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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

A unified finite strain gradient-enhanced micropolar continuum approach for modeling quasi-brittle failure of cohesive-frictional materials

Here, in this work, a novel framework for modeling quasi-brittle crack propagation and shear band dominated failure of cohesive-frictional materials like concrete, mortar, rock, tough ceramics, energetic materials, but also granular materials like sands or powders in terms of a unified continuum approach is proposed. It is based on a combination of the gradient-enhanced continuum with gradients of internal variables for representing quasi-brittle cracking, and the micropolar continuum, accounting for the deformation of the microstructure. For developing the gradient-enhanced micropolar framework, the set of balance equations and the kinematic relations are derived, and the constitutive relations are established in a general manner. The framework is formulated in a geometrically exact setting, based on the thermodynamically sound theory of hyperelasto-plasticity, and the numerical implementation by means of the finite element method is discussed. For assessing the approach, realizations of this new approach in terms of constitutive models for particular materials are developed. They are applied to numerical benchmark examples, investigating various loading conditions, and the obtained results are validated by means of a comparison with experiments from the literature.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Indirect additive manufacturing process for producing SiC—B4C—Si composites

A method for indirect additive manufacturing of an object constructed of boron carbide, silicon carbide, and free silicon, comprising: (i) producing a porous preform constructed of boron carbide and silicon carbide by an indirect ceramic additive manufacturing (ICAM) process in which particles of a powder mixture become bonded together with an organic binder, wherein the powder mixture comprises: a) boron carbide particles, and b) silicon carbide particles, wherein at least 80 vol % of the silicon carbide particles are larger than the boron carbide particles; and wherein the boron carbide and silicon carbide particles are each included in an amount of 40-60 wt. % of the powder mixture, provided that the foregoing amounts sum to at least 95 wt. %; (ii) subjecting the porous preform to a temperature of 500-900° C. to volatilize the organic binder; and (iii) infiltrating molten silicon into pores of the porous preform to produce the object.

Cramer, Corson L.↗
DOE OSTI2020

Failure Analysis of Gas Spray Atomization Crucible Materials

An attempted induction melt for gas spray atomization of a Pd alloy at Savannah River National Laboratory experienced a series of faulty thermocouple readings leading to failure of multiple alumina ceramic components and the loss of the metal charge. The spherical powders are used in research and development efforts for hydrogen storage applications. The failure of the thermocouples led to high operating temperatures exceeding the expected operating temperatures. Estimated temperatures of the liquid metal were established by the comparison of the radio frequency power output and multiple temperature readings and determined to have exceeded the functional temperature range of the alumina components. Failure analyses of the event included characterization of the components using visual observation and X-Ray computed tomography of the frozen ingot.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Nanoparticle Impact 2023 Report

Micro-cold spray (MCS) is a thermal spray process that can be used to apply thick ceramic films (1-100 μm) using kinetic energy to consolidate aerosolized powders into a dense film. While this process is compatible with many substrates due to the low working temperatures, the fundamental mechanisms that enable MCS and shape the operational window are poorly understood.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

An epoxy-reinforced ceramic sheet as a durable solid electrolyte for solid state Na-ion batteries

In a conventional Na-ion battery system using liquid electrolyte, there are critical safety issues due to the instability of the liquid electrolyte. Na 3 Zr 2 Si 2 PO 12 (NASICON) solid electrolyte is a material that is sufficient to replace a liquid electrolyte as it has high ionic conductivity and thermal and electrochemical stability. However, as there is a large interfacial resistance in the NASICON solid electrolyte powder, even when used in combination with a polymer electrolyte, the advantageous effects of ceramics are not easily exhibited. In this study, we propose a top-down method of combining a polymer with a ceramic in which an ion transport channel is previously formed. In this method, a NASICON solid electrolyte is partially sintered to form ion transport channels. Then the NASICON solid electrolyte pores are filled with an epoxy polymer to increase the strength of the epoxy-NASICON composite electrolyte. This method demonstrates the possibility of our composite electrolyte being used as a thin and strong film. As a result of our methods, the ionic conductivity and thermal and electrochemical stability of NASICON were maintained, while the physical strength was enhanced by approximately 2 times. In addition, a capacity of 120 mA h g -1 and stability of 20 cycles were confirmed in a half cell with a Na 3 V 2 (PO 4 ) 3 cathode and Na metal. This method proposes a new direction for research regarding composite electrolytes created using an oxide-based solid electrolyte.

