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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 OSTI2019

On the evolution of microstructure and defect control in 316L SS components fabricated via directed energy deposition

To identify the critical issues that affect the evolution of microstructure during additive manufacturing, we investigated the influence of process parameters on the evolution of the dimensional and surface quality, microstructure, internal defects, and mechanical properties in 316L stainless steel (SS) components fabricated using laser engineered net shaping (LENS®), a directed energy deposition (DED) additive manufacturing (AM) technique. The results show that the accumulation of un-melted powder particles on the side walls of deposited sections can be avoided by selecting a laser under-focused condition. Moreover, we report that the variation of melt pool width is more sensitive to laser power than to the depth of the melt pool. The formation of a so-called “hierarchical” microstructure with cellular morphology is attributable to a combination of layer deposition and rapid solidification, which are characteristics of AM. Finally, we discuss microstructure evolution and defect formation, particularly the formation of multiple interfaces and the presence of un-melted powder particles and pores, in light of the dynamic convective fluid flow and rapid solidification that occur in the melt pool. X-ray computed tomography (X-CT) was used to precisely map the spatial distribution of pores in the DED components. The evolution of microstructure during DED is discussed in the context of related thermal phenomena in an effort to provide fundamental insight into the mechanisms that govern defect formation.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Evaluation of the interfacial bonding strength between hafnia and silica layers deposited by electron-beam evaporation

Factors contributing to the mechanical strength of multilayer optical coatings involving alternating layers of electron-beam evaporated hafnia and silica is investigated. It is observed that upon rupture resulting from nanosecond laser damage, fragments consisting of layer pairs are produced. These pairs are formed as a result of a strong asymmetry in adhesion strength between interfaces, leading to preferential delamination at interfaces where silica is deposited on hafnia, and not the reverse, despite the fact that both interface types consist of the same pair of materials. The observed disparity in adhesion strength was further studied using nanomechanical scratch tests, revealing loads at which fracture occurs, and fracture morphology, both of which are highly dependent on deposition order. Based on these measurements, along with the morphological analysis of the nanostructure of the coatings, we conclude that the surface microstructure in each coating layer affects its adhesion strength with the succeeding layer. The findings outlined here are particularly relevant to the production of large aperture, high-performance optics designed for use in next-generation lasers.

adhesion strength↗
DOE OSTI2018

Electrocatalytic transformation of HF impurity to H 2 and LiF in lithium-ion batteries

The formation of solid electrolyte interphase on graphite anodes plays a key role in the efficiency of Li-ion batteries. However, to date, fundamental understanding of the formation of LiF as one of the main solid electrolyte interphase components in hexafluorophosphate-based electrolytes remains elusive. In this paper, we present experimental and theoretical evidence that LiF formation is an electrocatalytic process that is controlled by the electrochemical transformation of HF impurity to LiF and H 2 . Although the kinetics of HF dissociation and the concomitant production of LiF and H 2 is dependent on the structure and nature of surface atoms, the underlying electrochemistry is the same. The morphology, and thus the role, of the LiF formed is strongly dependent on the nature of the substrate and HF inventory, leading to either complete or partial passivation of the interface. Finally, our finding is of general importance and may lead to new opportunities for the improvement of existing, and design of new, Li-ion technologies.

