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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 1,045 records · Page 58
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Graphite for Advanced Nuclear Reactors: Deployment Readiness Review

Historically, graphite has been used in numerous reactor technologies, including research/test reactors and, commercially, in advanced gas reactors. These non-metallic materials can play a key role as internal core structures, reflectors, or neutron moderators, making them important for deployment of certain advanced reactor technologies. This report explores the industry readiness for graphite material deployment, documenting Codes and Standards applicable to their design, qualification, and manufacturing. Discussions also examine the manufacturing processes, aging/degradation, inspection techniques, and disposal options. The report covers the current status, documents gaps, and proposes some conclusions about approaches to managing some of the current gaps.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

An efficient synthesis of graphenated carbon nanotubes over the tailored mesoporous molecular sieves by chemical vapor deposition

Highlights: ► Tailored 3D cubic Ni/KIT-6 with large pores was synthesized successfully. ► The new hybrid g-CNTs in large scale were synthesized using Ni/KIT-6 by CVD method. ► The use of mesoporous material by CVD method would be an ideal choice to prepare g-CNTs at reasonable cost. ► This type of g-CNTs might be a new avenue for nano-electronic applications. - Abstract: The new hybrid of graphenated carbon nanotubes (g-CNTs) was superior to either CNTs or graphene. Mesoporous 3D cubic Ni/KIT-6 were synthesized hydrothermally through organic template route and then were used as catalytic template for the production of g-CNTs using acetylene as a carbon precursor by chemical vapor deposition (CVD) method. The deposited new hybrid carbon materials were purified and analyzed by various physico-chemical techniques such as XRD, TGA, SEM, TEM and Raman spectroscopy techniques. The graphitization of CNTs was confirmed by TGA and HRTEM studies. Thermal stability, surface morphology, and structural morphology of these materials were revealed by TGA, SEM and TEM analysis, respectively. Moreover, the tailored mesoporous Ni/KIT-6 molecular sieves were found to possess better quality and massive quantity of g-CNTs produced compared to other catalytic template route.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Designing the Structure of Carbon Fibers for Optimal Mechanical Properties

Carbon fiber manufacturing follows generic processing steps: formation of thermoplastic fibers, stabilization, and carbonization. The final structures and end properties of the carbon fiber can differ significantly depending on the precursor chemistry and the associated processing sciences. Polyacrylonitrile (PAN) and mesophase pitch are the predominant precursors used in the production of carbon fibers. PAN-based carbon fibers consist of nanocrystalline graphitic domains typically 1.5 5 nm in size surrounded by amorphous carbon; in contrast, pitch-based carbon fibers are 10 50 nm crystallites with the graphitic (002) planes mostly aligned parallel to the fiber axis. It has been seen that the skin core structure of PAN-based carbon fibers plays a significant role in their mechanical properties. Designing a more homogenous carbon fiber microstructure by controlling the starting polymer and process parameters results in a different set of tensile strengths and elastic moduli. In this study the microstructural defect distribution (0.1 200 nm), measured by small-angle X-ray scattering, was shown to be directly related to the tensile strength of the carbon fibers. Here the formation of carbon structures from various polymer precursors is reviewed. Such a comprehensive understanding offers the opportunity to design carbon fiber microstructures with improved properties and to ultimately create new types of carbon fibers from alternative precursors at reduced cost.

Ozcan, Soydan↗
DOE OSTI2015

Enhanced lithium ion storage in nanoimprinted carbon

Disordered carbons processed from polymers have much higher theoretical capacity as lithium ion battery anode than graphite, but they suffer from large irreversible capacity loss and have poor cyclic performance. Here, a simple process to obtain patterned carbon structure from polyvinylpyrrolidone was demonstrated, combining nanoimprint lithography for patterning and three-step heat treatment process for carbonization. The patterned carbon, without any additional binders or conductive fillers, shows remarkably improved cycling performance as Li-ion battery anode, twice as high as the theoretical value of graphite at 98 cycles. Localized electrochemical strain microscopy reveals the enhanced lithium ion activity at the nanoscale, and the control experiments suggest that the enhancement largely originates from the patterned structure, which improves surface reaction while it helps relieving the internal stress during lithium insertion and extraction. This study provides insight on fabricating patterned carbon architecture by rational design for enhanced electrochemical performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1985

Composite materials for space structures

Composite materials have been extensively used for spacecraft structures because of their unique combination of high specific strength and stiffness, low weight, good dimensional stability, and high specific damping capacity. High-modulus graphite reinforced epoxies have been the principal composite material system used. For early applications composites were selected primarily to reduce weight. However, the development of high precision structures such as The Space Telescope required high modulus composites with a coefficient of thermal expansion close to zero to meet design requirements. The use of advanced composites for space structures is reviewed in this paper. Barriers likely to limit further applications of composites are discussed and highlights of current research to improve composites are presented. New developments Jn composites technology which could impact future spacecraft systems are also reviewed.

