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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Evolution of noncollinear magnetism in magnetocaloric MnPtGa

MnPtGa crystallizes in the hexagonal Ni 2 In structure type in space group P6 3 /mmc and has been reported to display a ferromagnetic Curie temperature near 220K. Here we find a transition near T c = 236 K to a ferromagnetic state, albeit with a reduced moment from what is expected for collinear ordering. The peak magnetocaloric entropy change was determined to be ΔS M = –1.9 J kg –1 K –1 for an applied magnetic field of H = 5 T at the ferromagnetic ordering temperature. Magnetostructural coupling manifests as a change in the slope of the thermal expansion coefficients of the c lattice parameter near T c , with a negative spontaneous volume magnetostriction; ω = –300 ppm at 190K. In this work, neutron powder diffraction studies of the magnetic ground state reveal an evolution in complexity as temperature decreases: from a ferromagnet, to a canted antiferromagnet, to the eventual formation of a spin-density-wave state at low temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Scaling patch analysis of turbulent planar plume

Proper scaling in turbulent planar plumes is investigated in this study using a scaling patch approach. Based on the scaled boundary conditions, a proper velocity scale for the mean axial flow is the plume centerline velocity U ref = U ctr , and a proper temperature scale for the temperature excess is Θ ref = T ctr – T ∞ , where T ctr is the plume centerline temperature and T ∞ is the ambient fluid temperature. By seeking an admissible scaling, a key concept in the scaling patch approach, for the mean continuity, mean momentum, and mean energy equations, respectively, the following is found: (1) a proper scale for the mean transverse flow is V ref = ( d δ / d x ) U ctr , where d δ / d x is the growth rate of the plume width. (2) A proper scale for the Reynolds shear stress is R vu , ref = U ctr V ref = ( d δ / d x ) U ctr 2 , a mix of the scales for the mean axial and transverse flows. (3) A proper scale for the turbulent heat flux is R v θ , ref = V ref Θ ctr , a mix of the scales for the mean transverse flow and mean temperature excess. The mean transverse flow thus plays a critical role in the scaling of turbulent planar plumes. Approximate functions are developed for the scaled mean transverse flow, Reynolds shear stress, and turbulent temperature flux, and are found to agree favorably with experimental and numerical simulation data. The integral analysis of the mean momentum equation yields a Richardson number Ri, which remains invariant in the axial direction. The Richardson number is defined as Ri = def g β Θ ctr δ t / ( U ctr V ref ) ≈ 1 / 2 , where g is the gravitational acceleration, β is the thermal expansion coefficient, and δ t is the plume half-width based on the mean temperature profile. This Richardson number arises directly from the scaling patch analysis of the mean momentum equation, including both the streamwise and transverse velocity scales.

42 ENGINEERING↗
DOE OSTI2021

Using Computationally-Determined Properties for Machine Learning Prediction of Self-Diffusion Coefficients in Pure Liquids

The ability to predict transport properties of liquids quickly and accurately will greatly improve our understanding of fluid properties both in bulk and complex mixtures, as well as in confined environments. Such information could then be used in the design of materials and processes for applications ranging from energy production and storage to manufacturing processes. As a first step, we consider the use of machine learning (ML) methods to predict the diffusion properties of pure liquids. Recent results have shown that Artificial Neural Networks (ANNs) can effectively predict the diffusion of pure compounds based on the use of experimental properties as the model inputs. In the current study, a similar ANN approach is applied to modeling diffusion of pure liquids using fluid properties obtained exclusively from molecular simulations. A diverse set of 102 pure liquids is considered, ranging from small polar molecules (e.g., water) to large nonpolar molecules (e.g., octane). Self-diffusion coefficients were obtained from classical molecular dynamics (MD) simulations. Since nearly all the molecules are organic compounds, a general set of force field parameters for organic molecules was used. The MD methods are validated by comparing physical and thermodynamic properties with experiment. Computational input features for the ANN include physical properties obtained from the MD simulations as well as molecular properties from quantum calculations of individual molecules. Furthermore, fluid properties describing the local liquid structure were obtained from center of mass radial distribution functions (COM-RDFs). Feature sensitivity analysis revealed that isothermal compressibility, heat of vaporization, and the thermal expansion coefficient were the most impactful properties used as input for the ANN model to predict the MD simulated self-diffusion coefficients. The MD-based ANN successfully predicts the MD self-diffusion coefficients with only a subset (2 to 3) of the available computationally determined input features required. A separate ANN model was developed using literature experimental self-diffusion coefficients as model targets. Although this second ML model was not as successful due to a limited number of data points, a good correlation is still observed between experimental and ML predicted self-diffusion coefficients.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Warpage-Resistant, Under-Extrusion-Free, High-Surface-Quality Additive Manufacturing Process for Polyethylene-Based Composite Radiation Shielding Material

