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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 1,027 records · Page 57
All sourcesNASA NTRSDOE OSTI
NASA NTRS1979

Solar cell with improved N-region contact and method of forming the same

An improved solar cell, and method of forming the same are disclosed. It is characterized by a semiconductor silicon wafer of P-type material having diffused therein a shallow N-type region. A sintered silver contact is affixed to the surface of the N-type region at the outer surface. The improved solar cell is formulated from silver powder blended with silver metaphosphate for establishing a zone of increased carrier concentration. An aluminum or silver-aluminum alloy contact is affixed to the P-type wafer at the outer surface opposite the N-type region.

Bube, K. R.↗
NASA NTRS1994

Synthesis and decomposition of a novel carboxylate precursor to indium oxide

Reaction of metallic indium with benzoyl peroxide in 4-1 methylpyridine (4-Mepy) at 25 C produces an eight-coordinate mononuclear indium(III) benzoate, In(eta(sup 2)-O2CC6H5)3(4-Mepy)2 4H2O (I), in yields of up to 60 percent. The indium(III) benzoate was fully characterized by elemental analysis, spectroscopy, and X-ray crystallography; (I) exists in the crystalline state as discrete eight-coordinate molecules; the coordination sphere around the central indium atom is best described as pseudo-square pyramidal. Thermogravimetric analysis of (I) and X-ray diffraction powder studies on the resulting pyrolysate demonstrate that this new benzoate is an inorganic precursor to indium oxide. Decomposition of (I) occurs first by loss of 4-methylpyridine ligands (100 deg-200 deg C), then loss of benzoates with formation of In2O3 at 450 C. We discuss both use of carboxylates as precursors and our approach to their preparation.

Hepp, Aloysius F.↗
NASA NTRS1999

X-Ray Diffraction Techniques for a Field Instrument: Patterns of Lithologic Provences

Future exploration of Mars will attempt to shed light on the mineralogy of surface materials. Instruments deployed from remote platforms should have the capability to conduct both intensive analyses as well as rapid, reconnaissance surveys while they function in the martian environment as surrogate geologists. In order to accommodate the reconnaissance mode of analysis and to compensate for analytical limitations imposed by the space-flight conditions, data analysis methods are being developed that will permit interpretation of data by recognition of signatures or "fingerprints". Specifically, we are developing a technique which will allow interpretation of diffraction patterns by recognition of characteristic signatures of different lithologic provences. This technique allows a remote vehicle to function in a rapid-scan mode using the lithologic signature to determine where a more thorough analysis is needed. An x-ray diffraction pattern is characterized by the angular positions of diffracted x-rays, x-ray intensity levels and background radiation levels. These elements may be used to identify a generalized x-ray signature. Lithologic signatures are being developed in two ways. A signature is composed using the ideal powder diffraction indices from the mineral assembledge common to a specific lithologic provence. This is then confirmed using a laboratory diffraction pattern of a whole rock powder. Preliminary results comparing the diffraction signatures of the major mineral assembledges common to basalt, carbonate, and evaporite basin deposits indicate that lithologies are differentiable as a "fingerprint". Statistical analyses are being performed to establish the confidence levels of this technique.

Marshall, J.↗
NASA NTRS2015

Materials Characterization of Electron Beam Melted Ti-6Al-4V

An in-depth material characterization of Electron Beam Melted (EBM) Ti-6Al-4V material has been completed. Hot Isostatic Pressing (HIP) was utilized to close porosity from fabrication and also served as a material heat treatment to obtain the desired microstructure. The changes in the microstructure and chemistry from the powder to pre-HIP and post-HIP material have been analyzed. Computed tomography (CT) scans indicated porosity closure during HIP and high-density inclusions scattered throughout the specimens. The results of tensile and high cycle fatigue (HCF) testing are compared to conventional Ti-6Al-4V. The EBM Ti-6Al-4V had similar or superior mechanical properties compared to conventionally manufactured Ti-6Al-4V.