Composites↗
DOE OSTI2019

Fabricating Fe nanocrystals via encapsulation at the graphite surface

In this paper, the authors describe the conditions under which Fe forms encapsulated nanocrystals beneath the surface of graphite, and they characterize these islands (graphite + Fe) thoroughly. The authors use the experimental techniques of scanning tunneling microscopy (STM) plus x-ray photoelectron spectroscopy (XPS) and the computational technique of density functional theory (DFT). Necessary conditions for encapsulation are preexisting ion-induced defects in the graphite substrate and elevated deposition temperature of 875–900 K. Evidence of encapsulation consists of atomically resolved STM images of a carbon lattice, both on top of the islands and on the sloping sides. The nature of the images indicates that this carbon lattice corresponds to a graphene blanket consisting of more than one graphene sheet that drapes continuously from the top of the island to the graphite substrate. The formation of iron carbide is not observed based on XPS. Shapes of the island footprints are consistent with metallic Fe, predominantly in the hcp or fcc form, though larger islands tend toward bcc. Island structures with hexagonally close-packed lateral hcp or fcc planes are stabilized by their excellent lattice match with the graphite substrate. Evolution of island density with prolonged deposition time provides evidence of coarsening, perhaps via Smoluchowski ripening. The encapsulated Fe clusters are stable in air at room temperature, protected by smaller Fe clusters that decorate defect sites and block permeation of gases. DFT shows that two configurations of Fe are more stable within the gallery than adsorbed on top of the surface: a single atom of Fe and a film (slab) of metallic Fe. Comparison with other metals shows that encapsulated Fe is similar to Cu but dissimilar to Ru or Dy, leading the authors to conclude that carbon dissolution in the metal does not play a role in encapsulation.

36 MATERIALS SCIENCE↗
DOE OSTI2014

New reactor cavity cooling system having passive safety features using novel shape for HTGRs and VHTRs

A new, highly efficient reactor cavity cooling system (RCCS) with passive safety features without a requirement for electricity and mechanical drive is proposed for high temperature gas cooled reactors (HTGRs) and very high temperature reactors (VHTRs). The RCCS design consists of continuous closed regions; one is an ex-reactor pressure vessel (RPV) region and another is a cooling region having heat transfer area to ambient air assumed at 40 (°C). The RCCS uses a novel shape to efficiently remove the heat released from the RPV with radiation and natural convection. Employing the air as the working fluid and the ambient air as the ultimate heat sink, the new RCCS design strongly reduces the possibility of losing the heat sink for decay heat removal. Therefore, HTGRs and VHTRs adopting the new RCCS design can avoid core melting due to overheating the fuels. The simulation results from a commercial CFD code, STAR-CCM+, show that the temperature distribution of the RCCS is within the temperature limits of the structures, such as the maximum operating temperature of the RPV, 713.15 (K) = 440 (°C), and the heat released from the RPV could be removed safely, even during a loss of coolant accident (LOCA). Finally, when the RCCS can remove 600 (kW) of the rated nominal state even during LOCA, the safety review for building the HTTR could confirm that the temperature distribution of the HTTR is within the temperature limits of the structures to secure structures and fuels after the shutdown because the large heat capacity of the graphite core can absorb heat from the fuel in a short period. Therefore, the capacity of the new RCCS design would be sufficient for decay heat removal.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2014

Synthesis of branched, nano channeled, ultrafine and nano carbon tubes from PET wastes using the arc discharge method

Highlights: • Polymer wastes are converted into ultrafine and nano carbon tubes and spheres. • Simple process with a minimal processing time. • It is a catalyst free and solvent free approach. • This process forms branched ultrafine carbon tubules with nano channels. - Abstract: Upcycling polymer wastes into useful, and valuable carbon based materials, is a challenging process. We report a novel catalyst-free and solvent-free technique for the formation of nano channeled ultrafine carbon tubes (NCUFCTs) and multiwalled carbon nanotubes (MWCNTs) from polyethylene terephthalate (PET) wastes, using rotating cathode arc discharge technique. The soot obtain from the anode contains ultrafine and nano-sized solid carbon spheres (SCS) with a mean diameter of 221 nm and 100 nm, respectively, formed at the lower temperature region of the anode where the temperature is approximately 1700 °C. The carbon spheres are converted into long “Y” type branched and non-branched NCUFCTs and MWCNTs at higher temperature regions where the temperature is approximately 2600 °C, with mean diameters of 364 nm and 95 nm, respectively. Soot deposited on the cathode is composed of MWCNTs with a mean diameter of 20 nm and other nanoparticles. The tubular structures present in the anode are longer, bent and often coiled with lesser graphitization compared to the nanotubes in the soot on the cathode.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Elucidating the Role of Carbon Conductive Additive in the Processing and Electrochemical Behavior of Surface-Modified Si Anodes

