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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 OSTI2018

Effect of overcharge on Li(Ni 0.5 Mn 0.3 Co 0.2 )O 2 /Graphite lithium ion cells with poly(vinylidene fluoride) binder. I - Microstructural changes in the anode

Cells based on NMC/graphite, containing poly(vinylidene difluoride) (PVDF) binders in the positive and negative electrodes, were systematically overcharged to 100, 120, 140, 160, 180, and 250% state-of-charge (SOC). At 250% SOC the cell vented. Scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) of the anodes showed several state-of-overcharge-dependent trends. Starting at 120% SOC, dendrites appeared and increased in concentration as the SOC increased. Dendrite morphology appeared to be dependent on whether the active material was on the “dull” or “shiny” side of the copper collector. Significantly more delamination of the active material from the collector was seen on the “shiny” side of the collector particularly at 180 and 250% SOC. Transition metals were detected at 120% SOC and increased in concentration as the SOC increased. Finally, there was considerable spatial heterogeneity in the microstructures across each laminate with several regions displaying complex layered structures.

25 ENERGY STORAGE↗
NASA NTRS1974

Eutectic bonding of boron-aluminum structural components. II

Eutectic bonding is a diffusion brazing process developed for fabricating boron-aluminum components from composite monolayer. This process relies on the diffusion of a thin surface film of copper into the aluminum matrix to form a liquid phase when heated above the copper-aluminum eutectic temperature of 1018 F. This type of fabrication offers design flexibility in that skin thickness may be varied, the stiffness geometry and orientation can be varied, and local reinforcement can be added. In addition, this type of boron-aluminum structure offers high efficiency. Also, this method of construction can be cost-comparative with complex titanium shapes; simple tooling permits easy layup, bonding is a one-step operation, and little finish machining is required.

Niemann, J. T.↗
NASA NTRS1978

Application of NASTRAN to TFTR toroidal field coil structures

The primary applied loads on the TF coils were electromagnetic and thermal. The complex structure and the tremendous applied loads necessitated computer type of solutions for the design problems. In the early stage of the TF coil design, many simplified finite element models were developed for the purpose of investigating the effects of material properties, supporting schemes, and coil case material on the stress levels in the case and in the copper coil. In the more sophisticated models that followed the parametric and scoping studies, the isoparametric elements, such as QUAD4, HEX8, and HEXA, were used. The analysis results from using these finite element models and the NASTRAN system were considered accurate enough to provide timely design information.

Chen, S. J.↗
DOE OSTI2019

Process–structure–property relationships in bimodal machined microstructures using robust structure descriptors

Machining is a severe plastic deformation process that subjects materials to high rates of deformation and elevated temperatures. Dynamic recrystallization during severe plastic deformation drives grain refinement into the sub-micron range but the ductility and thermal stability of these structures is poor. In contrast, bimodal microstructures consisting of both fine and coarse grains have been shown to exhibit attractive strength and ductility properties at these temperatures. In this paper, we study the process–structure–property relationships for pure copper subject to a machining process where the cutting speeds are varied. Further, we investigate the role of thermal effects by varying the post-deformation cooling rates. Microstructures generated under these deformation conditions are quantified using angularly resolved chord length statistics. The derived metrics are found to be robust descriptors of the studied microstructures as they automatically capture complex features such as unimodal and bimodal distributions of grain structure, grain constituent length scales, and morphological anisotropy induced by shear deformation. The uniaxial equivalent yield strength of the generated structures are estimated using spherical nanoindentation and inverse modeling techniques. Lastly, we present a methodology for identifying the constrained property-process inverse mapping for machining using a Bayesian framework and the established forward process–structure–property mapping.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Deciphering electrocatalysts with multimodal operando approaches