Titanium↗
DOE OSTI2025

Laser powder bed fusion of ODS Fe–Cr–Al (0.3Zr, 0.3Y 2 O 3 ): Unveiling processing-microstructure- mechanical property relationships

Here, this study investigates the fabrication of oxide dispersion strengthened (ODS) Fe-Cr-Al alloys via laser powder bed fusion (LPBF) with strategic additions of 0.3 wt% Zr and 0.3 wt% Y 2 O 3 for enhanced mechanical performance in nuclear applications. Systematic processing parameter optimization yielded three distinct conditions: one low-density product with significant defects and two near-full-density materials with improved consolidation. Comprehensive characterization confirmed single-phase α-ferrite matrix formation with successful incorporation of Y-, Zr-, O-, and C-rich precipitates characteristic of ODS alloys. However, precipitate density remained low (∼10 7 cm −3 ), resulting in sink strength values substantially below optimal levels for radiation resistance. Microhardness values (mid-200s HV) correlated inversely with grain size following the Hall-Petch relationship, indicating grain boundary strengthening as the dominant mechanism rather than precipitation strengthening. The optimized processing conditions achieved excellent mechanical properties with room temperature yield strength of approximately 500 MPa and 30 % elongation, demonstrating superior strength-ductility synergy compared to other additively manufactured ODS materials and performance consistent with literature values for LPBF-processed ODS-FeCrAl alloys. This investigation reveals both the potential and limitations of LPBF processing for ODS Fe-Cr-Al alloys. While successful defect-free fabrication was achieved, results highlight the critical need for systematic optimization of processing parameters and post-processing heat treatments to enhance precipitate density for effective dispersion strengthening and radiation resistance while maintaining additive manufacturing advantages.

Additive manufacturing↗
DOE OSTI2022

Determination of physically based pseudo-Voigt powder diffraction profile terms from the fundamental parameters approach

In this study, a methodology is developed where a fundamental parameters approach (FPA) description of a laboratory powder diffraction instrument (configured in divergent-beam Bragg–Brentano geometry) is used to determine GSAS-II profile parameters for peak asymmetry and instrumental peak widths. This allows the instrumental contribution to peak shapes to be robustly determined directly from a physical description of the instrument, even though GSAS-II does not directly implement FPA for peak shape computation. The FPA-derived parameters can be used as the starting point for instrument characterization, or to characterize sample broadening without the use of a standard to determine the instrument profile function. This new method can facilitate generation of training sets for machine learning. A plot is generated that shows the differences between the two approaches, demonstrating upper bounds for the accuracy of the GSAS-II profile model for a particular instrumental configuration.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Critical Review of LPBF Metal Print Defects Detection: Roles of Selective Sensing Technology

The integrative potential of LPBF-printed parts for various innovative applications depends upon the robustness and infallibility of the part quality. Eliminating or sufficiently reducing factors contributing to the formation of defects is an integral step to achieving satisfiable part quality. Significant research efforts have been conducted to understand and quantify the triggers and origins of LPBF defects by investigating the material properties and process parameters for LPBF-printed geometries using various sensing technologies and techniques. Frequently, combinations of sensing techniques are applied to deepen the understanding of the investigated phenomena. The main objectives of this review are to cover the roles of selective sensing technologies by (1) providing a summary of LPBF metal print defects and their corresponding causes, (2) informing readers of the vast number and types of technologies and methodologies available to detect defects in LPBF-printed parts, and (3) equipping readers with publications geared towards defect detection using combinations of sensing technologies. Due to the large pool of developed sensing technology in the last few years for LPBF-printed parts that may be designed for targeting a specific defect in metal alloys, the article herein focuses on sensing technology that is common and applicable to most common defects and has been utilized in characterization for an extended period with proven efficiency and applicability to LPBF metal parts defect detection.