In the present work, we explore the impact of conducting carbon on the processing of silicon (Si)-rich electrodes, their resulting cycling performance, and parasitic side reactions. We employed three different carbon additives, Super C45 (carbon black), Super C65 (carbon black), and TIMCAL C-NERGY KS 6L (graphite), with varying sizes and morphologies to determine how these parameters influence the structure and the electrochemical behavior of the cast electrodes. Raman mapping indicates that the improved performance achieved using C45 can be explained by the homogeneous distribution of Si and carbon, enabling the formation of continuous electrical pathways throughout the electrode. Further, this finding aligns with the results of ζ potential measurements, which indicate that C45 can maintain more stable dispersions in N-methyl-2-pyrrolidone (NMP) compared with the other carbon additives. However, electrodes with C45 as the conducting agent exhibited increased parasitic side reactions, as evidenced by the leakage current obtained from voltage hold experiments. These side reactions can have adverse effects on the calendar life of the electrode. Furthermore, the Raman maps of the electrodes reveal heterogeneities in Si and carbon distribution with lower carbon content, especially with only 2% carbon. This drastically impacts the cyclability of the electrodes, with portions of the low-carbon electrodes that remain unable to undergo cycling even at slow rates (0.2 Ah g –1 ). Additionally, we found that slower formation rates are favored in the context of parasitic side reactions, although slower formation rates can potentially create thicker passivating films that could hinder Li + -ion transport. Therefore, we emphasize the need for an intricate balance in materials selection and cycling protocol for optimal electrode processing and electrochemical behavior.

25 ENERGY STORAGE↗
DOE OSTI2023

Synthesis and Characterization of Carbon Microbeads

We report a microfluidic-based droplet generation platform for synthesizing micron-sized porous carbon microspheres. The setup employs carbon materials such as graphite, carbon nanotubes, graphene, fullerenes, and carbon black as starting materials. Custom composition, structure, and function are achieved through combinations of carbon materials, cross-linkers, and additives along with variations in process parameters. Carbon materials can be assembled into spheres with a mean diameter of units to hundreds of μm with relatively tight size distribution (<25% RSD). Pore structure and size (tens to hundreds of angstrom) can be modulated by incorporating porogen/coporogen dilutants during synthesis. The microbeads have excellent mechanical stability with an elastic modulus of hundreds of MPa. They can sustain high dynamic fluid flow pressures of up to 9000 psi. This work lays the foundation for synthesizing novel tailorable and customizable carbon microbeads. It opens avenues for applying these novel materials for composite and additive manufacturing, energy, life science, and biomedical applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Extending carbon chemistry at high-pressure by synthesis of CaC 2 and Ca 3 C 7 with deprotonated polyacene- and para-poly(indenoindene)-like nanoribbons

Metal carbides are known to contain small carbon units similar to those found in the molecules of methane, acetylene, and allene. However, for numerous binary systems ab initio calculations predict the formation of unusual metal carbides with exotic polycarbon units, [C 6 ] rings, and graphitic carbon sheets at high pressure (HP). Here we report the synthesis and structural characterization of a HP-CaC 2 polymorph and a Ca 3 C7 compound featuring deprotonated polyacene-like and para-poly(indenoindene)-like nanoribbons, respectively. We also demonstrate that carbides with infinite chains of fused [C6] rings can exist even at conditions of deep planetary interiors (~140 GPa and ~3300 K). Hydrolysis of high-pressure carbides may provide a possible abiotic route to polycyclic aromatic hydrocarbons in Universe.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Gas phase formation of phenalene via 10π-aromatic, resonantly stabilized free radical intermediates

For the last few decades, the Hydrogen-Abstraction/aCetylene-Addition (HACA) mechanism has been fundamental in aiding our understanding of the source of polycyclic aromatic hydrocarbons (PAHs) in combustion processes and in circumstellar envelopes of carbon rich stars. However, the reaction mechanisms driving high temperature molecular mass growth beyond triphenylene (C 18 H 12 ) along with the link between PAHs and graphene-type nanostructures as identified in carbonaceous meteorites such as in Murchison and Allende has remained elusive. By exploring the reaction of the 1-naphthyl radical (C 10 H 7 ˙) with methylacetylene (CH 3 CCH) and allene (H 2 CCCH 2 ) under conditions prevalent in carbon-rich circumstellar environments and combustion systems, we provide compelling evidence on a facile formation of 1H-phenalene (C 13 H 10 ) – the central molecular building block of graphene-type nanostructures. Beyond PAHs, molecular mass growth processes from 1H-phenalene via ring-annulation through C3 molecular building blocks may ultimately lead to two-dimensional structures such as graphene nano flakes and after condensation of multiple layers to graphitized carbon. Furthermore, these fundamental reaction mechanisms are of crucial significance to facilitate an understanding of the origin and chemical evolution of carbon in our Galaxy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Features of Pulsed Laser Annealing of BC{sub 3} Films on a Sapphire Substrate

