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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 775 records · Page 43
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Advanced Characterization to Inform Sustainable Recovery of Critical Minerals from Fossil Energy Waste Feedstocks

Rare earth elements (REE) and other critical minerals (CM, e.g., Co, Li) have important uses in green energy and modern technologies, yet are vulnerable to potential supply chain disruptions. One potential domestic source of CM is fossil energy wastes, such as acid mine drainage (AMD) and treatment solids (AMD solids), coal combustion ash, and Oil and Gas (O&G) drilling wastes (drill cuttings and produced waters). CM recovery from these waste feedstocks is promising due to their abundances and fast availability as waste products. On the other hand, the CM occurrence in these wastes is in small quantities compared to traditional ore bodies. Thus, novel and strategic separation and extraction processes are under exploration. Researchers at DOE’s National Energy Technology Laboratory (NETL) are collecting and analyzing CM data for aforementioned fossil energy wastes, and utilizing advanced geochemical characterization (e.g., synchrotron microprobe and sequential extraction) to understand the CM speciation and binding environments in these materials to better inform sustainable and effective recovery. Successful examples discussed in this talk include: (1) the discovery of easily mobile REE phases in Ca-rich coal combustion ash and developing a patented REE recovery process from Ca-rich Powder River Basin coal ash; (2) the successful identification of REE/Co/Ni/Zn hosting phases in acid mine drainage treatment solids (AMD solids) with diverse chemical composition (Al, Mn, or Fe-rich) informing the sequential recovery of different REE/CMs from AMD solids; (3) the recovery potential of Li and other CMs in O&G produced waters and drill cuttings. The innovations driven by characterization have the potential to offset the cost of waste management and wastewater treatments while reducing the cost and environmental footprint of CM extraction.

characterization and extraction↗
DOE OSTI2019

Development of Fe-9Cr Alloy via High-Energy Ball Milling and Spark Plasma Sintering

Iron and chromium powders were mixed and mechanically alloyed via high-energy ball milling for different time durations (2–20 h) to produce an alloy powder with a nominal composition of Fe-9Cr (wt.%). The milled Fe-9Cr powders were analyzed using scanning electron microscopy (SEM), x-ray diffraction (XRD) and transmission electron microscopy (TEM) to understand the impact of ball milling (BM) time on the characteristics of the milled powder. The optimized milled powder samples were then consolidated via spark plasma sintering (SPS) for different dwell times and temperatures. The density of consolidated samples was found to reach a maximum of 98%. Microstructural characterization of the SPS samples were performed using XRD, SEM, TEM and electron backscatter diffraction. This study highlights the principles and importance of high-energy BM and SPS of Fe-9Cr model alloy for the future development of more complex oxide dispersion-strengthened alloys for various applications including advanced nuclear reactor applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Catalysts Prepared from Atomically Dispersed Ce(III) on MgO Rival Bulk Ceria for CO Oxidation

Atomically dispersed cerium catalysts on an inert, crystalline MgO powder support were prepared by using both Ce(III) and Ce(IV) precursors. The materials were used as catalysts for CO oxidation in a once-through flow reactor and characterized by atomic-resolution scanning transmission electron microscopy, X-ray absorption near edge structure spectroscopy, X-ray photoelectron spectroscopy, and temperature-programmed reduction, among other techniques, before and after catalysis. The most active catalysts, formed from the precursor incorporating Ce(III), displayed a performance similar to that reported for bulk ceria under comparable conditions. The catalyst provided stable time-on-stream performance for as long as it was kept on stream, two days, increasing slightly in activity as the atomically dispersed cerium ions were transformed into ceria nanodomains represented as CeO x and having increased reducibility on the MgO support. Furthermore, the results suggest how highly dispersed supported ceria catalysts with low cerium loadings can be prepared and may pave the way to improved efficiencies of cerium utilization in oxidation catalysis.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Microstructural characterization of random packings of cubic particles

