SEARCH · Search NASA

Results for “Micro”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 775 records · Page 43

All sources NASA NTRS DOE OSTI

DOE OSTI2020

Identifying factors controlling the selective ethane dehydrogenation on Pt-based catalysts from DFT based micro-kinetic modeling

Herein, a detailed EDH reaction mechanism on Pt(111), Pt(211), Pt 3 Sn(111) and Pt 3 Sn(211) surfaces has been systematically computed with DFT. A mean-field micro-kinetic model has been established to simulate the product distribution and selectivity on each surface at experimentally relevant conditions. We have uncovered a number of different factors controlling the catalytic performance of Pt-based EDH catalysts, thus leading to a better understanding of experimentally detected phenomenon. In this study, the (111) and (211) model surfaces of Pt and Pt 3 Sn catalysts were chosen to represent the terrace and step-edge sites when simulating the EDH reaction mechanisms.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Manufacturing Process Design of a Micro-Scale Liquid-Liquid Extractor and Multi-phase Separator

Advances in process innovation within the chemical process industry are impeded by the cost of producing new innovative components. In this paper, various manufacturing process routes were evaluated for scaling up a micro-scale liquid-liquid extractor and multi-phase separator capable of separating immiscible phases that are used for the extraction of a chemical product into a lower boiling point solvent to make downstream distillation easier. A manufacturing process design methodology was used to evaluate both photochemical machining and binder jetting as a means for producing the micropost arrays within the separator. Cost curves show that for a 0.3 mm deep micropost array, photochemical machining was found to be much cheaper than binder jetting. However, because binder jetting processes enable microposts with over 13 times higher depth-to-width aspect ratios, binder jetting was found to decrease the overall costs of the extractor/separator by more than half for a 500 barrel per day plant, with breakeven as low as 15 barrels per day. These economics were confirmed by building extractor/separator plates and characterizing them dimensionally and functionally. The binder jet plates were found to perform better than photochemical plates leading to the complete separation of the organic phase from water. The utilization of slower sintering cycles combined with surface grinding provided acceptable dimensional tolerances for the binder jet plates. Using pressurized air during depowdering improved the economics for the binder jetting process.

42 ENGINEERING↗

DOE OSTI2020

Plasticity of irradiated materials at the nano and micro-scales

Here, we review here our recent work on plastic deformation in irradiated materials at the nano- and micro-scales, as revealed by Discrete Dislocation Dynamics (DDD) simulations. Two methods of including irradiation effects in the DDD framework are presented. The first directly captures the atomistic interaction mechanisms, while the second can effectively study high-dose irradiation. Computer simulations lead to new understanding of the dynamics of collective dislocation-irradiation defect interactions, as well as the quantitative analysis of the temporal and spatial characteristics associated with plastic instabilities. Based on these insights, theoretical models are developed to predict the critical conditions for dislocation channel formation. A simple probability model is proposed and demonstrated to predict the width of dislocation channels in bulk irradiated materials with good agreement with experimental data. The fundamental understanding of the origins of plastic flow localization in irradiated materials sheds light on the design of future generations of radiation-resistant materials.

36 MATERIALS SCIENCE↗

DOE OSTI2021

A linked-scale coupled model of mass erosion and redistribution in plasma-exposed micro-foam surfaces