Polyethylene (PE) is one of the best shielding materials for primary space radiation due to its high hydrogen content. For effective secondary neutron shielding, boron-rich fillers are incorporated to enhance performance. The semicrystalline nature and high thermal expansion coefficient of PE impede its adoption for in situ additive manufacture in space via the fused deposition modeling (FDM) 3D printing. Here, we developed an optimized PE blend to mitigate the effects of under-extrusion and warpage. Guided by studies on extrusion and warpage, we developed an optimal set of printing parameters for the proposed PE blend. The optimum PE blend─both in its pure form and when doped with fillers─has been tested on different FDM printers. The printed structures exhibit high and uniform density, smooth surfaces, no warpage, and competitive mechanical properties. The FDM-printed plates demonstrate efficient shielding from thermal neutrons, predicted via modeling and confirmed experimentally using extended Q-range small-angle neutron scattering.

additive manufacturing↗
DOE OSTI2023

Dependence of predicted bulk properties of hexagonal hydroxyapatite on exchange-correlation functional

Hydroxyapatite (HA) is the main component of human bones and teeth. HA has also been widely applied in various technological fields due to its unique properties. Reliable computational simulations for this critical material often require input parameters obtained from the first-principles density functional theory (DFT) calculations with appropriate exchange–correlation functionals. Previous DFT calculations are insufficient to verify the reliabilities of various functionals, particularly as they fail to assess predictions for multiple properties of the material. In this paper, we first select 18 different functionals to calculate geometric, elastic, electronic, and thermodynamic properties of hexagonal HA bulk crystal. We find that the results from optB86b-vdW and optB88-vdW functionals with dispersion corrections have the overall best agreement with available experimental data. Then, we choose optB88-vdW functional, as well as PBE functional without dispersion corrections as a comparison, to perform extensive first-principles DFT phonon calculations under the quasiharmonic approximation. Various thermodynamic properties (including phonon contributions to internal energy, entropy, and Helmholtz free energy) and thermal parameters (including thermal expansions of volume, thermal expansion coefficients, heat capacities, isothermal bulk moduli, etc.) versus temperature are consequently obtained. By comparing these quantities, we report that the results from optB88-vdW functional have significantly better agreement with available experimental data than those from PBE functional although the latter has been widely used in previous DFT calculations for HA-based material systems.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Autonomous Fracture Conductivity Using Expandable Proppants in Enhanced Geothermal Systems

Summary Early thermal breakthrough in enhanced geothermal systems (EGS) due to the presence of preferential flow channels is a major challenge that endangers efficient and economic heat extraction in such systems. Previous studies mainly focused on adjusting circulation rates of the working fluid, which still leaves significant amounts of untapped heat behind. Currently, there is a lack of technologies for altering flow distribution within the fracture network to achieve uniform heat sweeping in the reservoir. This work presents a novel concept for making proppants to autonomously control fracture conductivity based on the surrounding temperature. Here, proppants with negative thermal expansion coefficients have demonstrated the capability for appropriate fracture conductivity adjustment as a function of temperature to achieve uniform flow across the fracture network. Particle-particle interactions governing such functions are explicitly modeled, and then the Lattice Boltzmann methods (LBM) is used to determine the potential impact of closure stress and temperature changes on the permeability of the proposed proppant packs. Microscale analyses are further used to determine the required material properties to achieve a certain improvement in the permeability of the proppant pack. Our analyses show an enhancement in permeability and the associated fracture conductivity by half of their initial values. Field-scale analysis further confirms the effectiveness of the proposed concept as 31.4% more heat can be extracted from EGS over 50 years of production when the proposed proppants are used. Such novel proppants may effectively delay thermal breakthrough, sweep heat from larger rock volumes, and elongate the life span of the EGS project.