Understanding the properties of random packings of solid objects is of critical importance to a wide variety of fundamental scientific and practical problems. The great majority of the previous works focused, however, on packings of spherical and sphere-like particles. We report the first detailed simulation and characterization of packings of non-overlapping cubic particles. Such packings arise in a variety of problems, ranging from biological materials, to colloids and fabrication of porous scaffolds using salt powders. In addition, packing of cubic salt crystals arise in various problems involving preservation of pavements, paintings, and historical monuments, mineral-fluid interactions, CO 2 sequestration in rock, and intrusion of groundwater aquifers by saline water. Not much is known, however, about the structure and statistical descriptors of such packings. We have developed a version of the random sequential addition algorithm to generate such packings, and have computed a variety of microstructural descriptors, including the radial distribution function, two-point probability function, orientational correlation function, specific surface, and mean chord length, and have studied the effect of finite system size and porosity on such characteristics. Here, the results indicate the existence of both spatial and orientational long-range order in the packing, which is more distinctive for higher packing densities.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Come for predictions, stay for complexity: synthesis and experimental probing of ionic conductivity in Li 9 B 19 S 33

Lithium thioborates, despite their potential cost-effectiveness and low density, have received considerably less attention as solid electrolytes compared to their thiophosphate counterparts. A primary obstacle to their widespread investigation has been the inherent challenge in synthesizing single-phase materials. Computational studies have predicted several lithium thioborate phases exhibiting high ionic conductivity, with Li 9 B 19 S 33 notably predicted to reach 80 mS cm −1 . However, experimental validation of these theoretical predictions remains absent. This work addresses this gap by detailing a successful synthesis of the previously elusive Li 9 B 19 S 33 phase, facilitated by in situ temperature dependent powder X-ray diffraction. Our findings reveal the peritectic nature of phase formation, necessitating an excess of boron sulfide in the reaction mixture. We further present a comprehensive structural characterization of Li 9 B 19 S 33 utilizing spectroscopic techniques like NMR, FT-IR, and diffuse reflectance and report on its ionic conductivity. Solid-state 6 Li NMR line narrowing experiments revealed an ion mobility activation energy of 0.26 eV whereas activation energies derived from impedance spectroscopy measurements were significantly higher, resulting in lower than theoretically predicted ionic conductivity.

Oppong, Richeal A. [Iowa State Univ., Ames, IA (Un↗
DOE OSTI2020

Measurement of Palladium Hydride and Palladium Deuteride Isotherms Between 130 K and 393 K

The data collected in the present work extend the measured phase diagram for palladium hydride and palladium deuteride to a region that has been sparsely reported in open literature. Absorption isotherms were measured using a 2.5-g bed of palladium powder at temperatures between 130 K and 393 K and pressures less than 1.3 x 10 5 Pa. Such low-pressure and low-temperature measurements are useful for characterizing palladium beds used for tritium pumping and storage. For tritium storage, pressures are kept below a few millibar for safety reasons. Low temperatures increase the tritium storage capacity of palladium. The measured absorption isotherms show the well-documented, two-phase behavior for this system: two solubility regions and a mixed, hydride-forming region. The isotherms show that an increased quantity of hydride is formed at lower temperatures, as marked by an increase in the hydride-forming region. This region exceeds hydrogen to metal ratios of 0.75 for T ≤ 273 K. Equilibrium pressures in the mixed region decrease with decreasing temperatures until a critical temperature is reached for each isotope. Below these critical temperatures, the rate of pressure decrease with decreasing temperature is significantly reduced. This change in trend suggests hydrogen isotopes are adsorbed onto the palladium surface, rather than forming a hydride. Using the equilibrium pressures recorded at temperatures between 236 K and 393 K for protium and between 211 K and 354 K for deuterium, the van’t Hoff constants were calculated to be A = –36 ± 1 kJ/mol and B = 88 ± 3 J/K for protium and A = -32 ± 2 kJ/mol and B = 88 ± 9 J/K for deuterium. As a result, these constants agree favorably with literature in the range where the temperatures of the measured isotherms overlap.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Selective Deposition and Fusion of AISI 316L: An Additive Manufacturing Process for Space Environments via Direct Ink Writing and Laser Processing

Unlocking the potential of additive manufacturing (AM) for space exploration hinges on overcoming key challenges, notably the ability to manufacture or repair parts on-site during exploration missions with consideration of quality, feedstock utilization, and challenges involved in microgravity environments. While there are multiple efforts to investigate the use of existing metal AM processes such as powder bed fusion (PBF), directed energy deposition (DED), and filament-based material extrusion, each process comes with a different set of challenges in space environments. Here, in this work, we introduce a new AM method that integrates the benefits of direct ink writing (DIW) to selectively deposit metallic pastes with laser-based processing to locally debind and subsequently melt and fuse metal powder, layer by layer, enabling the manufacturing of AISI 316L samples with densities exceeding 99.0%. The impact of process parameters on single-track dimensions, surface morphology, and porosity was characterized. The efficacy of laser debinding was assessed via secondary-ion mass spectrometry, permitting the carbon content to be estimated at 0.0152%, which is safely below the acceptable limit (0.03 wt%) for AISI 316L.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Updated ASME design correlations and qualification plan for powder bed fusion 316H stainless steel