Surface evolution due to exposure to harsh environments is of importance in many scientific and technological applications. In plasma-exposed materials, the surface receives charged particles from the plasma, leading to a series of processes that drive the system far from equilibrium and may lead to the severe deterioration of the surface properties. Although surface morphological changes are driven by atomic collisions taking place over picoseconds and nanometers, these processes result in mass loss and redistribution of matter over much larger length and time scales. This necessitates a multi-scale approach capable of capturing the range of processes linking primary atomic collision events with engineering-level surface geometry changes. In this paper, we develop a computational model to simulate the morphological evolution and effective erosion rate of micro-architected tungsten foams during low-energy plasma ion bombardment. Furthermore, the model acts on several length scales, with the energy and angular dependence of the sputtering yield of flat tungsten surfaces determined using the SRIM code based on the binary collision approximation. This information is introduced into a low-fluence, short-term Monte Carlo raytracing model, and further into a high-fluence, long-term particle transport model. In the latter, material particles representing billions of atoms are described in a digitized 3-D representation of the foam structure from X-ray tomography data, and are sputtered off and redeposited using the atomistic information. We show that the redeposition of sputtered atoms leads to partial self-healing in the bottom layers with a sharp reduction in the sputtering coefficient of low density foams, roughly 25% of the solid W value. This is in qualitative agreement with recent experiments on low porosity W structures. At high fluence, the foam structure degrades considerably as there are fewer ligaments available to recapture sputtered atoms and, consequently, the sputtering rate increases again.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Effects of radiation damage and precipitate distribution on micro-pillar compression testing of irradiated CuCrZr

The results of small-scale mechanical tests are convoluted by the so-called size effect, whereby materials appear stronger when the scale of the test is reduced to the order of microns or less. The dimensional range over which this occurs has been shown to be linked to a change in sample microstructure, such as the addition of defects induced by irradiation. To investigate this response, a CuCrZr alloy was subjected to proton irradiation and mechanically tested using micro compression of pillars with a range in size. It was found that irradiation defects dominate over the extrinsic size effect and the sensitivity to differences in precipitate microstructure was also somewhat reduced, suggesting that size-independent results could be obtained from much smaller test volumes in irradiated material compared to their non-irradiated counterparts. Lastly, comparison was made between the increase in yield strength predicted by models and the experimentally measured values to establish the key parameters driving the strengthening behaviour.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Length scale effects of micro- and meso-scale tensile tests of unirradiated and irradiated Zircaloy-4 cladding

Zircaloy-4 is an essential material for cladding structures within fission-based reactors. To explore the changes in properties measured on differing length scales, FIB-machined micro-scale tensile tests were performed on both irradiated and control groups of Zircaloy-4. This was correlated with tensile testing on femtosecond laser-machined meso-scale specimens. Pronounced size effects were found when varying specimen geometry. Increases in tensile geometry size were associated with a reduction in measured yield stress for both irradiated and unirradiated samples. Here, meso-scale testing found strength and strain values similar to that of bulk-scale testing.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Effect of particle size on pore three-dimensional characteristics of SiCp preforms by X-ray micro-computed tomography

Highlights: • X-ray μ-CT was used to characterize 3D structures of the pores in SiCp preforms. • 3D pore network models of the pore structure were extracted and analyzed. • With the increase of particle size, the homogeneity of pore distribution decreased. • Small particles in large spaces of coarse particles decreased preform connectivity. - Abstract: Silicon-carbide particle (SiC{sub p}) preforms with particle sizes of 20, 50, 100 and 150 μm were prepared by compression mold forming and heat treatment. A high resolution (~ 1.0 μm) three-dimensional (3D) X-ray micro-computed tomography (X-ray μ-CT) combined with 3D pore-network models were used to study the effect of particle size on 3D characteristics and spatial structures of pores in the preforms. The results demonstrated that as the particle size increased, the gap expansion caused by burning of starch reduced. When the particle size increased from 20 to 100 μm, the average areal porosity, homogeneity of pore distribution, connectivity, the numbers of small pores and throats, and average pore coordination number decreased; the average effective sizes of pores and throats increased. When the particle size further increased to 150 μm, the large gaps were filled by small particles resulted from the broken coarse particles, which decreased the homogeneity and connectivity of pores. As a result, the pore-network analysis shows that the numbers of small pores and throats and average pore coordination number increased.