36 MATERIALS SCIENCE↗
NASA NTRS2012

New Technology for Microfabrication and Testing of a Thermoelectric Device for Generating Mobile Electrical Power

Thermoelectric (TE) power generation is an increasingly important power generation technology. Major advantages include: no moving parts, low-weight, modularity, covertness/silence, high power density, low amortized cost, and long service life with minimum or no required maintenance. Despite low efficiency of power generation, there are many specialized needs for electrical power that TE technologies can uniquely and successfully address. Recent advances in thermoelectric materials technology have rekindled acute interest in thermoelectric power generation. We have developed single crystalline n- and p- type PbTe crystals and are also, developing PbTe bulk nanocomposites using PbTe nano powders and emerging filed assisted sintering technology (FAST). We will discuss the materials requirements for efficient thermoelectric power generation using waste heat at intermediate temperature range (6500 to 8500 K). We will present our recent results on production of n- and p- type PbTe crystals and their thermoelectric characterization. Relative characteristics and performance of PbTe bulk single crystals and nano composites for thermoelectric power generation will be discussed.

Prasad, Narasimha S.↗
DOE OSTI2022

Ultrasonic Testing (UT) and Computed Tomography (CT) Comparative Scanning of Proposed Additive Manufacturing Reference Standard

This report presents qualitative results of ultrasonic full matrix capture/total focusing method (FMC/TFM) scanning of two series of blocks, additively manufactured by powder bed fusion, containing a variety of internal features and structures that would not be achievable by conventional manufacturing techniques. The purpose of the first series of additively manufactured (AM) blocks was to explore the possibility of building calibration blocks for FMC/TFM ultrasonic testing (UT). It was confirmed that AM is a suitable candidate for generation of unusual and novel reflector forms, such as rotating slots, purposely embedded voids, and tapering holes, and that FMC/TFM was very capable of characterizing them. The intended use of the second series of AM blocks was as UT reference blocks to characterize the AM process quality or the interrogating UT technique. The larger block in this series was scanned from multiple faces, using multiple UT methods (conventional UT and FMC/TFM) and X-ray computed tomography for comparative purposes. The performance of each method was quantified by a metric corresponding to the detection limit of each feature, and the quantitative results are discussed.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Production and Characterization of Additively Manufactured Radiator Panels with Integral Branching Heat Pipes for High-Temperature Heat Rejection

Emerging concepts for fission surface power and nuclear electric propulsion necessitate lightweight, mechanically robust, and thermally efficient heat rejection radiators. State-of-the-art intermediate-temperature (~400 K) composite radiator assemblies have been developed based on titanium-water heat pipes bonded to metal, graphite, and carbon-fiber-based panels. NASA has identified a need for new radiator concepts that can operate at even higher temperatures (500 – 600 K), minimize thermal resistances and thermal stress failures at bond interfaces, and approach areal densities of 2 – 3 kg m -2 . To meet these needs, our team is developing additively manufactured (AM) radiator panels with integral branching wicking heat pipe networks. Water is selected as the working fluid for this temperature range. Based on simulations and thermal vacuum experiments, these branching embedded heat pipe networks can efficiently distribute heat over panels for finned surface efficiencies of η f >70% at T H = 500 K input heat. This paper first presents laser powder-bed fusion AM strategies to produce embedded porous structures for wicking heat pipes in Inconel 718 and titanium alloys (commercially pure and Ti-6Al-4V alloys). Post-build chemical and thermal treatments are described that yield hydrophilic wicking surfaces for operation with water. Transient rate-of-rise experiments with water and acetone are reported that yield estimates for AM wick porosity (ϵ), permeability (K), and effective pore radius (r pore ). Based on the wick characterization results, small prototype radiator panels (75 × 125 mm) with integrated heat pipe networks were manufactured. Heat rejection performance data are presented from cold thermal vacuum testing, with heat input temperatures up to ~510 K. Future efforts will focus on improving heat pipe performance, optimizing radiator mass, and evaluating larger panels to assess scalability.

thermal management↗
NASA NTRS2024

Production and Characterization of Additively Manufactured Radiator Panels With Integral Branching Heat Pipes for High-Temperature Heat Rejection

