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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

The Relation Between Alloy Chemistry and Hot-Cracking

Hot cracking is a problem in welding 2195 aluminum-lithium alloy. Weld wire additives seem to reduce the problem. This study proposes a model intended to clarify the way alloying elements affect hot-cracking. The brittle temperature range of an alloy extends wherever the tensile stress required to move the meniscus of the liquid film at the grain/dendrite boundaries is less than the bulks flow stress Sigma(sub B) of the grains: 2gamma/delta <= sigma(sub B) + P where gamma is boundary film surface tension delta= boundary film thickness P = gas pressure (Some alloys outgas.) If the above condition is not met, the grains deform under stress and the liquid film remains in place. Curves of 2gamma/delta and sigma(sub B) vs. temperature in the range just below the melting temperature determine the hot cracking susceptibility of an alloy. Both are zero at onset of solidification. sigma(sub B) rises as the thermal activation of the slip mechanism is reduced. 2gamma/delta rises as the film thickness delta which can be estimated from the Scheil equation, drops. But, given an embrittled alloy, whether the alloy actually cracks is determined by the strain imposed upon it in the embrittled condition. A critical strain is estimated, Epsilon(sub C) on the order of Epsilon(sub C) is approximately delta/l where L = grain size and where the the volume increment due to the strain, concentrated at the liquid film, is on the order of the liquid film volume. In the early 80's an empirical critical strain cracking envelope Epsilon(sub C)(T) was incorporated into a damage criterion to estimate the effect of welding parameters on the formation of microfissures in a superalloy with good results. These concepts, liquid film decoherence vs. grain bulk deformation and critical strain, form the key elements of a quantitative theory of hot-cracking applicable for assessing the effect of alloying elements on hot-cracking during welding.

Nunes, A. C., Jr.↗
NASA NTRS2002

Assessment of Al-Li Alloys for Cryotanks

This viewgraph presentation provides information on steps undertaken to determine the suitability of Aluminum and Lithium alloys in cryogenic tank construction. Major characteristics are offered for several different candidate alloys including reliability, weldability, flammability, and required thicknesses.

Babel, Henry W.↗
DOE OSTI2020

Optimization of Graphite–SiO blend electrodes for lithium-ion batteries: Stable cycling enabled by single-walled carbon nanotube conductive additive

Lithium-alloying materials are of great interest to improve the gravimetric and volumetric energy density of lithium-ion batteries, though their associated volume fluctuation with cycling often leads to poor cycling performance. Active-inactive alloys and blending alloys with carbon materials are common strategies to accommodate volume fluctuation. Herein we set out to optimize graphite-SiO blend electrode formulations to eliminate rapid capacity fade. Electrodes with highly stable cycling were prepared by simple planetary mixing procedures, enabled by the use of just a fraction of a weight percent of commercial SWCNTs as the only conductive additive, and by the appropriate choice of binder/stabilizing agent. In fact, the use of SWCNTs allowed for graphite-free SiO electrodes with approximately 74% higher volumetric energy density relative to traditional graphite electrodes, and superior capacity retention in coin-type full-cell testing versus NMC532 cathodes.

25 ENERGY STORAGE↗
DOE OSTI2023

Nanoparticle Surface Passivation Strategies to Improve the Cycle and Calendar Lifetime of Silicon Anodes in Standard Carbonate Electrolytes

Silicon Lithium alloys (SiLix) as the anode active material in a Li-Ion battery configuration offer possible energy densities paralleled only by pure lithium metal. However, the extreme mechanical deformation of alloying and dealloying SiLix through charge/discharge cycles paired with the highly reactive interface of SiLix which generates an interfacial layer known as the solid-electrolyte-interphase are large barriers to industrial adoption of high-silicon-content negative electrodes. Moreover, these challenges are magnified when the thickness of the electrode is brought to relevant levels (>3 mg/cm2). Here, I describe our efforts to address these challenges by utilizing single-nanometer-scale silicon nanoparticles to reduce capacity fade related to mechanical failure. I also detail our efforts to modify the silicon surface through interfacial chemical engineering strategies to passivate the silicon surface. This development three different majority silicon electrodes (50-74 wt%) to achieve cycle capacity retention of greater than 73% through 1000 charge/discharge cycles against capacity-matched NMC-based cathodes and calendar lifetimes greater than one year. This research is a part of the multi-national lab Silicon Consortium Project.