36 MATERIALS SCIENCE↗

DOE OSTI2018

A micro-mechanism to explain the post-DRX grain growth at temperatures > 0.8Tm

Highlights: • Austenitic grain growth during working at temperature > 0.8T{sub m} is reduced by > 50%. • Growth mechanism during loading is distinct from growth in absence of loading. • During loading, growth occurs due to alignment of slip planes and grain merging. • Interruption of loading causes competitive growth and limits grain size. • Interrupted loading results in optimal microstructural and mechanical properties. - Abstract: A micro-mechanism responsible for the occurrence of post-dynamic recrystallization (DRX) grain growth during deformation at T > 0.8T{sub m} is described. Thermo-mechanical testing, microstructural characterization and diffraction studies reveal the link between slip and grain growth. If deformation is imparted in a single stage, grains grow by a cooperative growth process involving grain rotation and alignment of slip planes. This mechanism changes when deformation is interrupted and controlled intermediate soaking is performed before re-loading. A premeditated control of mechanism is shown to yield favourable microstructural and mechanical properties. A strategy to apply this control to industrial hot deformation is outlined.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Micro- and macro-structural heterogeneities in 316L stainless steel prepared by electron-beam melting

Highlights: • Electron beam melting manufactured parts has a complicated thermal history. • The microstructure varies with the position in the sample. • Pronounced molybdenum segregation at the top disappears at the bottom. • Fast molybdenum diffusion in cell boundaries as well as grain boundaries. - Abstract: This is a study of the micro- and macrostructural variations in samples of stainless steel with the overall composition of the grade 316L, produced using electron beam melting. Electron beam melting is one of the processing methods under consideration for manufacturing some of the International Thermo- Nuclear Experimental Reactor In-Vessel components. Therefore further studies of the homogeneity of the material were conducted. Electron beam melting results in a complicated thermal history of the manufactured part giving a significant impact on the microstructure. A cellular structure that is often observed in samples prepared by selective laser melting was found in the top layers of the specimens. Further down, the structure changed until the cellular structure was almost non-existing, and the grain boundaries had become more pronounced. This revelation of a heterogeneous structure throughout the entire part is crucial for large-scale industrial applications like the Thermo- Nuclear Experimental Reactor to make sure that it is understood that the properties of the material might not be the same at every point, as well as to assure that the correct post-treatment is done. It is also exposed that a significant part of this change is due to molybdenum redistribution inside the sample when it diffuses from the cell boundaries into the cells, and into bigger agglomerates in the grain boundaries. This diffusion seems not to affect the microhardness of the samples.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Mapping 3D grain and precipitate structure during in situ mechanical testing of open-cell metal foam using micro-computed tomography and high-energy X-ray diffraction microscopy

Open-cell metal foams are ultra-low-density cellular metals with complex hierarchical structures that span bulk, cell, ligament, and sub-ligament scales and give rise to desirable properties such as high strength-to-weight ratio and excellent energy absorption. Although literature suggests that intrinsic material structures at sub-ligament length scales (e.g., grains and precipitates) play an important role in mechanical behavior of open-cell metal foams, there are very few experimental measurements of such structures in three dimensions and for meaningful volumes of foam. This study seeks to map and track the three-dimensional (3D) grain and precipitate structures of an intact volume of open-cell aluminum foam by advancing microstructural characterization techniques that leverage X-ray micro-computed tomography (μCT) and far-field high-energy X-ray diffraction microscopy (FF-HEDM). A 6%-relative-density aluminum foam sample was mechanically tested in compression while μCT and FF-HEDM measurements were collected at interrupted loading states at beamline 1-ID of the Advanced Photon Source. Further, a new scanning strategy and reconstruction algorithm were established to enable characterization of a foam volume with diameter approximately four times wider than the nominal width of the X-ray beam. The result is a set of maps that detail both the 3D grain and precipitate structures throughout the foam volume at successive strain steps. A novel grain tracking procedure was developed to track individual grains within the foam volume by accounting for the large rigid-body motions that individual ligaments can undergo during mechanical loading. The ability to track grains and precipitate structures in three dimensions throughout large bulk deformation of ultra-low-density polycrystalline materials enables new possibilities for validating numerical models and investigating local failure mechanisms. Furthermore, the methods and procedures developed in this study could be applied to other ultra-low-density structures, such as additively manufactured lattices.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Recent advances in the mechanical characterization of shales at nano-to micro-scales: A review

