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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 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Real-time process monitoring for direct ink write additive manufacturing

Direct ink write (DIW) printing of reactive resins presents a unique challenge due to the time-dependent nature of the rheological and chemical properties of the ink. As a result, careful print optimization or process control is important to obtain consistent, high quality prints. The present invention uses a flow-through characterization cell for in situ chemical monitoring of a resin ink during DIW printing. Additionally, in-line extrusion force monitoring can be combined with off-line post inspection using machine vision. By combining in-line spectroscopy and force monitoring, it is possible to follow reaction kinetics (for example, curing of a reactive resin) and viscosity changes during printing, which can be used for a closed-loop process control. Additionally, the capability of machine vision to automatically identify and quantify print artifacts can be incorporated on the printing line to enable real-time, AI-assisted quality control of the printed products. Together, these techniques can form the building blocks of an optimized process control strategy when complex reactive ink must be used to produce printed hardware.

Cook, Adam W.↗
DOE OSTI2025

Mesoscale Modeling of Dislocation Cell Structure Evolution and Radiation-Induced Segregation in Additively Manufactured Austenitic Stainless Steel

Structural alloys under irradiation develop radiation-induced segregation (RIS) at point defect sinks, which lead to undesired changes in the alloy's properties. Additively manufactured austenitic stainless steels are expected to yield a distinct response to irradiation damage owing to their unique as-printed dislocation cell structure. In this talk, we present the development of a mesoscale model for dislocation cell structure evolution coupled with RIS using the MOOSE framework. The evolution of network dislocations within spatially distinct cells and cell walls are modeled using climb-mediated edge annihilation and generation processes. Starting with initial microstructures of as-printed non-equilibrium segregations at dislocation cell walls, our 2D and 3D simulations explore the effects of irradiation temperature, dose rate, dislocation sink bias, and specimen thickness on microstructure evolution. The results will be compared against experimental characterizations of in-situ and ex-situ ion-irradiated samples, and the implications of evolving cell structure on irradiation damage response will be discussed.

additive manufacturing↗
NASA NTRS2023

Solidification Furnace for In Situ Observation of Bulk Transparent Systems and Image Analysis Methods

This paper aims to describe the experimental framework of the Directional Solidification Insert (DSI), installed onboard the International Space Station (ISS), dedicated to the in situ and real-time characterization of the dynamic selection of the solid-liquid interface morphology in bulk samples of transparent materials under diffusive growth conditions. The in situ observation of the solid-liquid interface is an invaluable tool for gaining knowledge on the time-evolution of the interface pattern because the initial morphological instability evolves nonlinearly and undergoes a reorganization process. The result of each experiment, characterized by the sample concentration, a thermal gradient and a pulling rate, is a large number of images. Interpretation of these images necessitates a robust identification of each cell/dendrite position and size during the entire solidification. Several image analysis methods have been developed to achieve this goal reliably despite varying contrast and noise levels, and are described in details. Typical solidification experiments are presented and the dynamics of the pattern formation are analyzed to illustrate the application of the image analysis methods.

Programming languages↗
NASA NTRS2008

In Situ Irradiation and Measurement of Triple Junction Solar Cells at Low Intensity, Low Temperature (LILT) Conditions

The performance of triple junction InGaP/(In)GaAs/Ge space solar cells was studied following high energy electron irradiation at low temperature. Cell characterization was carried out in situ at the irradiation temperature while using low intensity illumination, and, as such, these conditions reflect those found for deep space, solar powered missions that are far from the sun. Cell characterization consisted of I-V measurements and quantum efficiency measurements. The low temperature irradiations caused substantial degradation that differs in some ways from that seen after room temperature irradiations. The short circuit current degrades more at low temperature while the open circuit voltage degrades more at room temperature. A room temperature anneal after the low temperature irradiation produced a substantial recovery in the degradation. Following irradiation at both temperatures and an extended room temperature anneal, quantum efficiency measurement suggests that the bulk of the remaining damage is in the (In)GaAs sub-cell

