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NASA NTRS1981

Development and validation of cryogenic foam insulation for LH2 subsonic transports

Fourteen foam insulation specimens were tested. Some were plain foam while others contained flame retardants, chopped fiberglass reinforcement and/or vapor barriers. The thermal performance of the insulation was determined by measuring the rate at which LH2 boiled from an aluminum tank insulated with the test material. The test specimens were approximately 50 mm (2 in.) thick. They were structurally scaled so that the test cycle would duplicate the maximum thermal stresses predicted for the thicker insulation of an aircraft liquid hydrogen fuel tank during a typical subsonic flight. The simulated flight cycle of approximately 10 minutes duration heated the other insulation surface to 316 K (110 F) and cooled it to 226 K (20 F) while the inner insulation surface remained at liquid hydrogen temperature of 20 K (-423 F). Two urethane foam insulations exceeded the initial life goal of 2400 simulated flight cycles and sustained 4400 cycles with only minor damage. The addition of fiberglass reinforcement of flame retardant materials to an insulation degraded thermal performance and/or the life of the foam material. Installation of vapor barriers enhanced the structural integrity of the material but did not improve thermal performance. All of the foams tested were available materials; none were developed specifically for LH2 service.

Anthony, F. M.↗

NASA NTRS1993

Combustion for future supersonic transport propulsion

Even with it's marginal performance, Concorde has demonstrated that supersonic civil aircraft are a practical proposition. A second generation machine will need sufficiently good performance for a robust operating system that can provide reliable, frequent service with competitive economics. Additionally, the propulsion system must be acceptable environmentally. That is it must create acceptable noise levels around airports and have acceptable emissions throughout its mission including cruise. Whatever devices may be used to improve the acceptability at subsonic flight conditions, the high operating temperatures at cruise can create difficult targets for the operation of the combustion system both mechanically and in the combustion process itself. While the driving force is ever better fuel consumption and weight to achieve economic viability, a future supersonic transport engine will have cycle temperatures limited only by the mechanical integrity of the major components. The environment of the major components in modern gas turbine engines is dominated by the air delivered by the compressor system. Consequently the maximum compression temperature is governed by materials available for the turbine and compressor discs. The continued improvement of the disc material leads to combustion inlet temperatures beyond today's experience and sets difficult targets for combustion system emissions. This is worsened by the requirement being at cruise and therefore maintained for the major part of the mission. Problems such as creep and oxidation of metallic parts are also considered.

B. W. Lowrie↗

NASA NTRS1998

Stratified Diffractive Optic Approach for Creating High Efficiency Gratings

Gratings with high efficiency in a single diffracted order can be realized with both volume holographic and diffractive optical elements. However, each method has limitations that restrict the applications in which they can be used. For example, high efficiency volume holographic gratings require an appropriate combination of thickness and permittivity modulation throughout the bulk of the material. Possible combinations of those two characteristics are limited by properties of currently available materials, thus restricting the range of applications for volume holographic gratings. Efficiency of a diffractive optic grating is dependent on its approximation of an ideal analog profile using discrete features. The size of constituent features and, consequently, the number that can be used within a required grating period restricts the applications in which diffractive optic gratings can be used. These limitations imply that there are applications which cannot be addressed by either technology. In this paper we propose to address a number of applications in this category with a new method of creating high efficiency gratings which we call stratified diffractive optic gratings. In this approach diffractive optic techniques are used to create an optical structure that emulates volume grating behavior. To illustrate the stratified diffractive optic grating concept we consider a specific application, a scanner for a space-based coherent wind lidar, with requirements that would be difficult to meet by either volume holographic or diffractive optic methods. The lidar instrument design specifies a transmissive scanner element with the input beam normally incident and the exiting beam deflected at a fixed angle from the optical axis. The element will be rotated about the optical axis to produce a conical scan pattern. The wavelength of the incident beam is 2.06 microns and the required deflection angle is 30 degrees, implying a grating period of approximately 4 microns. Creating a high efficiency volume grating with these parameters would require a grating thickness that cannot be attained with current photosensitive materials. For a diffractive optic grating, the number of binary steps necessary to produce high efficiency combined with the grating period requires feature sizes and alignment tolerances that are also unattainable with current techniques. Rotation of the grating and integration into a space-based lidar system impose the additional requirements that it be insensitive to polarization orientation, that its mass be minimized and that it be able to withstand launch and space environments.