Engineering↗
DOE OSTI2025

Thermal expansion of LaB 6 from 298 to 998 K

We propose LaB 6 as a temperature calibration standard for high-temperature (HT) X-ray diffractometry owing to its high temperature stability. Such HT applications require a reliable HT lattice parameter or, equivalently, peak position data, which have not been readily accessible to the diffraction community to date. As such, the thermal expansion behavior of NIST SRM 660a LaB6 was assessed in the temperature range 298–998 K using HT Bragg–Brentano parafocusing θ:θ X-ray diffractometry in conjunction with Rietveld analysis. Data were collected in the 2θ range 20–150° at a data collection rate of 0.5° θ min −1 in air and at 1 atm. The temperature was stepped in 50 K increments. The cubic unit-cell lattice parameter [a(T)] of LaB 6 in Å was found to vary as a(T) = 4.15678 (±0.00001) + Ξ(T − 298 K) + Ψ(T − 298 K) 2 , where Ξ = 2.4645 × 10 −5 (±4.8904 × 10 −8 ) Å K −1 and Ψ = 1.0325 × 10 −8 (±6.7376 × 10 −11 ) Å K −1 . The isobaric volume thermal expansion coefficient (TEC) was obtained as α V P = (5.9291 × 10 −6 ) + (4.9680 × 10 −9 )(T − 298 K) K −1 , from which the corresponding linear TEC was obtained as α L P = (1.9764 × 10 −6 ) + (1.6560 × 10 −9 )(T − 298 K) K −1 . The 3 × 3 matrix representations of the single-crystal isobaric linear TEC and the volume expansivity were obtained for the cubic crystal class to which LaB 6 belongs. Also, the temperature dependence of the lattice parameter data of this study was compared with past landmark studies on LaB 6 by Dutchak et al. [Inorg. Mater. (1972), 8, 1877–1880] and Aivazov et al. [Inorg. Mater. (1979), 15, 1015–1016].

LaB6 standard material↗
DOE OSTI2022

Fabrication and accelerated long-term stability test of asymmetrical hollow fiber-supported thin film oxygen separation membrane

Asymmetrical hollow fiber-supported thin film membrane may provide microstructural advantages for air separation and oxygen production. The fabrication of such a membrane is usually very difficult, particularly the sintering behaviors and thermal expansion coefficient (TEC) mismatch among multiple layers. This directly affects the reliability and long-term stability of the membrane. Here, in this research, the sintering behaviors of a set of simple oxides are systematically studied and ZnO is identified as a material component for composite substrate La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3-δ (LSCF)-ZnO. The LSCF-ZnO ratios are further optimized by trading off several factors, e.g., matching the sintering behaviors and TECs of the LSCF-ZnO composite with those of LSCF thin film separation layer while enhancing the substrate strength. With the identified LSCF-ZnO ratio, the LSCF-ZnO composite hollow fiber substrate precursor is formed through slurry spinning process with porous microstructure being formed via phase inversion process. The thin film LSCF dense separation layer is then dip-coated on the substrate followed by co-sintering process. A thin, porous PrBaCo(Fe 0.6 Zr 0.2 Y 0.2 )O 5+δ (PBCFZY) catalyst layer is fabricated on the dense LSCF separation layer with dip-coating and sintering process, forming an asymmetrical membrane device LSCF-ZnO/LSCF/PBCFZY. Oxygen permeation test of the device is systematically conducted, and the fundamental mechanisms are analyzed. An accelerated long-term stability test of the membrane is also conducted (~550h, 46 thermal cycling loads), demonstrating excellent robustness and durability. The device is characterized and analyzed before and after the test. By replacing a considerable amount of high cost LSCF with low cost ZnO in the substrate, it not only enhances the stability but also reduces the capital cost of the membrane for practical applications.