anodes↗
NASA NTRS1993

Effect of thermal processing practices on the properties of superplastic Al-Li alloys

The effect of thermal processing on the mechanical properties of superplastically formed structural components fabricated from three aluminum-lithium alloys was evaluated. The starting materials consisted of 8090, 2090, and X2095 (Weldalite(TM) 049), in the form of commercial-grade superplastic sheet. The experimental test matrix was designed to assess the impact on mechanical properties of eliminating solution heat treatment and/or cold water quenching from post-forming thermal processing. The extensive hardness and tensile property data compiled are presented as a function of aging temperature, superplastic strain and temper/quench rate for each alloy. The tensile properties of the materials following superplastic forming in two T5-type tempers are compared with the baseline T6 temper. The implications for simplifying thermal processing without degradation in properties are discussed on the basis of the results.

Hales, Stephen J.↗
NASA NTRS1991

Materials and light thermal structures research for advanced space exploration

The Light Thermal Structures Center at the University of Virginia sponsors educational and research programs focused on the development of reliable, lightweight structures to function in hostile thermal environments. Technology advances in materials and design methodology for light thermal structures will contribute to improved space vehicle design concepts with attendant weight savings. This paper highlights current research activities in three areas relevant to space exploration: low density, high temperature aluminum alloys, composite materials, and structures with thermal gradients. Advances in the development of new aluminum-lithium alloys and mechanically alloyed aluminum alloys are described. Material properties and design features of advanced composites are highlighted. Research studies in thermal structures with temperature gradients include inelastic panel buckling and thermally induced unstable oscillations. Current and future research is focused on the integration of new materials with applications to structural components with thermal gradients.

Thornton, Earl A.↗
NASA NTRS2003

Superplastic Forming/Adhesive Bonding of Aluminum (SPF/AB) Multi-Sheet Structures

A significant fraction of airframe structure consists of stiffened panels that are costly and difficult to fabricate. This program explored a potentially lower-cost processing route for producing such panels. The alternative process sought to apply concurrent superplastic forming and adhesive bonding of aluminum alloy sheets. Processing conditions were chosen to balance adequate superplasticity of the alloy with thermal stability of the adhesive. As a first objective, an air-quenchable, superplastic aluminum-lithium alloy and a low-volatile content, low-viscosity adhesive with compatible forming/curing cycles were identified. A four-sheet forming pack was assembled which consisted of a welded two-sheet core separated from the face sheets by a layer of adhesive. Despite some preliminary success, of over 30 forming trials none was completely successful. The main problem was inadequate superplasticity in the heat-affected zones of the rib welds, which generally fractured prior to completion of the forming cycle. The welds are a necessary component in producing internal ribs by the 'four-sheet' process. Other challenges, such as surface preparation and adhesive bonding, were adequately solved. But without the larger issue of tearing at the weld locations, complex panel fabrication by SPF/AB does not appear viable.

Wagner, John A.↗
NASA NTRS1990

The electrochemical generation of useful chemical species from lunar materials

Electrochemical cells have been fabricated for the simultaneous generation of oxygen and lithium from a Li2O-containing molten salt (Li2O-LiCl-LiF). The cell utilizes an oxygen vacancy conducting solid electrolyte, yttria-stabilized zirconia (YSZ), to effect separation between oxygen evolving and lithium reduction half-cell reactions. The cell, which operates at 700-850 C, possesses rapid electrode kinetics at the lithium-alloy electrode with exchange current density values being greater than 60 mA/sq cm. When used in the electrolytic mode, lithium produced at the negative electrode would be continuously removed from the cell for later use (under lunar conditions) as an easily storable reducing agent for the chemical refining of lunar ores. Because of the high reversibility of this electrochemical system, it has also formed the basis for the lithium-oxygen secondary battery system which possesses the highest theoretical energy density yet investigated.

