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Material Properties and Modeling of Room Temperature Vulcanizing Silicone

Room Temperature Vulcanizing silicone (RTV) is a high-temperature adhesive that has successfully been used as a gap-filler between Thermal Protection System (TPS) tiles for heatshields on numerous missions. It is also used to bond instrumentation plugs such as temperature and pressure sensors into the heatshields. While RTV has been traditionally assumed to be a non-porous and non-ablating material, numerous experiments have shown that RTV pyrolyzes and becomes highly porous as it is heated. Heating RTV has also shown swelling, or intumescence, which can pose unique problems that lead to roughness induced boundary-layer transition, surface oxide formation and contamination of heat shield sensors. Therefore, it is crucial to understand and model the intumescence phenomenon of RTV. As data for RTV material properties is limited, the first step in modeling RTV is to collect material properties such as pyrolysis mass-loss, microstructure change, virgin and char porosity, etc. which was performed in our initial study. Additionally, thermomechanical properties such as Young’s modulus and Poisson ratio are required for modeling the intumescence of RTV, which were taken from literature and the coefficient of thermal expansion was collected using in-situ heating and Micro Computed Tomography (µ-CT) in previous studies. Finally, numerous other properties such as pyrolysis gas properties, virgin and char thermal conductivity and specific heat were compiled from previous experiments and literature into a material database that can be used for simulations. In Porous Material Analysis Toolbox based on OpenFOAM (PATO) [4], structural mechanics coupled with material response was used for simulating the intumescence of RTV as it is heated. However, since the permeability of the material is very low, the pyrolysis gas creates an internal pressure build-up as the material is being heated, significantly contributing to the deformation of the material. To correctly characterize this phenomenon, additional physics models were implemented into PATO's stress analysis solver, and results were compared with RTV dilatometry test data as a preliminary verification case. Future work will include experiments of RTV at the Plasmatron X facility and the in-situ heating cell with µ-CT, and improvement of simulation tools to more accurately model RTV intumescence.

PATO

An Overview of CMIP5 and CMIP6 Simulated Cloud Ice, Radiation Fields, Surface Wind Stress, Sea Surface Temperatures and Precipitation over Tropical and Subtropical Oceans

The potential links between ice water path (IWP), radiation, circulation, sea surface temperature (SST) and precipitation over the Pacific and Atlantic Oceans resulting from the falling ice radiative effects (FIREs) are examined from present day model outputs of CMIP5 and CMIP6. The latter is divided into two subsets with (SON6) and without FIREs (NOS6) as more models with FIREs are included in CMIP6 than in CMIP5. Improvement in floating cloud ice (~20 g m-2) is noticeable over convective regions in CMIP6 relative to CMIP5. The inclusion of FIREs in SON6 subset may contribute to reduce biases of overestimated outgoing longwave radiation and downward surface shortwave and overestimated reflected shortwave at the top of the atmosphere (TOA) by magnitudes of 4?8 W m-2 over convective regions against CERES, compared to NOS6 subset. The reduced biases in radiative fluxes in convective regions stabilize the atmosphere and lead to circulation, SST, cloud and precipitation changes over the trade-wind regions, as seen from improved radiative fluxes (4?15 W m-2), surface wind stress biases, SST (0.2?0.8 K) and precipitation (1 mm day-1) biases. The significant improvement from NOS6 to SON6 leads to improved multi-model means for CMIP6 relative to CMIP5 for radiation fields over the trade wind regions but the degradation over convective zones is attributed to NOS6 subset. The results suggest that other sources of uncertainty and deficiencies in climate models may play significant roles for reducing discrepancies although FIREs, via radiation-circulation coupling, may be one of the factors that help to reduce regional biases.

