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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 631 records · Page 35
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Design, Fabrication, and Screening of Environmental‐Thermal Barrier Coatings Prepared by Ultrafast High‐Temperature Sintering

Abstract The demand for more efficient gas turbines relies heavily on the development of new environmental‐thermal barrier coatings (ETBCs). However, there is still uncertainty about which alloys and composites will be used for the next generation of turbine blades, as well as the most promising coating materials. Herein, an ETBCs development strategy is presented by integrating the coating design, synthesis, and screening using an ultrafast high temperature sintering (UHS) technique to accelerate coating improvements. The initial basis for composition selection is their thermal expansion mismatch with the substrate alloys; for which a temperature‐dependent coefficient of thermal expansion database is created. By combining tape casting method with the UHS technique a high‐throughput synthesis of single and multi‐layer coatings are realized with different compositions, layer stacking sequences, and layer thicknesses. To evaluate the coatings, thermal cycling tests from room temperature to 1300 °C are conducted. The approach enabled coatings on objects with complex geometries, multi‐layer ETBCs, and porosity tailoring by using staged UHS that runs with different temperatures and durations. The fast iteration strategy is more cost‐effective for the screening of ETBCs compared to conventional methods and greater throughput which can be further extended for rapid optimization of other materials systems.

Xie, Hua↗
DOE OSTI2024

Breaking Barriers in Chalcogenide Perovskite Synthesis: A Generalized Framework for Fabrication of BaMS 3 (M═Ti, Zr, Hf) Materials

Abstract Chalcogenide perovskites have garnered increasing attention as stable, non‐toxic alternatives to lead halide perovskites. However, their conventional synthesis at high temperatures (>1000 °C) has hindered widespread adoption. Recent studies have developed low‐to‐moderate temperature synthesis methods (<600 °C) using reactive precursors, yet a comprehensive understanding of the pivotal factors affecting reproducibility and repeatability remains elusive. This study delineates the critical factors in the low‐temperature synthesis of BaMS 3 (M═Zr, Hf, Ti) compounds and presents a generalized framework. Innovative approaches are developed for synthesizing BaMS 3 compounds using this framework involving organometallics for solution deposition. The molecular precursor routes, employing metal acetylacetonates to generate soluble metal–sulfur bonded complexes and metal–organic compounds to produce soluble metal‐thiolate, metal‐isothiocyanate, and metal‐trithiocarbonate species, are demonstrated to yield carbon‐free BaMS 3 . These methods have achieved the most contiguous films of BaZrS 3 and BaHfS 3 using solution deposition to date. Furthermore, a hybrid solution processing method involving stacking sputter‐deposited Zr and solution‐deposited BaS layers is employed to synthesize a contiguous, oxygen‐free BaZrS 3 film. The diffuse reflectance measurements indicate a direct bandgap of ≈ 1.85 eV for the BaZrS 3 films and ≈ 2.1 eV for the BaHfS 3 film under investigation.

25 ENERGY STORAGE↗
DOE OSTI2022

Fabrication of Arrays of Topological Solitons in Patterned Chiral Liquid Crystals for Real-Time Observation of Morphogenesis

Topological solitons have knotted continuous field configurations embedded in a uniform background, and occur in cosmology, biology, and electromagnetism. However, real-time observation of their morphogenesis and dynamics is still challenging because their size and timescale are enormously large or tiny. Liquid crystal (LC) structures are promising candidates for a model-system to study the morphogenesis of topological solitons, enabling direct visualization due to the proper size and timescale. We report a new way is found to rationalize the real-time observation of the generation and transformation of topological solitons using cholesteric LCs confined in patterned substrates. The experimental demonstration shows the topologically protected structures arise via the transformation of topological defects. Numerical modeling based on minimization of free energy closely reconstructs the experimental findings. The fundamental insights obtained from the direct observations pose new theoretical challenges in understanding the morphogenesis of different types of topological solitons within a broad range of scales.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fluorine-Free Superhydrophobic Coatings: Rapid Fabrication and Highly Efficient Oil/Water Separation

In this work, a rapid method is demonstrated to obtain a fluorine-free superhydrophobic/superoleophilic coating by a simple two-step method: dip-coating and oven curing. The chemical structure of the coating is based on the crosslinking reaction of an alkyl methacrylate, a dimethacrylate (crosslinker) and a silane (adhesive), using AIBN as initiator, toluene as solvent, and silica nanoparticles to enhance surface roughness. Chemorheology results show that the coating is fully cured even in 20 min at 100 °C, exhibiting a water contact angle (CA) of 162 ± 2°, sliding angle (SA) of 4 ± 1°, nanometrical structures throughout the surface, and excellent adhesion properties for the mesh screen. The coating exhibits outstanding oil/water separation efficiency (96–99%) for seven different types of oil (gasoline, diesel, petroleum ether, hexane, toluene, chloroform, and dichloromethane), and in addition presents high recyclability. Based on nonisothermal TGA, the activation energy of degradation, calculated using the Kissinger and Ozawa models, is 113.5 and 114 kJ mol -1 , respectively. Finally, the coating is thermally aged at 150 °C: the CA exhibits a smooth decrease up to 129 ± 1° at 120 min, and FTIR analysis shows structural changes possibly related to the generation of thermal oxidation products.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Fabrication of diatomite‐based microencapsulated flame retardant and its improved fire safety of unsaturated polyester resin

