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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 1,117 records · Page 62
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Results of the Workshop on Impact Cratering: Bridging the Gap Between Modeling and Observations

On February 7-9,2003, approximately 60 scientists gathered at the Lunar and Planetary Institute in Houston, Texas, for a workshop devoted to improving knowledge of the impact cratering process. We (co-conveners Elisabetta Pierazzo and Robert Herrick) both focus research efforts on studying the impact cratering process, but the former specializes in numerical modeling while the latter draws inferences from observations of planetary craters. Significant work has been done in several key areas of impact studies over the past several years, but in many respects there seem to be a disconnect between the groups employing different approaches, in particular modeling versus observations. The goal in convening this workshop was to bring together these disparate groups to have an open dialogue for the purposes of answering outstanding questions about the impact process and setting future research directions. We were successful in getting participation from most of the major research groups studying the impact process. Participants gathered from five continents with research specialties ranging from numerical modeling to field geology, and from small-scale experimentation and geochemical sample analysis to seismology and remote sensing.With the assistance of the scientific advisory committee (Bevan French, Kevin Housen, Bill McKinnon, Jay Melosh, and Mike Zolensky), the workshop was divided into a series of sessions devoted to different aspects of the cratering process. Each session was opened by two invited t a b , one given by a specialist in numerical or experimental modeling approaches, and the other by a specialist in geological, geophysical, or geochemical observations. Shorter invited and contributed talks filled out the sessions, which were then concluded with an open discussion time. All modelers were requested to address the question of what observations would better constrain their models, and all observationists were requested to discuss how their observations can constrain modeling efforts.

Herrick, Robert↗
NASA NTRS1999

Double Diffusive Convection in Materials Processing

A great number of crystals grown in space are plagued by convective motions which contribute to structural flaws. The character of these instabilities is not well understood but is associated with density variations in the presence of residual gravity (g-jitter). As a specific example, past HgCdTe crystal growth space experiments by Lehoczky and co-workers indicate radial compositional asymmetry in the grown crystals. In the case of HgCdTe the rejected component into the melt upon solidification is HgTe which is denser than the melt. The space grown crystals indicate the presence of three dimensional flow with the heavier HgTe-rich material clearly aligned with the residual gravity (0.55-1.55 micro g) vector. This flow stems from double-diffusive convection, namely, thermal and solutal buoyancy driven flow in the melt. The study of double-diffusive convection is multi-faceted and rather vast. In our investigation, we seek to focus on one specific aspect of this discipline that is of direct relevance to materials processing especially crystal growth, namely, the side ways heating regime. This problem has been widely studied, both experimentally and numerically, in the context of solar ponds wherein the system is characterized by a linear salt (solutal) gradient with an imposed lateral temperature gradient. The induced flow instabilities arise from the wide disparity between the fluid thermal diffusivity and the solute diffusivity. The extension of the analysis to practical crystal growth applications has however not been rigorously made and understood. One subtle but important difference in crystal growth systems is the fact that die system solute gradient is non-linear (typically exponential). Besides, the crystal growth problem has the added complexities of solidification, both lateral and longitudinal thermal gradients and segregation phenomena in systems where binary and ternary compounds are being grown. This paper treats the side ways heating problem alone in a model fluid system. Results from detailed numerical calculations, mainly two dimensional are provided. The interactions between a non-linear solute gradient and an imposed transverse thermal gradient are investigated. The buoyancy effects are treated in the traditional Boussinesq approximation and also in a more complete density formulation to address recent concerns of the first approach especially in simulations of the system response in a reduced gravity environment. Detailed flow, temperature and solute field plots along with heat and mass transfer results are presented in the paper. Implications to practical crystal growth systems as discerned from the modeling results are also explored and reported.

Ramachandra, Narayanan↗
DOE OSTI2021

High Temperature Acclimation of Leaf Gas Exchange, Photochemistry, and Metabolomic Profiles in Populus trichocarpa