Jui-Lin F Li

Lubricating Properties of Ceramic-Bonded Calcium Fluoride Coatings on Nickel-Base Alloys From 75° to 1900° F

The endurance life and the friction coefficient of ceramic-bonded calcium fluoride (CaF2) coatings on nickel-base alloys were determined at temperatures from 75° to 1900° F. The specimen configuration consisted of a hemispherical rider (3/16-in. rad.) sliding against the flat surface of a rotating disk. Increasing the ambient temperature (up to 1500° F) or the sliding velocity generally reduced the friction coefficient and improved coating life. Base-metal selection was critical above 1500° F. For instance, cast Inconel sliding against coated Inconel X was lubricated effectively to 1500° F, but at 1600° F severe blistering of the coatings occurred. However, good lubrication and adherence were obtained for René 41 sliding against coated René 41 at temperatures up to 1900° F; no blisters developed, coating wear life was fairly good, and the rider wear rate was significantly lower than for the unlubricated metals . Friction coefficients were 0.12 at 1500° F, 0.15 at 1700° F, and 0.17 at 1800° and 1900° F. Because of its ready availability, Inconel X appears to be the preferred substrate alloy for applications in which the temperature does not exceed 1500° F. René 41 would have to be used in applications involving higher temperatures. Improved coating life was derived by either preoxidizing the substrate metals prior to the coating application or by applying a very thin (<0.0002 in.) burnished and sintered overlay to the surface of the coating. Preoxidation did not affect the friction coefficient. The overlay generally resulted i n a higher friction coefficient than that obtained without the overlay. The combination of both modifications resulted in longer coating life and in friction coefficients intermediate between those obtained with either modification alone.

Nickel alloy

Tunable high Néel temperature and large anomalous Hall response in antiferromagnetic Weyl semimetal Mn 3 Sn 1− x Ga x thin films

Antiferromagnetic Weyl semimetals based on Mn 3 X(X = Ge, Sn, Ga) kagome compounds exhibit the same ferromagnetic-like responses, including anomalous Hall, Nernst, and magneto-optical effects, as recently discussed for altermagnets. Driven by the Berry curvature due to Weyl fermions, these materials show a disproportionately large magnitude of electromagnetic effects even in the absence of large magnetization. For applications it is crucial to realize these responses in a wide range of temperatures both below and above 300 K. While stoichiometric Mn 3 X materials do not offer optimal performance, we show that Mn 3 Sn 1−x Ga x sputtered films with a variable composition offers a tunable Néel temperature, T N ≈ 425 ± 6–500 ± 15 K, which is crucial for device applications, together with a large tunable anomalous Hall effect. Our thin film growth method enables continuous and precise control over the film composition between x = 0 and x = 1. Through a detailed magnetization and Hall transport, we establish the magnetic phase diagram for the hexagonal Mn 3 Sn 1−x Ga x . Our results reveal an enhanced T N and antichiral magnetic phase in Ga-doped Mn 3 Sn and an enhanced anomalous Hall magnitude in Sn-doped Mn 3 Ga compared to their stoichiometric undoped forms. Our work demonstrates a route to optimize the technologically relevant antiferromagnets for various applications.

Magnetic properties and materials

Chromium versus Aluminum: Impact of Nickel Alloy Composition and Interfacial Kinetics on High-Temperature Passivating Oxide Formation

High-temperature corrosion resistance depends critically on the formation of a passivating surface oxide, which is highly sensitive to alloy composition and structure. Such details often elude experimental investigation, and simplified analytical models fail to provide a truly chemical view of passivating oxide evolution. Here, we explicitly compare the fundamental chemistry of Cr and Al as prototypical passivating elements in Ni alloys by directly simulating competing reaction and diffusion processes within the oxide film using kinetic Monte Carlo and density functional theory. We find that the origin and expression of passivating behavior during early-stage thermal oxidation are qualitatively different between the two alloy systems. Ni–Cr alloys feature a sudden onset of passivation associated with a sharp phase transition upon Cr enrichment that directly couples oxidation kinetics to phase transformation behavior. In contrast, Ni–Al alloys display more continuous oxide phase variation with Al enrichment, ultimately resulting in a lower composition threshold for passivation and a thinner passivating layer. In addition, we elucidate the nonobvious role of metal exchange within the alloy near the oxide boundary, which fundamentally alters film composition and passivating behavior. Furthermore, our results have key implications for engineering improved corrosion-resistant alloys, both in terms of compositional variation and processing.

Alloys

Implementation of A Self-Controlling Heater

Temperature control of radiation sensors, targets, and other critical components is a common requirement in modern scientific instruments. Conventional control systems use a heater and a temperature sensor mounted on the body to be controlled. For proportional control, the sensor provides feedback to circuitry which drives the heater with an amount of power proportional to the temperature error. It is impractical or undesirable to mount both a heater and a sensor on certain components such as ultra-small parts or thin filaments. In principle, a variable current through the element is used for heating, and the change in voltage drop due to the element's temperature coefficient is separated and used to monitor or control its own temperature. Since there are no thermal propagation delays between heater and sensor, such control systems are exceptionally stable.