This report provides an update on the Advanced Materials and Manufacturing Technologies (AMMT) program effort to qualify Laser-Powder Bed Fusion (L-PBF) 316H stainless steel for use with the ASME Boiler & Pressure Vessel Code Section III, Division 5 rules. The report summarizes progress in testing and characterizing L-PBF material at elevated temperatures by providing preliminary design data for L-PBF 316H and by comparing the elevated temperature performance of the L-PBF material to wrought and conventional fusion welded 316H. The report then updates the initial AMMT qualification plan for L-PBF 316H, originally developed in 2023, to update the accelerated qualification strategy adopted in that plan to account for the new high temperature test data. The report also explores a few methods for further accelerating the qualification process using machine learning techniques to supplement the more conventional, empirical analysis methods typically used by ASME to correlate and extrapolate time-dependent material test data.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Development of PNNL’s Plutonium Metallography Capability

The goal of this project was to develop plutonium metallography capabilities and establish workflows for characterization at PNNL’s Radiological Processing Facility (RPL). Developing and expanding on this capability opens more opportunities for PNNL to better support science through collaborations with other labs, plants, and sites withing the Department of Energy Complex and through programs within the National Nuclear Security Administration. This project established metallography equipment in an air glovebox, polishing protocols, as well as radiological and facility controls and procedures so that gram quantities of plutonium metal could be analyzed on multiple characterization tools. Data was collected and analyzed on two different delta phase plutonium - Gallium samples and a calciothermically reduced alpha plutonium metal using a combination of optical and electron microscopy, powder X-ray diffraction, and atom probe tomography. This report highlights the metallography capabilities, some preliminary data collections, and plans at PNNL to support plutonium material science.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Spectral X-ray Radiography for Safeguards at Nuclear Fuel Fabrication Facilities: A Feasibility Study

The methods currently used by the International Atomic Energy Agency to account for nuclear materials at fuel fabrication facilities are time consuming and require in-field chemistry and operation by experts. Spectral X-ray radiography, along with advanced inverse algorithms, is an alternative inspection that could be completed noninvasively, without any in-field chemistry, with inspections of tens of seconds. The proposed inspection system and algorithms are presented here. The inverse algorithm uses total variation regularization and adaptive regularization parameter selection with the unbiased predictive risk estimator. Performance of the system is quantified with simulated X-ray inspection data and sensitivity of the output is tested against various inspection system instabilities. Material quantification from a fully-characterized inspection system is shown to be very accurate, with biases on nuclear material estimations of < 0.02%. It is shown that the results are sensitive to variations in the fuel powder sample density and detector pixel gain, which increase biases to 1%. Options to mitigate these inaccuracies are discussed.

Gilbert, Andrew J.↗
DOE OSTI2021

The onset of alloying in Cu-Ni powders under high-shear consolidation

Friction consolidation (FC) is a solid phase processing methodology that densifies a material through high-shear deformation and pressure at elevated temperature. The method has garnered interest in the scientific community because of its ability to produce extremely refined and homogeneous microstructures, off-axis texture development, and improved material properties. This manuscript presents an investigation of Cu and Ni material mixing via evaluation of morphological evolution, grain boundary characterization, and compositional analysis to provide insights on the operational alloying mechanisms occurring under high shear and elevated temperature. Using correlative microscopy techniques, we show alloying progresses via a combination of grain boundary diffusion and interfacial roughening at heterophane boundaries. Evidence supporting Cu infiltration along Ni-Ni grain boundaries along with asymmetric diffusion of Cu into Ni grains is highlighted. The resultant, consolidated microstructure was produced directly from a powder compact in ~30 s and exhibited a submicron, equiaxed grain size.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Cation Adaptive Structures Based on Manganese Cyanide Prussian Blue Analogues: Application of Powder Diffraction Data to Solve Complex, Unprecedented Stoichiometries and New Structure Types