Here, the electrocatalytic processes of a copper catalyst during nitrate electroreduction are unveiled by correlated operando microscopy and spectroscopy. Catalysts are vital to the modern chemical industry, yet their development has largely relied on trial-and-error approaches. Optimizing catalysts requires a fundamental understanding of their structure–chemical property behaviour under operational conditions. However, operando characterization remains challenging, especially for reactions occurring in the complex and dynamic liquid environments of electrochemical systems. Over the past decade, the rapid development of in situ and operando environmental transmission electron microscopy (ETEM) and microelectromechanical system (MEMS)-based closed-cell holders, enabling environmental studies within the vacuum environment of transmission electron microscopy (TEM), has substantively advanced understanding of heterogeneous catalysis, notably for gas-phase reactions. In situ ETEM enables the direct observation of the catalyst evolution in terms of structure, morphology and chemical state at the nano-to-atomic scale, providing insights into their correlation with catalytic performance.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Metastable Fluid Decay During Electric Explosion of Metallic Foils

Results of experimental investigations into overheated metastable fluid decay during electric explosion of metallic foils are presented. Experiments have been performed using an experimental complex consisting of three current generators, one of which provides explosion of foil and two others – X-pinch-based radiographs – are used for diagnostic purposes. The upper limit of the decay time of an overheated metastable metal is determined experimentally. For aluminum conductor with deposited energy of (5.3 ± 0.5) kJ/g, the metastable state decay time is ~110 ns; for copper foil with deposited energy of (2.4 ± 0.2) kJ/g, it is ~260 ns; and for nickel foil with deposited energy of (1.3 ± 0.3) kJ/g, it is ~350 ns.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Water-Nucleophilic Attack Mechanism for the Cu II (pyalk) 2 Water-Oxidation Catalyst

Here, we investigate the mechanism of water oxidation catalyzed by the Cu II (pyalk) 2 complex, combining density functional theory with experimental measurements of turnover frequencies, UV–visible spectra, H/D kinetic isotope effects (KIEs), electrochemical analysis, and synthesis of a derivative complex. We find that only in the cis form does Cu II (pyalk) 2 convert water to dioxygen. In a series of alternating chemical and electrochemical steps, the catalyst is activated to form a metal oxyl radical species that undergoes a water-nucleophilic attack defining the rate-limiting step of the reaction. The experimental H/D KIE (3.4) is in agreement with the calculated value (3.7), shown to be determined by deprotonation of the substrate nucleophile upon O–O bond formation. The reported mechanistic findings are particularly valuable for rational design of complexes inspired by Cu II (pyalk) 2 .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

CuCl Complexation in the Vapor Phase: Insights from Ab Initio Molecular Dynamics Simulations

We investigated the hydration of the CuCl 0 complex in HCl-bearing water vapor at 350°C and a vapor-like fluid density between 0.02 and 0.09 g/cm 3 using ab initio molecular dynamics (MD) simulations. The simulations reveal that one water molecule is strongly bonded to Cu(I) (first coordination shell), forming a linear [H 2 O-Cu-Cl] 0 moiety. The second hydration shell is highly dynamic in nature, and individual configurations have short life-spans in such low-density vapors, resulting in large fluctuations in instantaneous hydration numbers over a timescale of picoseconds. The average hydration number in the second shell ( m ) increased from ~0.5 to ~3.5 and the calculated number of hydrogen bonds per water molecule increased from 0.09 to 0.25 when fluid density (which is correlated to water activity) increased from 0.02 to 0.09 g/cm 3 ( f H 2 O 1.72 to 2.05). These changes of hydration number are qualitatively consistent with previous solubility studies under similar conditions, although the absolute hydration numbers from MD were much lower than the values inferred by correlating experimental Cu fugacity with water fugacity. This could be due to the uncertainties in the MD simulations and uncertainty in the estimation of the fugacity coefficients for these highly nonideal “vapors” in the experiments. Finally, our study provides the first theoretical confirmation that beyond-first-shell hydrated metal complexes play an important role in metal transport in low-density hydrothermal fluids, even if it is highly disordered and dynamic in nature.