High temperatures alter the thermal sensitivities of numerous physiological and biochemical processes that impact tree growth and productivity. Foliar and root applications of methanol have been implicated in plant acclimation to high temperature via the C 1 pathway. Here, we characterized temperature acclimation at 35°C of leaf gas exchange, chlorophyll fluorescence and extractable metabolites of potted Populus trichocarpa saplings and examined potential influences of mM concentrations of methanol added during soil watering over a two-month period. Relative to plants grown under the low growth temperature (LGT), high growth temperature (HGT) plants showed a suppression of leaf water use and carbon cycling including transpiration (E), net photosynthesis (P n ), an estimate of photorespiration (R p ), and dark respiration (R d ), attributed to reductions in stomatal conductance and direct negative effects on gas exchange and photosynthetic machinery. In contrast, HGT plants showed an upregulation of non-photochemical quenching (NPQ t ), the optimum temperature for ETR, and leaf isoprene emissions at 40°C. A large number of metabolites (867) were induced under HGT, many implicated in flavonoid biosynthesis highlighting a potentially protective role for these compounds. Methanol application did not significantly alter leaf gas exchange but slightly reduced the suppression of R d and R p by the high growth temperature while slightly impairing ETR, Fv’/Fm’, and q p . However, we were unable to determine if soil methanol was sufficiently taken up by the plant to have a direct effect on foliar processes. A small number of extracted leaf tissue metabolites (55 out of 10,015) showed significantly altered abundances under LGT and methanol treatments relative to water controls, and this increased in compound number (222) at the HGT. The results demonstrate the large physiological and biochemical impacts of high growth temperature on poplar seedlings and highlights the enhancement of the optimum temperature of ETR as a rapid thermal acclimation mechanism. Finally, although no large effect on leaf physiology was observed, the results are consistent with methanol both impairing photochemistry of the light reactions via formaldehyde toxicity, and stimulating photosynthesis and dark respiration through formate oxidation to CO 2 .

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Fabrication of α-Fe 2 O 3 Nanoparticles/g-C 3 N 4 Direct Z-Scheme Heterojunction of Durable Photocatalytic Activity

The fabrication of a nanohybrid photocatalyst that combines α-Fe 2 O 3 nanoparticles with graphitic carbon nitride (g-C 3 N 4 ) is reported. The ensuing direct Z-scheme heterojunction greatly boosts the photocatalytic activity of the α-Fe 2 O 3 /g-C 3 N 4 nanohybrids. This results in organic dye degradation rates more than two times higher than its individual components, promoted by the efficient charge separation and transfer of the Z-scheme heterojunction mechanism of the nanohybrid photocatalyst. In addition, recyclability tests show an outstanding stability of the nanohybrids spanning five consecutive dye degradation experiments, during which the degradation rate is slightly improved. The origin of the improved photocatalytic performance of the nanohybrid lies in the intimate interaction between α-Fe 2 O 3 and g-C 3 N 4 afforded by the two-step fabrication process, which enables the direct and controlled growth of α-Fe 2 O 3 nanoparticles on g-C 3 N 4 . A first ultrasound impregnation step promotes the effective anchoring of stable Fe species via Fe–N and C–N/C–O bonding, while a second microwave phase conversion step induces the subsequent growth of α-Fe 2 O 3 nanoparticles on the g-C 3 N 4 sheets. Careful control of the FeCl 3 precursor concentration up to a threshold value of 0.25 M during impregnation enables complete control over their size and phase. This approach clearly highlights the benefits of microwave reactor systems in the fabrication of hematite-based Z-scheme photocatalytic, overcoming the limitations of conventional thermal treatment technology.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Fatigue Performance of Ti-6Al-4V Additively Manufactured Specimens with Integrated Capillaries of an Embedded Structural Health Monitoring System

Additive manufacturing (AM) of metals offers new possibilities for the production of complex structures. Up to now, investigations on the mechanical response of AM metallic parts show a significant spread and unexpected failures cannot be excluded. In this work, we focus on the detection of fatigue cracks through the integration of a Structural Health Monitoring (SHM) system in Ti-6Al-4V specimens. The working principle of the presented system is based on the integration of small capillaries that are capable of detecting fatigue cracks. Four-point bending fatigue tests have been performed on Ti-6Al-4V specimens with integrated capillaries and compared to the reference specimenswithout capillaries. Specimens were produced by conventional subtractive manufacturing of wrought material and AM, using the laser based Directed Energy Deposition (DED) process. In this study, we investigated the effect of the presence of the capillary on the fatigue strength and fatigue initiation location. Finite element (FEM) simulations were performed to validate the experimental test results. The presence of a drilled capillary in the specimens did not alter the fatigue initiation location. However, the laser based DED production process introduced roughness on the capillary surface that altered the fatigue initiation location to the capillary surface. The fatigue performance was greatly reduced when considering a printed capillary. It is concluded that the surface quality of the integrated capillary is of primary importance in order not to influence the structural integrity of the component to be monitored.

