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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 793 records · Page 44
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Complete the Design of Benchtop Fiber-Optic Based Photo-Thermal Radiometry System

Thermal transport properties of nuclear fuels, i.e., thermal conductivity and diffusivity, are critical parameters in the thermal design of a nuclear reactor. It is well known that thermal transport properties change temporally and spatially due to dynamic microstructural evolution as a result of neutron irradiation. A real-time instrument to monitor the local thermal property change, which can survive the harsh in-pile environment, will give researchers unprecedented access to fuel behavior during irradiation. Laser-based photothermal techniques are an ideal candidate to accomplish this specific task, because of the remote, non-contact, and non-destructive features. In this report, we present the progress in the development of a bench-top photothermal radiometry (PTR) system to measure the thermal diffusivity of solid samples, and the preliminary design of a fiber-based PTR instrument to measure the real-time, in-pile thermal diffusivity of nuclear fuels. The PTR technique measures the local temperature response from a modulated heat source by detecting the sample radiation heat flux. Initially a well-developed thermal wave analytical model was fit to the data to obtain the thermal diffusivity. However, systematic errors from the diffraction effect and non-linearity issues resulted in thermal diffusivity measurements higher than literature values. These effects have been studied and an improved analytical model has been developed, and the physics behind the phenomena are still under investigation. A procedure for optimizing measurements from the bench-top system has been provided. The experiences from the bench top measurement were then used to guide the fiber-based system.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Effect of Pore Connectivity on Li Dendrite Propagation within LLZO Electrolytes Observed with Synchrotron X-ray Tomography

Li 7 La 3 Zr 2 O 12 (LLZO) is a garnet type material that demonstrates promising characteristics for all solid-state battery applications due to its high Li-ion conductivity and its compatibility with Li metal. The primary limitation of LLZO is the propensity for short-circuiting at low current densities. Microstructure features such as grain boundaries, pore character, and density all contribute to this shorting phenomenon. Toward the goal of understanding structure-processing relationships for practical design of solid electrolytes, the present study tracks structural transformations in solid electrolytes processed at three different temperatures (1000, 1050 and 1150 °C) using synchrotron x-ray tomography. A sub volume of 300 μm 3 captures the heterogeneity of the solid electrolyte microstructure while minimizing the computational intensity associated with 3D reconstructions. While the porosity decreases with increasing temperature, the underlying connectivity of the pore region increases. In conclusion, solid electrolytes with interconnected pores short circuit at lower critical current densities than samples with less connected pores.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Catalytic water splitting kinetics and optimization

This project was motivated primarily by the opportunity of turning photocatalysis into a cost efficient hydrogen generation method for domestic energy and chemical production, and by the need to provide detailed mechanisms of photocatalytic reactions of broad scientific and technological interest. Specifically, we focused on the development of a new technique for analysis of (photo)catalytic reaction mechanisms to guide photocatalyst design. Our approach was based on applying velocity map imaging (VMI) to surface catalyzed reactions in order to identify photocatalytic reaction products, intermediates, and relate these to photocatalyst composition, dimensions, size and other characteristics. By coupling VMI with other spectroscopic and microstructural characterization, we aimed to reveal the features that limit performance of photocatalysis. As a first step to achieve this goal, we constructed a custom VMI microscope specifically designed for investigation of surface photocatalytic reactions and validated it’s design using a photodissociatinon of MnBr(CO) 5 adsorbed on a metallic surface. Using both 230 nm and 266 nm pulsed laser excitations, we observed that there are likely three main pathways for photodissociation of Mn(CO)5Br: from the gas phase, the surface, and ejected Mn complex from the surface increasing the gas phase concentration.

08 HYDROGEN↗
DOE OSTI2015

First Annual Progress Report on Radiation Tolerance of Controlled Fusion Welds in High Temperature Oxidation Resistant FeCrAl Alloys

The present report summarizes and discusses the first year efforts towards developing a modern, nuclear grade FeCrAl alloy designed to have enhanced radiation tolerance and weldability under the Department of Energy (DOE) Nuclear Energy Enabling Technologies (NEET) program. Significant efforts have been made within the first year of this project including the fabrication of seven candidate FeCrAl alloys with well controlled chemistry and microstructure, the microstructural characterization of these alloys using standardized and advanced techniques, mechanical properties testing and evaluation of base alloys, the completion of welding trials and production of weldments for subsequent testing, the design of novel tensile specimen geometry to increase the number of samples that can be irradiated in a single capsule and also shorten the time of their assessment after irradiation, the development of testing procedures for controlled hydrogen ingress studies, and a detailed mechanical and microstructural assessment of weldments prior to irradiation or hydrogen charging. These efforts and research results have shown promise for the FeCrAl alloy class as a new nuclear grade alloy class.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Evolution of microstructure and strength of a high entropy alloy undergoing the strain-induced martensitic transformation

