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At least 1,135 records · Page 63

Salt hydrate-based phase change thermal energy storage and encapsulation thereof

Among other things, the present disclosure relates to phase change material (PCM) composites composed of an PCM mixed with a nucleating agent contained within the pores of a graphite matrix and/or a hydrogel. The process to create these PCM composites includes coating the surface of graphite with a surfactant, compressing the graphite to form a matrix, then filling the graphite matrix with the PCM.

Odukomaiya, Adewale↗

VPS GRCop-84 Liner Development Efforts

For the past several years, NASA's Marshall Space Flight Center (MSFC) has been working with Plasma Processes, Inc. (PPI) to fabricate combustion chamber liners using the Vacuum Plasma Spray (VPS) process. Multiple liners of a variety of shapes and sizes have been created. Each liner has been fabricated with GRCop-84 (a copper alloy with chromium and niobium) and a functional gradient coating (FGC) on the hot wall. While the VPS process offers versatility and a reduced fabrication schedule, the material system created with VPS allows the liners to operate at higher temperatures, with maximum blanch resistance and improved cycle life. A subscal unit (5K lbf thrust class) is being cycle tested in a LOX/Hydrogen thrust chamber assembly at MSFC. To date, over 75 hot-fire tests have been accumulated on this article. Tests include conditions normally detrimental to conventional materials, yet the VPS GRCop-84 liner has yet to show any signs of degradation. A larger chamber (15K lbf thrust class) has also been fabricated and is being prepared for hot-fire testing at MSFC near the end of 2003. Linear liners have been successfully created to further demonstrate the versatility of the process. Finally, scale up issues for the VPS process are being tackled with efforts to fabricate a full size, engine class liner. Specifically, a liner for the SSME's Main Combustion Chamber (MCC) has recently been attempted. The SSME size was chosen for convenience, since its design was readily available and its size was sufficient to tackle specific issues. Efforts to fabricate these large liners have already provided valuable lessons for using this process for engine programs. The material quality for these large units is being evaluated with destructive analysis and these results will be available by the end of 2003.

Elam, Sandra K.↗

Tunable Solid‐State Properties and Anisotropic Charge Mobility in Hydrogen‐Bonded Diketopyrrolopyrrole Polymers via Automated Device Fabrication and Characterization

The optoelectronic properties of semiconducting polymers and device performance rely on a delicate interplay of design and processing conditions. However, screening and optimizing the relationships between these parameters for reliably fabricating organic electronics can be an arduous task requiring significant time and resources. To overcome this challenge, Polybot is developed—a robotic platform within a self‐driving lab that can efficiently produce organic field‐effect transistors (OFETs) from various semiconducting polymers via high‐throughput blade coating deposition. Polybot not only handles the fabrication process but also can conduct characterization tests on the devices and autonomously analyze the data gathered, thus facilitating the rapid acquisition of data on a large scale. This work leverages the capabilities of this platform to investigate the fabrication of OFETs using hydrogen bonding‐containing semiconducting polymers. Through high‐throughput fabrication and characterization, various data trends are analyzed, and large extents of anisotropic charge mobility are observed in devices. The materials are thoroughly characterized to understand the role of processing conditions in solid state and electronic properties of these organic semiconductors. The findings demonstrate the effectiveness of automated fabrication and characterization platforms in uncovering novel structure–property relationships, facilitating refinement of rational chemical design, and processing conditions, ultimately leading to new semiconducting materials.