Chambers, Diana M.↗

NASA NTRS1978

Development and evaluation of elastomeric materials for geothermal applications

A material for a casing packer for service for 24 hours in a geothermal environment was developed by synthesis of new elastomers and formulation of available materials. Formulation included use of commercial elastomer gumstocks and also crosslinking of plastic (high Tg) materials. Fibrous reinforcement of fluorocarbon rubbers was emphasized. Organic fiber reinforcement did not increase hot properties significantly. Glass fiber reinforcement gave significant increase in tensile properties. Elongation was reduced, and the glass-reinforced composition examined so far did not hold up well in the geothermal environment. Colloidal asbestos fibers were also investigated. A few experiments with polyphenyl ether gave material with low tensile and high compression set. Available high styrene SBR compositions were studied. Work to date suggests that new synthetic polymers will be required for service in geothermal environments.

Mueller, W. A.↗

DOE OSTI2022

Understanding the Solution Dynamics and Binding of a PVDF Binder with Silicon, Graphite, and NMC Materials and the Influence on Cycling Performance

The impact of the binding, solution structure, and solution dynamics of poly(vinylidene fluoride) (PVDF) with silicon on its performance as compared to traditional graphite and Li 1.05 Ni 0.33 Mn 0.33 Co 0.33 O 2 (NMC) electrode materials was explored. Through refractive index (RI) measurements, the concentration of the binder adsorbed on the surface of electrode materials during electrode processing was determined to be less than half of the potentially available material resulting in excessive free binder in solution. Using ultrasmall-angle neutron scattering (USANS) and small-angle neutron scattering (SANS), it was found that PVDF forms a conformal coating over the entirety of the silicon particle. This is in direct contrast to graphite–PVDF and NMC–PVDF slurries, where PVDF only covers part of the graphite surface, and the PVDF chains make a network-like graphite–PVDF structure. Conversely, a thick layer of PVDF covers NMC particles, but the coating is porous, allowing for ion and electronic transport. The homogeneous coating of silicon breaks up percolation pathways, resulting in poor cycling performance of silicon materials as widely reported. These results indicate that the Si–PVDF interactions could be modified from a binder to a dispersant.

25 ENERGY STORAGE↗

NASA NTRS1992

Combustor materials requirements and status of ceramic matrix composites

The HSCT combustor will be required to operate with either extremely rich or lean fuel/air ratios to reduce NO(x) emission. NASA High Speed Research (HSR) sponsored programs at Pratt & Whitney (P&W) and GE Aircraft Engines (GEAE) have been studying rich and lean burn combustor design approaches which are capable of achieving the aggressive HSCT NO(x) emission goals. In both of the combustor design approaches under study, high temperature (2400-3000 F) materials are necessary to meet the HSCT emission goals of 3-8 gm/kg. Currently available materials will not meet the projected requirements for the HSCT combustor. The development of new materials is an enabling technology for the successful introduction to service of the HSCT.

Hecht, Ralph J.↗

DOE OSTI2025

Si-Cr-Al-Mn Alloy for High Specific Resistivity

Laboratory material produced in budget period one met the target resistivity, mechanical and magnetic requirements for the Go/No-Go decision to move to industrial trials. The chosen chemistry settled on a high Cr strategy, with moderate Mn and Al additions, providing a good comprise on core loss and induction with minimal impact on mechanical properties, important to successful downstream processing. Industrial trials began in budget period two with the chosen chemistry, referred to as Alloy X. Difficulties occurred during initial hot rolling trials. Reheating the material using the standard NOES practice caused slab cracking from high thermal gradients in areas exposed to the roof burners, this was solved using a modified reheat practice. High Cr caused poor dynamic recrystallization during hot rolling, which was solved using a modified hot rolling practice. The high Cr content of the steel also caused poor decarburization during final annealing, which necessitated lowering the melt carbon aim for the final heat, together with a modified decarburization practice. Steel was finished to final thicknesses of 0.20 – 0.50 mm and evaluated for magnetic and mechanical properties. Although the target core loss for the 0.25 and 0.35 mm material was not achieved, significant reductions in high frequency core loss were measured, compared to equivalent commercially available material. Alloy X at 0.35 mm showed a 26 % and 23 % improvement at 400 HZ and 1000 Hz respectively, over Cliffs’ M-19 (0.35 mm) commercially available NOES. At 0.25 mm, Alloy X showed a 23 % and a 26 % improvement at 400 HZ and 1000 Hz respectively, over Cliffs’ HF-10 (0.25 mm) commercially available NOES. The 0.25 mm product was chosen for motor efficiency evaluation. ORNL collaborated with Cleveland-Cliffs (CC) to build, assemble, and test two 5HP motors: a baseline motor with M19 steel and a motor made with high efficiency steel (Alloy X) developed for the project. Overall, results were as expected with comparable performance at low speeds, and with more than 8% efficiency improvement for high speeds. Increased motor steel efficiency at high frequencies not only results in direct efficiency improvements but can yield reductions in motor size and cost by facilitating higher operation speeds, or by increasing the number of poles in the machine. This allows the production of more power-dense motors which are sometimes avoided with conventional material due to increased core losses. The material developed on this project provides more viable options for achieving improved motor efficiency or reduced motor size and cost.

