context of characterization, mechanical properties such as density, roughness, thermal expansion and glass transition, viscosity and wettability behavior; and microstructural properties such as glass chemistries, defect formation (cracks and pores), phase transformations (devitrification) and glass-interface reactions are investigated. Results and discussions are provided with a focus on the degradation of the properties over long term interrupted testing.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Novel Tools for Analyzing Life Cycle Energy Use, Carbon Emissions, and Cost of Additive Manufacturing

Decarbonizing industrial manufacturing is a significant challenge in the effort to limit the impacts of global climate change. Additive manufacturing (AM) is one pathway for reducing the impacts of manufacturing as it creates parts layer-by-layer rather than by removing (i.e., subtracting) material from solid stock as with conventional techniques. This reduces material inputs and generates less waste, which can substantially lower life cycle energy consumption and greenhouse gas emissions. However, AM adoption in the manufacturing sector has been slow, partly due to challenges in making a strong business case compared with more traditional and widely available techniques. This paper highlights the need for the development of simple screening analysis tools to speed the adoption of AM in the manufacturing sector by providing decision-makers easy access to important production life cycle emissions, and cost information. Details on the development of two Microsoft Excel software tools are provided: upgrades to an existing tool on the energy and carbon impacts of AM and a new tool for analyzing the major cost components of AM. A case study applies these two tools to the production of a lightweight aerospace bracket, showing how the tools can be used to estimate the environmental benefits and production costs of AM.

GHG emissions↗
NASA NTRS1994

Copper-containing ceramic precursor synthesis: Solid-state transformations and materials technology

Three copper systems with relevance to materials technology are discussed. In the first, a CuS precursor, Cu4S1O (4-methylpyridine)(sub 4)- (4-MePy), was prepared by three routes: reaction of Cu2S, reaction of CuBr-SMe2, and oxidation of copper powder with excess sulfur in 4-methylpyridine by sulfur. In the second, copper powder was found to react with excess thiourea (H2NC(S)NH2) in 4-methylpyridine to produce thiocyanate (NCS(-)) complexes. Three isolated and characterized compounds are: Cu(NCS)(4-MePy)(sub 2), a polymer, (4-MePy-H)(Cu(NCS)(sub 3)(4-MePy)(sub 2)), a salt, and t-Cu(NCS)(sub 2)(4-MePy)(sub 4). Finally, an attempt to produce a mixed-metal sulfide precursor of Cu and Ga in N-methylimidazole (N-MeIm) resulted in the synthesis of a Cu-containing polymer, Cu(SO4)(N-MeIm). The structures are presented; the chemistry will be briefly discussed in the context of preparation and processing of copper-containing materials for aerospace applications.

Hepp, Aloysius F.↗
NASA NTRS2012

Mechanical and Vibration Testing of Carbon Fiber Composite Material with Embedded Piezoelectric Sensors

Piezoelectric materials have been proposed as a means of decreasing turbomachinery blade vibration either through a passive damping scheme, or as part of an active vibration control system. For polymer matrix fiber composite (PMFC) blades, the piezoelectric elements could be embedded within the blade material, protecting the brittle piezoceramic material from the airflow and from debris. Before implementation of a piezoelectric element within a PMFC blade, the effect on PMFC mechanical properties needs to be understood. This study attempts to determine how the inclusion of a packaged piezoelectric patch affects the material properties of the PMFC. Composite specimens with embedded piezoelectric patches were tested in four-point bending, short beam shear, and flatwise tension configurations. Results show that the embedded piezoelectric material does decrease the strength of the composite material, especially in flatwise tension, attributable to failure at the interface or within the piezoelectric element itself. In addition, the sensing properties of the post-cured embedded piezoelectric materials were tested, and performed as expected. The piezoelectric materials include a non-flexible patch incorporating solid piezoceramic material, and two flexible patch types incorporating piezoelectric fibers. The piezoceramic material used in these patches was Navy Type-II PZT.