automated fabrication and characterization↗

Integrated Electrode Arrays for Neuro-Prosthetic Implants

Arrays of electrodes integrated with chip-scale packages and silicon-based integrated circuits have been proposed for use as medical electronic implants, including neuro-prosthetic devices that might be implanted in brains of patients who suffer from strokes, spinal-cord injuries, or amyotrophic lateral sclerosis. The electrodes of such a device would pick up signals from neurons in the cerebral cortex, and the integrated circuit would perform acquisition and preprocessing of signal data. The output of the integrated circuit could be used to generate, for example, commands for a robotic arm. Electrode arrays capable of acquiring electrical signals from neurons already exist, but heretofore, there has been no convenient means to integrate these arrays with integrated-circuit chips. Such integration is needed in order to eliminate the need for the extensive cabling now used to pass neural signals to data-acquisition and -processing equipment outside the body. The proposed integration would enable progress toward neuro-prostheses that would be less restrictive of patients mobility. An array of electrodes would comprise a set of thin wires of suitable length and composition protruding from and supported by a fine-pitch micro-ball grid array or chip-scale package (see figure). The associated integrated circuit would be mounted on the package face opposite the probe face, using the solder bumps (the balls of the ball grid array) to make the electrical connections between the probes and the input terminals of the integrated circuit. The key innovation is the insertion of probe wires of the appropriate length and material into the solder bumps through a reflow process, thereby fixing the probes in place and electrically connecting them with the integrated circuit. The probes could be tailored to any distribution of lengths and made of any suitable metal that could be drawn into fine wires. Furthermore, the wires could be coated with an insulating layer using anodization or other processes, to achieve the correct electrical impedance. The probe wires and the packaging materials must be biocompatible using such materials as lead-free solders. For protection, the chip and package can be coated with parylene.

Brandon, Erik↗

Advancements in Manufacturing of High-Performance Perovskite Solar Cells and Modules Using Printing Technologies

Perovskite photovoltaic technology carries immense opportunity for the solar industries because of its remarkable efficiency and prospect for cost-effective production. However, the successful deployment of perovskite solar modules (PSMs) in the solar market necessitates tackling stability-based obstacles, scalability, and environmental considerations. This paper unveils a comprehensive examination of the cutting-edge advancements in the manufacturing of perovskite solar cells (PSCs) and modules, with an emphasis on high-speed, large-area printing. The paper underscores the substantial progress achieved in printed PSCs and PSMs, demonstrating promising electrical performance and long-term device durability. This review paper categorizes printing techniques compatible with large-area high-speed manufacturing into three distinct families: blade coating, slot die coating, and screen printing, as these common printing practices offer precise control, scalability, cost-effectiveness, high resolution, and efficient material usage. Additionally, this paper presents an in-depth investigation and comparison of superior PSCs and PSMs fabricated by printing on power conversion efficiency (PCE), stability, and scalability.

14 SOLAR ENERGY↗

Silicon carbide reinforced zirconium based cladding

A method for making an improved nuclear fuel cladding tube includes reinforcing a Zr alloy tube by first winding or braiding ceramic yarn directly around the tube to form a ceramic covering, then physically bonding the ceramic covering to the tube by applying a first coating selected from the group consisting of Nb, Nb alloy, Nb oxide, Cr, Cr oxide, Cr alloy, or combinations thereof, by one of a thermal deposition process or a physical deposition process to provide structural support member for the Zr tube, and optionally applying a second coating and optionally applying a third coating by one of a thermal deposition process or a physical deposition process. If the tube softens at 800° C.-1000° C., the structural support tube will reinforce the Zr alloy tube against ballooning and bursting, thereby preventing the release of fission products to the reactor coolant.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Ultra-High Temperature Thermal Barrier Coating Development and Validation

The most effective method to improve industrial gas turbine power is to increase firing temperature. To maintain component durability at these higher temperatures, thermal barrier coatings (TBC’s) are playing an increasing role in protecting turbine hardware. TBC’s have been successfully used on Solar Turbines’ combustor liners and turbine airfoils, but there is a need for TBC’s that can operate at higher temperatures. Based on recent, favorable rig testing experience, Solar recognized that yttrium aluminum garnet (YAG) TBC’s made by the Solution Precursor Plasma Spray Process (SPPS) has great potential for higher turbine temperatures. This testing verified the thermal cycle durability of the SPPS YAG TBC’s, as well as demonstrated that the temperature drop through the SPPS YAG TBC was twice that measured across a companion APS YSZ TBC. The SPPS YAG TBC with the potential for a 200°C improvement in temperature capability represents a materials breakthrough. The SPPS process also produces a number of unique microstructural features that confer superior properties. SPPC TBC’s have ultra-fine splats that increase toughness and erosion resistance, and the process can be tailored to produce through-thickness cracks for strain-tolerance and control porosity for lower thermal conductivity and increase coating abradability. This proposal would include further development of SPPS YAG density-graded coatings, optimization of the application process, and validation of higher temperature capability and durability through rig and engine testing of coated combustion liners and turbine outer air seals. The technology would be advanced from a TRL 3 to a proposed TRL 6 by overcoming processing concerns on efficiency, application distance and optimization of a graded coating without impacting coating durability by demonstrating the coating performance on components in rig and development gas turbine engine testing.