58 GEOSCIENCES↗
DOE OSTI2021

Performance of the A-01 Constructed Wetland over 20 Years

The A-01 wetland treatment system (WTS) was designed to remove metals from the effluent at the A-01 National Pollution Discharge Elimination System (NPDES) outfall at the Savannah River Site, Aiken, SC. The A-01 effluent flows from a retention basin to a splitter box, where it is distributed to four pairs of cells in series before discharge to a stream. Each treatment cell is a one-acre wetland that contains Schoenoplectus californicus (giant bulrush) and has a nominal 24-hour retention time. The purpose of this research was to investigate metal removal, distribution and retention in the A-01 WTS over a period of 20 years. During 20 years of operation, systematic water and sediment sampling validated the wetlands' performance. After passage through the treatment cells, Cu concentrations were well below permit limits (22 pg L -1 ) during all years of operation, often falling below 10 pg L -1 . Cu removal has been consistent over time, averaging about 80% despite large changes in influent Cu concentrations. Most divalent metals were rapidly removed from the water and held in the sediments shortly after the water entered the treatment wetlands. Average removal of Pb from water by the wetland system was 67 and 74%, respectively, in 2004, and 2020. Comparable values for Zn were 52 and 65%, respectively. Generally, the highest concentrations of Cu, Pb, and Zn were found in the sediment from the first cell in each pair of cells suggesting that most of the Cu, Pb, and Zn in the A-01 effluent was bound to the sediment quickly. Diffusive gradients in thin films (DGT) measurements of Cu and Zn in the sediments were much lower than bulk sediment concentrations. These results suggest that most of the Cu and Zn in the A-01 WTS sediments was not bioavailable, hence not toxic to aquatic organisms, as a likely consequence of adsorption to sediment particles and complexation with organic and inorganic substances.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Design and Optimization of Structured Multi-Functional Trapping Catalysts for Conversion of Hydrocarbons and NOx from Diesel and Advanced Combustion Engines

Oxides of nitrogen in the form of nitric oxide (NO) and nitrogen dioxide (NO 2 ) commonly referred to as NOx, is one of the two chemical precursors that lead to ground-level ozone, a ubiquitous air pollutant in urban areas. A major source of NOx is generated by equipment and vehicles powered by diesel engines, which have a combustion exhaust that contains NOx in the presence of excess O 2 . Vehicular emission control catalysts are ineffective in eliminating CO, hydrocarbons, and NOx during engine cold-start when exhaust temperatures are below 200°C. The objective of the project was to develop and demonstrate a multi-functional, catalyzed trap that enables vehicles with advanced combustion strategies to meet Tier 3 emissions standards while achieving the 150 °C challenge for sustained co-oxidation of HCs and CO and ≥90% NO trapping and release during warmup. Specifically, the multi-functional Lean HC+NOx (LHCNT) was developed for application in the exhaust aftertreatment of conventional diesel engines and engines having low temperature combustion (LTC) regimes. Activities included the design and synthesis of adsorbents and catalysts, screening and evaluation. Passive NOx absorbers (PNA), hydrocarbon (HC) traps, and oxidation catalysts (OC) were evaluated for use in series or as integrated devices. Predictive tools were developed utilizing the characterization and analysis of these materials, and an emission system was designed and optimized utilizing the catalyst systems. Microkinetic models were developed for the PNA for the simple NO-only feed and complex feed containing CO, H 2 , and model hydrocarbons (ethylene and dodecane). A first-principles, mechanistic-based model of the PNA was developed which utilized molecular-scale estimates (density functional theory) of energy barriers, mechanistic-based kinetics and realistic treatments of the flow and transport processes. Two new oxidation catalysts were developed (PdCu alloy, mixed copper-ceria-cobalt oxide), both of which significantly lessened the detrimental inhibition by CO on hydrocarbon and NO oxidation. A method for lessening the detrimental impact of CO on PNA activity was developed that involves use of an oxidation catalyst upstream of the PNA. The SwRI Ectolab TM burner system was applied to evaluate the baseline PNA material and confirmed performance comparable to the benchflow PNA studies using simulated exhaust. Spatially-resolved mass spectrometry (SpaciMS) was used to measure the transient spatial profiles of reacting species spanning the length of a three-function LHCNT containing PNA, HCT, and OC. The findings from this study provide diesel vehicle and catalyst companies valuable information to develop more cost effective emission control catalysts which helps to expand the use of more fuel efficient diesel power. The fundamental modeling and experimental tools and findings from this project can be applied to catalyst technologies used in the energy and chemical industries. The project led to 14 publications in the peer-reviewed literature with 2 additional currently under review. Finally, the project also led to training of several doctoral students who were placed in research jobs in industry and academia. Specifically, Mugdha Ambast (UH) has joined Cummins, Kevin Gu (UVa) has joined GM, and Abhay Gupta (UH) is to join Caterpillar.