25 ENERGY STORAGE↗
DOE OSTI2026

Fabrication of ceramic to metal graded structure for high temperature CSP receiver application using solid state additive manufacturing

The overarching goal of this project is to come up with an innovative joining solution for integration of SiC ceramic to structural materials such as stainless steels (SS)/Ni-base alloys, where intimate metallurgical bonding between SiC ceramic and the structural metallic alloy is demonstrated at the interface. Implementation of a simple, yet robust joining method would help in increasing the application space of SiC in a high-temperature CSP (concentrated solar power) plant, especially in the receiver section. This research goal has been achieved by creating a functionally graded material (FGM) interface between SiC and the selected structural material with the help of powder metallurgy (PM) approach and demonstrate intimate metallurgical bonding between monolithic RB-SiC and 316L stainless steel alloy blanks.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Doping Effects on Multivalence States, Electronic Structure, and Optical Band Gap in LaCrO 3 under Varied Atmospheres: An Integrated Experimental and Density Functional Theory Study

Doping effects on the valence state, electronic structure, and optical band and the effects on electrical conductivity were studied on the doped lanthanum chromite (LaCrO 3 ) system. The specific compositions studied were La 1–x Ca x CrO 3 (LCCx), La 1–x Sr x CrO 3 (LSCx), and La 0.8 Sr 0.2 Cr 1–x Mn x O 3 (LSCMx) (0.1 ≤ x ≤ 0.4). The powders were synthesized using a modified Pechini sol–gel method, and the ceramic samples were densified using a reactive sintering method resulting in densities >96% theoretical. X-ray photoelectron spectroscopy (XPS) was completed to characterize the defect states and cationic valence compensation as a result of divalent (Ca 2+ or Sr 2+ ) and trivalent (Mn 3+ ) substitutions. XPS was completed for samples tested in oxidizing and reducing atmospheres (up to 1500 °C), which provided insights into the oxidation state transitions induced by the Ca 2+ and Sr 2+ dopants. The work notably demonstrated, for the first time, the oxidation/reduction transitions of Cr 4+ to Cr 3+ in Sr 2+ /Mn 3+ co-doped samples under reducing atmospheres. Reflectance UV–vis spectrophotometry optical band gap measurements were also completed for the same materials; a decrease in the optical band gap (2.81–3.12 eV) was shown with increased substitution, suggesting electronic structure modifications in the LaCrO 3 perovskite. Density functional theory calculations validated experimental trends, predicting a diminishing band gap with a rising dopant concentration. The transition in Cr oxidation states was attributed to the presence of divalent/trivalent cations. These findings contribute some insights into methods to tune the LaCrO 3 electrical properties for various low- and high-temperature applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Applying molecular dynamics simulations to the study of micro cold spray of yttria

Micro cold spray (MCS) is a novel manufacturing process with proven success depositing dense, thick films of technical ceramics without the need for elevated processing temperatures or chemical precursors. The process transforms a loose sub-micrometer powder into an adherent film with mechanical properties approaching that of the bulk material through a phenomenon known as room temperature impact consolidation. While this phenomenon has been demonstrated for a wide variety of ceramic materials and film substrates, yttria stands out as a material that is both well-characterized in experiments and of significant interest for industrial applications due to its excellent refractory properties. This dissertation seeks to investigate the fundamental mechanisms that enable room temperature impact consolidation by using molecular dynamics (MD) simulations of yttria particle impacts and characterizing the deformation behavior of the system.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Solution-assisted densification of NaSICON ceramics

A sodium-ion conducting NaSICON ceramic can be densified via the addition of a solvent to a NaSICON powder and subsequent pressing under high pressure and mild heat. Densification to ˜90% relative density can be achieved, providing a path toward low-temperature fabrication of Na-ion conductors.