Abstract A Mn(II) salt and A + CN − under anaerobic conditions react to form 2‐D and 3‐D extended structured compounds of A m Mn II n (CN) m+2n stoichiometry. Here, the creation and characterization of this large family of compounds, for example AMn II 3 (CN) 7 , A 2 Mn II 3 (CN) 8 , A 2 Mn II 5 (CN) 12 , A 3 Mn II 5 (CN) 13 , and A 2 Mn II [Mn II (CN) 6 ], where A represents alkali and tetraalkylammonium cations, is reviewed. Cs 2 Mn II [Mn II (CN) 6 ] has the typical Prussian blue face centered cubic unit cell. However, the other alkali salts are monoclinic or rhombohedral. This is in accord with smaller alkali cation radii creating void space that is minimized by increasing the van der Waals stabilization energy by reducing ∠Mn−N≡C, which, strengthens the magnetic coupling and increases the magnetic ordering temperatures. This is attributed to the non‐rigidity of the framework structure due the significant ionic character associated with the high‐spin Mn II sites. For larger tetraalkylammonium cations, the high‐spin Mn sites lack sufficient electrostatic A + ⋅⋅⋅NC stabilization and form unexpected 4‐ and 5‐coordinated Mn sites within a flexible, extended framework around the cation; hence, the size, shape, and charge of the cation dictate the unprecedented stoichio‐metry and unpredictable cation adaptive structures. Antiferromagnetic coupling between adjacent Mn II sites leads to ferrimagnetic ordering, but in some cases antiferromagnetic coupling of ferrimagnetic layers are compensated and synthetic antiferromagnets are observed. The magnetic ordering temperatures for ferrimagnetic A 2 Mn II [Mn II (CN) 6 ] with both octahedral high‐ and low‐spin Mn II sites increase with decreasing ∠Mn−N≡C. The crystal structures for all of the extended structured materials were obtained by powder diffraction.

Chemistry↗
DOE OSTI2019

Embedded Sensor Development in Metallic Structures for the Transformational Challenge Reactor

The ability to make minimally intrusive measurements of process conditions has tremendous potential for improving system performance and control in applications such as nuclear power generation. Towards this end, emerging and evolving advanced manufacturing methods, such as additive manufacturing, present new opportunities for more seamlessly integrating sensing with structure. This technical report summarizes the progress of work performed to assess the feasibility of embedding commercial off-the-shelf (COTS) sensors in a metallic reactor core using advanced manufacturing methods. The progress of four research and development tasks are documented: 1) A survey of COTS sensors for nuclear applications that are candidates for embedded fabrication, 2) Development of a conceptual framework for investigating the feasibility of sensor embedment, 3) Definition of structural geometries and other characteristics that will represent compelling proof-of-concept, and 4) Preliminary prototyping of embedded sensors. For the purposes of this initial study, nuclear grade K-type thermocouples were selected for investigation of embedment methodologies. This sensor was selected as an initial candidate because it represents one of the simplest sensor configurations that can provide useful process information. A selective laser melting (SLM) additive manufacturing process was used to fabricate structures with complexity representative of the core design of the transformational challenge reactor (TCR) and methods were developed to embed a thermocouple with a complex two-dimensional routing path. There are many challenges associated with embedding sensors during the additive manufacturing process including securing the sensor in the structure, relocating the part in the additive machine if using a “pick and place” sensor placement method, mitigating the potential for powder contamination, optimizing energy deposition parameters to build as closely as possible around the sensor path and improve structural integrity of the part, and tuning energy deposition to mitigate thermally induced warpage of the sensor and part as well as potential for damaging the sensing device. Preliminary results indicate that it is feasible to integrate the sensor while minimally compromising the structural integrity of the part and preserving sensor performance. This first phase of this work focused on developing a workflow for embedding sensors and controlling energy deposition during the additive manufacturing process to better understand the build characteristics around the sensor. Future work will perform more in-depth characterization of prototype parts using X-ray computed tomography and scanning electron microscopy to better understand fabricated structures, performance testing of embedded sensors in high temperature environments, adding new embedded measurement modalities, embedding devices with dissimilar materials in contact with additive powders, and the development of methods for embedding sensors with three-dimensional routing paths.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Growth and characterization of detector-grade CdMnTe by the vertical Bridgman Technique

Here, we grew Cd1-xMnxTe crystals with a nominal Mn concentration of 5% by the vertical Bridgman growth technique. The compositional variation along the length of the grown ingot was studied by powder X-ray diffraction. The composition was found to be uniform along the growth direction. The achieved resistivity was 1-2.5 x10 10 ohm-cm with a mobility-lifetime (μτ) product value for electrons of ~1.7x10 -3 cm 2 /V. An energy resolution of ~7.5% at 662 keV was achieved or a 9-mm long Frisch grid detector fabricated from an ingot grown using as-received starting materials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Proposed crystal structure of carbadox, C 11 H 10 N 4 O 4