Tsai, Kan J.↗
NASA NTRS1989

The electrochemical generation of useful chemical species from lunar materials

Electrochemical cells have been fabricated for the simultaneous generation of oxygen and lithium from a Li2O containing molten salt (Li2O-LiCl-LiF). The cell utilizes an oxygen vacancy conducting solid electrolyte, yttria-stabilized zirconia (YSZ), to effect separation between oxygen evolving and lithium reduction half-cell reactions. The cell, which operates at 700 to 850 C, possesses rapid electrode kinetics at the lithium-alloy electrode with exchange current density (i sub o) values being greater than 60mA sq cm. When used in the electrolytic mode, lithium produced at the negative electrode would be continuously removed from the cell for later use (under lunar conditions) as an easily storable reducing agent (compared to H2) for the chemical refining of lunar ores. Because of the high reversibility of this electrochemical system, it has also formed tha basis for the lithium oxygen secondary battery system which possesses the highest theoretical energy density yet investigated.

Tsai, Kan J.↗
NASA NTRS2002

Cryogenic Fracture Toughness Improvement for the Super Lightweight Tank's Main Structural Alloy

Marshall Space Flight Center has developed a two-step (TS) artificial aging technique that can significantly enhance cryogenic fracture toughness and resistance to stress corrosion cracking (SCC) in aluminum-copper-lithium alloy 2195. The new TS aging treatment consists of exposures at 132 C (270 F)/20 hr + 138 C (280 F)/42 hr, which can be readily applied to flight hardware production. TS aging achieves the same yield strength levels as conventional aging, while providing much improved ductility in the short transverse direction. After TS aging, five previously rejected lots of alloy 2195 (lots 950M029B, 960M030F, 960M030J, 960M030K, and 960M030L) passed simulated service testing for use in the super lightweight tank program. Each lot exhibited higher fracture toughness at cryogenic temperature than at ambient temperature. Their SCC resistance was also enhanced. All SCC specimens passed the minimum 10-day requirement in 3.5-percent sodium chloride alternate immersion at a stress of 45 ksi. The SCC lives ranged from 57 to 83 days, with an average of 70 days.

Chen, P. S.↗
NASA NTRS1989

The electrochemical generation of useful chemical species from lunar materials

The current status of work on an electrochemical technology for the simultaneous generation of oxygen and lithium from a Li2O containing molten salt (Li2O-LiCl-LiF) is discussed. The electrochemical cell utilizes an oxygen vacancy conducting solid electrolyte, yttria-stabilized zirconia, to effect separation between the oxygen evolving and lithium reduction half-cell reactions. The cell, which operates at 700 to 800 C, possesses rapid electrode kinetics at the lithium-alloy electrode with exchange current density values being greater than 60 mA/sq cm, showing high reversibility for this reaction. When used in the electrolytic mode, lithium produced at the negative electrode would be continuously removed from the cell for later use (under lunar conditions) as an easily storable reducting agent (compared to H2) for the chemical refining of lunar ores via the general reaction: 2Li + MO yields Li2O + M where MO represents a lunar ore. Emphasis to this time has been on the simulated lunar ore ilmenite (FeTiO3), which we have found becomes chemically reduced by Li at 432 C. Furthermore, both Fe2O3 and TiO2 have been reduced by Li to give the corresponding metal. This electrochemical approach provides a convenient route for producing metals under lunar conditions and oxygen for the continuous maintenance of human habitats on the Moon's surface. Because of the high reversibility of this electrochemical system, it has also formed the basis for the lithium-oxygen secondary battery. This secondary lithium-oxygen battery system posses the highest theoretical energy density yet investigated.

Tsai, Kan J.↗
NASA NTRS1989

Advances in ambient temperature secondary lithium cells

The Jet Propulsion Laboratory is involved in a Research and Development program sponsored by NASA/OAST on the development of ambient temperature secondary lithium cells for future space applications. Some of the projected applications are planetary spacecraft, planetary rovers, and astronaut equipment. The main objective is to develop secondary lithium cells with greater than 100 Wh/kg specific energy while delivering 1000 cycles at 50 percent Depth of Discharge (DOD). To realize these ambitious goals, the work was initially focused on several important basic issues related to the cell chemistry, selection of cathode materials and electrolytes, and component development. The performance potential of Li-TiS2, Li-MoS3, Li-V6O13 and Li-NbSe3 electrochemical systems was examined. Among these four, the Li-TiS2 system was found to be the most promising system in terms of realizable specific energy and cycle life. Some of the major advancements made so far in the development of Li-TiS2 cells are in the areas of cathode processing technology, mixed solvent electrolytes, and cell assembly. Methods were developed for the fabrication of large size high performance TiS2 cathodes. Among the various electrolytes examined, 1.5M LiAsF6/EC + 2-MeTHF mixed solvent electrolyte was found to be more stable towards lithium. Experimental cells activated with this electrolyte exhibited more than 300 cycles at 100 percent Depth of Discharge. Work is in progress in other areas such as selection of lithium alloys as candidate anode materials, optimization of cell design, and development of 5 Ah cells. The advances made at the Jet Propulsion Laboratory on the development of secondary lithium cells are summarized.