36 MATERIALS SCIENCE↗

NASA NTRS1998

High Performance Materials Applications to Moon/Mars Missions and Bases

Two classes of material processing scenarios will feature prominently in future interplanetary exploration: in situ production using locally available materials in lunar or planetary landings and high performance structural materials which carve out a set of properties for uniquely hostile space environments. To be competitive, high performance materials must typically offer orders of magnitude improvements in thermal conductivity or insulation, deliver high strength-to-weight ratios, or provide superior durability (low corrosion and/or ablative character, e.g., in heat shields). The space-related environmental parameters of high radiation flux, low weight, and superior reliability limits many typical aerospace materials to a short list comprising high performance alloys, nanocomposites and thin-layer metal laminates (Al-Cu, Al-Ag) with typical dimensions less than the Frank-Reed-type dislocation source. Extremely light weight carbon-carbon composites and carbon aerogels will be presented as novel examples which define broadened material parameters, particularly owing to their extreme thermal insulation (R-32-64) and low densities (<0.01 g/cu cm) approaching that of air itself. Even with these low-weight payload additions, rocket thrust limits and transport costs will always place a premium on assembling as much structural and life support resources upon interplanetary, lunar, or asteroid arrival. As an example, for in situ lunar glass manufacture, solar furnaces reaching 1700 C for pure silica glass manufacture in situ are compared with sol-gel technology and acid-leached ultrapure (<0.1% FeO) silica aerogel precursors.

Noever, David A.↗

NASA NTRS1998

High Performance Materials Applications to Moon/Mars Missions and Bases

Two classes of material processing scenarios will feature prominently in future interplanetary exploration- in situ production using locally available materials in lunar or planetary landings and high performance structural materials which carve out a set of properties for uniquely hostile space environments. To be competitive, high performance materials must typically offer orders of magnitude improvements in thermal conductivity or insulation, deliver high strength-to-weight ratios, or provide superior durability (low corrosion and/or ablative character, e.g. in heat shields). The space-related environmental parameters of high radiation flux, low weight and superior reliability limits many typical aerospace materials to a short list comprising high performance alloys, nanocomposites and thin-layer metal laminates (Al-Cu, Al-Ag) with typical dimensions less than the Frank-Reed-type dislocation source. Extremely light weight carbon-carbon composites and car on aerogels will be presented as novel examples which define broadened material parameters, particularly owing to their extreme thermal insulation (R-32-64) and low densities (less than 0.01 g/cc) approaching that of air itself. Even with these low weight payload additions, rocket thrust limits and transport costs will always place a premium on assembling as much structural and life support resources upon interplanetary, lunar or asteroid arrival. As an example for in situ lunar glass manufacture, solar furnaces reaching 1700 C for pure silica glass manufacture in situ are compared with sol-gel technology and acid-leached ultrapure (less than 0.1% FeO) silica aerogel precursors.

Noever, David A.↗

NASA NTRS2010

The Spatial Distribution and Mineralogical Association of Organics in the Tagish Lake and Bells Carbonaceous Chondrites

Chondritic meteorites represent some of the most primitive Solar System materials available for laboratory analysis. While the presence of simple organic molecules has been well documented in such materials [1], little is known about their spatial distribution and to what extent, if any, they exhibit specific mineralogical associations. This dichotomy arises since organic analysis typically involves solvent extraction as a preliminary step. To address these issues we have used two-step laser mass spectrometry (L 2MS) to map in situ the spatial distribution of aromatic and conjugated organics at the micron scale in freshly exposed surfaces of the Tagish Lake and Bells carbonaceous chondrites. Our specific goals are two-fold; firstly to investigate if and how abundance of organic species varies within the meteorite matrix both as an ensemble, and with respect to functional group (e.g., R-OH vs. RCH3) and between members of the same homologous series (e.g., R-H vs. R-(CH2)H). Secondly, to determine whether observed spatial variations can be related to specific mineralogical and/or physical characteristics of the host matrix. In regard to the latter we are particularly interested in the role that carbonaceous nanoglobules [2] play as reservoirs of organic matter. Such globules, which are believed to have formed by photochemical processing of organic-rich ices in the presolar cold molecular cloud or the outermost reaches of the early protosolar disk, are abundant in both the Bells and Tagish Lake chondrites and are noteworthy for having particularly high enrichments in 2H and 15N [3,4].