42 ENGINEERING↗
DOE OSTI2022

Microstructure of Methylammonium Lead iodide Perovskite Thin Films: A Comprehensive Study of the Strain and Texture

Controlling the microstructure of hybrid halide perovskite thin films is essential for optimizing their performance in optoelectronic devices. It is well established that the strain state of the perovskite layer affects its stability. Likewise, the orientation of the perovskite lattice is a determining parameter as these materials have shown pronounced anisotropies in their physical and mechanical properties. In this work, the authors focus on the understanding of the mechanisms that govern the strain and texture observed in MAPbI 3 thin films deposited on various oxide substrates. A thorough study of the evolution of the strain of the perovskite layer upon cooling down to room temperature from the crystallization temperature (100 °C) shows an essentially relaxed behavior of the perovskite layers. This result contradicts the commonly accepted hypothesis according to which MAPbI 3 layers synthesized above ambient temperature are strained due to the large mismatch in the thermal expansion coefficients of the perovskite and its substrate. The texture in MAPbI 3 layers is investigated by means of synchrotron full-field diffraction X-ray microscopy. This technique allows the direct observation of the [hh0] and [00l]-oriented domains at the origin of the observed textures, demonstrating both their twin and ferroelastic nature. The stability of the different domain orientations is investigated by DFT calculations, illustrating the determining role of the chemical environment at the film-substrate interface. PbI 2- terminated surfaces are found to favor the [hh0] orientations while for MAI-terminated ones, both [hh0] and [00l] domains are equally stabilized. The different results constitute an important step of clarification and understanding from the perspective of controlling the microstructure of perovskite layers.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Oxidation Behavior of Heat-Resistant Type $\mathrm{HK}$ Steel ($\mathrm{HK30Nb}$) at 800 °C

We report the cyclic oxidation behavior of HK30Nb heat-resistant steel processed by laser powder bed fusion (LPBF) was compared to its cast counterpart during exposures in air and air + 10% H 2 O at 800 °C. The specific finer microstructure and lower Mn of the LPBF alloy resulted in lower oxidation rates in dry air and faster establishment of a continuous Cr 2 O 3 scale in air + 10% H 2 O compared to coarse-grained cast HK30Nb with higher Mn. Differences in alloy mechanical strength and therefore their ability to accommodate high temperature and oxidation-induced stresses as well as differences in thermal expansion coefficients between the alloy and the formed oxides (Cr 2 O 3 only for the LPBF and Cr 2 O 3 and MnCr 2 O 4 for the cast specimens) during temperature cycling were found to result in a greater extent of spallation for the LPBF than for the cast alloy in dry air at 800 °C.

36 MATERIALS SCIENCE↗
DOE OSTI2020

First-principles study on the mechanical and thermodynamic properties of MoNbTaTiW

Refractory high-entropy alloys (RHEAs) are emerging as new materials for high temperature structural applications because of their stable mechanical and thermal properties at temperatures higher than 2273 K. In this study, the mechanical properties of MoNbTaTiW REDEA are examined by applying calculations based on first-principles density functional theory (DFT) and using a large unit cell with 100 randomized atoms. The phase calculation of MoNbTaTiW with CALPHAD method shows the existence of a stable body-centered cubic structure at a high temperature and a hexagonal closely packed phase at a low temperature. The predicted phase, shear modulus, Young’s modulus, Poisson’s ratio, and hardness values are consistent with available experimental results. The linear thermal expansion coefficient, vibrational entropy, and vibrational heat capacity of MoNbTaTiW RHEA are investigated in accordance with Debye-Grüneisen theory. These results may provide a basis for future research related to the application of RHEAs.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Multiscale porosity characterization in additively manufactured polymer nanocomposites using micro-computed tomography