36 MATERIALS SCIENCE↗

Application of hard coatings to substrates at low temperatures

BIRL, the industrial research laboratory of Northwestern University, has conducted unique and innovative research, under sponsorship from the NASA Marshall Space Flight Center (MSFC), in the application of hard, wear resistant coatings to bearing steels using the high-rate reactive sputtering (HRRS) process that was pioneered by Dr. William Sproul, the principal investigator on this program. Prior to this program, Dr. Sproul had demonstrated that it is possible to apply hard coatings such as titanium nitride (TiN) to alloy steels at low temperatures via the HRRS process without changing the metallurgical properties of the steel. The NASA MSFC program at BIRL had the specific objectives to: apply TiN to 440C stainless steel without changing the metallurgical properties of the steel; prepare rolling contact fatigue (RCF) test samples coated with binary hard coatings of TiN, zirconium nitride (ZrN), hafnium nitride (HfN), chromium nitride (CrN), and molybdenum nitride (MoN), and metal coatings of copper (Cu) and gold (Au); and develop new alloyed hard coatings of titanium aluminum nitride (Ti(0.5)Al(0.5)N), titanium zirconium nitride (Ti(0.5)Zr(0.5)N), and titanium aluminum vanadium nitride.

Sproul, William D.↗

Monte Carlo modeling of atomic oxygen attack of polymers with protective coatings on LDEF

Characterization of the behavior of atomic oxygen interaction with materials on the Long Duration Exposure Facility (LDEF) will assist in understanding the mechanisms involved, and will lead to improved reliability in predicting in-space durability of materials based on ground laboratory testing. A computational simulation of atomic oxygen interaction with protected polymers was developed using Monte Carlo techniques. Through the use of assumed mechanistic behavior of atomic oxygen and results of both ground laboratory and LDEF data, a predictive Monte Carlo model was developed which simulates the oxidation processes that occur on polymers with applied protective coatings that have defects. The use of high atomic oxygen fluence-directed ram LDEF results has enabled mechanistic implications to be made by adjusting Monte Carlo modeling assumptions to match observed results based on scanning electron microscopy. Modeling assumptions, implications, and predictions are presented, along with comparison of observed ground laboratory and LDEF results.

Banks, Bruce A.↗

Direct Recycling of Lithium-Ion Battery Cathodes: A Multi-Stage Annealing Process to Recover the Pristine Structure and Performance

Direct recycling is an alternative low-cost process that retains the structure of the lithium-ion battery cathode rather than going through materials dissolution and repurification. While the process shows promise, various steps need to be better understood and studied to identify possible roadblocks, cost intensive steps, and needed variations in protocol that may be necessary based on the feedstock of recycled cathodes available. In this study, we have evaluated the process of thermal relithiation as it applies to end-of-life cathode materials. For recovered end-of-life cathodes, approximately 20% of the useable lithium has been lost due to solid electrolyte interface formation, parasitic reactions, and particle isolation; this lost lithium contributes to higher cell impedance and a gradual shift in electrode potentials. As a first step in the direct recycling process, this lithium needs to be restored not only to recover capacity but also to eliminate surface vacancies and hinder surface reconstruction that may increase impedance and impact performance. Here, we have optimized a coating method followed by a two-stage annealing process that restores a model delithiated NMC333 material to pristine performance. Comparisons to single-stage processes are made, and new characterization tools have been used to better understand the processes.