25 ENERGY STORAGE↗
DOE OSTI2020

Adhesion-force micro-scale study of desiccating granular material

Experiments on five-, four-, three- and two-wet-hydrophilic-grain clusters were performed to investigate evolution of adhesion of granular media during drying on the micro-scale. The experiments show that the adhesion-force of a cluster initially grows at most to three times the original value before decreasing to zero by the end of evaporation. The adhesion-force is composed of capillary pressure force acting over the liquid/solid contact surface area, and surface tension forces acting over the three-phase contact perimeter length. This is in contrast with most macro-scale phenomenological models, in which the only desaturation process variables affecting strength are suction and saturation. Both the contact surface area and contact perimeter length are reduced to zero upon complete liquid evaporation. The morphology of an evaporating water body evolves through slow flow controlled by evaporation rate, interrupted by various modes of fast air entry, which are non-equilibrium jumps of liquid/gas interfaces (Haines jumps). The instabilities involve large adhesion force discontinuities and substantial water mass reconfiguration with water flow in an extremely short time, which makes the process transient. The reconfigurations can reduce the original multi-grain water clusters to four-, three- and two-grain clusters by way of three different instability modes: of thin-sheet instability, or meniscus snap-through instability, depending on the sign of the Gauss curvature of the liquid surface, or finally, for two-grain bridges only, a liquid wire pinch-off. For larger meso-scale assemblies, however, the global adhesion-force evolution is little affected by the jumps. The air entries are potential sites for drying cracks. The (approximately) calculated capillary pressure for two- and three-grain clusters, in no cases is seen to reach high values, predicted from water retention curves.

Engineering↗
NASA NTRS1995

Observations in the vicinity of substorm onset: Implications for the substrom process

Multi-instrument data sets from the ground and satellites at both low and high altitude have provided new results concerning substorm onset and its source region in the magnetosphere. Twenty-six out of 37 substorm onset events showed evidence of azimuthally spaced auroral forms (AAFs) prior to the explosive poleward motion associated with optical substorm onset. AAFs can span 8 hours of local time prior to onset and generally propagate eastward in the morning sector. Onset itself is, however, more localized spanning only about 1 hour local time. AAF onset occur during time periods when the solar wind pressure is relatively high. AAFs brighten in conjunction with substorm onset leading to the conclusion that they are a growth phase activity casually related to substorm onset. Precursor activity associated with these AAFs is also seen near geosynchronous orbit altitude and examples show the relationship between the various instrumental definitions of substorm onset. The implied mode number (30 to 135) derived from this work is inconsistent with cavity mode resonances but is consistent with a modified flute/ballooning instability which requires azimuthal pressure gradients. The extended source region and the distance to the open-closed field line region constrain reconnection theory and local mechanisms for substorm onset. It is demonstrated that multiple onset substorms can exist for which localized dipolarizations and the Pi 2 occur simultaneously with tail stretching existing elsewhere. These pseudobreakups can be initiated by auroral streamers which originate at the most poleward set of arc systems and drift to the more equatorward main UV oval. Observations are presented of these AAFs in conjunction with low- and high-altitutde particle and magnetic field data. These place the activations at the interface between dipolar and taillike field lines probably near the peak in the cross-tail current. These onsets are put in the context of a new scenario for substorm morphology which employs individual modules which operate independently or couple together. This allows particular substorm events to be more accurately described and investigated.

Elphinstone, R. D.↗
NASA NTRS1995

Geophysical phenomena classification by artificial neural networks

Space science information systems involve accessing vast data bases. There is a need for an automatic process by which properties of the whole data set can be assimilated and presented to the user. Where data are in the form of spectrograms, phenomena can be detected by pattern recognition techniques. Presented are the first results obtained by applying unsupervised Artificial Neural Networks (ANN's) to the classification of magnetospheric wave spectra. The networks used here were a simple unsupervised Hamming network run on a PC and a more sophisticated CALM network run on a Sparc workstation. The ANN's were compared in their geophysical data recognition performance. CALM networks offer such qualities as fast learning, superiority in generalizing, the ability to continuously adapt to changes in the pattern set, and the possibility to modularize the network to allow the inter-relation between phenomena and data sets. This work is the first step toward an information system interface being developed at Sussex, the Whole Information System Expert (WISE). Phenomena in the data are automatically identified and provided to the user in the form of a data occurrence morphology, the Whole Information System Data Occurrence Morphology (WISDOM), along with relationships to other parameters and phenomena.