36 MATERIALS SCIENCE↗
NASA NTRS2004

Extraction of Oxygen from the Martian Atmosphere

A mechanical process was designed for direct extraction of molecular oxygen from the martian atmosphere based on liquefaction of the majority component, CO2, followed by separation of the lower-boiling components. The atmospheric gases are compressed from about 0.007 bar to 13 bar and then cooled to liquefy most of the CO2. The uncondensed gases are further compressed to 30 bar or more, and then cooled again to recover water as ice and to remove much of the remaining CO2. The final gaseous products consisting mostly of nitrogen, oxygen, and carbon monoxide are liquefied and purified by cryogenic distillation. The liquefied CO2 is expanded back to the low-pressure atmosphere with the addition of heat to recover a majority of the compression energy and to produce the needed mechanical work. Energy for the process is needed primarily as heat to drive the CO2-based expansion power system. When properly configured, the extraction process can be a net producer of electricity. The conceptual design, termed 'MARRS' for Mars Atmosphere Resource Recovery System, was based on the NASA/JSC Mars Reference Mission (MRM) requirement for oxygen. This mission requires both liquid oxygen for propellant, and gaseous oxygen as a component of air for the mission crew. With single redundancy both for propellant and crew air, the oxygen requirement for the MRM is estimated at 5.8 kg/hr. The process thermal power needed is about 120 kW, which can be provided at 300-500 C. A lower-cost nuclear reactor made largely of stainless steel could serve as the heat source. The chief development needed for MARRS is an efficient atmospheric compression technology, all other steps being derived from conventional chemical engineering separations. The conceptual design describes an exceptionally low-mass compression system that can be made from ultra-lightweight and deployable structures. This system adapts to the rapidly changing martian environment to supply the atmospheric resource to MARRS at constant conditions.

England, C.↗
DOE OSTI2023

Electrodeposition and analysis of thick bismuth films

Due to its unique physical and chemical properties, bismuth is an attractive candidate for a wide range of applications such as battery anodes, radiation shielding, and semiconductors, to name a few. This work presents the electrodeposition of mechanically stable and homogenous bismuth films at micron-scale thicknesses. A simple one-step electrodeposition process using either a pulse/reverse or direct current source yielded thick, homogenous, and mechanically stable bismuth films. Morphology, electrochemical behavior, adhesion, and mechanical stability of bismuth coatings plated with varying parameters were characterized via optical profilometry, cyclic voltammetry, electron microscopy, and tribology. Scratch testing on thick electroplated coatings (> 100 µm) revealed similar wear resistance properties between the pulse/reverse plated and direct current electroplated films. This study presents a versatile bismuth electroplating process with the possibility to replace lead in radiation shields with an inexpensive, non-toxic metal, or to make industrially relevant electrocatalytic devices.

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

Feature Based Qualification (FBQ) of Wire Arc Additively Manufactured (WAAM) 17-4PH Martensitic Stainless Steels

The Department of Defense (DOD) programs of records desire to reduce the time and cost of the development and delivery loop in metal additive manufacturing (AM), including establishing forwarded AM capabilities. The success of these efforts relies on a robust and qualified process. To achieve this, the United States Army Combat Capabilities Development Command Ground Vehicle Systems Center Materials Engineering (GVME) needs to be able to quickly evaluate, test, and develop feedstocks, processes, and parts. This report is directed towards demonstrating the need for a framework for metal AM processes, defining and exploring geometries for metal AM process qualification, testing resultant deposition, and delivering actionable data.

36 MATERIALS SCIENCE↗
NASA NTRS1997

Multicriteria Gain Tuning for Rotorcraft Flight Controls (also entitled The Development of the Conduit Advanced Control System Design and Evaluation Interface with a Case Study Application Fly by Wire Helicopter Design)

Handling qualities analysis and control law design would seem to be naturally complimenting components of aircraft flight control system design, however these two closely coupled disciplines are often not well integrated in practice. Handling qualities engineers and control system engineers may work in separate groups within an aircraft company. Flight control system engineers and handling quality specialists may come from different backgrounds and schooling and are often not aware of the other group's research. Thus while the handling qualities specifications represent desired aircraft response characteristics, these are rarely incorporated directly in the control system design process. Instead modem control system design techniques are based on servo-loop robustness specifications, and simple representations of the desired control response. Comprehensive handling qualities analysis is often left until the end of the design cycle and performed as a check of the completed design for satisfactory performance. This can lead to costly redesign or less than satisfactory aircraft handling qualities when the flight testing phase is reached. The desire to integrate the fields of handling qualities and flight,control systems led to the development of the CONDUIT system. This tool facilitates control system designs that achieve desired handling quality requirements and servo-loop specifications in a single design process. With CONDUIT, the control system engineer is now able to directly design and control systems to meet the complete handling specifications. CONDUIT allows the designer to retain a preferred control law structure, but then tunes the system parameters to meet the handling quality requirements.