Subbarao, S.↗
NASA NTRS1991

Superplastic forming of Al-Li alloys for lightweight, low-cost structures

Superplastic forming of advanced aluminum alloys is being evaluated as an approach for fabricating low-cost, light-weight, cryogenic propellant tanks. Built-up structure concepts (with inherent reduced scrap rate) are under investigation to offset the additional raw material expenses incurred by using aluminum lithium alloys. This approach to fabrication offers the potential for significant improvements in both structural efficiency and overall manufacturing costs. Superplasticity is the ability of specially processed material to sustain very large forming strains without failure at elevated temperatures under controlled deformation conditions. It was demonstrated that superplastic forming technology can be used to fabricate complex structural components in a single operation and increase structural efficiency by as much as 60 percent compared to conventional configurations in skin-stiffened structures. Details involved in the application of this technology to commercial grade superplastic aluminum lithium material are presented. Included are identification of optimum forming parameters, development of forming procedures, and assessment of final part quality in terms of cavitation volume and thickness variation.

Hales, Stephen J.↗
NASA NTRS1998

Friction Stir Weld Tooling Development for Application on the 2195 Al-Cu-Li Space Transportation System External Tank

Friction Stir Welding (FSW) is a new and innovative solid-state joining process which can be applied to difficult-to- weld aluminum alloys. However, the large forces involved with the process have posed a production tooling challenge. Lockheed Martin Michoud Space Systems has overcome many of these challenges on the Super Lightweight External Tank (ET) program. Utilizing Aluminum-Copper-Lithium alloy 2195 in the form of plate and extrusions, investigations of FSW process parameters have been completed. Major loading mechanisms are discussed in conjunction with deflection measurements. Since the ET program is a cryogenic application, a brief comparison of cryogenic material properties with room temperature material properties is offered for both FSW and fusion welds. Finally, a new approach to controlling the FSW process from a load perspective is introduced. Emphasis will be put on tooling development, as well as the impact of tooling design and philosophy on Friction Stir Weld success probability.

Loftus, Zachary↗
NASA NTRS2008

Solid-State High-Temperature Power Cells

All-solid-state electrochemical power cells have been fabricated and tested in a continuing effort to develop batteries for instruments for use in environments as hot as 500 C. Batteries of this type are needed for exploration of Venus, and could be used on Earth for such applications as measuring physical and chemical conditions in geothermal and oil wells, processing furnaces, and combustion engines. In the state-of-the-art predecessors of the present solid-state power cells, fully packaged molten eutectic salts are used as electrolytes. The molten-salt-based cells can be susceptible to significant amounts of self-discharge and corrosion when used for extended times at elevated temperatures. In contrast, all-solid-state cells such as the present ones are expected to be capable of operating for many days at temperatures up to 500 C, without significant self-discharge. The solid-state cell described here includes a cathode made of FeS2, an electrolyte consisting of a crystalline solid solution of equimolar amounts of Li3PO4 and Li4SiO4, and an anode made of an alloy of Li and Si (see figure). The starting material for making the solid electrolyte is a stoichiometric mixture of Li3PO4, SiO2, and Li3CO2. This mixture is ball-milled, then calcined for two hours at a temperature of 1,100 C, then placed in a die atop the cathode material. Next, the layers in the die are squeezed together at a pressure between 60 and 120 MPa for one hour at a temperature of 600 C to form a unitary structure comprising the solid electrolyte and cathode bonded together. Finally, the lithium-alloy anode is pressure-bonded to the solid electrolyte layer, using an intermediate layer of pure lithium. In one test of a cell of this type, a discharge rate of about 1 mA per gram of cathode material was sustained for 72 hours at a temperature of about 460 C. This is about three times the discharge rate required to support some of the longer duration Venus-exploration mission scenarios.