Maxwell G Strange

Thermodynamically informed priors for uncertainty propagation in first-principles statistical mechanics

Here, this work demonstrates how first-principles statistical mechanics approaches within a Bayesian framework can quantify and propagate uncertainties to downstream thermodynamic calculations. To address the issue of Bayesian prior selection, knowledge of 0 K ground states in the material system of interest is incorporated into the prior. The effectiveness of this framework is shown by creating a phase diagram for the fcc zirconium nitride system, including confidence intervals on order-disorder transition temperatures.

Bayesian methods

Recirculating and Sub-Atmospheric Rapid Cycle Amine Swing Bed Testing at Various Metabolic Profiles, Temperatures, and Half-Cycle Times

Sixty years since the first spacewalk, NASA’s Extravehicular Mobility Unit (xEMU) exploration space suit has undergone numerous design improvements and iterations. As commercial manufacturers develop next-generation systems to support increasingly complex missions, including Moon-to-Mars architecture prototyping and the design of the Martian Portable Life Support System (PLSS), material selection and individual subunit testing under realistic metabolic and pressure conditions are paramount. To determine whether a reusable carbon dioxide (CO 2 ) scrubber design and adsorbent can be utilized in new suit configurations, an all-encompassing test rig is required to compare existing and newly developed technologies. The test rig must be capable of sub-atmospheric testing, calibrated humid CO 2 dosing, and facilitation of the evaluation of sorbents across a wide range of operational requirements. Recently, XploSafe has developed an Extravehicular Mobility Unit (xEMU) testing rig specifically designed to explore CO 2 and humidity control materials for spacesuits. This closed-loop recirculating swing bed (Rapid Cycle Amine Test Rig) was utilized to compare adsorbent utility across a wide range of xEMU operating conditions. Following successful testing with Xplo-SA9T over multiple simulated eight-hour Extravehicular Activity (EVA) tests, improvements to the test stand were considered. Regeneration vacuum supply within the test rig was updated to more closely resemble space vacuum, theoretically increasing half-cycle timing. An improved water vapor delivery system was incorporated to dose a wider calibrated range of humidity over both short and long-duration EVAs. A range of metabolic profiles between 800 and 3000 BTU/h were tested, and the corresponding average CO 2 steady-states were compared. The effect of dosing temperature at the adsorbent bed inlet between 10 and 40 ̊C and the corresponding CO 2 removal efficiency was also evaluated.

John R Tidwell

Helmholtz Motor: A Novel Electric Machine That Enables High Temperature Superconducting Armatures

Electrified aircraft are being developed to increase the efficiency and reduce the cost of operating subsonic transport aircraft. Achieving a substantial impact necessitates focusing on single- and twin-aisle aircraft which use propulsion systems with >20 MW ratings. For these aircraft, multi-MW superconducting electric machines are being developed due to their high specific power and high efficiency. Cryogenic electric machines are a promising technology for multi megawatt electric aircraft drivetrains. Second generation high temperature superconductors (HTS) are the ideal conductor for the field winding (typically the rotor) of superconducting machines, and they have attractive features for the armature winding (typically the stator) of these machines. However, their use in armature windings has been severely limited due to excessive AC losses in conventional electric machines. This presentation will present the working principle, design, and a performance trade study of a novel electric machine – termed a Helmholtz machine – that enables HTS armatures by significantly reducing AC losses. The working principle of the patent pending Helmholtz motor is to optimize the rotor-produced magnetic field (i.e., the field winding) so that it produces a magnetic field almost purely in the plane of the HTS. This is accomplished using 2 rotors that contain a set of matched Helmholtz coil pairs (or matched permanent magnet Halbach arrays). The armature (stator) HTS coils are positioned between the rotors and oriented to minimize the out of plane magnetic field. The armature HTS coils are also designed to minimize the out of plane component of their self field. The presentation will include the lessons learned in the sizing and design of this motor, including equations for how to match the magnet arrays. A performance trade study will be presented for a partially superconducting, radial flux version of the motor. The trade study involved an optimization of a motor design code based on analytical calculations (electromagnetic, AC loss, thermofluid, mechanical, and motor sizing) that determine the motor’s total efficiency and total specific power. The design code will be described in the presentation, with an emphasis on the calculation of magnetic fields, AC loss, and temperature distribution.