Understanding geomechanical properties of shales, such as stiffness properties and fracture toughness, is important in different areas of petroleum industry-related activities. Nanoscale to microscale experiments on shale samples require a much smaller sample compared to macroscale experiments. This is a major advantage because irregularly-shaped drill cuttings from shales can be used for experimental analyses, such as nanoindentation or atomic force microscopy (AFM). However, characterization of mechanical properties at the nano- to micro-scale is a relatively new addition to classical geomechanical experiments on shales, and there is still a lack of both fundamental knowledge and standard procedures for conducting experiments at this scale. The theoretical principles of nanoindentation-based (Gridded Nanoindentation and Modulus Mapping) and AFM-based experimental methods (PeakForce QNMTM and AFM-IR), a review of the literature results and the major findings are explained in Sections 2 and 3, respectively. These experimental techniques are compared in Section 4. Overall, nanoindentation experiments reveal the anisotropy of organic matter (OM)-rich shales at the nanoscale, and it is shown that gridded nanoindentation is capable of characterizing different minerals with respect to their stiffness properties. The capability of AFM (PeakForce QNMTM) to differentiate between different minerals within OM-rich shales with distinct mechanical properties, in particular stiffness, is also demonstrated. It is shown that AFM-based methods are more straightforward than gridded-nanoindentation to characterize OM-rich shales based on the stiffness of different constituent minerals of OM-rich shales, but nanoindentation can apply higher loads than AFM-based methods. Therefore, they can measure creep properties and fracture toughness of OM-rich shales. Here, it is shown that the OM is the most compliant part of the OM-rich shales, but it is still unclear if thermal maturation has an impact on the stiffness of OM. It is necessary to investigate if there is a relationship between the OM type (kerogen, bitumen, etc.) and mechanical properties such as Young’s modulus and Creep rate.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Synthesis, microstructure and micro-mechanical characterization of metal (Nb, Ti) – MAX phase (Ti 2 AlC) nanolaminates

We utilize elevated temperature physical vapor deposition (PVD) techniques to design metal/MAX multilayered nanocomposite thin films with alternating nanoscale metallic (Nb, Ti) and MAX phase (Ti 2 AlC) layer thicknesses. These metal/MAX nanolaminate architectures attempt to exploit a unique hierarchical topology – as interfaces between the layers are expected to be in direct competition with the internal interfaces within the MAX layers, to drive their tunable macroscopic mechanical behavior. Two metal/MAX nanolaminates – Nb/Ti 2 AlC and Ti/Ti 2 AlC – were deposited. The Nb/Ti 2 AlC metal/MAX system showed highly diffused layer interfaces with distinct Ti – rich and Nb–Al – rich layers, with the presence of MAX phase alongside TiC and other Ti–Al and Nb–Al intermetallic phases. The Nb/Ti 2 AlC system possessed a layered architecture, though the MAX phases were not found to be continuously present in each alternating layer. The second Ti/Ti 2 AlC system showed a non-lamellar nanocomposite microstructure and the formation of mixed Ti n+1 AlC n phases (a mix of n = 1, 2), and no indication of layering. Diffusion occurring between the metal/MAX layers in both cases, likely due to the elevated temperatures during the deposition process, is speculated as the likely cause of these resultant microstructures. The mechanical properties of both systems were evaluated using micromechanical (nanoindentation and micro-pillar compression) techniques, which demonstrated high strengths for both systems (Nb system: yield and instability strengths of 4.88 ± 0.1 GPa and 5.57 ± 0.03 GPa, Ti system: yield and instability strength of 5.61 ± 0.28 GPa and 6.21 ± 0.25 GPa). In conclusion, this work highlights the promising mechanical properties of metal/MAX multilayered depositions and summarizes the challenges in PVD synthesis of metal/MAX multilayered nanolaminates.