In a recent work, we have reported outstanding strength and work hardening exhibited by a metastable high entropy alloy (HEA), Fe 42 Mn 28 Co 10 Cr 15 Si 5 (in at. %), undergoing the strain-induced martensitic transformation from metastable gamma austenite (γ) to stable epsilon martensite (ε). However, the alloy exhibited poor ductility, which was attributed to the presence of the brittle sigma (σ) phase in its microstructure. The present work reports the evolution of microstructure, strength, and ductility of a similar HEA, Fe 38.5 Mn 20 Co 20 Cr 15 Si 5 Cu 1.5 (in at. %), designed to suppress the formation of σ phase. A cast and then rolled plate of the alloy was processed into four conditions by annealing for 10 and 30 min at 1100 °C and by friction stir processing (FSP) at tool rotation rates of 150 and 400 revolutions per minute (RPM) to facilitate detailed examinations of variable initial grain structures. Neutron diffraction and electron microscopy were employed to characterize the microstructure and texture evolution. The initial materials had variable grain size but nearly 100% γ structure. Diffusionless strain induced γ→ε phase transformation took place under compression with higher rate initially and slower rate at the later stages of deformation, independent on the initial grain size. The transformation facilitated part of plastic strain accommodation and rapid strain hardening owing to a transformation-induced dynamic Hall-Petch-type barrier effect, increase in dislocation density, and texture. Here, the peak strength of nearly 2 GPa was achieved under compression using the structure created by double pass FSP (150 RPM followed by 150 RPM). Remarkably, the tensile elongation exhibited by the alloy was nearly 20% with fracture surfaces featuring a combination of ductile dimples and cleavage.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Comparison on the properties of ITZs in fly ash-based geopolymer and Portland cement concretes with equivalent flowability

Highlights: • Modelled ITZs can effectively avoid the effects caused by different factors and test locations of ITZ. • ITZ properties of PC and geopolymer concretes are compared based on equivalent flowability of binders. • Geopolymer ITZ exhibits stronger bonding than that of PC, and higher mechanical properties than geopolymer paste. • Strong ITZs in geopolymer concrete are attributed to the layer of gel-rich paste with dense microstructures. • Elastic modulus and hardness properties of ITZs in PC concrete are increased due to the CH crystals. This paper aims to compare the properties of interfacial transition zones (ITZs) in Portland cement (PC) concrete and geopolymer concrete. Portland cement and geopolymer pastes were designed with the equivalent flowability to provide similar mix and casting condition of ITZs. Two types of modelled ITZs were prepared to facilitate the nanoindentations across ITZs, microstructural characterization, and comparison on the properties of ITZs with less influential factors. The results showed that the interfacial bonding of ITZs between geopolymer matrix and aggregate is relatively stronger than the counterpart in the PC concrete. There is a high amount of crystalline hydration products in the ITZs of PC concrete, but a layer gel-rich paste with denser microstructures in the ITZs of geopolymer concrete. Additionally, the interface morphology and nanoindentation analysis indicate that the property of ITZs in the modelled geopolymer concrete is not poorer than that of the corresponding geopolymer paste.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Microstructure and mechanical behavior of a TiC nanoprecipitate strengthened V Alloy

The V-4Cr-4Ti (V44) alloys have been proposed as the prime candidate structural material for self-cooled liquid Li blanket and other designs for fusion energy applications. However, the applications of the V44 alloy are limited to a narrow operation temperature window, due to reduction in creep strength at or above 700 °C and susceptibility to irradiation hardening and embrittlement when irradiated below 400 °C. Here, in this work, we explore the feasibility of designing a novel V alloy to form a high number density of TiC nanoprecipitates, in order to simultaneously improve creep strength and provide defect sinks to mitigate irradiation hardening. Computational thermodynamics was used to design a new alloy (V44C) to achieve our goal of high TiC nanoprecipitates density within the alloy V44 matrix. To ensure scalability, the new alloy was made through arc-melting and ingot-casting followed by hot forging, cold rolling and heat treatments of homogenization and precipitation aging. The microstructure was characterized by SEM, TEM, XRD and APT, confirming the existence of nanoprecipitates predicted in the thermodynamic calculations. In addition to microstructural evaluation tensile properties at room temperature and 700 °C, and Charpy impact energy at room temperature were measured. The microstructure and mechanical properties were then compared with those from a historic reference V44 alloy. The tensile strength improvement in V44C was rationalized based on particle and solid solution strengthening mechanism. The fracture behavior was discussed based on the fractography results and necking deformation behavior.