Quantum Efficiency↗
DOE OSTI2025

Structure evolution and tin redistribution during oxidation of Zircaloy-4 at 500°C

Zirconium (Zr) alloys are widely used as fuel cladding in nuclear power reactors due to their thermal stability, mechanical durability, corrosion resistance, and low neutron absorption cross-section. However, their performance is challenged by oxidation in reactor environments, making the study of Zr alloy corrosion behavior crucial for ensuring the safety, longevity, and economic viability of nuclear power systems. While the oxidation behavior of Zr-based cladding materials has been extensively studied since the 1950s, a mechanistic understanding into the relationship between structure evolution, solute element redistribution, and properties remains elusive. Valuable insights may be obtained through advanced experimental methods, such as in-situ and high resolution microscopy techniques. Here, in this study, the oxidation behavior of Zircaloy-4 at 500 °C in O 2 is characterized using a multimodal advanced characterization approach. Using in-situ X-ray diffraction, the phase evolution from metastable to stable oxides is tracked in real time. Complementary high-resolution techniques, including electron microscopy and atom probe tomography, reveal nanoscale insights into the microstructural changes and solute redistribution across the oxide/metal interface. Nanohardness mapping across the oxide/metal interface highlights localized mechanical property variations that may be linked to changes in microstructure and crystal structure within the oxide layer. These findings offer valuable insights into the microstructure and property evolution of Zircaloy-4 during oxidation, contributing to a better understanding of microstructural changes in Zr-based alloys under oxidative environments.

APT↗
DOE OSTI2024

Trends in electrocatalytic activity and stability of transition-metal nitrides

Transition metal nitrides (TMNs) are a class of electrocatalyst support materials similar to transition metal carbides (TMCs) with the advantage of avoiding the issues arising from graphitic carbon surface deposits during synthesis. Inspired by previous studies suggesting that TMCs could be used to reduce Pt loading for the hydrogen evolution reaction (HER), this work explored the feasibility of TMN-supported Pt and Au as HER electrocatalysts. Here this study established a volcano-like trend between electrochemical HER activity and hydrogen-binding energy (HBE) calculated from density functional theory. The Pt/TiN and Au/TiN materials were used to extend knowledge from well-characterized thin films to powder catalysts. In situ X-ray absorption spectroscopy (XAS) measurements provided additional characterization of the Pt/TiN and Au/TiN catalysts under HER conditions. Trends in the electrochemical stability of TMNs were also investigated over a wide range of potentials and pH values, which can be used to guide future studies for TMN-supported electrocatalysts.

58 GEOSCIENCES↗
NASA NTRS2015

Earth-Facing Antenna Characterization in a Complex Ground Plane/Multipath Rich Environment

The Space Communications and Navigation (SCAN) Testbed was a Software Defined Radio (SDR)-based payload launched to the International Space Station (ISS) in July of 2012. The purpose of the SCAN Testbed payload was to investigate the applicability of SDRs to NASA space missions in an operational space environment, which means that a proper model for system performance in said operational space environment is a necessary condition. The SCAN Testbed has line-of-sight connections to various ground stations with its S-Band Earth-facing Near-Earth Network Low Gain Antenna (NEN-LGA). Any previous efforts to characterize the NEN-LGA proved difficult, therefore, the NASA Glenn Research Center built its own S-Band ground station, which became operational in 2015, and has been successfully used to characterize the NEN-LGAs in-situ pattern measurements. This methodology allows for a more realistic characterization of the antenna performance, where the pattern oscillation induced by the complex ISS ground plane, as well as shadowing effects due to ISS structural blockage are included into the final performance model. This paper describes the challenges of characterizing an antenna pattern in this environment. It will also discuss the data processing, present the final antenna pattern measurements and derived model, as well as discuss various lessons learned.