25 ENERGY STORAGE↗

Improving knife milling performance for biomass preprocessing by using advanced blade materials

Mechanical preprocessing of biomass, including size reduction, is a crucial step in converting biomass into biofuel. However, feedstock inevitably contains abrasive intrinsic and extrinsic inorganics that may cause excessive tool wear in preprocessing. Here, this work demonstrates that performance of a knife mill can be significantly improved by applying a more wear-resistant blade material. A series of full-scale knife mill tests were performed for size reduction of forest residue using blades of tungsten carbide (WC–Co), iron-borided tool steel, and diamond-like carbon (DLC) coated tool steel. Blade material loss was quantified in correlation to the amount of feedstock processed and wear mechanisms were investigated via worn surface characterization. While the thin DLC coating was removed quickly, the WC-Co and iron-borided blades improved the tool life by 8X and 3X compared with the M2 tool steel blades (baseline), respectively. The in-situ throughput and power consumption measurements provided additional insights. The WC-Co and iron-borided blades had ~3X higher throughput than the baseline blades by the end of the test with lower normalized power consumption. The experimental results were then used as input for a techno-economic analysis, which suggested that the more wear resistant blades could cut the knife milling cost by $2–3 per ton of biomass processed with downtime reduced by 65–85%.

36 MATERIALS SCIENCE↗

Laser Processed Condensing Heat Exchanger Technology Development

The reliance on non-permanent coatings in Condensing Heat Exchanger (CHX) designs is a significant technical issue to be solved before long-duration spaceflight can occur. Therefore, high reliability CHXs have been identified by the Evolvable Mars Campaign (EMC) as critical technologies needed to move beyond low earth orbit. The Laser Processed Condensing Heat Exchanger project aims to solve these problems through the use of femtosecond laser processed surfaces, which have unique wetting properties and potentially exhibit anti-microbial growth properties. These surfaces were investigated to identify if they would be suitable candidates for a replacement CHX surface. Among the areas researched in this project include microbial growth testing, siloxane flow testing in which laser processed surfaces were exposed to siloxanes in an air stream, and manufacturability.

Hansen, Scott↗

Crack Detection in High-Velocity Oxygen-Fuel-Sprayed Al{sub 59.2}Cu{sub 25.5}Fe{sub 12.3}B{sub 3} Quasicrystalline Coatings Using Piezoelectric Active Sensors

Quasicrystals have received some attention in recent years regarding their potential usefulness as low friction and wear resistant materials. When quasicrystalline (QC) coatings are exposed to different levels of external loading or are subjected to thermal stresses, crack nucleation, and propagation become life-limiting factors. In this investigation, Al{sub 59.2}Cu{sub 25.5}Fe{sub 12.3}B{sub 3} QC coatings were deposited onto AISI-A36 steel substrates using the high-velocity oxygen-fuel (HVOF) technique. The coatings were deposited at different oxygen-to-fuel ratios. To characterize the integrity of the coatings, the active piezoceramic excitation technique was applied to detect the propagation of cracks during three-point bending tests. The piezoelectric transducer signal was processed using wavelet transformation analysis. The results revealed that the coated samples displayed different densities of cracks depending on the oxygen-to-fuel. The crack density was found higher for coatings formed using a slightly oxidizing flame. The opening of the pre-existing cracks in the coating was the main reason of signal attenuation during piezoelectric excitation. The HVOF-sprayed AlCuFeB quasicrystalline coating, with thickness between 150 and 180 μm, withstands a flexural stress as high as 340 MPa. To the best of our knowledge, this study is the first that provides a quantitative assessment of the viability of QC coatings in mechanical applications in spite of their intrinsic brittleness.

36 MATERIALS SCIENCE↗

Chromium Tolerant, Highly Active and Stable Electrocatalytic Internal Surface Coating for Cathode of Commercial SOFCs (Final Report)