Superconducting electric machines

Characterization of lateral amorphous selenium photodetectors for low-photon and VUV detection at cryogenic temperatures

The performance of amorphous selenium (a-Se) as a cryogenic photodetector material is evaluated through a series of experiments using laterally structured devices operated in a custom optical test stand. These studies investigate the response of a-Se detectors to low-photon fluxes at high electric fields near avalanche conditions, the linearity of the photoconductive response over a wide dynamic range and the direct detection of narrowband 130 nm vacuum ultraviolet (VUV) illumination. At 87 K, matched-filter analysis shows reliable single-shot detection with efficiencies ≥80% and area under the curve (AUC) ≥ 0.85 using as few as ∼ 6800 incident 401 nm photons, corresponding to ∼ 3400 photons within field-active regions after accounting for geometric constraints. Measurements are performed at cryogenic temperatures using calibrated photon fluxes derived from a silicon photomultiplier reference and a characterized optical filter stack. Additional experiments using a tellurium-doped a-Se (a-SeTe) device explore the material's behavior under identical test conditions and demonstrate that avalanche is achievable in a-SeTe at cryogenic temperatures. The results demonstrate reproducible low-noise operation, VUV sensitivity and field-dependent gain behavior in a lateral a-Se architecture, representing the first reported observation of avalanche multiplication in laterally structured a-Se and a-SeTe devices at cryogenic temperatures. These findings support the potential integration of laterally structured a-Se devices into next-generation pixelated liquid-argon time projection chambers (TPCs) requiring scalable, high-field-compatible photon detection systems.

Amorphous selenium

The Shape Effect: Influence of 1D and 2D Boron Nitride Nanostructures on the Radiation Shielding, Thermal, and Damping Properties of High-Temperature Epoxy Composites

In space exploration, lightweight multifunctional materials capable of shielding neutron radiation, dissipating heat, and providing damping are essential. Polymer composites reinforced with boron nitride (BN) nanomaterials—specifically one-dimensional boron nitride nanotubes (BNNTs) and two-dimensional boron nitride nanoplatelets (BNNPs)—offer promising solutions. This study investigates how BN nanomaterial morphology influences the performance of high-temperature (HT) epoxy composites. We developed ultralightweight, three-dimensional BN foams comprising 1D BNNTs, 2D BNNPs, and hybrid 1D BNNT/2D BNNP structures via freeze-drying, then infiltrated them with HT epoxy to form dense composites. The BNNT foam exhibited the highest neutron radiation shielding, with a mass absorption coefficient of 26.64 cm2 g −1 , outperforming the hybrid foam (18.18 cm 2 g −1 ) and the BNNP foam (11.12 cm 2 g −1 ). A similar trend was observed in the HT epoxy composites; incorporating these foams at least doubled the mass absorption coefficient compared to the neat polymer. In terms of thermal conductivity, the BNNT/BNNP foam-epoxy composite achieved the highest value of 0.34 W m −1 K −1 , a 2.13-fold increase over neat HT epoxy. The BNNT/BNNP foam-epoxy composites also improved by 1.88 and 1.75 times, respectively. Mechanical testing revealed that BNNP foams withstood the highest loads during nanoindentation (3.53 kN), followed by BNNT/BNNP foams (1.93 kN) and BNNT foams (1.56 kN). All BN foam-epoxy composites exhibited enhanced damping properties, with tan δ increasing by at least 30 % compared to neat HT epoxy. These findings elucidate the impact of BN nanomaterial morphology on the multifunctional performance of HT epoxy composites, offering insights for developing high-performance, tailorable materials for demanding environments.