Alloys development↗
DOE OSTI2025

Development of mechanistic, microstructure-informed BISON models for fission product-induced failure mechanisms in advanced nuclear fuels

The US continues to prioritize commercial deployment of advanced reactors—particularly those utilizing U-Zr metallic and TRISO particle fuels. Fission product-induced failure mechanisms for these systems include fuel–cladding chemical interaction in metallic fuel rods, which threatens cladding integrity, and Pd penetration in TRISO particles, which degrades SiC layer properties. Empirical models can be applied within the bounds of existing irradiation databases, but their utility is limited when considering new designs or investigating fundamental material behaviors. The Nuclear Energy Advanced Modeling and Simulation Program is therefore developing mechanistic models for these behaviors, which are expected to aid in fuel design, assist in development of failure mitigation strategies, and provide support for qualification and licensing. These efforts leverage multiscale capabilities to capture the microstructural features and processes that govern these behaviors. This talk summarizes past and ongoing efforts to develop and validate these models for the BISON fuel performance code.

FCCI↗
DOE OSTI2024

A Finite Difference informed Random Walk solver for simulating radiation defect evolution in polycrystalline structures with strongly inhomogeneous diffusivity

Diffusivity of species and defects on grain boundaries is usually several orders of magnitude larger than that inside grains. Such strongly inhomogeneous diffusivity requires prohibitively high computational demands for modeling microstructural evolution. Here, this paper presents a highly-efficient numerical solver, combining the Finite Difference method and Random Walk model, designed for accurately modeling strongly inhomogeneous diffusion within polycrystalline structures. The proposed solver, termed Finite Difference informed Random Walk (FDiRW), integrates a customized Finite Difference (cFD) scheme tailored for fast diffusion along thin grain boundaries represented by a single-layer of nodes. Numerical experiments demonstrate that the FDiRW solver achieves an impressive efficiency gain of 1560x compared to traditional Finite Difference methods while maintaining accuracy, making it feasible for personal computer machines to handle diffusional systems with strongly inhomogeneous diffusivity across static polycrystalline microstructures. The model has been successfully applied to simulate radiation defect evolution, showcasing its scalability to engineering scales in both length and time dimensions.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Large area InN terahertz emitters based on the lateral photo-Dember effect

Large area terahertz emitters based on the lateral photo-Dember effect in InN (indium nitride) are presented. The formation of lateral photo-Dember currents is induced by laser-illumination through a microstructured metal cover processed onto the InN substrate, causing an asymmetry in the lateral photogenerated charge carrier distribution. Our design uses simple metal structures, which are produced by conventional two-dimensional micro-structuring techniques. Having favoring properties as a photo-Dember material InN is particularly well-suited as a substrate for our emitters. We demonstrate that the emission intensity of the emitters can be significantly influenced by the structure of the metal cover leaving room for improvement by optimizing the masking structures.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

In situ irradiation of spent nuclear fuels

To improve the economics of commercial nuclear reactors, nuclear vendors and utilities are seeking approval for increased burnup usage of the existing nuclear fleet. This is especially critical for meeting the clean energy initiative by the United States Government, Department of Energy (DOE). However, one of the key challenges the nuclear industry faces in this regard is that the regions exposed to high burnup and low temperatures exhibit a fine-grained microstructure with large bubbles known as high-burnup structure (HBS) [1]. The formation of HBS has been correlated to the diminished performance of the reactor, as well as fuel fragmentation and pulverization during transient and accidental conditions [2]. Therefore, it is paramount to understand the mechanisms for HBS formation along with its impact on the properties and performance of nuclear fuels. While existing programs, such as Nuclear Energy Advanced Modeling and Simulation (NEAMS) and Advanced Fuel Campaign (AFC) are focusing on evaluating the performance impact of HBS, the physical mechanisms contributing to HBS formation are still not fully understood. In addition, having predictive capabilities and sound understanding of the microstructural evolution of nuclear fuel is essential for accelerated development, qualification, and deployment of new nuclear materials and novel reactor designs for advanced nuclear reactors. There is a lack of consensus among researchers regarding the mechanisms leading to such restructuring observed in HBS. Grain subdivision due to polygonization versus recrystallization, continuous versus discrete recrystallization occurring in tandem or conjunction, etc., have been proposed and debated. In general, it is hypothesized that defect accumulation and dislocation interaction within the grains cause the realignment of dislocations into grain boundaries, leading to the new subgrain formation, which over time transforms into new grains. However, due to the lack of transient data, the importance of fission rate, irradiation, thermal, and stress history of the fuel on the restructuring could not be assessed. In situ microstructural evolution under various irradiation conditions is desired to bridge this gap. Alternatively, phase-field-based models have been developed to capture HBS formation via discrete recrystallization utilizing the classical nucleation approach [3–5]. However, in these models, the grain nucleation criteria are often defined based on empirical relations for burnup and fission gas density leading to dislocation density change. A mechanistic approach to capture the dislocation interaction with the microstructural features leading to grain subdivision is lacking.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Evaluation of MSNDs for Fast-Neutron Detection and the TREAT Hodoscope