MAX phase↗

DOE OSTI2024

Formation of tunable diamond micro- and nanopillars for field effect enhancement applications

Here, we developed a process for the fabrication of tunable single crystal diamond micro- and nanopillars, with tip widths ranging from 40 to 460 nm, densities ranging from 0.5 to 53.5 pillars/μm 2 , and heights greater than 4.5 μm. A self-assembled Au nanodot ensemble etch mask was formed from an annealed Au thin film. The nanodot diameter and density can be tuned using the initial film thickness. The pillars were etched from the nanodot mask using an RIE O 2 plasma, which has infinite selectivity for the diamond when applied at low RF powers (50 W). Finally, the pillars can be sharpened to ~40 nm tip widths by annealing in air at 650 °C. These pillars can be used for applications such as field effect enhancement of diamond photocathode devices, enhancement of optical emission from N-V centers, and antireflective coatings.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Micro X-ray computed tomography examination of mini plate fuel with hot isostatic pressed aluminum cladding

In order to minimize proliferation risks and improve security of nuclear material, the United States high performance research and test reactors (USHPRR) program is tasked with converting nuclear reactors that are fueled with highly enriched uranium (HEU) fuels to operate with low-enriched uranium (LEU) nuclear fuels. One favorable LEU fuel configuration is plate fuel with a metallic uranium-molybdenum foil clad within an aluminum alloy (AA 6061). In this fuel, the aluminum cladding is bonded with a hot isostatic pressing (HIP) method to seal the cladding around the fuel meat. However, the HIP process parameters influence the cladding performance, as a defective or incomplete bond can cause a pathway for corrosion. Micro X-ray computed tomography (XCT), a nondestructive technique that provides volumetric imaging, can be applied to inspect fuel plate cladding at the engineering scale. In this work, XCT methodology was developed and successfully utilized to not only observe the bond line of unirradiated mini fuel plates, but to also identify subsurface abnormalities in the plates’ cladding. Importantly, in future work, this technique could be applied to fuel plates, pre- and post-irradiation, to quantify irradiation effects on cladding defects and bond line integrity.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Investigation of neutron noise in a micro-scale, natural circulation molten salt fission battery system

The Molten Salt Reactor (MSR) concept is a rapidly evolving Generation IV design that has recently attracted favorable attention due to the potential for reducing waste generation, realizing passive safety features, and seizing on the opportunity for cost effective economics. A specific novel micro-MSR, natural circulation, battery design concept involves placing all primary components within a single reactor vessel containment without the need of primary forced pumping. This small modular, integral design presents potential cost savings while producing safety, reliable, and transportable carbon-free power for decades. This investigation evaluates the neutron noise induced by density and flow fluctuations in a natural circulation MSR battery concept being developed at the University of Idaho. This study finds numerical solutions to the one-dimensional, one-group, coupled diffusion equations for a bare, homogeneous core, and evaluates neutron flux and delayed neutron precursor concentration noise due to core flow and fuel salt density perturbation sources. Noise analysis shows both point kinetic and space-dependent behavior is present despite the small size, low-flow, closely-coupled nature of the natural circulation MSR concept. Analysis shows that the low flow of the convective system results in noise behavior typically representative of a larger forced-circulation MSR system. Finally, noise techniques may also be useful in MSR core diagnostics as a non-invasive, low-cost radiological option to traditional monitoring schemes.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

In situ contact angle measurements of liquid CO 2 , brine, and Mount Simon sandstone core using micro X-ray CT imaging, sessile drop, and Lattice Boltzmann modeling