Kazue Orikasa

Development, Characterization, and Validation of Elevated-Temperature Constitutive Models: Deformation and Damage

This report provides a brief review of experimentally observed hereditary and nonhereditary material behavior along with background information on standard as well as advanced internal state variable constitutive modeling at elevated temperature. A description of exploratory, characterization, and validation testing is presented along with a detailed outline of what constitutes “sufficient” data content (i.e., quality and quantity) for developing or enhancing, characterizing, and validating a particular sophisticated nonlinear time- and history-dependent (hereditary) class of constitutive models known as GVIPS (generalized viscoplasticity with potential structure). The tests described are necessary to reveal a material’s behavior in the reversible (or viscoelastic) and irreversible (or viscoplastic) regimes, for the identification of both deformation and damage model parameters. Results presented are primarily for metallic materials. In all cases, both uniaxial and multiaxial tests are described, and the linkage between the specific tests and the parameters within the model that can be characterized from the results of these tests are also discussed. Discussion is also provided relative to the role information management must play relative to material data collection, analysis, maintenance, and dissemination. The need for such an information system is particularly important as both analyst and designer move toward utilizations of sophisticated, nonlinear time- and history dependent (hereditary) constitutive models. Lastly, the concept of state space and its utility in understanding and establishing constitutive models is addressed throughout. The intent behind this document is to help both the modeler and experimentalist understand each other’s specific points of view and provide guidance for both model development and characterization. Emphasis has been placed on providing the mechanician with information regarding how tests are performed and what issues to be aware of when interpreting results. It is hoped that experimentalists will take away a new perspective on the types of information that modelers and analysts are looking for from them.

Constitutive Modeling

Advanced Non-Intrusive Instrumentation for Propulsion Engines

Changes in engine technology such as higher temperatures, higher tip speeds, new metal/composite/ceramic materials together with radical changes in design philosophy will require amongst other prerequisites the ability to measure and to monitor key internal gas and structural characteristics. The symposium papers presented non-intrusive measurement and analysis technologies in the following categories: Laser Point Measurements (11); Absorption and Infrared Techniques (4); Paints - Surface Sensors (6); Laser Induced Fluorescence (6); Mechanical (7); Films (5); Laser Planar Measurement (9); and a Keynote Address.

Propulsion

Comparative neutron-irradiation effects on thermal conductivity degradation and dimensional stability of TiC, TiB 2 , and ZrB 2 at 200–1000 °C

Ultra-high-temperature ceramics (UHTCs), including TiC, Ti 11 B₂, and Zr 11 B₂, show great potential for plasma-facing components due to their excellent high-temperature properties prior to irradiation. However, their response to neutron irradiation remains insufficiently understood, limiting robust assessment of their viability for fusion energy applications. Here, this study examines the thermal conductivity, dimensional stability and microstructure of TiC, TiB₂, and ZrB₂ following neutron irradiation at temperatures of 200–1000 °C and fast neutron fluences of 2.0 × 10 25 to 1.1 × 10 26 n/m 2 (E > 0.1 MeV). Lattice swelling measured by synchrotron X-ray diffraction in all three UHTCs was maximized at 200 °C and decreased with increasing irradiation temperature, with no evidence of amorphization observed at 200 °C. Above 600 °C, significant macroscopic volume swelling was observed in irradiated Ti 11 B₂ and Zr 11 B₂, but not in TiC, likely due to cavity formation in the diborides. The post-irradiation thermal conductivity, measured at the irradiation temperature, ranged from 28 to 45 W/m·K, representing a 34–45% reduction relative to the unirradiated material. Notably, neutron-irradiated UHTCs exhibit recoverable thermal conductivity at elevated temperatures, comparable to ferritic–martensitic steels and potentially superior to W when transmutation effects are considered, highlighting promise for shielding or armor plasma-facing components. At 600 °C, both thermal conductivity degradation and lattice swelling saturated at doses exceeding 2–4 dpa.

fusion materials

The Thermal and Kinematic Sunyaev–Zeldovich Effect in Galaxy Clusters and Filaments Using Multifrequency Temperature Maps of the Cosmic Microwave Background A399–A401 Cluster Pair Case Study