Biezad, Daniel↗
DOE OSTI2020

A Bayesian Approach for Statistical–Physical Bulk Parameterization of Rain Microphysics. Part II: Idealized Markov Chain Monte Carlo Experiments

Observationally informed development of a new framework for bulk rain microphysics, the Bayesian Observationally Constrained Statistical–Physical Scheme (BOSS; described in Part I of this study), is demonstrated. This scheme’s development is motivated by large uncertainties in cloud and weather simulations associated with approximations and assumptions in existing microphysics schemes. Here, a proof-of-concept study is introduced using a Markov chain Monte Carlo sampling algorithm with BOSS to probabilistically estimate microphysical process rates and parameters directly from a set of synthetically generated rain observations. The framework utilized is an idealized steady-state one-dimensional column rainshaft model with specified column-top rain properties and a fixed thermodynamical profile. Different configurations of BOSS—flexibility being a key feature of this approach—are constrained via synthetic observations generated from a traditional three-moment bulk microphysics scheme. The ability to retrieve correct parameter values when the true parameter values are known is illustrated. For cases when there is no set of true parameter values, the accuracy of configurations of BOSS that have different levels of complexity is compared. It is found that addition of the sixth moment as a prognostic variable improves prediction of the third moment (proportional to bulk rain mass) and rain rate. In contrast, increasing process rate formulation complexity by adding more power terms has little benefit—a result that is explained using further-idealized experiments. BOSS rainshaft simulations are shown to well estimate the true process rates from constraint by bulk rain observations, with the further benefit of rigorously quantified uncertainty of these estimates.

58 GEOSCIENCES↗
DOE OSTI2019

Mineral-Organic Interface on Clay Minerals: Imaging and Analytical Approaches

Soil microbes are responsible for contributing to the main components of the soil organic matter (SOM). Their micro- and nano-scale organo-mineral associations with soil minerals are the sites where complex processes including aggregate formation, microbial mineral weathering, and soil organic matter stabilization all occur in a narrow zone of biogeochemical gradients. This study aimed at identifying the mechanisms underlying soil organic matter stabilization in clay minerals, by characterizing organic matter (OM) association with mineral surfaces with high resolution multiscale visualization by chemical imaging and EDS mapping, to understand the mechanisms of OM formation and stabilization. Multiscale and high resolution TEM imaging and chemical imaging by high resolution EDS revealed very low concentrations of dissolved cations and a variety of newly formed nanominerals specifically associated with microbial surfaces and microbial EPS. It provided a new perspective on newly formed minerals as a physico- chemical way of SOM stabilization in clay minerals. This contributed to our understanding of the role of microbes in soil organic matter persistence in ecosystems, and it supported hypotheses in literature that were lacking the direct imaging of these processes.

Dohnalkova, Alice↗
DOE OSTI2023

An effective air–liquid contactor for CO 2 direct air capture using aqueous solvents

Here, the development of a cost-effective, corrosion resistant, high-flux direct air capture (HiDAC) contactor for a solvent-based direct air capture (DAC) process is reported. Literature technoeconomic analyses suggest that the air–liquid contactor can cost over 20 % of the overall DAC plant’s annualized capital costs. To bring down the overall cost of DAC, it is imperative that an effective contactor is developed. A hybrid contactor consisting of a commercial polyvinylchloride structured packing enhanced with stainless-steel 410 random packing has been developed to provide a high surface area for air–liquid contact. The contactor geometry, wettability, corrosion resistance, pressure drop, along with its CO 2 uptake efficiency, CO 2 uptake rates, and extended loading potential using potassium sarcosinate solutions are investigated. Results show that the HiDAC contactor has a relatively high specific surface area (885 m 2 /m 3 ), which allows for CO 2 uptake efficiencies of up to 75 % and capture rates of up to 550 g of CO 2 per day for a 0.3 × 0.25 × 0.3 m contactor. The contactor also exhibits high levels of wettability and corrosion resistance with amino acid-based DAC solvents. A CO 2 uptake model was developed, and modeling results are compared to experimental data to simulate and predict the performance of the contactor in a DAC process using potassium sarcosinate solvent. The system’s overall mass transfer coefficient and theoretical pressure drop were also calculated, and these results were compared to DAC data found in literature. The results presented indicate that the HiDAC contactor is well suited for DAC due to its high specific surface area, resistance to corrosion, and high degree of wettability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2013