Three techniques to measure and understand the contact angle, θ, of a CO 2 /brine/rock system relevant to geologic carbon storage were performed with Mount Simon sandstone. Traditional sessile drop measurements of CO 2 /brine on the sample were conducted and a water-wet system was observed, as is expected. A novel series of measurements inside of a Mount Simon core, using a micro X-ray computed tomography imaging system with the ability to scan samples at elevated pressures, was used to examine the θ of residual bubbles of CO 2 . Within the sandstone core the matrix appeared to be neutrally wetting, with an average θ around 90°. A large standard deviation of θ (20.8°) within the core was also observed. To resolve this discrepancy between experimental measurements, a series of Lattice Boltzmann model simulations were performed with differing intrinsic θ values. The model results with a θ = 80° were shown to match the core measurements closely, in both magnitude and variation. The small volume and complex geometry of the pore spaces that CO 2 was trapped in is the most likely explanation of this discrepancy between measured values, though further work is warranted.

42 ENGINEERING↗

DOE OSTI2024

Optimizing and Exploring Untapped Micro-Hydro Hybrid Systems: a Multi-Objective Approach for Crystal Lake as a Large-Scale Energy Storage Solution

Increasing electricity demand and concerns about climate change and fossil fuel consumption have highlighted the importance of renewable energy resources and storage systems. This paper proposes a method for exploring untapped pumped hydro storage potentials to accommodate intermittent renewable energy generation profiles. Hourly measured data from 2022 in Benzie County, Michigan, United States, were gathered for system sizing and a thorough, realistic analysis. By employing the multi-objective grey wolf optimization algorithm, we formulated optimal sizing and energy-management strategies for three different scenarios. Unlike similar studies, the 3rd with triple objective functions (OFs) scenario aims to maximize both reliability and ecological OFs while minimizing the cost OF. It has shown promising results with multiple solutions, considering economic, environmental, and reliability factors. A case study conducted in Crystal Lake, Michigan, revealed that although Crystal Lake would function only as a micro-hydro power facility, it is a promising and huge storage unit with a substantial storage capacity of around 14.9734GWh. The system investigated is significant in the USA due to its rapid deployment capabilities, minimal construction requirements, and ease of integration with the distribution grid. The fuzzy logic method was employed to identify the best non-dominant solution among the other solutions. Furthermore, these outcomes include a notably low levelized cost of energy at 0.046147$/kWh, a robust index of reliability of 99.705%, and a significant reduction in CO₂ emissions amounting to 7.9142×10 3 tons/year, when considering the triple OFs. The paper’s methodology provides valuable insights for regions aiming to utilize renewable energy from untapped storage sources.

13 HYDRO ENERGY↗

DOE OSTI2025

Investigation of the temperature-dependent failure processes in PVD Cr-coated ZIRLO nuclear fuel cladding using in situ X-ray micro-tomography imaging

In this work, an accident tolerant fuel cladding system with Cr coating deposited using physical vapour deposition (PVD) method onto commercial Optimized ZIRLO™ was studied. The cladding tubes were machined into C-rings and loaded to failure under compression with real-time synchrotron micro-X-ray computed tomography (XCT) imaging at room temperature (RT), 345 °C, 650 °C and 950 °C in argon (Ar) atmosphere. The mechanical behaviour and failure processes were found strongly temperature-dependent where the Cr coating showed brittle fracture at RT and 345 °C, ductile fracture at 650 °C and a reversion to brittle fracture at 950 °C. Nanoindentation measurements and scanning electron microscopy (SEM) imaging were conducted on the materials after high temperature testing. It was found that recrystallisation of the Cr coating occurred at elevated temperatures, which significantly affected its local properties hence the failure behaviour at different temperatures. This work represents the first in situ 3D XCT observation of progressive failure processes in PVD Cr-coated ZIRLO claddings up to 950 °C providing critical insights into its brittle-to-ductile transition (BDTT) behaviour and subsequent ductile-to-brittle reversion with the increase in temperature. Moreover, results are compared with other PVD Cr-coated Zircaloy materials from open literature; the influences of the coating microstructure and local properties on the failure stress/strain and fracture processes are discussed.

Yuan, Guanjie↗