We present a multifrequency and multi-instrument methodology to study the physical properties of galaxy clusters and cosmic filaments using cosmic microwave background observations. Our approach enables simultaneous measurement of both the thermal (tSZ) and kinematic Sunyaev–Zeldovich (kSZ) effects, incorporates relativistic corrections, and models astrophysical foregrounds such as thermal dust emission. We do this by jointly fitting a single physical model across multiple maps from multiple instruments at different frequencies, rather than fitting a model to a single Compton-y map. We demonstrate the success of this method by fitting the A399–A401 galaxy cluster pair and filament system using archival data from the Planck satellite and new, targeted deep data from the Atacama Cosmology Telescope, covering 11 different frequencies over 14 maps from 30 GHz to 545 GHz. Our tSZ results are consistent with previous work using Compton-y maps. We measure the line-of-sight peculiar velocities of the cluster–filament system using the kSZ effect and find statistical uncertainties on individual cluster peculiar velocities of ≲600 km s −1 , which are competitive with current state-of-the-art measurements. Additionally, we measure the optical depth of the filament component with a signal-to-noise of 8.5σ and reveal hints of its morphology. This modular approach is well-suited for application to future instruments across a wide range of millimeter and submillimeter wavebands.

Ajay S Gill

Are There Opportunities To Re-Think How We Manufacture Synthetic Graphite?

This manuscript contributes a Viewpoint article to ACS Sustainable Resource Management and discusses the graphite supply chain, growing mismatch between graphite demand and global manufacturing capacity, current graphite manufacturing technologies, and different feedstocks.

alternative carbon feedstocks

Influence of microstructure and temperature on impact toughness of H13 steel produced by binder jet additive manufacturing

Binder Jet Additive Manufacturing (BJAM) is a promising manufacturing pathway to produce H13 steel dies and tooling with complex geometries for applications in high pressure aluminum die casting, hot stamping, and injection molding. While fully dense H13 coupons produced using BJAM have been subjected to detailed microstructure characterization, properties which are critical and relevant to the aforementioned applications, such as impact toughness, have not been reported. Here, this work evaluated the influence of microstructural characteristics and test temperature on the impact toughness of H13 produced by BJAM. Coupons were produced from three different powder size distributions (PSDs), with nominal powder size ranges of −22 μm, 10-32 μm, and 15-53 μm. Coupons were printed, sintered, hot isostatically pressed (HIPed), and heat treated by quenching and tempering. After HIPing, the measured porosities of the different PSDs were all less than 0.015 vol%. The −22 μm PSD BJAM material exhibited the best impact toughness of all three PSDs across the entire test temperature range from 25 to 400 °C, and also exhibited an ambient temperature impact toughness of 10.9 J at a hardness of 46 HRC, equivalent to minimum threshold requirements for premium grade H13. However, all three BJAM PSDs exhibited moderately lower impact toughness than premium grade wrought H13 from RT to 400 °C. We attribute this in part due to the very large prior-austenite grain (PAG) sizes near 400 μm and segregation from former liquid channels leading to greater amounts of carbide precipitation on PAG boundaries. Technical pathways for optimizing processing and chemistry of BJAM H13 to further improve impact toughness are discussed.

Binder jet additive manufacturing

Development of large-scale, 3D Printed high temperature ceramic material

Through this collaborative effort, a new 3D printing platform for ceramics called laser-induced slip casting (LIS) was explored and developed for improving the processing and manufacture of silicon carbide (SiC), a high temperature ceramic material. This method prints layers of ceramic slips/slurries with subsequent selective-laser heating to dry each layer to build a 3D structure. The completed and dried part is then sintered. This manufacturing process is inherently lower cost than alternative ceramic printing methods such as binder jet technology or stereolithography when it comes to the feedstock material but is more expensive than robocasting or direct ink writing. However, it has the potential to make more controlled parts with less defects compared to robocasting. The largest cost is the heating source for the printer. With this technique, there is potential to make large ceramic parts in a near-net shape. Further, there is no known commercial manufacturing of 3D printed ceramics that creates a large range of different high-density ceramics at large scale. The goals and outcomes for the development of the new printing technology were: 1) assessing the technology with alumina by characterizing coupons, 2) printing and sintering of silicon carbide (SiC), and 3) characterization and properties testing of materials printed and a scale-up of SiC part(s). Through this collaborative project, it was sought to provide the best solution to achieving highly dense and near-net shaped ceramic parts at large scale and reduced cost. The goal was to produce high density sintered materials for applications in defense, energy generating systems, armor, and wear parts using 3D printing methods. Variables including powder particle sizes, dispersant molecular weights (MWs), binders, printing parameters, and post processing were explored as well as the characterization of the physical properties (add specifics here).

36 MATERIALS SCIENCE