High-Efficiency Nested Hall Thrusters for Robotic Solar System Exploration

This work describes the scaling and design attributes of Nested Hall Thrusters (NHT) with extremely large operational envelopes, including a wide range of throttleability in power and specific impulse at high efficiency (>50%). NHTs have the potential to provide the game changing performance, powerprocessing capabilities, and cost effectiveness required to enable missions that cannot otherwise be accomplished. NHTs were first identified in the electric propulsion community as a path to 100- kW class thrusters for human missions. This study aimed to identify the performance capabilities NHTs can provide for NASA robotic and human missions, with an emphasis on 10-kW class thrusters well-suited for robotic exploration. A key outcome of this work has been the identification of NHTs as nearly constant-efficiency devices over large power throttling ratios, especially in direct-drive power systems. NHT systems sized for robotic solar system exploration are predicted to be capable of high-efficiency operation over nearly their entire power throttling range. A traditional Annular Hall Thruster (AHT) consists of a single annular discharge chamber where the propellant is ionized and accelerated. In an NHT, multiple annular channels are concentrically stacked. The channels can be operated in unison or individually depending on the available power or required performance. When throttling an AHT, performance must be sacrificed since a single channel cannot satisfy the diverse design attributes needed to maintain high thrust efficiency. NHTs can satisfy these requirements by varying which channels are operated and thereby offer significant benefits in terms of thruster performance, especially under deep power throttling conditions where the efficiency of an AHT suffers since a single channel can only operate efficiently (>50%) over a narrow power throttling ratio (3:1). Designs for 10-kW class NHTs were developed and compared with AHT systems. Power processing systems were considered using either traditional Power Processing Units (PPU) or Direct Drive Units (DDU). In a PPU-based system, power from the solar arrays is transformed from the low voltage of the arrays to the high voltage needed by the thruster. In a DDU-based system, power from the solar arrays is fed to the thruster without conversion. DDU-based systems are attractive for their simplicity since they eliminate the most complex and expensive part of the propulsion system. The results point to the strong potential of NHTs operating with either PPUs or DDUs to benefit robotic and human missions through their unprecedented power and specific impulse throttling capabilities. NHTs coupled to traditional PPUs are predicted to offer high-efficiency (>50%) power throttling ratios 320% greater than present capabilities, while NHTs with direct-drive power systems (DDU) could exceed existing capabilities by 340%. Because the NHT-DDU approach is implicitly low-cost, NHT-DDU technology has the potential to radically reduce the cost of SEP-enabled NASA missions while simultaneously enabling unprecedented performance capability.

Hofer, Richard R.↗
NASA NTRS2015

Multiscale and Multiphysics Modeling of Additive Manufacturing of Advanced Materials