Bock, Jonathan Anton↗
DOE OSTI2024

Percolating Interfacial Layers Enhance Conductivity in Polymer–Composite Electrolytes

Here, this study investigates the impact of the ceramic particle size on the bulk and interfacial ion transport properties of composite polymer electrolytes. The ceramic particles used for this study are micrometer-sized commercial lithium lanthanum titanate (LLTO) powders and LLTO nanorods (NR) prepared in the laboratory. The polymer matrices are vinylene carbonate (VEC) based single-ion-conducting (SIC) and dual-ion-conducting (DIC) polymer electrolytes. Our results reveal that the addition of LLTO NR results in improved ion transport, while the addition of commercial LLTO is ineffective or even detrimental. We ascribe these results to the formation of an interfacial polymer layer around the LLTO particles with enhanced Li + mobility and estimate the thickness of the interfacial layer to be ∼5 nm. The high surface-to-volume ratio of the LLTO NR leads to the percolation of the interfacial region at a relatively low ceramic loading of 30 wt %. This study highlights the importance of achieving percolation of the interface region (as opposed to the particles themselves) within the composite electrolyte when the interfacial layer is the enhancement mechanism.

Ock, Ji-young↗
DOE OSTI2020

Ultra‐Uniform Nanocrystalline Materials via Two‐Step Sintering

Abstract Nanocrystalline materials with superior properties are of great interest. Much is discussed about obtaining nanograins, but little is known about maintaining grain‐size uniformity that is critical for reliability. An especially intriguing question is whether it is possible to achieve a size distribution narrower than what Hillert theoretically predicted for normal grain growth, a possibility suggested—for growth with a higher growth exponent—by the generalized mean‐field theory of Lifshitz, Slyozov, Wagner (LSW), and Hillert but never realized in practice. Following a rationally designed two‐step sintering route, it has been made possible in bulk materials by taking advantage of the large growth exponent in the intermediate sintering stage to form a uniform microstructure despite residual porosity, and freezing the grain growth thereafter while continuing densification to reach full density. The bulk dense Al 2 O 3 ceramic thus obtained has an average grain size of 34 nm and a size distribution much narrower than Hillert's prediction. Bulk Al 2 O 3 with a grain‐size distribution narrower than the particle‐size distribution of starting powders is also demonstrated, as are highly uniform bulk engineering metals (refractory Mo and W‐Re alloy) and complex functional ceramics (BaTiO 3 ‐based alloys with superior dielectric strength and energy capacity).

Dong, Yanhao↗
DOE OSTI2024

Binder systems and methods for tape casting lithium garnet electrolytes

Slurry compositions, tape casting binder systems and fabrication methods for the fabrication of lithium-garnet electrolyte scaffolds for use in solid state batteries and other devices are provided. Slurry compositions may be optimized mixtures of LLZO powder, a dispersant, a lithium salt, a wetting agent a binder, a plasticizer and at least one solvent. The optimized ceramic slurry compositions may include MgO as a sintering additive to improve density and ionic conductivity of the doped-LLZO sheets and produce a fine-grained microstructure. Sintering protocols for cast slurries of commercially available doped LLZO powders eliminate the requirement of mother-powder coverings or externally applied pressure. An environmentally friendly water-based system using methylcellulose as a binder is also provided producing green tape and final properties comparable to those obtained with organic solvent-based systems.

Jonson, Robert↗
DOE OSTI2024

Production of Readily Compressible Dies for the Enhanced Sintering of Solids (PRESS) Preliminary Investigations

Non-oxide ceramics, which consist of predominantly carbides, borides, and nitrides, are of great interest to modern engineering because of their resistance to extreme conditions. Properties of such materials include high temperature resistance, high hardness, chemical resistance, and high fracture toughness. However, the main method for manufacturing parts of these materials is by machining cylindrical billets to the desired geometry. Not only does this produce waste, but the cost of machining is high since the part materials are of such high hardness. This method is used because these non-oxide ceramics must be sintered to high density using simultaneous heat and pressure within a hot-pressing unit. These units are inherently restricted to cylindrical geometries. A proposed way to expand the capabilities of a hot-press is by using intermediate compressible dies. This method consists of surrounding a ceramic part green body with a material that will shrink at the same rate as the part and survive the hot-pressing conditions. At the end, the compressible die material would be removed leaving a nearly net shaped hot-pressed part. In this study, graphite powder was investigated as the compressible die material with its shrinkage rate being controlled by particle size mixing. Both ceramic materials and graphite were then cast into parts and compressible dies respectively to show the feasibility of the compressible die hot-pressing method.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Exploring laser-material interactions of zirconium carbide under additive manufacturing conditions