software defined radio↗
DOE OSTI2021

A Non-Invasive Approach for Elucidating the Spatial Distribution of In-Situ Stress in Deep Subsurface Geologic Formations Considered for CO 2 Storage (Task 3 Report Laboratory Characterization of Stress Dependent Wavespeed)

This report presents a summary of Task 3 (Laboratory Experimental Characterization of Stress Dependent Wavespeed in Rocks and Application for In-Situ Stress Estimation) of the project titled “A Non-Invasive Approach for Elucidating the Spatial Distribution of In-Situ Stress in Deep Subsurface Geologic Formations Considered for CO 2 Storage”. The main objective of this component of the project was to employ non-destructive techniques to determine how compressional (P)-wave and shear (S)-wave propagation velocities are related to triaxial-stress conditions in laboratory test samples of targeted reservoir rocks. The overarching principle is that such laboratory measurements can provide a basis whereby field measurements of wave-propagation velocities in rocks can be used to ascertain the stress state that would be expected to generate the observed wave-propagation behavior.

58 GEOSCIENCES↗
DOE OSTI2023

Research tool development for catalyst, catalyst/ionomer, and ionomer characterization above 100°C (CRADA Final Report)

There is a need to develop experimental tools that address the catalyst and ionomer interface under high-temperature proton-exchange-membrane (HT-PEM) operating conditions (dry, >100°C). These conditions mean traditional water-based measurements for membrane and ionomer properties are insufficient; new ex-situ techniques are required to address and characterize expected novel materials. In this project we develop a microelectrode cell for high temperature kinetics and gas transport properties and ex-situ ionomer thin-film characterization under these conditions. We use baseline Nafion and phosphoric-acid imbibed membranes as prototype materials for measuring the membrane/acid/ionomer systems with Pt microelectrodes and demonstrate feasibility of the tools.

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

High‐Resolution Electron Tomography of Ultrathin Boerdijk–Coxeter–Bernal Nanowire Enabled by Superthin Metal Surface Coating

Abstract The rapid advancement of transmission electron microscopy has resulted in revolutions in a variety of fields, including physics, chemistry, and materials science. With single‐atom resolution, 3D information of each atom in nanoparticles is revealed, while 4D electron tomography is shown to capture the atomic structural kinetics in metal nanoparticles after phase transformation. Quantitative measurements of physical and chemical properties such as chemical coordination, defects, dislocation, and local strain have been made. However, due to the incompatibility of high dose rate with other ultrathin morphologies, such as nanowires, atomic electron tomography has been primarily limited to quasi‐spherical nanoparticles. Herein, the 3D atomic structure of a complex core–shell nanowire composed of an ultrathin Boerdijk–Coxeter–Bernal (BCB) core nanowire and a noble metal thin layer shell deposited on the BCB nanowire surface is discovered. Furthermore, it is demonstrated that a new superthin noble metal layer deposition on an ultrathin BCB nanowire could mitigate electron beam damage using an in situ transmission electron microscope and atomic resolution electron tomography. The colloidal coating method developed for electron tomography can be broadly applied to protect the ultrathin nanomaterials from electron beam damage, benefiting both the advanced material characterizations and enabling fundamental in situ mechanistic studies.

Song, Xiaohui↗
DOE OSTI2021

Anisotropy evolution of elastomeric foams during uniaxial compression measured via in-situ X-ray computed tomography