The objective of this proposed project is to research and develop a prediction tool for advanced additive manufacturing (AAM) processes for advanced materials and develop experimental methods to provide fundamental properties and establish validation data. Aircraft structures and engines demand materials that are stronger, useable at much higher temperatures, provide less acoustic transmission, and enable more aeroelastic tailoring than those currently used. Significant improvements in properties can only be achieved by processing the materials under nonequilibrium conditions, such as AAM processes. AAM processes encompass a class of processes that use a focused heat source to create a melt pool on a substrate. Examples include Electron Beam Freeform Fabrication and Direct Metal Deposition. These types of additive processes enable fabrication of parts directly from CAD drawings. To achieve the desired material properties and geometries of the final structure, assessing the impact of process parameters and predicting optimized conditions with numerical modeling as an effective prediction tool is necessary. The targets for the processing are multiple and at different spatial scales, and the physical phenomena associated occur in multiphysics and multiscale. In this project, the research work has been developed to model AAM processes in a multiscale and multiphysics approach. A macroscale model was developed to investigate the residual stresses and distortion in AAM processes. A sequentially coupled, thermomechanical, finite element model was developed and validated experimentally. The results showed the temperature distribution, residual stress, and deformation within the formed deposits and substrates. A mesoscale model was developed to include heat transfer, phase change with mushy zone, incompressible free surface flow, solute redistribution, and surface tension. Because of excessive computing time needed, a parallel computing approach was also tested. In addition, after investigating various methods, a Smoothed Particle Hydrodynamics Model (SPH Model) was developed to model wire feeding process. Its computational efficiency and simple architecture makes it more robust and flexible than other models. More research on material properties may be needed to realistically model the AAM processes. A microscale model was developed to investigate heterogeneous nucleation, dendritic grain growth, epitaxial growth of columnar grains, columnar-to-equiaxed transition, grain transport in melt, and other properties. The orientations of the columnar grains were almost perpendicular to the laser motion's direction. Compared to the similar studies in the literature, the multiple grain morphology modeling result is in the same order of magnitude as optical morphologies in the experiment. Experimental work was conducted to validate different models. An infrared camera was incorporated as a process monitoring and validating tool to identify the solidus and mushy zones during deposition. The images were successfully processed to identify these regions. This research project has investigated multiscale and multiphysics of the complex AAM processes thus leading to advanced understanding of these processes. The project has also developed several modeling tools and experimental validation tools that will be very critical in the future of AAM process qualification and certification.

Liou, Frank↗
DOE OSTI2017

Low-Cost Bio-Based Carbon Fibers for High Temperature Processing

GrafTech International Holdings Inc. (GTI), under Award No. DE-EE0005779, worked with Oak Ridge National Laboratory (ORNL) under CRADA No. NFE-15-05807 to develop lignin-based carbon fiber (LBCF) technology and to demonstrate LBCF performance in high-temperature products and applications. This work was unique and different from other reported LBCF work in that this study was application-focused and scalability-focused. Accordingly, the executed work was based on meeting criteria based on technology development, cost, and application suitability. High-temperature carbon fiber based insulation is used in energy intensive industries, such as metal heat treating and ceramic and semiconductor material production. Insulation plays a critical role in achieving high thermal and process efficiency, which is directly related to energy usage, cost, and product competitiveness. Current high temperature insulation is made with petroleum based carbon fibers, and one goal of this protect was to develop and demonstrate an alternative lignin (biomass) based carbon fiber that would achieve lower cost, CO2 emissions, and energy consumption and result in insulation that met or exceeded the thermal efficiency of current commercial insulation. In addition, other products were targeted to be evaluated with LBCF. As the project was designed to proceed in stages, the initial focus of this work was to demonstrate lab-scale LBCF from at least 4 different lignin precursor feedstock sources that could meet the estimated production cost of $5.00/pound and have ash level of less than 500 ppm in the carbonized insulation-grade fiber. Accordingly, a preliminary cost model was developed based on publicly available information. The team demonstrated that 4 lignin samples met the cost criteria. In addition, the ash level for the 4 carbonized lignin samples was below 500 ppm. Processing as-received lignin to produce a high purity lignin fiber was a significant accomplishment in that most industrial lignin, prior to purification, had greater than 4X the ash level needed for this project, and prior to this work there was not a clear path of how to achieve the purity target. The lab scale development of LBCF was performed with a specific functional application in mind, specifically for high temperature rigid insulation. GTI is a consumer of foreign-sourced pitch and rayon based carbon fibers for use in its high temperature insulation products, and the motivation was that LBCF had potential to decrease costs and increase product competitiveness in the marketplace through lowered raw material costs, lowered energy costs, and decreased environmental footprint. At the end of this project, the Technology Readiness Level (TRL) remained at 5 for LBCF in high temperature insulation.

09 BIOMASS FUELS↗
NASA NTRS2007

Electron Beam Freeform Fabrication in the Space Environment

This viewgraph presentation describes the effect of microgravity on the fabrication of electron beam freeform (EBF) in aerospace environments. The contents include: 1) Electron Beam Freeform Fabrication (EBF3) Process Description; 2) Portable Electron Beam Freeform Fabrication System at NASA LaRC; 3) Electron Beam Freeform Fabrication in the Space Environment; 4) Effect of Gravity on Surface Tension; 5) Effect of Deposit Height on Cooling Path; 6) Microgravity Testing Aboard JSC's C-9; 7) Typical Test Flight Plates; 8) Direction and Height Trials for Process Control; 9) Effect of Wire Entry Direction into Molten Pool; 10) Microstructure of Single Layer EBF Deposits; 11) 0-g Deposit with Incorrect Standoff Distance; 12) Successful Demonstration of EBF in 0-g; and 13) Conclusion.