Gough, M. P.↗
NASA NTRSDate not supplied

Progressive Damage Failure Analysis of a Multi-Stringer Post-Buckled Panel

Validation of a progressive damage finite element analysis model using the CompDam material model was performed on a large multi-stringer panel subjected to compressive loading. The panel had a Teflon insert embedded between the skin panel and stiffener to cause an ultimate failure mode of stiffener separation. The compressive loading of the panel caused the skin between the stiffeners to locally buckle before any damage began to occur. The post-buckled behavior of the panel was the driving mechanism to the onset of damage and the damage growth that led to skin-stiffener separation. An integrated global-local modeling approach was used to validate several aspects the overall behavior of the panel from start to failure. The global region captured the pre-buckled stiffness of the test panel within 10% and the buckling load of the skin panel at the critical location within 2%. The skin’s five half-wave buckled mode shape was accurately predicted by the model. The integrated local model captured the load corresponding to the onset of damage within 5% of the average test data. Comparisons are made for key aspects of the damage morphology, such as a growth pattern that included a significant matrix split in the first ply of the skin and a migration of the delamination from the skin-stiffener interface to the skin’sply1-ply2 interface. The ultimate failure mode was shown to be an unstable growth of delamination damage under the stiffeners which led to a peak load of the analysis that was approximately 5% above the average peak load of the testing. The validated global-local modeling approach used on the multi-stringer post-buckled panel with a Teflon insert used a methodology and lessons learned using smaller specimens applied to a subcomponent that captured several aspects of a modern aircraft design.

Jason Action↗
DOE OSTI2023

Understanding Interfacial Block Copolymer Structure and Dynamics

Here, block copolymer (BCP) structure and dynamics were studied using small-angle neutron scattering (SANS), neutron spin echo (NSE) spectroscopy, and molecular dynamics (MD) simulations to obtain a fundamental understanding of the impact of an interfacial block on chain dynamics. A glassy block acted as the interface, and the dynamics of a rubbery block was studied. The rubbery block was protonated near the interface in one sample and near the chain end in another sample to observe the interfacial effect on the rubbery polymer. Analysis of the structure and dynamics revealed that the interfacial rubbery block was confined in layered morphologies and exhibited much slower dynamics than the chain-end rubbery block that was dispersed in the rubbery matrix. The interfacial rubbery block showed weaker dynamical relaxation than that at the chain end, and it also had critically important length scale dependence. Dynamical slowing was only observed at length scales significantly larger than the characteristic segmental length, and the disparity between interfacial and chain-end dynamics increased with increasing length.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Development of Polycrystalline Photoelectrodes with Optimum Compositions and Morphologies for Solar Fuel Production via Electrochemical Synthesis (Final Technical Report)

Photoelectrochemical cells (PECs) can utilize solar energy for water splitting to produce H 2 as a clean fuel. The most critical components of a water-splitting PEC are semiconductor electrodes (photoelectrodes) that absorb solar energy to generate photoexcited charge carriers and transport them to the electrode/electrolyte interface for water reduction and oxidation reactions. While efficient PEC hydrogen production has been successfully demonstrated on the laboratory scale, the commercial viability of PECs depends critically on the cost of H 2 produced by the PECs, which is affected by the cost of PEC construction. Therefore, identifying promising inexpensive semiconductor electrodes is important. The goal of this project was to bring an advancement in the synthesis and understanding of inexpensive polycrystalline photoelectrodes based on oxides. Oxide-based semiconductors are inexpensive, easy to fabricate, and relatively more stable in aqueous media compared to other types of semiconductors. This project developed new electrodeposition methods to produce a variety of oxide-based semiconductor electrodes with precisely controlled compositions and morphologies to enhance photon absorption, electron-hole separation, and the use of electrons and holes for desired chemical reactions. The resulting high-quality photoelectrodes were investigated to establish the structure-composition-morphology-photoelectrochemical property relationships to identify the advantages and limitations of each oxide semiconductor system.