Extrusion-based additive manufacturing (AM) of polymer composites exhibits complex thermally driven phenomena that introduce severe discontinuities in the internal structure across length scales, especially voids or porosity. This study utilizes a high-throughput porosity characterization technique to analyze large datasets from numerous micro-computed tomography (mu CT) scans to capture the influence of AM print parameters on the size, shape, and location of porosity across multiple print layers (up to a few cm) on fused granular fabrication (FGF) printers. The materials investigated include nanocomposite formulations based on commercially relevant nylon-12 and polyether ketone ketone (PEKK) materials comprising nano- or micro- sized fillers. The estimated global porosity follows an inverse linear correlation against the bulk density of the printed samples. Increasing the extrusion multiplier (EM) and the nozzle temperature while decreasing the print speeds reduces the global porosity. Outlier analyses (local porosity morphology) show that faster print speeds and higher extrusion rates result in long, slender inter-layer voids, while lower nozzle temperatures lead to large, symmetrical, inter-bead voids (at the bead junction). Lack of active chamber temperature increases inter-layer and intra-bead voids with a two-fold increase in global porosity. Overall, the micro filler-reinforced composites exhibit higher global porosity than nanofiller-reinforced composites, which is attributed to the increased mismatch in the thermal expansion coefficient between the filler and the polymers used in the study.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Microstructure characteristics of LPBF&HIP fabricated graded composite transition joint between ferritic steel and austenitic stainless steel

Graded composite transition joints (GCTJs) offer a promising alternative to conventional dissimilar metal welds (DMWs) by enabling smooth compositional and microstructural transitions. However, GCTJs fabricated solely through additive manufacturing (AM) face challenges such as heat accumulation, complex parameter control, and elemental segregation. In this study, we propose a novel approach that relies on AM to design a spatially graded structure in one alloy and then employs hot isostatic pressing (HIP) as a diffusion bonding method to join it with a second alloy. Here, this method combines the flexibility of AM with the powder net-shaping advantage of HIP. Specifically, a series of closely packed austenitic stainless steel 304 conical structures were printed using laser powder bed fusion (LPBF) and then combined with ferritic steel P91 powder via HIP. By using electron backscatter diffraction (EBSD), electron probe microanalysis (EPMA), and transmission electron microscopy (TEM) techniques, the microstructure characteristics of the GCTJ of 304&P91, especially the interdiffusion zone (IDZ), have been systematically investigated. The microstructure at the interface transitions from austenite-ferrite (A+F) to austenite-martensite-ferrite (A+M+F), and finally to martensite-ferrite (M+F) due to diffusion. Additionally, the diffusion width between 304 and P91 increases with the volume fraction of P91. This unique design also ensures a gradual transition in both hardness and thermal expansion coefficient from 304 to P91, thereby enabling a smooth gradient in functional properties. Overall, this study proposes a novel approach for fabricating GCTJs and contributes to advancing design concepts in the field of dissimilar metal joining.

Additively manufacturing (AM)↗
DOE OSTI2022

Conceptual core design of the molten metal fueled microreactor with self-regulating capability

The microreactor concept has received significant attention in the United States for its lower capital investment, siting flexibility and high mobility. A microreactor aims to provide reliable electricity in remote communities, mining areas, or isolated islands, which will save the high fuel transportation cost. Thus, minimizing the staff level for operating and maintaining a microreactor is desirable. The objective of the study is to design a self-regulated Molten Metal fueled microReactor core (MMR) and to demonstrate the self-regulating capability of the MMR core. The control of the reactor is solely relying on reactivity feedbacks from fuel temperature perturbation. Molten UMn (liquid form at the temperature over 720°C) was utilized as the fuel material in MMR due to the larger thermal expansion coefficient compared to the conventional solid fuel. The MMR core has a fast neutron spectrum, which corresponds to a small burnup reactivity swing. The core design parameters were selected based on DAKOTA, REBUS, and ANLHTP calculations. The MMR is designed to run for 10 years at a power level of 15 MWth. Furthermore, no refueling is needed during the reactor lifetime. The system dynamic analyses were performed, and it was found that the reactor can be self-regulating within a temperature range of 800 ± 80°C for a loss of heat sink transient.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Electrical, thermal, and H 2 O and CO 2 poisoning behaviors of PrNi 0.5 Co 0.5 O 3-δ electrode for intermediate temperature protonic ceramic electrochemical cells