Clemett, S. J.↗

NASA NTRS2015

Na, K-Rich Rim Around a Chondrule in Unequilibrated Ordinary Chondrite Lew 86018 (L3.1)

Ordinary chondrites represent the most abundant early Solar system extra-terrestrial (approximately 85% abundance) material available for laboratory studies and expectedly record the most extensive range of alterations effects from unmetamorphosed chondritic material to the highest temperatures of thermal metamorphism. The least metamorphosed chondrites belonging to petrologic type 3, the so called unequili-brated ordinary chondrites (UOCs), provide insights into alteration that happened during the primeval, ear-liest stage of Solar system formation. The higher grade petrologic types 4-6 ordinary chondrites on the other hand document up to near textural equilibrium (in type 6) extensive thermal metamorphism consisting of minerals and phases providing evidence of equilibration of heterogeneous mineral composition, solid-state recrystallization. Despite being the most abundant, the effect of alteration is less explicitly understood in ordinary chondrites (even less in UOCs) compared to other groups (e.g. CV, CO, CR). Additionally, the relationship between metasomatism (also referred as aqueous alteration or fluid-assisted metamorphism) and metamorphism (primarily thermal driven) has not been studied and alterations in the ordinary chondrites have been considered to have occurred in absence of fluids in general. Despite this conventional view, UOCs of lowest grades (3.0-3.2) show some evidence of low temperature (approximately 200 C), fluid assisted metamorphism in the form of the presence of phyllosilicates, ferroan olivine, and magnetites in their matrices and occasionally in chondrules. Here, we present petrographic and mineralogical studies of UOC, Lewis Hills (LEW) 86018 to further our understanding of the extent and relative importance of metasomatism and/or metamorphism in UOCs.

Mishra, R. K.↗

DOE OSTI2023

High-Performance Coal-Based Commercial Facade Panels and Architectural Components (Phase I Final Report)

Semplastics has developed, tested, and documented the viability for commercialization of a new class of composite architectural panel materials that use coal as the primary constituent. This project produced sample panels using these novel materials that comprise 55% coal by mass (71% carbon by mass) and are comparable in dimensions to commercially available materials, while displaying superior mechanical strength, significant weight savings, and better insulating ability at a competitive cost. Phase I moved this coal-based composite materials technology from a Technology Readiness Level (TRL) of 3 to TRL 5. Semplastics’ new coal-based composite materials display an array of high-performance characteristics, including light weight, mechanical durability, temperature stability, and water resistance. These new materials require less energy to produce than comparable commercial products and could be manufactured on existing conventional plastic resin processing equipment in commercial quantities. The coal particles are completely encapsulated in ceramic from a polymer-derived ceramic (PDC) precursor, then bonded together by another inorganic resin. The material can be molded and cured to produce fireproof components such as ceiling panels, facades, and extruded underlayment, blocking, and backer boards, as well as other architectural design components such as moldings. The project included the production of sample panels for proof of concept, testing of the panels to show their improved characteristics, and development of a scale-up strategy to demonstrate the viability of the coal-based panels as a commercial alternative to existing building materials.

36 MATERIALS SCIENCE↗

NASA NTRS1990

Dielectric properties measurement of substrate and support materials

In this paper a fast and straightforward waveguide measurement technique is described for the determination of the dielectric constant and loss tangent of many commercially available materials. These dielectric materials include Cuflon, Teflon, Arlon's polyimides, Lockheed's ceramic foams, and Rogers Duroid materials. The effective dielectric constant and loss tangent of Hexsel's honeycomb material is also measured by this method and is compared to the predicted data obtained using the volume averaging theory. The accuracy and other features of this measurement technique are also discussed.

Wu, Te-Kao↗

DOE OSTI2020

Shell Element Material Model Verification Problems for DYNA3D: Part II

A suite of supplementary shell element material model verification tests were developed for the explicit finite element program DYNA3D, in continuation of the work performed in LLNL-TR-792469 (Shell Element Material Model Verification Problems for DYNA3D). The testing procedure developed in the preceding report is extended, and used to verify all remaining untested shell model features and inputs. A collection of 78 feature-specific verification tests are proposed, some of which are applicable to multiple material models, though many are specialized to a particular model. The collective suite of tests cover all 27 currently available material models in DYNA3D. In the course of developing the proposed test suite, 24 separate shell model-related issues were identified and have subsequently been resolved.