Whitacre, Jay↗
NASA NTRS1991

Weldability of Weldalite (tm) 049 with and without TiB2 reinforcement

The effects are assessed of TiB2 reinforcement and parent alloy Li content on the weldability of Weldalite (tm) 049 type alloys. Welding trials were performed using either AC or DC polarity gas tungsten arc (GTA) welding according to described procedures. The welding was performed under conditions of high restraint on 5 cm (2 in) wide x 25.4 cm (10 in) long plates machined from the 0.952 cm (0.375 in) extruded bar parallel to the extrusion direction. A 37.5 deg bevel was machined on the center edge of the extruded bar. Cut rod filler wire was machined from three alloys, and one commercially available 2319 filler wire was also used. The preliminary assessment of the weldability revealed no propensity for hot cracking under conditions of high restraint. This result is significant, because hot cracking has been reported for all other leading aluminum lithium alloys welded with certain conventional filler alloys. The strengths for Weldalite parent welded with parent filler obtained were higher than those for alloys used in launch systems, such as 2219 and 2014 welded with 2319 and 4043 fillers, respectively. Even higher values were obtained by variable polarity plasma arc welding (e.g., 54 ksi (372 MPa) mean tensile strength).

Source record↗
NASA NTRS1991

The effect of TiB2 reinforcement on the mechanical properties of an Al-Cu-Li alloy-based metal-matrix composite

The addition of ceramic particles to aluminum based alloys can substantially improve mechanical properties, especially Young's modulus and room and elevated temperature strengths. However, these improvements typically occur at the expense of tensile ductility. The mechanical properties are evaluated to a metal matrix composite (MMC) consisting of an ultrahigh strength aluminum lithium alloy, Weldalite (tm) 049, reinforced with TiB2 particles produced by an in situ precipitation technique called the XD (tm) process. The results are compared to the behavior of a nonreinforced Weldalite 049 variant. It is shown that both 049 and 049-TiB2 show very attractive warm temperature properties e.g., 625 MPa yield strength at 150 C after 100 h at temperature. Weldalite 049 reinforced with a nominal 4 v pct. TiB2 shows an approx. 8 pct. increase in modulus and a good combination of strength (529 MPa UTS) and ductility (6.5 pct.) in the T3 temper. And the high ductility of Weldalite 049 in the naturally aged and underaged tempers makes the alloy a good, high strength matrix for ceramic reinforcement.

Source record↗
NASA NTRS1991

Mixed solvent electrolytes for ambient temperature secondary lithium cells

The present invention comprises an improved electrolyte for secondary lithium-based cells as well as batteries fabricated using this electrolyte. The electrolyte is a lithium containing salt dissolved in a non-aqueous solvent, which is made from a mixture of ethylene carbonate, ethylene propylene diene terpolymer, 2-methylfuran, and 2-methyltetrahydrofuran. This improved, mixed solvent electrolyte is more conductive than prior electrolytes and much less corrosive to lithium anodes. Batteries constructed with this improved electrolyte utilize lithium or lithium alloy anodes and cathodes made of metal chalcogenides or oxides, such as TiS.sub.2, NbSe.sub.3, V.sub.6 O.sub.13, V.sub.2 O.sub.5, MoS.sub.2, MoS.sub.3, CoO.sub.2, or CrO.sub.2, dissolved in a supporting polymer matrix, like EPDM. The preferred non-aqueous solvent mixture comprises approximately 5 to 30 volume percent ethylene carbonate, approximately 0.01 to 0.1 weight percent ethylene propylene diene terpolymer, and approximately 0.2 to 2 percent 2-methylfuran, with the balance being 2-methyltetrahydrofuran. The most preferred solvent comprises approximately 10 to 20 volume percent ethylene carbonate, about 0.05 weight percent ethylene propylene diene terpolymer, and about 1.0 percent 2-methylfuran, with the balance being 2-methyltetrahydrofuran. The concentration of lithium arsenic hexafluoride can range from about 1.0 to 1.8 M; a concentration 1.5 M is most preferred. Secondary batteries made with the improved electrolyte of this invention have lower internal impedance, longer cycle life, higher energy density, low self-discharge, and longer shelf life.

Shen, David H.↗