14 SOLAR ENERGY↗
DOE OSTI2021

Particle emission with identification from an atmospheric pressure plasma liquid interface

A conspicuous emission phenomenon of luminous particles from the liquid anode surface of an atmospheric pressure DC glow discharge is reported. The emission has been shown to occur when the plasma forms a pattern on the surface of the liquid electrolyte. Here, the spatial-temporal evolutions of the trajectories of emitted particles were studied using a high-speed imaging system. Particles were sampled in flight using a witness plate for analysis. Critical particle characteristics were examined using electron microscope technologies. The morphology of the resulting splats and compositions suggest that they are molten droplets with a great deal of structure, including evidence of nanoprecipitation. A theoretical model was employed to estimate the particle size from the measured splats, which provides a radius range within a hundred micrometers. This experiment leads to the postulation of a mechanism in which particle emission at the plasma liquid interface is likely driven by the Taylor cone effect.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Optimizing $\mathrm{ACRT}$ to reduce inclusion formation during the $\mathrm{VGF}$ growth of cadmium zinc telluride: I. Computational approach

Theoretical computations reveal insight into parameters that govern the accelerated crucible rotation technique (ACRT) applied to the gradient freeze (VGF) growth of cadmium zinc telluride (CZT). A metric based on the classic Mullins and Sekerka instability criterion is put forth that provides a quantitative means of assessing the impact of different ACRT rotation schedules on morphological stability and inclusion formation during CZT growth. Here this metric is employed in a 2-k factorial design of experiments that identifies the maximum rotation rate as the most important ACRT parameter, followed by the acceleration period and the rest period. Subsequent optimization of rotation schedule is performed for a specific VGF growth system, and mechanistic explanations are provided for the preferred ACRT schedule, which improves interface stability via slower rotation rates and longer acceleration periods than would be applied using classical ACRT schedules.

36 MATERIALS SCIENCE↗
DOE OSTI2018

TiN diffusion barrier for stable W/SiC(0001) interfaces in inert ambient at high temperature

The effect of high-temperature annealing on tungsten (W) films deposited on silicon carbide (SiC) with and without a titanium nitride (TiN) diffusion barrier was examined as a function of time. Evolutions in phase composition, surface morphology, and roughness from annealing at 1273 K were investigated for up to 24 h. Without a TiN diffusion barrier, solid state reactions between the W film and SiC substrate led to the formation of W 5 Si 3 , W 2 C, and WC species and the rise of an inhomogeneous surface structure that was initially web-like and later discontinuous. Severe roughening on the order of the initial film thickness was observed. Incorporation of a 100 nm TiN diffusion barrier suppressed the formation of W 5 Si 3 and W 2 C and only trace WC could be detected due to species diffusion through TiN grain boundaries. Changes in the surface structure and roughness were minimal. Our results warrant consideration of TiN as an effective diffusion barrier for W on SiC systems where structural stability at high temperatures is highly desired.

36 MATERIALS SCIENCE↗
NASA NTRS1988

The surface morphology of crystals melting under solutions of different densities

Examples of solids melting beneath liquids are described for cases where the bulk liquid volume is stabilized against convection by a positive vertical temperature gradient, either with, or without local density inversion at the melting interface. The examples include ice melting beneath brine or methanol solutions and tin or lead melting under molten Sn-20 wt pct Pb or Pb-20 wt pct Sn, respectively. Without density inversion the melting is slow, purely diffusion controlled and the interfaces are smooth; with convection assisted melting the rate increases by some two orders of magnitude and the interfaces develop a rough profile - in the case of ice both irregular and quasi-steady state features are observed. The observations are discussed in terms of prevailing temperature and concentration gradients.

Fang, Dacheng↗
DOE OSTI2025

Valuation of Anode Materials for High-Performance Lithium Batteries: From Graphite to Lithium Metal and Beyond