We have characterized the three-dimensional evolution of microstructural anisotropy of a family of elastomeric foams during uniaxial compression via in-situ X-ray computed tomography. Flexible polyurethane foam specimens with densities of 136, 160 and 240 kg/m 3 were compressed in uniaxial stress tests both parallel and perpendicular to the foam rise direction, to engineering strains exceeding 70%. The uncompressed microstructures show slightly elongated ellipsoidal pores, with elongation aligned parallel to the foam rise direction. The evolution of this microstructural anisotropy during deformation is quantified based on the autocorrelation of the image intensity, and verified via the mean intercept length as well as the shape of individual pores. Trends are consistent across all three methods. In the rise direction, the material remains transversely anisotropic throughout compression. Anisotropy initially decreases with compression, reaches a minimum, then increases up to large strains, followed by a small decrease in anisotropy at the largest strains as pores collapse. Compression perpendicular to the foam rise direction induces secondary anisotropy with respect to the compression axis, in addition to primary anisotropy associated with the foam rise direction. In contrast to compression in the rise direction, primary anisotropy initially increases with compression, and shows a slight decrease at large strains. These surprising non-monotonic trends and qualitative differences in rise and transverse loading are explained based on the compression of initially ellipsoidal pores. Microstructural anisotropy trends reflect macroscopic stress-strain and lateral strain response. These findings provide novel quantitative connections between three-dimensional microstructure and anisotropy in moderate density polymer foams up to large deformation, with important implications for understanding complex three-dimensional states of deformation.

36 MATERIALS SCIENCE↗
NASA NTRS2004

Dielectric Constant Measurements on Lunar Soils and Terrestrial Minerals

The return to the Moon has ignited the need to characterize the lunar regolith using in situ methods. An examination of the lunar regolith samples collected by the Apollo astronauts indicates that only a few minerals (silicates and oxides) need be considered for in situ resource utilization (ISRU). This simplifies the measurement requirements and allows a detailed analysis using simple methods. Characterizing the physical properties of the rocks and soils is difficult because of many complex parameters such as soil temperature, mineral type, grain size, porosity, and soil conductivity. In this presentation, we will show that the dielectric constant measurement can provide simple detection for oxides such as TiO2, FeO, and water. Their presence is manifest by an unusually large imaginary permittivity.

Anderson, R. C.↗
NASA NTRS2015

Earth-Facing Antenna Characterization in Complex Ground Plane/Multipath Rich Environment

The Space Communications and Navigation (SCAN) Testbed was a Software Defined Radio (SDR)-based payload launched to the International Space Station (ISS) in July of 2012. The purpose of the SCAN Testbed payload was to investigate the applicability of SDRs to NASA space missions in an operational environment, which means that a proper model for system performance in said operational space environment is a necessary condition. The SCAN Testbed has line-of-sight connections to various ground stations with its S-Band Earth-facing Near-Earth-Network Low Gain Antenna (NEN-LGA). Any previous efforts to characterize the NEN-LGA proved difficult, therefore, the NASA Glenn Research Center built its own S-Band ground station, which became operational in 2015, and has been used successfully to characterize the NEN-LGA's in-situ pattern measurements. This methodology allows for a more realistic characterization of the antenna performance, where the pattern oscillation induced by the complex ISS ground plane, as well as shadowing effects due to ISS structural blockage are included into the final performance model. This paper describes the challenges of characterizing an antenna pattern in this environment. It will also discuss the data processing, present the final antenna pattern measurements and derived model, as well as discuss various lessons learned

ground station↗
DOE OSTI2020

Detecting keyhole porosity and monitoring process signatures in additive manufacturing: an in situ pyrometry and ex situ X-ray radiography correlation

Creation of pores and defects during laser powder bed fusion (LPBF) can lead to poor mechanical properties and thus must be minimized. Post-build inspection is required to ensure the printed parts contain acceptably low defect concentrations. These inspections are time consuming and costly, especially for large or complex parts. As a potential solution, in situ process monitoring can be used to detect the creation of defects, characterize local material behavior and predict expected component properties. However, the precise relationship between pore creation and in situ process monitoring still needs to be understood. In this work, high-speed infrared diode-based pyrometry and high-speed optical imaging signals were used to monitor LPBF printing of 446 stainless steel 316 L single tracks with varying laser power and velocity. Results indicate an increase in pyrometer signal and melt pool dimensions with increasing laser power and decreasing velocity in agreement with previous work. In addition, careful analysis of pyrometer signal reveals a distinct signature of the conduction-to-keyhole mode transition which was confirmed by metallography. Critically, pore defect initiation as characterized by ex situ X-ray radiography was correlated with in situ thermal monitoring signals to derive the probability of defect creation. Our results show that, in principle, a probabilistic prediction of pore formation can be achieved based on in situ high-speed pyrometry monitoring of the LPBF melt pool.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Charpy Impact Characterization of Surveillance Specimens Harvested from Palisades High Fluence A-60 Capsule