To achive excellent fire resistance, new microcapsule flame retardants (DMCAD and DMPPD) were prepared using 9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide combined with melamine cyanurate or melamine polyphosphate as the shell material and diatomite as the core material. The successful assembly of DMCAD and DMPPD was detailed characterized by Fourier transform infrared (FT‐IR) spectra, X‐ray photoelectron spectroscopy (XPS), and scanning electron microscopy (SEM). Meanwhile, the flame retardancy and thermal stability of the unsaturated polyester resin (UPR)/DMCAD and UPR/DMPPD composites were also studied. The addition of DMCAD and DMPPD effectively improves the flame retardance properties of UPR, and the effect of DMPPD was better. The limiting oxygen index (LOI) of UPR/DMPPD‐3 increased by 11.6% when compared with that of UPR, and the sample achieved V‐0 rating. Moreover, the peak heat release rate (pHRR) and the total heat release (THR) rate of UPR/DMPPD‐3 were reduced by 67% and 26%, respectively. Under nitrogen condition and air condition, UPR/DMPPD showed better thermal stability and char‐forming ability from the thermogravimetric (TG) results. Residual char of the UPR composites was systematically analyzed with SEM and XPS. Finally, the flame retardant mechanism of DMPPD was proposed.

Chen, Gang↗
DOE OSTI2021

The effect of WAAM process parameters on process conditions and production metrics in the fabrication of single-pass multi-layer wall artifacts

The present work seeks to understand the impact of varying dwell time and input deposition power on part quality and overall production time for wire arc additive manufacturing. In this work, multi-layer wall geometries were deposited under different input power conditions without affecting the material deposition rate by setting traverse speed and wire feed speed constant and varying the contact tip-to-workpiece distance and the deposition power settings. Current and voltage data and optical imaging of the deposition zone were captured in situ, and wall geometry was characterized using laser scanning, so to understand the applicability of these methods for determining part height in situ. Furthermore, the present results demonstrate that alternating dwell times with lower input deposition power can result in significantly reduced overall production time and minimal material underbuilding, despite increased deposition geometry width. Furthermore, it is shown that while elimination of process dwell results in severe underbuilding of the deposition, it also yields the highest production rate for a hybrid-finished (e.g., deposited, machined) wall in terms of mm in build direction per minute and the highest buy-to-fly ratio.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Fatigue crack growth resistance of a mesoscale composite microstructure Haynes 282 fabricated via electron beam melting additive manufacturing

Materials synthesis via additive manufacturing gives unprecedented control over the solidified microstructure. While a number of studies have demonstrated the ability to produce spatially varying microstructures, little work exists to understand the behavior of such “composite” materials. In this work, we utilized electron beam melting to process Ni-based superalloy Haynes 282 and produce compact tension samples with a spatially varying mesoscale structure. Fatigue crack growth experiments reveal that the crack growth rate is dependent on the degree of microstructural heterogeneity. This work demonstrates that the crack growth resistance can be tailored within a component using electron beam melting additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fabrication and Radio Frequency Properties of 3-GHz SRF Cavities Coated with MgB 2

Magnesium diboride (MgB 2 ) is considered a potential material for superconducting radio frequency cavities. MgB 2 coated Cu cavity will allow for a higher operational temperature than a bulk Nb cavity because of the higher transition temperature of MgB 2 and the high thermal conductivity of Cu. Using the hybrid physical chemical vapor deposition technique, MgB 2 coatings were successfully achieved on the inner wall of 3-GHz Cu cavities. The surface and superconducting properties of the coatings were characterized using small samples on Cu plugs mounted at different locations of mock cavities. RF measurement of a MgB 2 coated single-cell 3-GHz test cavity was carried out and it showed superconducting transition at 36 K. Here, the quality factor of this test cavity was lower than expected due to poor connectivity and inclusion of Mg-Cu alloy in the MgB 2 coating.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Microstructure and Properties of Inconel 718 Fabricated by Directed Energy Deposition with In-Situ Ultrasonic Impact Peening

Many inherent issues, such as the detrimental residual stress, columnar grains with anisotropy, and weak mechanical properties, have severely impeded the adoption of metal additive manufacturing (AM) techniques including powder bed fusion and directed energy deposition (DED) processes. In this study, a hybrid AM process that consists of layer-wise laser metal deposition (i.e., a DED process) and in-situ ultrasonic impact peening (UIP) was applied to obtain Inconel 718 superalloy workpieces. Also, for further property enhancement, a post-heat treatment was applied to the deposited material obtained by the hybrid AM process. Scanning electron microscopy and transmission electron microscope were used to investigate the microstructure morphology and reveal the underlying strengthening mechanism. Electron backscatter diffraction was employed to quantitatively study the microstructure resulted from the hybrid AM process and the post-heat treatment. The profile of residual stress along the depth direction was obtained through X-ray diffraction. The results demonstrate that this hybrid AM process is capable of producing high-quality metal parts with significantly refined microstructure, and beneficial compressive residual stress along the depth into surface. Severe plastic strains are introduced by UIP, and the resulted mechanical twinning and dynamic recrystallization play an important role in refining microstructure. The material microstructure is further refined down to 100 µm, and the texture anisotropy is significantly diminished after solution treatment at 980 °C for 1 hour. Under the as-built condition, in-situ ultrasonic peening alters the residual stress component from a tensile state to an overall compressive state with a maximum value of − 190 MPa within the range of measurement depth.

36 MATERIALS SCIENCE↗