Emerging concepts for fission surface power and nuclear electric propulsion necessitate lightweight, mechanically robust, and thermally efficient heat rejection radiators. State-of-the-art intermediate-temperature (~400 K) composite radiator assemblies have been developed based on titanium-water heat pipes bonded to metal, graphite, and carbon-fiber-based panels. NASA has identified a need for new radiator concepts that can operate at even higher temperatures (500 – 600 K), minimize thermal resistances and thermal stress failures at bond interfaces, and approach areal densities of 2 – 3 kg m -2 . To meet these needs, our team is developing additively manufactured (AM) radiator panels with integral branching wicking heat pipe networks. Water is selected as the working fluid for this temperature range. Based on simulations and thermal vacuum experiments, these branching embedded heat pipe networks can efficiently distribute heat over panels for finned surface efficiencies of η f >70% at T H = 500 K input heat. This paper first presents laser powder-bed fusion AM strategies to produce embedded porous structures for wicking heat pipes in Inconel 718 and titanium alloys (commercially pure and Ti-6Al-4V alloys). Post-build chemical and thermal treatments are described that yield hydrophilic wicking surfaces for operation with water. Transient rate-of-rise experiments with water and acetone are reported that yield estimates for AM wick porosity (ϵ), permeability (K), and effective pore radius ( r pore ). Based on the wick characterization results, small prototype radiator panels (75 × 125 mm) with integrated heat pipe networks were manufactured. Heat rejection performance data are presented from cold thermal vacuum testing, with heat input temperatures up to ~510 K. Future efforts will focus on improving heat pipe performance, optimizing radiator mass, and evaluating larger panels to assess scalability.

nuclear electric propulsion↗
DOE OSTI2021

Characterization of injection and confinement improvement through impurity induced profile modifications on the Wendelstein 7-X stellarator

Pulsed injections of boron carbide granules into Wendelstein 7-X stellarator (W7-X) plasmas transiently increase the plasma stored energy and core ion temperatures above the reference W7-X experimental programs by up to 30%. In a series of 4 MW electron cyclotron resonance heating experiments, the PPPL Probe Mounted Powder Injector provided 50 ms bursts of 100 μm granules every 350 ms at estimated quantities ranging from approximately 1 mg/pulse to over 30 mg/pulse. For each injection, the stored energy was observed to initially drop and the radiated power transiently increased, while the radial electron density profile rose at the edge as material was assimilated. Once the injected boron carbide was fully absorbed, the density rise transitioned to the core while the stored energy increased above the previous baseline level by an amount linearly correlated with the injection quantity. During the injection, the ion temperature gradient steepened with peak core ion temperatures observed to increase from a nominal 1.7 keV to over 2.6 keV for the largest injection amounts. Enhanced performance is accompanied by a reversal of the radial electric field at ρ < 0.3, indicating that the core transport has switched to the ion root. These observations are suggestive of a change in transport and provide further evidence that externally induced profile modifications provide a possible path to enhanced W7-X performance metrics.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Carbon nanotube (CNT) reinforced 316L stainless steel composites made by laser powder bed fusion: Microstructure and wear response

Carbon nanotube (CNT) reinforced 316L stainless steel (SS) composites were fabricated by laser powder bed fusion (LPBF) additive manufacturing (AM). This study focuses on microstructure evolution, hardness, and wear behavior. The wear behavior for AM 316L SS and 1 wt% CNT/316L SS was studied by a dry sliding test under normal loads of 10, 15, and 25 N. The addition of CNT to 316L SS led to the change of solidification mode from cellular/columnar to dendritic growth, producing grain refinement. Nanoscale dendrites were observed. Although TEM characterization confirmed the existence of CNT in cell interior, most CNT were damaged, resulting in carbon material segregation along cellular/dendritic boundaries. The wear rate was found dramatically decreased due to the improved hardness. Compared to the adhesive and abrasive wear in AM 316L SS, the wear mechanism of CNT/316L composite was adhesion and oxidative wear. Furthermore, enhanced cellular/dendritic boundary strengthening by carbon segregation was the main strengthening mechanism of CNT/316L composite.