The need for next-generation, accident-tolerant fuels has generated significant interest in the restart of domestic fuels testing at the Transient Reactor Test (TREAT) facility. A key feature of the TREAT reactor core is an open, horizontal channel that allows line-of-sight viewing of test specimens using various instrumentation during steady-state and transient operation. This instrumentation includes the hodoscope, which consists of over 300 steel-collimated channels coupled to Hornyak buttons (and other detectors) for detection of fast neutrons emitted from fission of the test specimen. Posterior analysis can be used to reconstruct fuel motion and other properties from the collimated channel signals. A large-scale effort is underway to develop next generation instrumentation for transient testing at TREAT (and, potentially, other facilities). Work at KSU specifically aims to provide improved detection systems for hodoscope applications. It was initially proposed to adapt KSU-developed Microstructured Semiconductor Neutron Detectors (MSNDs) for use as fast-neutron detectors. The current generation of MSNDs is designed for thermal-neutron detection based on {sup 6}Li and can achieve intrinsic efficiencies nearing 30% owing to the large (n, t) cross section of {sup 6}Li and clever optimization of the geometry. In order to evaluate MSNDs for fast-neutron detection, two approaches were considered: (1) use of a hydrogenous material to thermalize neutrons to exploit the intrinsic efficiencies of current MSNDs, and (2) substitution of a fast-sensitive reactant for {sup 6}Li. The former approach is attractive because it makes use of proven, off-the-shelf technology and leads to reasonable time resolution and efficiency. Unfortunately, use of thermalization leads to prohibitive degradation of spatial resolution. The second approach will require further experimental efforts, but scoping analyses suggest {sup 235}U- or {sup 237}Th-loaded MSNDs may achieve sufficient efficiencies. The rest of this summary examines these issues in more detail. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2011

Plasma Spray-Physical Vapor Deposition (PS-PVD) of Ceramics for Protective Coatings

In order to generate advanced multilayer thermal and environmental protection systems, a new deposition process is needed to bridge the gap between conventional plasma spray, which produces relatively thick coatings on the order of 125-250 microns, and conventional vapor phase processes such as electron beam physical vapor deposition (EB-PVD) which are limited by relatively slow deposition rates, high investment costs, and coating material vapor pressure requirements. The use of Plasma Spray - Physical Vapor Deposition (PS-PVD) processing fills this gap and allows thin (< 10 microns) single layers to be deposited and multilayer coatings of less than 100 microns to be generated with the flexibility to tailor microstructures by changing processing conditions. Coatings of yttria-stabilized zirconia (YSZ) were applied to NiCrAlY bond coated superalloy substrates using the PS-PVD coater at NASA Glenn Research Center. A design-of-experiments was used to examine the effects of process variables (Ar/He plasma gas ratio, the total plasma gas flow, and the torch current) on chamber pressure and torch power. Coating thickness, phase and microstructure were evaluated for each set of deposition conditions. Low chamber pressures and high power were shown to increase coating thickness and create columnar-like structures. Likewise, high chamber pressures and low power had lower growth rates, but resulted in flatter, more homogeneous layers

Harder, Bryan J.↗
DOE OSTI2018

Influence of Process-Induced Anisotropy and Synovial Environment on Wear of EBM Built Ti6Al4V Joint Implants