Lithium-ion batteries have revolutionized energy storage, yet advanced technologies such as electric vehicles and eVTOLs demand even higher performance and safety. Anodes, the negative electrodes, are crucial in enhancing batteries’ safety, lifespan, and fast-charging capabilities. This review paper comprehensively evaluates the progression of anode materials from traditional graphite to advanced anodes like lithium metal. Graphite anodes, with a capacity of 372 mAh g −1 , enabled the first commercial lithium-ion batteries, but future applications require higher energy densities and fast-charging capabilities. Emerging anode materials, including alloying, and conversion types, as well as lithium metal, offer significantly higher capacities, with lithium metal offering a theoretical capacity of 3 860 mAh g −1 . However, these advanced anodes face challenges such as volume expansion, high surface reactivity, sluggish Li+ kinetics, and unstable lithium deposition morphologies. Here, this review critically examines the electrochemical performance, interfacial properties, mechanical attributes, and stability issues of various anode materials. It further discusses solid electrolyte interphase (SEI) formation, strategies for enhancing interface stability, and the requirements of anodes for solid-state batteries. Additionally, the review explores potential solutions for limitations with each anode type, highlights innovative anode-free architectures, and evaluates the current and future trends of battery anode industries. Ultimately, this paper aims to guide the development of high-performance anode materials, paving the way for the next generation of efficient, reliable lithium batteries.

Alloying anodes↗
DOE OSTI2018

Ensuring combination of strength, ductility and toughness in medium-manganese steel through optimization of nano-scale metastable austenite

Highlights: • Medium-Mn steel was innovatively designed for medium to heavy steel plates. • Three intercritical annealing processes were adopted to ensure TRIP effect. • Austenite-martensite submicro-laminate structure was obtained after annealing. • The reversed austenite with different stability led to improved ductility. • TRIP effect induced by metastable austenite contributed excellent impact properties. - Abstract: Medium-Mn steel was innovatively designed in terms of alloying elements for medium to heavy steel plates to obtain combination of high strength, good ductility, and excellent low temperature toughness. Martensite was the dominant microstructure in the directly quenched steel plate because of high hardenability obtained by the addition of 5.6 wt% Mn. Three intercritical annealing processes were adopted to ensure transformation-induced-plasticity (TRIP) effect through optimization of the volume fraction, morphology, and C and Mn-enriched reversed austenite. On annealing, the dislocation density of martensite plate was decreased because of recovery and recrystallization, and metastable austenite film nucleated at the interface. Both thermal and mechanical stability of austenite decreased with increase in annealing temperature. The high yield strength of 840 MPa, good elongation after fracture of 24.3%, and excellent toughness at − 60 °C of 130.3 J was obtained at intermediate annealing temperature of 650 °C, and the volume fraction of reversed austenite at room temperature and − 80 °C was 22% and 17%, respectively. The reversed austenite exhibited different stability with increased tensile strain, leading to improved ductility and delayed necking. Moreover, the crack initiation energy and crack propagation energy were increased via dynamic stress partitioning and relaxation together with the transformation of metastable austenite. Thus, significant degree of TRIP effect induced by moderate stability of austenite played an important role in governing mechanical properties.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2019

Reconfigurable Multicompartment Emulsion Drops Formed by Nematic Liquid Crystals and Immiscible Perfluorocarbon Oils

Liquid crystalline (LC) oils provide the basis of stimuli-responsive LC-in-water emulsions. Although past studies have explored the properties of single-phase LC emulsions, few studies have focused on complex multicompartment emulsions containing co-existing isotropic and LC domains. In this paper, we report a study of multiphase emulsions using LCs and immiscible perfluoroalkanes dispersed in water or glycerol (the latter continuous phase is used to enable characterization). We found that the nematogen 4'-pentyl-4-biphenylcarbonitrile (5CB) anchors homeotropically (perpendicularly) and weakly at liquid perfluorononane (F9) interfaces, consistent with the smectic layering of 5CB molecules. The proposed role of smectic layering is supported by experiments performed with 4-(trans-4-pentylcyclohexyl)benzonitrile, a nematogen that possesses a cyclohexyl group that frustrates the smectic packing and leads to tilted orientations at the F9 interface. By employing perfluorocarbon and hydrocarbon surfactants in combination with multiphase 5CB and F9 emulsion droplets dispersed in a continuous water or glycerol phase, we observe a range of emulsion droplet morphologies to form, including core–shell and Janus structures, with internal organizations that reflect an interplay of interfacial (anchoring energies; F9 and glycerol) and elastic energies within the confines of the geometry of the emulsion droplet. By comparing experimental observations to simulations of the LC–perfluorocarbon droplets based on a Landau-de Gennes model of the free energy, we place bounds on the orientation-dependent interfacial energies that underlie the internal ordering of these complex emulsions. Additionally, by forming core–shells emulsion droplets from 5CB (shell) and perfluoroheptane (cores), we demonstrate how a liquid-to-vapor phase transition in the perfluorocarbon core can be used to actuate the droplet and rapidly thin the nematic shell. Overall, the findingss reported in this paper demonstrate that multiphase LC emulsions formed from mixtures of perfluoroalkanes and LCs provide new opportunities to engineer hierarchical and stimuli-responsive emulsion systems.