Zirconium carbide (ZrC) is an ultra-high temperature ceramic with a melting temperature above 3000°C and a broad range of high temperature applications. Given the high melting and sintering temperatures of pure ZrC, producing near-net shape and fully dense parts remains challenging with conventional techniques. In this study, we investigate the fundamental laser-material interactions of ZrC under laser powder bed fusion (LPBF) additive manufacturing (AM) conditions. Normalized enthalpy, a scaling law term that is used in welding and AM literature for detailing laser-material interactions in metallic alloys, was calculated to determine the predictive capabilities of melt pool features in ZrC. Further, the melt pool quality of laser irradiated ZrC was used to compare LPBF relevant laser parameter combinations of laser power, scan speed, and beam diameter. Laser build parameters that resulted in desirable melt pool morphologies were applied to the fabrication of ZrC coupons using LPBF AM. A custom LPBF system was used to determine hatch spacing and layer height parameters that resulted in a fabricated sample with a density of 85% as measured by Archimedes and a Vicker's microhardness of 20.9 ± 1.9 GPa. This investigation reveals the laser-material interactions of ZrC under AM relevant conditions and is the first step towards LPBF fabrication of ZrC parts.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Effects of particle size, shape and loading rate on the normal compaction of an advanced granular ceramic

Compaction behavior of granular materials is influenced by strain rate, particle size, and shape. In this report, boron carbide powders with different particle sizes under uni-axial strain conditions are studied using quasi-static compression, dynamic Kolsky bar experiments and normal plate impact. A rounded powder is compacted to investigate the effect of particle shape. The normal plate impact technique is an excellent tool in characterization of powder compaction behavior up to strain rates of ~10 5 s -1 . From our experiments, granular boron carbide shows a highly compressible behavior with significant volume compaction. Constitutive responses are obtained for four powders. Particle fracture is identified as key deformation mechanism. Dynamic loading introduces more particle fragmentation than quasi-static loading. Morphological characterization of particle shapes shows that the deformation from powder compaction alters the particle shape distribution, which is also rate-dependent. Particle size, shape and strain rate effects on the normal stress are discussed accordingly.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Development of a Kollidon 90F-PEG300-Glycerin Binder for PZT 95/5 Ceramic Processing

This SAND Report documents the development of organic binder system for PZT 95/5 consisting of Kollidon 90F, PEG300, and glycerin. Binders are a critical component in the manufacture of ceramic components. Low performing binders can result in poor yield and lower performance of ceramic components. This study sought to develop a well performing binder system for PZT 95/5 ceramics to support Ferroelectric Neutron Generator manufacturing. The study explored the glass transition temperature, powder compaction properties, green strengths, and thermal decomposition over a wide composition range. An optimal composition was found consisting of 1.3 wt.% Kollidon 90F, 0.5 wt.% PEG300, and 0.2 wt.% glycerin, and incorporating humidity conditioning . The results showed that the optimized binder exhibited improved compaction performance and enhanced green strength compared to a baseline binder and at lower loading. Further, sintered PZT 95/5 parts prepared using the optimized binder exhibited ~5% improved polarization performance without alteration to the microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Compositional Exploration of Additively Manufactured Ultra-High-Temperature Ceramic Composites for Use in Concentrated Solar Power Plant Heat Exchangers

The DOE has research interest in new technologies for high temperature concentrated solar power plants. Our project this summer was to explore the use of additively manufactured ultra-high-temperature ceramics in a heat exchanger. The heat exchanger would transfer heat between a molten chloride salt and supercritical CO 2 . We selected 22 compositions to test and were able to mix 14 of these compositions. We sintered these compositions using pressureless sintering and direct current sintering. We also conducted high temperature TGA on some ceramic samples. We also performed preliminary binder jet additive manufacturing trials with tungsten carbide powder. Our work so far points towards one of our titanium diboride samples being promising, but much more research needs to be done.

14 SOLAR ENERGY↗