36 MATERIALS SCIENCE↗
DOE OSTI2018

SAPO-34/5A Zeolite Bead Catalysts for Furan Production from Xylose and Glucose

SAPO-34 zeolite crystals were grown on zeolite 5A beads, characterized, and then utilized to produce furfural from xylose and 5-hydroxymethylfurfural (HMF) from glucose. The SAPO-34/5A bead catalysts resulted in moderate furfural and HMF yields of 45% from xylose and 20% from glucose (463 K; 3 h) and were easier to recover than the SAPO-34 powder catalyst. At 463 K, the SAPO-34/5A beads were more selective than 0.02 M sulfuric acid for producing HMF and, unlike the sulfuric acid system, no levulinic acid was formed. The SAPO-34/5A bead catalysts had no significant loss in activity after three rounds of recycle when water washed or heated overnight between reactions; however, the heat-treated beads did show signs of thermal stress after the second reuse. The SAPO-34/5A bead catalysts show promise for dehydration reactions to produce furfural and HMF from xylose and glucose, respectively, and adapting the catalyst and the support bead could lead to even higher selectivities and yields.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Sol-gel synthesis of Mn1.5Co1.5O4 spinel nano powders for coating applications

Highlights: • Nano powder of Mn/Co spinel, applicable to solid oxide fuel cell, is synthesized. • The sol-gel synthesis of nanocrystalline Mn{sub 1.5}Co{sub 1.5}O{sub 4} spinel is investigated. • Sol-gel annealing temperature, time, and metal-to-citrate ratio are evaluated. • The optimum conditions for producing dual phase of Mn{sub 1.5}Co{sub 1.5}O{sub 4} are achieved. - Abstract: Mn{sub 1.5}Co{sub 1.5}O{sub 4} oxide spinels are widely used as protective coatings for stainless steel interconnects within planar solid oxide fuel cell stacks. Containing both cubic and tetragonal crystalline phases, these Mn/Co oxide spinels exhibit favorable thermal stability and electronic conductivity for the SOFC interconnect application. Slurry-based coating applications of Mn/Co oxides require precursor powders, which can benefit from being nano-structured. In this study, the sol-gel synthesis of nanocrystalline Mn{sub 1.5}Co{sub 1.5}O{sub 4} spinel is investigated. The decomposition of sol-gel precursors, as well as the crystalline phase structures and microstructures of the product Mn{sub 1.5}Co{sub 1.5}O{sub 4} are characterized by differential thermal and thermogravimetric (DTA/TG) analysis, X-ray diffraction (XRD), and transmission electron microscopy (TEM). The effects of various sol-gel annealing temperatures (T), treatment times (t), and citrate-to-metal ratios (Rc) are evaluated. Results suggest that nanocrystalline Mn{sub 1.5}Co{sub 1.5}O{sub 4} spinel can be synthesized around 1050 °C, and that T = 1050 °C, t = 6 h and Rc = 2 are optimum conditions for producing the smallest grain size. Image analysis of TEM results shows that the size of Mn{sub 1.5}Co{sub 1.5}O{sub 4} crystallites increases with increasing temperature, with average particle sizes ranging from ∼70 nm to ∼1 μm. Selected area diffraction pattern (SADP) of Mn{sub 1.5}Co{sub 1.5}O{sub 4} spinel synthesized at 800 °C confirms the dual (cubic/tetragonal) structure of Mn{sub 1.5}Co{sub 1.5}O{sub 4}.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2022

USE OF TWO-PISTON SPLAT QUENCHING TO INVESTIGATE & CHARACTERIZE THE IMPACT OF COMPOSITIONAL VARIATIONS ON RAPID SOLIDIFICATION MICROSTRUCTURES & SUB-MICROSCALE FEATURES IN STAINLESS STEEL ALLOY.