02 PETROLEUM↗
DOE OSTI2022

Design and Optimization of Structured Multi-Functional Trapping Catalysts for Conversion of Hydrocarbons and NOx from Diesel and Advanced Combustion Engines

Oxides of nitrogen in the form of nitric oxide (NO) and nitrogen dioxide (NO 2 ) commonly referred to as NOx, is one of the two chemical precursors that lead to ground-level ozone, a ubiquitous air pollutant in urban areas. A major source of NOx is generated by equipment and vehicles powered by diesel engines, which have a combustion exhaust that contains NOx in the presence of excess O 2 . Vehicular emission control catalysts are ineffective in eliminating CO, hydrocarbons, and NO x during engine cold-start when exhaust temperatures are below 200°C. The objective of the project was to develop and demonstrate a multi-functional, catalyzed trap that enables vehicles with advanced combustion strategies to meet Tier 3 emissions standards while achieving the 150 °C challenge for sustained co-oxidation of HCs and CO and ≥90% NO trapping and release during warmup. Specifically, the multi-functional Lean HC+NOx (LHCNT) was developed for application in the exhaust aftertreatment of conventional diesel engines and engines having low temperature combustion (LTC) regimes. Activities included the design and synthesis of adsorbents and catalysts, screening and evaluation. Passive NOx absorbers (PNA), hydrocarbon (HC) traps, and oxidation catalysts (OC) were evaluated for use in series or as integrated devices. Predictive tools were developed utilizing the characterization and analysis of these materials, and an emission system was designed and optimized utilizing the catalyst systems. Microkinetic models were developed for the PNA for the simple NO-only feed and complex feed containing CO, H 2 , and model hydrocarbons (ethylene and dodecane). A first-principles, mechanistic-based model of the PNA was developed which utilized molecular-scale estimates (density functional theory) of energy barriers, mechanistic-based kinetics and realistic treatments of the flow and transport processes. Two new oxidation catalysts were developed (PdCu alloy, mixed copper-ceria-cobalt oxide), both of which significantly lessened the detrimental inhibition by CO on hydrocarbon and NO oxidation. A method for lessening the detrimental impact of CO on PNA activity was developed that involves use of an oxidation catalyst upstream of the PNA. The SwRI Ectolab TM burner system was applied to evaluate the baseline PNA material and confirmed performance comparable to the benchflow PNA studies using simulated exhaust. Spatially-resolved mass spectrometry (SpaciMS) was used to measure the transient spatial profiles of reacting species spanning the length of a three-function LHCNT containing PNA, HCT, and OC. The findings from this study provide diesel vehicle and catalyst companies valuable information to develop more cost effective emission control catalysts which helps to expand the use of more fuel efficient diesel power. The fundamental modeling and experimental tools and findings from this project can be applied to catalyst technologies used in the energy and chemical industries. The project led to 14 publications in the peer-reviewed literature with 2 additional currently under review. Finally, the project also led to training of several doctoral students who were placed in research jobs in industry and academia. Specifically, Mugdha Ambast (UH) has joined Cummins, Kevin Gu (UVa) has joined GM, and Abhay Gupta (UH) is to join Caterpillar.