Duffy, Kirsten P.↗
NASA NTRS1980

The role of the micro environment on the tribological behavior of materials

The properties of the environment which exert an influence upon adhesion, friction, wear, and lubrication of materials in solid state contact are discussed. The effect of the environment upon lubricants and lubricant properties is considered in relation to the interaction of the lubricant with the material surfaces in solid state contact and the ability of lubricants to provide protective surface films.

Buckley, D. H.↗
NASA NTRS1978

Solid rocket booster thermal protection system materials development

A complete run log of all tests conducted in the NASA-MSFC hot gas test facility during the development of materials for the space shuttle solid rocket booster thermal protection system are presented. Lists of technical reports and drawings generated under the contract are included.

Dean, W. G.↗
DOE OSTI2025

Accelerating Discovery of Solid‐State Thin‐Film Metal Dealloying for 3D Nanoarchitecture Materials Design through Laser Thermal Gradient Treatment

Thin‐film solid‐state metal dealloying (thin‐film SSMD) is a promising method for fabricating nanostructures with controlled morphology and efficiency, offering advantages over conventional bulk materials processing methods for integration into practical applications. Although machine learning (ML) has facilitated the design of dealloying systems, the selection of key thermal treatment parameters for nanostructure formation remains largely unknown and dependent on experimental trial and error. To overcome this challenge, a workflow enabling high‐throughput characterization of thermal treatment parameters is demonstrated using a laser‐based thermal treatment to create temperature gradients on single thin‐film samples of Nb‐Al/Sc and Nb‐Al/Cu. This continuous thermal space enables observation of dealloying transitions and the resulting nanostructures of interest. Through synchrotron X‐ray multimodal and high‐throughput characterization, critical transitions and nanostructures can be rapidly captured and subsequently verified using electron microscopy. The key temperatures driving chemical reactions and morphological evolutions are clearly identified. While the oxidation may influence nanostructure formation during thin‐film treatment, the dealloying process at the dealloying front involves interactions solely between the dealloying elements, highlighting the availability and viability of the selected systems. Further, this approach enables efficient exploration of the dealloying process and validation of ML predictions, thereby accelerating the discovery of thin‐film SSMD systems with targeted nanostructures.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Challenges for and Pathways toward Li-Metal-Based All-Solid-State Batteries

Solid-state batteries utilizing Li metal anodes have the potential to enable improved performance (specific energy >500 Wh/kg, energy density >1500 Wh/L), safety, recyclability, and potentially lower cost (<$100/kWh) compared to advanced Li-ion systems.1,2 These improvements are critical for the widespread adoption of electric vehicles (EVs) and trucks and could create a short-haul electric aviation industry.1-3 Expectations for solid-state batteries are high, but there are significant materials and processing challenges to overcome.

25 ENERGY STORAGE↗
DOE OSTI2020

Transport Processes in a Li-ion Cell during an Internal Short-Circuit

Internal short-circuit in a lithium-ion cell causes an abrupt increase in cell temperature and triggers subsequent thermal runaway. In this work, we present a detailed electrochemical-thermal model to investigate the physical behavior during an internal short-circuit. Simulations at wide range of heat transfer coefficients and short-circuit resistances are conducted to illustrate electrochemical and thermal behavior under a wide range of conditions. The Joule heating at the shorted region promotes electrochemical reactions nearby, causing in-plane non-uniformity of electrolyte and active material transport. Furthermore, it is found that diffusion in solid active materials plays a significant role at very high shorting currents (~20 C), as electrochemical reactions rate are being controlled progressively more by availability of Li + at the interface, due to limitations in diffusion through the active material with increasing discharge rates. This diffusion limitation causes a drop in available energy, and subsequently a decrease in cell equilibrium potential and the heat generation rate at the location of the short. On the other hand, rapid depletion of lithium concentration in the electrolyte and accumulation on the electrode surface results in highly non-uniform transport properties resulting in higher heat generation rates. Hence, the heating regime shifts from "local heating" to "global heating". Based on the findings, important design parameters for battery safety are discussed.

25 ENERGY STORAGE↗