The morphology, chemical composition, microstructure, and electrical properties of BC{sub 3} thin films subjected to melting by a nanosecond laser pulse are investigated. The original films have been created by pulsed laser codeposition of B and C onto a sapphire substrate at 150 and 350°C. Morphological changes in the films depended on their initial structural state. However, a “frozen” structure of both films after irradiation corresponded to the B-saturated graphite-like phase, the local composition of which varied due to the formation of inclusions of amorphous boron carbide. Before and after irradiation, the films exhibited a slightly decreasing dependence of the surface resistance with increasing temperature from 4.2 to 330 K. After laser irradiation, the films resistance has decreased by a factor of ~2.6.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1976

Advanced composite rudders for DC-10 aircraft: Design, manufacturing, and ground tests

Design synthesis, tooling and process development, manufacturing, and ground testing of a graphite epoxy rudder for the DC-10 commercial transport are discussed. The composite structure was fabricated using a unique processing method in which the thermal expansion characteristics of rubber tooling mandrels were used to generate curing pressures during an oven cure cycle. The ground test program resulted in certification of the rudder for passenger-carrying flights. Results of the structural and environmental tests are interpreted and detailed development of the rubber tooling and manufacturing process is described. Processing, tooling, and manufacturing problems encountered during fabrication of four development rudders and ten flight-service rudders are discussed and the results of corrective actions are described. Non-recurring and recurring manufacturing labor man-hours are tabulated at the detailed operation level. A weight reduction of 13.58 kg (33 percent) was attained in the composite rudder.

Lehman, G. M.↗
NASA NTRS1983

A mobile work station concept for mechanically aided astronaut assembly of large space trusses

This report presents results of a series of truss assembly tests conducted to evaluate a mobile work station concept intended to mechanically assist astronaut manual assembly of erectable space trusses. The tests involved assembly of a tetrahedral truss beam by a pair of test subjects with and without pressure (space) suits, both in Earth gravity and in simulated zero gravity (neutral buoyancy in water). The beam was assembled from 38 identical graphite-epoxy nestable struts, 5.4 m in length with aluminum quick-attachment structural joints. Struts and joints were designed to closely simulate flight hardware. The assembled beam was approximately 16.5 m long and 4.5 m on each of the four sides of its diamond-shaped cross section. The results show that average in-space assembly rates of approximately 38 seconds per strut can be expected for struts of comparable size. This result is virtually independent of the overall size of the structure being assembled. The mobile work station concept would improve astronaut efficiency for on-orbit manual assembly of truss structures, and also this assembly-line method is highly competitive with other construction methods being considered for large space structures.

Heard, W. L., Jr.↗
NASA NTRS1985

Effect of measured material properties on the finite element analysis of an OH-58 composite tail boom

A static and dynamic finite element analysis is conducted on a U.S. Army OH-58 composite tail boom and compared with test data. The tail boom is a filament-wound graphite/epoxy monocoque structure. The structural design of the composite tail boom skin is based on 50-percent graphite fiber volume. However, material tests on representative samples of the tail boom skin reveal that the graphite fiber-volume fraction varied from 44.6 to 49.3 percent. To determine the effect of using measured material properties, static and dynamic finite element analyses are conducted for three fiber-volume conditions of 45, 48, and 50 percent. The static and dynamic model with the 45-percent fiber-volume graphite skins gives the closest agreement with test data.

Bowman, L. M.↗
NASA NTRS1991

Scale effects in buckling, postbuckling and crippling of graphite-epoxy Z-section stiffeners

The buckling, postbuckling and crippling of Hercules Inc. AS4/3502 graphite-epoxy Z-section stiffeners is investigated as a function of specimen structural parameters. Variables addressed are flange and web widths, flange-to-web corner radius, thickness and stacking sequence. Analytical, numerical and experimental results are discussed. Nondimensional parameters have been obtained from an analytical model which effectively normalize the initial local buckling data reported herein and in the references. The nature of the load redistribution after buckling and its impact on postbuckling stiffness is related to the geometric variables. A normalized total width concept is used to unify the crippling data.

Wieland, Todd M.↗