42 ENGINEERING↗
DOE OSTI2026

Recycling of Printed Circuit Boards to Recover Critical Materials

The printed circuit board (PCB), a central component of most electronic devices, represents a significant fraction of the electronic product waste stream. The complex composition of PCBs, consisting of metals, polymers, and fiberglass, requires specialized recovery steps to reclaim valuable and critical materials and the safe disposal of brominated compounds. In this review paper, we describe the current state of critical material recovery and traditional recycling technologies and identify key obstacles to large-scale implementation. Metals present at high concentrations, such as copper, lead, and iron, are conventionally recovered from PCBs using hydrometallurgical, pyrometallurgical, or electrometallurgical processes. Hydrometallurgical methods achieve high selectivity through chemical leaching but pose significant challenges for effluent and reagent recovery. Pyrometallurgical methods facilitate rapid metal separation through smelting but require substantial energy and may release harmful gases. Electrometallurgical techniques produce high-purity metals but are constrained by pretreatment requirements and the consumption of energy. The non-metallic fraction of PCB waste is recycled using thermochemical conversion, microwave-aided heating, and direct recycling of epoxy–fiberglass composites, enabling material or energy recovery. The recovered polymer from direct recycling may have reduced mechanical strength and poor compatibility with new polymer matrices, and the resulting products from the thermal conversion suffer from incomplete conversion, degradation of quality, and residual contamination, as compared to synthetic polymers. Recent process developments have focused on extracting rare earth and supply-critical materials present at lower concentrations in the waste stream. The literature on existing and emerging approaches for recycling PCB wastes is reviewed to identify sustainable, economically viable, and environmentally responsible strategies for the recovery and reuse of critical materials from waste streams.

36 MATERIALS SCIENCE↗
NASA NTRS1983

Size-specific composition of aerosols in the El Chichon volcanic cloud

A NASA U-2 research aircraft flew sampling missions in April, May, July, November, and December 1982 aimed at obtaining in situ data in the stratospheric cloud produced from the March-April 1982 El Chichon eruptions. Post flight analyses provided information on the aerosol composition and morphology. The particles ranged in size from smaller than 0.05 m to larger than 20 m diameter and were quite complex in composition. In the April, May, and July samples the aerosol mass was dominated by magmatic and lithic particles larger than about 3 m. The submicron particles consisted largely of sulfuric acid. Halite particles, believed to be related to a salt dome beneath El Chichon, were collected in the stratosphere in April and May. On the July 23 flight, copper-zinc oxide particles were collected. In July, November, and December, in addition to the volcanic ash and acid particles, carbon-rich particles smaller than about 0.1 m aerodynamic diameter were abundant.

Woods, D. C.↗
DOE OSTI2019

The Influence of Shell Mold Composition on the As-cast Macro- and Micro-structure of Thin-Walled IN713C Superalloy Castings

In the investment casting process, the building of ceramic layers around the wax pattern is the main time-consuming stage. Increasing their number ensures sufficient mechanical properties, but also lengthens the whole process, including drying time and preheating of the mold. Four molds for casting Ni-based superalloy IN713C were strengthened by glass fibers, included in the slurry, and metal powder, of Al, Cu, Fe or Ni, in the coverage. Castings were subjected to microstructural investigations in order to find out if the new design can be promising for the manufacture of jet engine components. Bend tests revealed that the green strengths of all new molds were higher, at least 3.65 MPa, than that of the unmodified molds, 3.0 MPa. Optical microscopy revealed that the composition of a mold had a strong influence on stereological parameters of equiaxed IN713C grains. Microstructural observation and hardness measurements of castings revealed differences in the volume fraction of strengthening phases, porosity and hardness. The microstructure due to the complex chemical composition of IN713C consisted of several phases including ternary eutectics as a consequence of L → γ + Ni{sub 7}Zr{sub 2} + (Nb, Zr)C.