This project is aimed to develop a chromium (Cr) tolerant, highly active, and stable coating layer on the internal surfaces of the porous composite cathode from commercially available SOFCs. Such coating layer was developed using the additive manufacturing process of Atomic Layer Deposition (ALD) and has been applied on the cathode consisting of either an electronic conductor of LaxSr 1-x MnyO 3-δ (LSM) or mixed ionic and electronic conducting La x Sr 1-x Co y Fe 1-y O 3-δ (LSCF). PI's work has demonstrated that the internal surface of cathode from the commercial cells, can be further tailored using ALD coating to dramatically enhance the cell performance. For instance, ALD layer consisting heterostructured nano composite of nano-Pt and nano-(Mn 0.8 Co 0.2 ) 3 O 4 oxide on the internal surface of porous LSM/YSZ cathode from SOFCs, has resulted in the large reduction of the cell polarizations resistance by up to 53%, and enormous increase of power density over 370%. For the cells with LSCF/Sm 2 O 3 doped CeO 2 (SDC) cathode, the conformal layer of nano-composite consisting of superjacent CoOx and subjacent minimum amount of Pt nano-grains has resulted in the power density enhancement by 126% for the large scale industry tubular cells at 750°C, and both the performance enhancement and nanostructure of the ALD layer are stable over ~ 2000 h continuous operation performed at industry test station. In the meanwhile, those ALD coating layer developed by PI's work is also inherently Cr-tolerant, and could act as physical barrier for preventing Cr diffusion into the cathode backbone, so as to mitigate the Cr poisoning effect on the cathode. In this project, the impact of Cr on the performance of those ALD coated commercial cells has been evaluated. Based on evolution of the cell performance, the ALD coating layer chemistry and ALD coating layer thickness has been optimized to maximize the overall Cr tolerance, cell power density and cell longevity. Different ALD coating has been applied onto the internal surface of LSM/YSZ and LSCF/SDC backbone respectively. The architecture/scaffold structures on the internal surface of different cathode, designed by this project, was catalogued and analyzed using High Resolution Transmission Electron Microscopy (HRTEM), and cell power/durability performance are assured via comprehensive electrochemical performance testing in the industry operation relevant conditions. The impact of the electrochemical operation current density, the water humidity, the cell operation temperature, and cell operation duration on the Cr tolerance of ALD coated cells has been systematically investigated. There is completely different nanostructure degradation mechanisms between LSM and LSCF cells induced by Cr contamination. For the LSCF/SDC baseline cell, With the Cr source, there is no apparent Sr surface segregation phase even for the baseline cell operated for 3000 h at 750 °C. With the Cr source, there is significant amorphous (SrCr)Ox phase accumulated in the original pore region. For the commercial baseline cells, Cr contaminants on the LSM electrode severely impacted the entire cell's electrochemical performance and nanostructure degradation. Those degradations include (1). Peak power density loss of 64 % after 109 h of operation. The dramatic increase in Rp (2). They are cracking at LSM/SSZ interface, LSM grains. SSZ remains intact but with (CrMn)Ox. By contrast, ALD coating (MnCo)Ox/Pt dramatically improves the Cr resistance, as follows (1). ALD-coated cell with a power density is 280-380 % of the baseline cell, depending on the ALD layer thickness. (2). For a cell with a 20 nm thick ALD layer, there is a large performance enhancement (> 200 % power density) induced by ALD coating of Cr-tolerant Mn 0.8 Co 0.2 Ox. (3). For a cell with a 20 nm thick ALD layer, after 168 h at 750 °C power density of the ALD-coated cell is ~ 600% of that baseline cell upon operation with Cr contamination for 109 h. The ALD coating on the internal surface of cathode developed by this project integrated multi-functions. Those multi-functions include (1). Dramatically improving the cell power density for the commercial cells; (2). Dramatically improving contamination resistance of the cathode, for being an excellent protection coating layer sealing off Cr contamination. (3). Dramatically increasing the cell longevity by potentially preventing the microstructure evolution and grain coarsening of the cathode. Overall, this project will provide a simple solution to simultaneously enhance power density and increase the reliability, robustness, and endurance of commercial SOFCs, over the entire operating temperature range of 650-800 °C. For the inherently functional SOFC, the ALD coating of LSM based cathode mitigate the Cr-contamination. Power density of ALD-coated cell is ~ 600% of that baseline cell upon operation with Cr contamination. In addition to SOFCs, the novel on-demand design approach and creation of multifunctional heterogeneous architecture on the electrode surface presented in this work opens further research for their application in other types of fuel cells, batteries, and sensors for which electrochemical reactions on the surface are similarly critical.