A model for the crystal structure of carbadox has been generated and refined using synchrotron X-ray powder diffraction data and optimized using density functional theory techniques. Carbadox crystallizes in space groupP2 1 (#4) witha= 13.8155(3),b= 21.4662(1),c= 16.3297(3) Å,β= 110.0931(7)°,V= 4548.10(3) Å 3 , andZ= 16. The crystal structure is characterized by approximately parallel stacking of the eight independent carbadox molecules parallel to thebc-plane. There are two different molecular configurations of the eight carbadox molecules; five are in the lower-energy configuration and three are in a ~10% higher-energy configuration. This arrangement likely achieves the lowest-energy crystalline packing via hydrogen bonding. Hydrogen bonds link the molecules both within and between the planes. Each of the amino groups forms a N–H⋯O hydrogen bond to an oxygen atom of the 1,4-dioxidoquinoxaline ring system of another molecule. The result is four pairs of hydrogen-bonded molecules, which form rings with graph setR2,2(14). Variation in specimen preparation can affect the preferred orientation of particles considerably. The powder pattern has been submitted to ICDD for inclusion in the Powder Diffraction File™ (PDF®).

Materials Science↗
DOE OSTI2019

Constitutive Behavior and Hot Workability of a Hot Isostatic Pressed Ti-22Al-25Nb Alloy during Hot Compression

A Ti-22Al-25Nb alloy was fabricated from prealloyed powders by hot isostatic pressing for 2 h at a temperature of 1050 °C and pressure of 100 MPa. The hot deformation behavior of the Ti-22Al-25Nb alloy was characterized by isothermal compression testing at deformation temperatures between 900 and 1060 °C and strain rates between 0.001 and 1 s{sup −1}. Based on the true stress–strain curves, a constitutive equation was constructed to describe the flow stress as a function of the strain rate and deformation temperature. Three-dimensional (3D) processing maps were developed based on dynamic material model theory using the stress flow data to identify the instability and optimization regions of the hot processing parameters. The results show that the flow stress decreases with increasing deformation temperature and decreasing strain rate, and the softening mechanisms are different under different deformation conditions. The apparent activation energies in the (α{sub 2} + β/B2 + O) and (α{sub 2} + B2) phase regions are calculated to be 865.177 and 590.661 kJ/mol, respectively, which suggests that the hot isostatic pressed (HIPed) Ti-22Al-25Nb alloy requires a high hot deformation activation energy. Combined with microstructural observations, the optimal processing domains are determined to be a temperature range of 1030-1060 °C and strain rate range of 0.01-0.1 s{sup −1} in the α{sub 2} + B2 phase region. Moreover, the results indicate that adiabatic shear bands and severe inhomogeneous deformation cause flow instability at lower temperatures (900-1005 °C) and higher strain rates (> 0.1 s{sup −1}).

36 MATERIALS SCIENCE↗
DOE OSTI2026

Multi-scale structural analysis of swift heavy ion-irradiated ZrO 2 and HfO 2

The radiation-induced monoclinic-to-tetragonal phase transition in ZrO 2 and HfO 2 has been the subject of many investigations, but the transformation pathways and underlying structural mechanisms are still not well understood. In this study, microcrystalline powder samples of ZrO 2 and HfO 2 were irradiated with 946 MeV and 1470 MeV Au ions to a wide fluence range up to 3 × 10 13 ions/cm 2 . To characterize beam-induced structural modifications across all spatial length scales, complementary experimental techniques such as synchrotron X-ray diffraction and spallation neutron total scattering were used. The phase evolution of the tetragonal polymorph with increasing ion fluence is accurately described by a heterogeneous track-overlap model that incorporates both direct- and double-impact processes. These damage accumulation processes are an expression of a core-shell ion track morphology that depends on irradiation conditions and target material. Neutron pair distribution function analysis revealed that ion-beam-induced tetragonal ZrO 2 is merely a configurational average of short-range orthorhombic (Pbcn) domains stabilized by a dense network of domain walls. Furthermore, this knowledge is critical for a better understanding of how crystalline-to-crystalline phase transformations proceed at the atomic scale under extreme conditions.

Monoclinic-to-tetragonal phase transformation↗