The objective of this dissertation was to use two-piston splat quenching (SQ) to investigate the impact of compositional modifications on the solidification and microstructure of rapidly solidified austenitic stainless steels (SS) and to demonstrate the ability of SQ to quickly and effectively simulate rapid solidification conditions similar to those found in powder bed fusion (PBF) additive techniques. PBF techniques like laser powder bed fusion (LPBF) are being implemented across a breadth of research and industrial applications to create parts with complex geometries and performance capabilities while pushing the current limits of processing conditions and understanding of material systems. In this work, SQ was used to experimentally produce rapid solidification in 20+ unique austenitic SS compositions with systematic variations of the chrome and nickel equivalency ratio (Cr/Nieq) through targeted compositional modifications. From the targeted change of Cr, Ni, and Mo concentrations in rapidly solidified SS alloys, the ferrite solidification mode was found to be the primary solidification mode at significantly lower Cr/Nieq than previously predicted for RS. Also, decreasing concentrations of Fe at a constant Cr/Nieq ratio (i.e., different Fe isopleths), or increased Mo concentrations at a constant Cr/Nieq ratio were found to suppress the ferrite to austenite massive transformation when compared to alloys with lower concentrations at the same Cr/Nieq. Using an established empirical relationship between cell size and cooling rate, the SQ technique was estimated to produce cooling rates between 106 and 108 K/s. Thermal gradients were extracted from 2-D heat transfer simulations of the SQ solidification event and used with these cooling rates to produce solidification rate estimates for SQ which were between 0.4-1.6m/s. The primary solidification mode was observed to be the determining factor in which elements segregated to the cell boundaries during RS, for which Cr and Mo were the main elements to segregate during primary austenite solidification and Ni during primary ferrite solidification. Finally, the solidification rates and conditions produced by SQ experiments resulted in similar microstructures, features, and microsegregation to what was found in LPBF samples of the same feedstock.

Hasenbusch, Zachary↗
DOE OSTI2023

Accelerating Additive Manufacturing Process Design for Energy Conversion Materials using In-situ Sensing and Machine Learning

One promising candidate for manufacturing of the bismuth Telluride thermoelectric legs is laser powder bed fusion (LPBF) additive Manufacturing (AM). AM processing parameters highly influence the material properties, however current processing parameter development methods in AM are costly and time consuming. In-situ sensors allow for the capture of physically relevant process information on a layer-by-layer basis and will be used to aide process development. To optimize the AM process for the best thermoelectric performance, process variables, in-situ process sensor data and ex-situ material characterization data are collected. Several different interpretable machine learning (ML) approaches are used, and the performance of each method are assessed. Significant input process variables include laser focus, hatch spacing and laser power. The best performing models are used to determine the manufacturing parameters that maximize the power factor. AM of bismuth telluride material provides the ability to create complex geometries enabling more efficient energy conversion.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2020

3D Ion-Conducting, Scalable, and Mechanically Reinforced Ceramic Film for High Voltage Solid-State Batteries

Concerning the safety aspects of Li+ ion batteries, an epoxy-reinforced thin ceramic film (ERTCF) is prepared by firing and sintering a slurry-casted composite powder film. The ERTCF is composed of Li + ion conduction channels and is made of high amounts of sintered ceramic Li 1+ x Ti 2-x Al x (PO 4 ) 3 (LATP) and epoxy polymer with enhanced mechanical properties for solid-state batteries. The two- and three-dimensional characterizations are conducted not only for showing continuous Li+ ion channels thorough LATP ceramic channels with over 10-4 S cm-1 of ionic conductivity but also to investigate small amounts of epoxy polymer with enhanced mechanical properties. Solid-state Li + ion cells are fabricated using the ERTCF and they show initial charge–discharge capacities of 139/133 mAh g -1 . Furthermore, the scope of the ERTCF is expanded to high-voltage (>8 V) solid-state Li + ion batteries through a bipolar stacked cell design. Hence, it is expected that the present investigation will significantly contribute in the preparation of the next generation reinforced thin ceramic film electrolytes for high-voltage solid-state batteries.

25 ENERGY STORAGE↗