36 MATERIALS SCIENCE↗

X-Ray Diffraction Measurements of Residual Stress in a Cold Sprayed Ni Coating

X-ray diffraction (XRD) was used to investigate the residual stress in a cold sprayed Ni coating which failed to form a bimetallic joint with NASA HR-1. The objective was to apply pure Ni by cold spray as a diffusion barrier between the Ni-based alloy NASA HR-1 and the Cu-based GRCop-42 for a thrust cell assembly. After additive manufacturing of the GRCop-42 cylinder, the commercially pure Ni coating was cold sprayed onto the cylinder. It was intended to have NASA HR-1 applied directly onto the Ni coating by Directed Energy Deposition (DED), however the bond failed during the first layer of DED. Residual stress measurements were collected via the Sin²ψ method in three equally spaced locations on the top surface of the Ni coating in both as-cold sprayed and heat-treated conditions. The results revealed both compressive and tension stresses on the as-cold sprayed sample and compressive stresses in the heat-treated sample. The results were illuminated when plotted at their respective positions and with their respective orientation angles around a circle. This showed rotational symmetry in the residual stress measurements, which correlated to the processing method used during application of the Ni coating.

Laura Wilson↗

An Overview of Magnetic Bearing Technology for Gas Turbine Engines

The idea of the magnetic bearing and its use in exotic applications has been conceptualized for many years, over a century, in fact. Patented, passive systems using permanent magnets date back over 150 years. More recently, scientists of the 1930s began investigating active systems using electromagnets for high-speed ultracentrifuges. However, passive magnetic bearings are physically unstable and active systems only provide proper stiffness and damping through sophisticated controllers and algorithms. This is precisely why, until the last decade, magnetic bearings did not become a practical alternative to rolling element bearings. Today, magnetic bearing technology has become viable because of advances in micro-processing controllers that allow for confident and robust active control. Further advances in the following areas: rotor and stator materials and designs which maximize flux, minimize energy losses, and minimize stress limitations; wire materials and coatings for high temperature operation; high-speed micro processing for advanced controller designs and extremely robust capabilities; back-up bearing technology for providing a viable touchdown surface; and precision sensor technology; have put magnetic bearings on the forefront of advanced, lubrication free support systems. This paper will discuss a specific joint program for the advancement of gas turbine engines and how it implies the vitality of magnetic bearings, a brief comparison between magnetic bearings and other bearing technologies in both their advantages and limitations, and an examination of foreseeable solutions to historically perceived limitations to magnetic bearing.

Clark, Daniel J.↗

Enhanced Tribological, Electrochemical, and Biocompatibility Properties of Ti6Al4V Alloy Through Gas Nitriding and CN Coating Deposition

The tribological properties, electrochemical corrosion resistance, and biocompatibility performance of Ti6Al4V alloy were improved through a duplex surface treatment process consisting of high-temperature gas nitriding followed by amorphous carbon nitride (CN) coating deposition. The tribological properties of the specimens were evaluated using a reciprocating sliding wear tester, while the electrochemical properties were examined by potentiodynamic polarization tests. Finally, the biocompatibility of the samples was investigated by means of cytotoxicity tests performed using mouse leukemic monocyte macrophage cells (Raw 264.7). The duplex treatment significantly improved the tribological performance of the Ti6Al4V sample. In particular, compared to an untreated Ti6Al4V sample, the duplex surface treatment (CN-NTs) reduced the wear depth by around 55 times when sliding against a 316L counterbody and 16 times when sliding against a Ti6Al4V counterbody. Of the various specimens, the CN-T sample showed the best corrosion resistance, while the CN-NT sample showed the best biocompatibility performance.

36 MATERIALS SCIENCE↗

Wear Resistance Enhancement of Ti-6Al-4 V Alloy by Applying Zr-Modified Silicide Coatings

Zr-modified silicide coatings were prepared on Ti-6Al-4 V alloy by pack cementation process to enhance its wear resistance. The microstructure and wear properties of the substrate and the coatings were comparatively investigated using GCr15 and Al{sub 2}O{sub 3} as the counterparts under different sliding loads. The obtained Zr-modified silicide coating had a multilayer structure, consisting of a thick (Ti,X)Si{sub 2} (X represents Al, Zr and V elements) outer layer, a TiSi middle layer and a Ti{sub 5}Si{sub 4} + Ti{sub 5}Si{sub 3} inner layer. The micro-hardness of the coating was much higher than the substrate and displayed a decrease tendency from the coating surface to the interior. Sliding against either GCr15 or Al{sub 2}O{sub 3} balls, the coatings showed superior anti-friction property to the Ti-6Al-4 V alloy, as confirmed by its much lower wear rate under each employed sliding condition.

36 MATERIALS SCIENCE↗