36 MATERIALS SCIENCE↗
DOE OSTI2018

A Copper Relay System Involving Two Periplasmic Chaperones Drives cbb 3 -Type Cytochrome c Oxidase Biogenesis in Rhodobacter capsulatus

PccA and SenC are periplasmic copper chaperones required for the biogenesis of cbb 3 -type cytochrome c oxidase (cbb 3 -Cox) in Rhodobacter capsulatus at physiological Cu concentrations. However, both proteins are dispensable for cbb 3 -Cox assembly when the external Cu concentration is high. PccA and SenC bind Cu using Met and His residues and Cys and His residues as ligands, respectively, and both proteins form a complex during cbb 3 -Cox biogenesis. SenC also interacts directly with cbb 3 -Cox, as shown by chemical cross-linking. Here we determined the periplasmic concentrations of both proteins in vivo and analyzed their Cu binding stoichiometries and their Cu(I) and Cu(II) binding affinity constants (KD) in vitro. Our data show that both proteins bind a single Cu atom with high affinity. In vitro Cu transfer assays demonstrate Cu transfer both from PccA to SenC and from SenC to PccA at similar levels. We conclude that PccA and SenC constitute a Cu relay system that facilitates Cu delivery to cbb 3 -Cox.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2018

Influence of Magnetic Confinement on the Yellow Excitons in Cuprous Oxide Subject to an Electric Field

We study the spectrum of the yellow exciton series in crossed electric and magnetic fields. The electric field, applied along the optical axis, tilts the Coulomb potential between electron and hole, so that at sufficiently high fields exciton dissociation becomes possible, roughly when the electric dipole interaction energy exceeds the binding energy of an exciton state with principal quantum number n. For an applied voltage of U = 20 V all excitons above n = 6 are dissociated. Additional application of a magnetic field normal to the optical axis introduces magnetic confinement, due to which above a threshold field strength around B = 2.5 T the exciton lines re-emerge. The complex dispersion with increasing fields suggests quantum chaotic behavior in this crossed field configuration, so that the search for exceptional points may be promising.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Experimental studies of a high-gradient X-band welded hard-copper split accelerating structure

We report on recent research on high-gradient radio frequency (RF) accelerating structures indicates that the use of hard copper alloys provides improvement in high gradient performance over annealed copper. Such structures are made by bonding individually manufactured parts. However, there are no well-established bonding techniques that preserve the hardness, surface finish and cleanliness required for high gradient operation. To preserve the copper hardness, RadiaBeam has developed a novel high-gradient split accelerating structure, based on electron beam welding joining technique. This technique provides efficient bonding with strong, clean welds and minimal thermal loading, while maintaining a clean inner RF environment. Our RF design and fabrication methodology limits the small heat affected zone to the outer cavity envelop, with virtually no distortions or thermal loading of critical RF surfaces. It also incorporates provisions to precisely control the gap despite conventional issues with weld joint shrinkage. To date we have manufactured and validated an RF accelerating structure joined by electron-beam welding that incorporates a novel open split design to significantly reduce the assembly complexity and cost. In this paper, we will present the electromagnetic design of this structure, discuss bonding, and present the results of high-power tests, where the accelerating gradients of 140 MV m -1 with surface peak fields of 400 MV m -1 were achieved for flat-top pulse length of 600 ns with an RF breakdown rate of 10 -4 1/(pulsecm).

43 PARTICLE ACCELERATORS↗
NASA NTRS1989

Aerospace applications of sodium batteries using novel cathode materials

Preliminary fundamental investigations aimed at evaluating sodium metal chloride systems for future aerospace applications are described. Since the sodium metal chloride systems are relatively new, the approach has been to characterize their fundamental properties in order to understand their limitations. To this end, a series of fundamental electrochemical investigations have been carried out, the results of which are reported here. The metal chloride cathodes show high exchange current densities which corroborate their good reversibility in a battery application. The reduction mechanisms appear to be complex and involve multielectron transfer steps and intermediates. Such intermediates in the reaction mechanism have already been identified in the case of FeCl2. Similar mechanisms may be operative in the case of NiCl2. CuCl2, however, exhibits a second relaxation loop in the impedance plot at low frequencies and also a sloping discharge curve, unlike FeCl2 and NiCl2, which may indicate the existence of monovalent copper in the reduction mechanism.

Ratnakumar, B. V.↗