Taminger, Karen M.↗
DOE OSTI2021

Tailoring Cementitious Materials Towards Value-Added Use of Large CO 2 Volumes

Hydraulic cements with alternative chemistries were developed for large-volume and value-added use of carbon dioxide. The hydraulic cements were processed using the energy-efficient mechanochemical technique at room temperature and atmospheric pressure. Carbon dioxide was captured directly from combustion emissions during processing. For this purpose, mechanochemical processing of hydraulic cements was accomplished under a flow of combustion emissions prior to the release of emissions to the atmosphere. The process removed a significant fraction of carbon dioxide from combustion emissions. The hydraulic cements captured carbon dioxide at about 10% of their weight. Two hydraulic cement chemistries were developed, and their mechanochemical processing was successfully scaled-up. The characteristic feature of one chemistry was its relatively low (near-neutral) pH where the integration of carbon dioxide yielded clear value. The second cement chemistry was based on alkali activation of industrial wastes. This chemistry could make value-added use of carbon dioxide, but it had to be refined to control the pH drop caused by CO 2 integration. These two cements render binding effects upon hydration by forming a combination of stable carbonates and aluminosilicates or phosphates. Efforts to develop cement chemistries based solely on carbonates were not successful. The mechanochemical process was found to integrate carbon dioxide into the alternative cement chemistries in the form of disordered and metastable carbonates. During hydration reactions, the disordered/metastable carbonates are either transformed into stable carbonate phases with desired binding efforts, or carbonates get integrated into the primary inorganic binders (hydrates). When compared with mechanochemical processing in pure carbon dioxide, mechanochemical processing in combustion emissions produced hydraulic cements with improved engineering properties. The mechanochemical process was scaled-up, and its variables as well as the raw materials formulations were optimized for implementation at pilot scale. Scale-up was found to enhance the carbon capture potential and the engineering qualities of the resulting hydraulic cements. This was because scale-up raises the intensity of mechanical energy input to raw materials. Certain mechanochemical phenomena cannot be induced, irrespective of the cumulative mechanical energy input, unless the intensity of impact is raised above a minimum level that cannot be achieved in laboratory-scale implementation of the process. Due to this effect, the duration of the mechanochemical process as well as its energy demand could be reduced significantly (by an order of magnitude) upon transition from laboratory to pilot scale, with the hydraulic cements produced at pilot scale offering engineering properties that were superior to those realized in laboratory-scale mechanochemical processing. The hydraulic cements produced at pilot scale via mechanochemical processing under a flow of combustion emissions were thoroughly characterized. They were found to meet standard requirements for ‘General Use’ hydraulic cements. They were compatible with the industrial-scale concrete production and construction practices that are used with the currently prevalent hydraulic cements. The new hydraulic cements with integrated carbon dioxide were found to offer distinct advantages over the currently prevalent Portland cement in terms of net carbon footprint and energy content. The combined raw materials and energy costs of the new hydraulic cements are competitive, and major cost savings can be realized because of the simplified production process that significantly lowers the capital investment in cement production plants. Mechanochemical processing of the new hydraulic cements under a flow of combustion emissions can be implemented using some existing components of cement manufacturing plants; this facilitates adoption of the technology by the cement industry.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Investigating stainless steel/aluminum bimetallic structures fabricated by cold metal transfer (CMT)-based wire-arc directed energy deposition

Here, this study investigated the process of fabricating a bimetallic structure of 316L stainless steel (SS) and 4043 aluminum (Al) using wire-arc directed energy deposition (DED) based on the cold metal transfer (CMT) process. The impact of heat input on the fabricated structure’s geometry, porosity, and microstructures at the interface, with a specific emphasis on the intermetallic compound (IMC) formation, and the subsequent impact on the joint strength of the structure, were studied. The IMC layer at the interface was predominantly comprised of FeAl 2 Si. For the various heat input conditions studied, the IMC layer's thickness varied from 5 µm to 18 µm. The tensile strength reached up to approximately 130 MPa, which is among the highest reported in the literature for steel/Al bimetallic structures. The specimens fabricated with high heat input conditions had a thicker IMC layer at the steel/Al interface, resulting in a more brittle interface and degradation of the mechanical properties.

36 MATERIALS SCIENCE↗