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

Crystallization Modes of Poly(3-dodecylthiophene)-Based Block Copolymers Depend on Regioregularity and Morphology

Conjugated block copolymers (BCPs) can self-assemble into highly ordered nanostructures in a melt state. Yet, when cooled below the melting temperature, crystal growth can disrupt the self-assembled structure and produce a poorly ordered fibrillar texture. We determine that crystallization modes of conjugated BCPs based on poly(3-dodecylthiophene) (P3DDT) and poly(2-vinylpyridine) (P2VP) can be tuned through P3DDT regioregularity (RR), as this attribute controls the melting temperature and crystallization rates of P3DDT. When RR is low (7080%), crystallization is observed at temperatures near or below the glass transition of P2VP, so crystal growth is largely confined by the glassy cylindrical or lamellar BCP structure. When RR is high (94%), crystallization occurs at 40 K above the glass transition of P2VP, so there is no longer a restriction of glassy domains. Importantly, crystal growth remains confined by the rubbery P2VP lamellae, but breaks through the rubbery P2VP cylinders. This morphology-dependent behavior is attributed to geometric compatibility of P3DDT crystal growth and the self-assembled symmetry. In a lamellar phase, the P3DDT chain orientations at the P3DDT- block -P2VP interface are compatible with crystal growth, and both the alkyl-stacking and $\pi\pi$ growth directions are unrestricted within a lamellar sheet. In a cylindrical phase, the radial orientation of P3DDT chains at the P3DDT- block -P2VP interface is not compatible with crystal growth, and the hexagonal close-packed symmetry only allows for one direction of unrestricted crystal growth. Significantly, these studies demonstrate that tuning RR of polyalkylthiophenes can open up multiple crystallization modes with the same monomer chemistries and block lengths, thereby decoupling the parameters that govern classical BCP self-assembly and crystal growth.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Adhesively-bonded Metal-CFRTP Bi-materials: Enhanced Crack Growth Resistance via Plasma and Quantified Fracture via Size Effect Method

This work investigated air plasma effect on the Mode I crack growth resistance of adhesively-bonded metal-CFRTP dissimilar joints by using aluminum alloy (AA6061) and short-carbon-fiber-reinforced polyamide 66 (CFRPA66) as an example, and the Double Cantilever Beam (DCB) fracture testing as an evaluation method. The results show that air plasma treatment can significantly improve the fracture resistance of adhesively-bonded AA6061-CFRPA66 dissimilar joints with about 140% enhanced Mode I fracture energy in maximum compared to non-treated ones. The quantified fracture energies from size effect method for both non-treated and plasma-treated cases are geometry-independent, whereas this is not true for modified beam theory causing geometry-dependent results. The foregoing improvement was confirmed from the failure surface morphology of plasma-treated specimens, showing fibers peeling off from CFRPA66 surface due to plasma-enhanced bonding between CFRPA66 and adhesive by the formation of covalent bonds at their interface. This study demonstrated air plasma as an efficient surface modification method to enhance the fracture resistance of adhesively-bonded metal-CFRTP dissimilar joints, and size effect method as a characterization method to properly quantify their fracture properties. These aspects are valuable in the area of multi-materials joining.

Plasma, Adhesive Bonding, Slow Crack Growth, fract↗