Located on the shores of Lake Michigan, the Palisades Nuclear Generating Station (PNGS) was a nuclear power plant that operated in Covert Township, Michigan. The plant had a single pressurized water reactor that produced electricity for the region. The PNGS was shut down in 2022 after more than four decades of service. The PNGS included in its surveillance program a surveillance capsule, designated A-60, containing specimens of a weld metal with nickel content of about 1.36 wt% and copper content of about 0.25 wt%. The capsule was removed from its surveillance position in early 1995 and has been resident in the spent fuel pool since that time. This capsule was irradiated to a fluence of 1.96×10 20 n/cm 2 (E>1MeV) that is equivalent for more than 150 effective full power years (EFPYs) for the US reactor pressure vessel (RPV) fleet. The material is also of special interest because of its very high nickel content and potential for development of NiMnSi (nickel-manganese-silicon) precipitates. Combination of very high fluence and very high Ni and Cu content makes the material in this capsule of great interest as benchmark for currently developing embrittlement trend curves (ETC) aiming to predict embrittlement at high fluences. Multi-year efforts by the Light Water Reactor Sustainability (LWRS) Program personnel from the Materials Research Pathway (MRP) to harvest this capsule finally succeeded in 2023. As a result, the Westinghouse Electric Company (WEC) through contract with Oak Ridge National Laboratory (ORNL) came to PNGS site, retrieved the A-60 capsule, brought it to WEC Churchill hot cell facility, opened the capsule and sent all surveillance specimens in the capsule to ORNL for future characterization by July 2023. Total of 9 tensile and 48 Charpy specimens were inventoried in the ORNL hot cells. Testing plan has been developed based on available specimens. It includes hardness, tensile, Charpy impact, Mini-CT fracture toughness testing, in-situ thermal annealing, and microstructural characterization, including Atom Probe Tomography (APT). Charpy impact testing has been completed and results are presented in this report. Moreover, negotiations with Pressurized Water Reactors Owners Group (PWROG) and Westinghouse resulted in Westinghouse donating to ORNL a piece of archive weld and base metal such that unirradiated characterization of these materials can be performed as part of this project. Comparison of measured hardening and embrittlement has been performed and data are compared to available large database.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2004

In situ Pulsed Laser Deposition of C-Axis Oriented MgB2 Films and Their Characterization

The recent discovery of an intermetallic superconductor MgB2 has renewed interest in the area of superconductivity not only because of fundamental understanding of superconductivity but also due to its potential applicability in devices such as thermal detectors. Considerable amount of research has been devoted to obtain MgB2 films by an all in situ growth technique. We have grown MgB2 thin films by an all in situ pulsed laser deposition process from pure B and Mg targets. Ultrathin layers of B and Mg were deposited in a multilayer configuration. Hundreds of such Mg-B bilayers with a capping Mg layer on the top were deposited on sapphire substrate. These depositions were done in high vacuum (approx. 10(exp -7) Torr) and at room temperature. After deposition, such a configuration was annealed at high temperature for a short time in a forming gas (4% H2 in Ar). The best films, obtained by this procedure, showed superconducting transition temperature approx. 30 K. These films have been characterized by x-ray diffraction, Rutherford Backscattering Spectrometry, AC susceptibility-, resistivity- (with and without magnetic field) and 1/f noise-measurements. The physical properties of these films will be presented and discussed.

Shinde, Sanjay↗