PrNi 0.5 Co 0.5 O 3-δ (PNC) exhibits adequate total electrical conductivity (~300 S/cm at 400–600 °C) and moisture has no significant effect on it. The thermal expansion coefficient of PNC is 17.6 × 10 –6 /K by dilatometry and 18.43 × 10 –6 /K by in situ XRD. PNC also demonstrates chemical stability against H 2 O and CO 2 . However, PNC symmetrical cell over proton-conducting BaZr 0.4 Ce 0.4 Y 0.1 Yb 0.1 O 3-δ (BZCYYb4411) electrolyte shows significant H 2 O and CO 2 poisoning when those are introduced into O 2 –N 2 mixture. In comparison, symmetrical cells with PNC electrode over the oxygen ion conducting Ce 0.9 Gd 0.1 O 2-δ (GDC) electrolyte show no H 2 O and CO 2 poisoning under similar conditions. Here, it is hypothesized that poisoning from H 2 O and CO 2 of the PNC proton conducting symmetrical cell is caused by their adsorption on the BZCYYb4411 electrolyte instead of PNC electrode. Such a hypothesis is supported by the H 2 O and CO 2 adsorption behaviors on PNC and BZCYYb4411 powder surfaces, as measured by temperature programmed desorption (TPD).

08 HYDROGEN↗
DOE OSTI2024

Mitigation of distortion of Al/steel part under simulated paint baking condition: Experiment and numerical model studies

Multi-material joining of lightweight structures is essential to reduce vehicle weight for more energy savings and less greenhouse gas emission. However, mismatch of thermal expansion coefficient for dissimilar materials during the paint baking process can induce part distortion and joint failure for adhesive bonding. Here, in the present work, a thermomechanical model based on contact mechanics and large deformation theory was developed for dissimilar high-strength Al alloy and steel components to study the distortion mechanism and influential factors of the residual gap. The established model was used to optimize joint conditions, such as pitch distance and part geometry. When a weld pitch is shorter than 100 mm, the maximum gap between Al and steel part can be greatly reduced to 0.1 mm, and the local stress and plastic strain around the joint during the oven heating and cooling cycle are also substantially reduced compared with the long pitch case (900 mm). The numerical modeling results revealed that a comparable bending stiffness ratio between the steel and Al cross sections is critical to the minimization of gap and distortion under paint baking condition. Digital image correlation technique was used to measure the overall part distortion and local strain distribution that were used to validate the model prediction. Weld bonding (adhesive bonding with friction bit joining) process was successfully employed to join Al to steel component without gap opening in adhesive after the paint baking and cooling.

36 MATERIALS SCIENCE↗
DOE OSTI2022

An ab initio molecular dynamics investigation of the thermophysical properties of molten NaCl-MgCl 2

Molten salts have many applications in the nuclear and solar energy industries for thermal storage and heat transfer applications. However, there is a knowledge gap in molten salt thermophysical properties which hinders the technical readiness level of molten salt applications, especially in the nuclear industry. A common method of investigating new materials is through ab initio Molecular Dynamics (AIMD) simulations which is an effective tool to investigate structural and thermophysical properties at realistic temperatures. NaCl-MgCl 2 is an inexpensive salt that is a good candidate for use as a heat transfer medium in solar power applications or in the secondary loop of a nuclear reactor. In this article, the thermophysical properties of NaCl-MgCl 2 are computed via AIMD calculations to supplement the limited experimental studies in the literature. Here a wide range of compositions and temperatures for the pseudo-binary NaCl-MgCl 2 were used to calculate the density, heat capacity, compressibility, enthalpy of mixing, and volumetric thermal expansion coefficient. AIMD is shown to accurately model the densities of molten NaCl-MgCl 2 as there is good agreement with the available literature. This work observed a transition to a monotonic increase of the density with respect to MgCl 2 composition occurring above 1100 K. The heat capacity values increase uniformly with respect to concentration of MgCl 2 at a rate of 2.85 J/mol-K per 10 mol% of MgCl 2 . Select thermophysical properties are fit to a Redlich-Kister expansion for utilization in multiphysics simulations.

36 MATERIALS SCIENCE↗