Additive manufacturing (AM) technology is identified as an ideal solution to overcome challenges in design and manufacturing of complex components. However, the layered fashion of AM process result in directionally solidified microstructures on the system. The anisotropic surface texture will affect wear and corrosion resistance. The current study investigates tribological responses of AM-made Ti6Al4V for joint implant applications during the combined effect from synovial lubrication and process-induced surface structure on surface fatigue damage response. Electron beam melting was used to produce Ti6Al4V specimens and mechanical characterizations were performed using nanoindentation and micro bending tests to determine their mechanical properties. A series of pin-on-disk wear tests were performed to quantify sliding contact fatigue damage in three simulated synovial fluids with variable concentrations of bovine serum albumin and hyaluronic acid in the PBS solution. Physical properties of simulated synovial fluids were measured using a nanoindenter-based technique and correlated to fatigue wear response. The lower wear rate is found in greater protein concentrations. The results presented AM build direction significantly affects sliding fatigue wear resistance on TI6Al4V surface in all synovial environments.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Development of cast alumina-forming austenitic stainless steels

Cast Fe-Ni-Cr chromia-forming austenitic stainless steels with Ni levels up to 45 wt. % are used at high temperatures in a wide range of industrial applications that demand microstructural stability, corrosion resistance, and creep strength. Although alumina scales offer better corrosion protection at these temperatures, designing cast austenitic alloys that form a stable alumina scale and achieve creep strength comparable to existing cast chromia-forming alloys is challenging. This work outlines the development of cast Fe-Ni-Cr-Al austenitic stainless steels containing about 25 wt. % Ni with good creep strength and the ability to form a protective alumina scale for use at temperatures up to 800 C - 850 C in H 2 O-, S-, and C- containing environments. Creep properties of the best alloy were comparable to that of HK-type cast chromia-forming alloy along with improved oxidation resistance typical of alumina-forming alloys. Lastly, challenges in the design of cast alloys and a potential path to increasing the temperature capability are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Microstructure Evolution and Mechanical Response of Nanolaminate Composites Irradiated with Helium at Elevated Temperatures

In this paper, we summarize recent work on helium (He) interaction with various heterophase boundaries under high temperature irradiation. We categorize the ion-affected material beneath the He-implanted surface into three regions of depth, based on the He/vacancy ratio. The differing defect structures in these three regions lead to the distinct temperature sensitivity of He-induced microstructure evolution. The effect of He bubbles or voids on material mechanical performance is explored. Finally, overall design guidelines for developing materials where He-induced damage can be mitigated in materials are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Advances and perspectives of hard carbon anode modulated by defect/hetero elemental engineering for sodium ion batteries

Sodium-ion batteries (SIBs) serve as a promising complement to lithium-ion batteries for large-scale energy storage, leveraging the abundance of sodium resources and notable safety advantages. The key advancement in SIB industrialization hinges on identifying a cost-effective and high-performance anode material, similar to the graphite anode in lithium-ion batteries. Hard carbon emerges as prime anode materials for SIBs, boasting high specific capacity, low sodium storage potential, and wide availability. However, practical applications of hard carbon encounters challenges such as low initial Coulombic efficiency (ICE), inadequate long-term cycling stability, and poor rate performance. Recent research has focused on the optimization of hard carbon electrodes through functional design. In this comprehensive review, we have meticulously examined the progress in enhancing sodium storage performance through microstructural modulation within hard carbon, encompassing four pivotal aspects: heteroatom doping, incorporation of oxygen functional groups, surface coating, and intrinsic defect engineering. Progress in implementing these strategies is scrutinized, while the merits and challenges of each defect engineering approach are discussed. In conclusion, this review also looks into forthcoming opportunities and challenges in the practical application process of hard carbon electrodes in SIBs.

25 ENERGY STORAGE↗
DOE OSTI2020

Database development and exploration of process–microstructure relationships using variational autoencoders

The paper demonstrates graphical representation of a large database containing process–microstructure relationships using an unsupervised machine learning algorithm. Correlating microstructural features to processing is an essential first step to answer the difficult problem of process sequence design. Here, a large database of 346,200 orientation distribution functions resulting from a variety of process sequences is constructed, where each sequence comprises up to four stages of tension, compression and rolling along different directions in various permutations. This open-source database is constructed for collaborative development of process design algorithms. The paper demonstrates a novel application of the large database: graphical representation of texture–process relationships. A variational autoencoder is used to reduce the entire database to a two dimensional latent space where variations in processes and properties can be visualized. Using proximity analysis in this latent space, we can quickly unearth multiple process solutions to the problem of texture or property design.

36 MATERIALS SCIENCE↗