42 ENGINEERING↗

DOE OSTI2023

Fusion Materials Research at Oak Ridge National Laboratory in FY22

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Fusion Materials Research at Oak Ridge National Laboratory in Fiscal Year 2023

The materials science challenge of providing a suite of suitable materials to satisfy the technology to achieve fusion energy is addressed in this ORNL program. The inability of currently available materials and components to withstand the harsh fusion nuclear environment requires development of new materials, and an understanding of their response to the fusion environment. The overarching goal of the ORNL Fusion Materials program is to provide the applied materials science support and materials understanding to underpin the ongoing DOE Office of Science—Fusion Energy Sciences program, in parallel with developing the materials for fusion power systems. In this effort the program continues to be integrated both with the larger U.S. and international fusion materials communities and with the U.S. and international fusion design and technology communities. The excitement of this program comes from the priorities given to this subject in the two recent fusion reviews, by the FESAC and NAS committees. An important element of those recommendations is the support for pivoting the national R&D emphasis to the Fusion Materials and Technologies (FM&T), the long-advocated Fusion Prototypic Neutron Source, and for the Fusion Pilot Plant study that will help focus program direction and efforts. Furthermore, the surge of venture capital investment into the private fusion industry start-ups over the last few years is anticipated to help accelerate all aspects of the fusion energy development. This twelfth annual report of the ORNL (Oak Ridge National Laboratory) Fusion Reactor Materials Program summarizes the accomplishments in Fiscal Year 2023 (FY2023). The year was the first to return to full post-COVID-restriction operations, with students and international assignees no longer impacted by COVID restrictions, as in FY20-21-22. Following the pattern of planning used in this program, work for the year FY2023 focused on having the data and productivity to support a strong presence at the International Conference on Fusion Reactor Materials (ICFRM) 21, organized by Spain and occurred in October 2023. Twenty-nine ORNL-led abstracts were submitted, with all accepted. Four were invited presentations, nine contributed oral, fourteen posters, and two withdrawn due to unforeseen circumstances. Additionally, nine external abstracts with ORNL contributing authors were presented. These will be reported in the FY24 report next year.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1985

Outdoor performance testing of thin-film devices

The Advanced Systems Research Group supports the photovoltaic advanced R&D (PV AR&D) project by providing outdoor (global) testing of PV cells, submodules, modules, and arrays. The group also provides in house engineering and analysis to identify and determine how technical issues such as cell/module/system adaptations, long term stability, reliability, economics, materials availability, safety, and environmental impacts affect the development and ultimate use of advanced PV thin film, innovative cell, and material technologies. A major thrust of the research effort is to develop and utilize instrumentation and procedures for monitoring and analyzing PV cells and submodules including outdoor performance and stability testing and life cycle accelerated stress testing. To accomplish the above, the solar energy research institute (SERI) outdoor PV test facility was established in 1982. The group has designed testing systems and analysis procedures for, and has tested, numerous amorphous silicon thin film submodules provided by SERI subcontractors and has performed long term outdoor stability tests on CdS/CuIr Se sub 2 and hydrogen passivated silicon solar cells. A significant contribution from this facility over the past year was the testing of large area amorphous silicon submodules.

Source record↗

DOE OSTI2024

Simulating strongly correlated molecules with a superconducting quantum processor

Many of the biggest challenges in expanding the nation’s access to clean and low-cost energy resources are fundamentally chemistry or materials challenges. An important case is the development of new catalysts for the up-conversion of cheap and readily available materials such as methane or water into materials suitable for use as a fuel such as methanol or oxygen. To understand and exploit such processes, computer simulations of chemical reactions provide a natural complement to experimental studies. Unfortunately, most catalytic reactions involve so-called “strongly correlated” molecules which are notoriously difficult to study with simulation algorithms that can be executed on existing (classical) computers. The recent growth in quantum information science offers an alternative potential route for simulating these difficult systems. As a result, an increasing number of computational chemists are becoming interested in quantum computing. At the same time, quantum information scientists have identified chemistry simulation as a possible first demonstration of a quantum computer providing an improvement over a classical computer. The objective of this project is to accurately simulate strongly correlated molecules on a quantum processor. To meet the high challenges of this objective, new hybrid quantum/classical algorithms will be co-designed with advanced quantum gate developments and computed on customized quantum hardware. Some of the developed techniques will be transferable to study other molecular systems, while the project as a whole will help define better strategies for advancing the quantum simulation of matter more generally.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