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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Tracking interface and common curve dynamics for two-fluid flow in porous media

Pore-scale studies of multiphase flow in porous medium systems can be used to understand transport mechanisms and quantitatively determine closure relations that better incorporate microscale physics into macroscale models. Multiphase flow simulators constructed using the lattice Boltzmann method provide a means to conduct such studies, including both the equilibrium and dynamic aspects. Moving, storing, and analyzing the large state space presents a computational challenge when highly-resolved models are applied. We present an approach to simulate multiphase flow processes in which in-situ analysis is applied to track multiphase flow dynamics at high temporal resolution. We compute a comprehensive set of measures of the phase distributions and the system dynamics, which can be used to aid fundamental understanding and inform closure relations for macroscale models. The measures computed include microscale point representations and macroscale averages of fluid saturations, the pressure and velocity of the fluid phases, interfacial areas, interfacial curvatures, interface and common curve velocities, interfacial orientation tensors, phase velocities and the contact angle between the fluid-fluid interface and the solid surface. Test cases are studied to validate the approach and illustrate how measures of system state can be obtained and used to inform macroscopic theory.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2017

Impact of Nano- and Mesoscales on Macroscopic Cation Conductivity in Perfluorinated-Sulfonic-Acid Membranes

A mean-field local-density theory is outlined for ion transport in perfluorinated-sulfonic-acid (PFSA) membranes. A theory of molecular-level interactions predict nanodomain and macroscale conductivity. The effects of solvation, dielectric saturation, dispersion forces, image charge, finite size, and confinement are included in a physically consistent 3D-model domain geometry. Probability-distribution profiles of aqueous cation concentration at the domain-scale are in agreement with atomistic simulations using no explicit fitting parameters. Measured conductivities of lithium-, sodium-, and proton-form membranes with equivalent weights of 1100, 1000, and 825 g/mol(SO3) validate the macroscale predictions using a single-value mesoscopic fitting parameter. Cation electrostatic interactions with pendant sulfonate groups are the largest source of migration resistance at the domain-scale. Tortuosity of ionically conductive domains is the largest source of migration resistance at the macroscale. In conclusion, our proposed transport model is consistent across multiple length scales. We provide a compelling methodology to guide material design and optimize performance in energy-conversion applications of PFSA membranes.

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

Communication: Diverse nanoscale cluster dynamics: Diffusion of 2D epitaxial clusters

The dynamics of nanoscale clusters can be distinct from macroscale behavior described by continuum formalisms. For diffusion of 2D clusters of N atoms in homoepitaxial systems mediated by edge atom hopping, macroscale theory predicts simple monotonic size scaling of the diffusion coefficient, D N ~ N –β , with β = 3/2. However, modeling for nanoclusters on metal(100) surfaces reveals that slow nucleation-mediated diffusion displaying weak size scaling β < 1 occurs for “perfect” sizes N p = L 2 and L(L+1) for integer L = 3,4,… (with unique square or near-square ground state shapes), and also for N p +3, N p +4,…. In contrast, fast facile nucleation-free diffusion displaying strong size scaling β ≈ 2.5 occurs for sizes N p +1 and N p +2. D N versus N oscillates strongly between the slowest branch (for N p +3) and the fastest branch (for N p +1). All branches merge for N = O(10 2 ), but macroscale behavior is only achieved for much larger N = O(10 3 ). Here, this analysis reveals the unprecedented diversity of behavior on the nanoscale.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Multiscale fatigue crack initiation in hierarchical additively manufactured alloys

Bioinspired hierarchical microstructures offer a route toward engineered fatigue resistance in additively manufactured alloys. However, it remains unclear how discrete structural constituents independently govern damage accumulation, particularly during the critical fatigue initiation regime where short cracks strongly interact with local microstructure. Here, we investigate multiscale fatigue initiation in a dual-phase, nanolamellar AlCoCrFeNi 2.1 high-entropy alloy. By comparing microscale specimens that isolate the nanolamellar structure against macroscale specimens containing the full melt-pool architecture, we identify size-dependent fatigue initiation mechanisms. We find that failure is dictated by nanolamellar interfaces at the microscale, whereas mesoscale melt pool boundaries serve to initiate fatigue at the macroscale. This mechanistic shift is accompanied by a transition from macroscale quasi-brittle failure to microscale plasticity-driven crack extension. Our results provide a physical framework for understanding how structural hierarchy governs the transition from discrete microstructural deformation to continuum fatigue fracture behavior, informing the design of damage-tolerant, additively manufactured alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Multiscale analysis in solids with unseparated scales: fine-scale recovery, error estimation, and coarse-scale adaptivity

There are several engineering applications in which the assumptions of homogenization and scale separation may be violated, in particular, for metallic structures constructed through additive manufacturing. Instead of resorting to direct numerical simulation of the macroscale system with an embedded fine scale, an alternative approach is to use an approximate macroscale constitutive model, but then estimate the model-form error using a posteriori error estimation techniques and subsequently adapt the macroscale model to reduce the error for a given boundary value problem and quantity of interest. Here, we investigate this approach to multiscale analysis in solids with unseparated scales using the example of an additively manufactured metallic structure consisting of a polycrystalline microstructure that is neither periodic nor statistically homogeneous. As a first step to the general nonlinear case, we focus here on linear elasticity in which each grain within the polycrystal is linear elastic but anisotropic.

42 ENGINEERING↗
DOE OSTI2024

A Multiscale Inelastic Internal State Variable Corrosion Model

We present a corrosion internal state variable (ISV) damage model based upon the integrated computational materials engineering (ICME) hierarchical multiscale paradigm. Structure–property experiments for magnesium alloys were used where the only inputs were the volume fractions of each element of the periodic table. This macroscale ISV corrosion model finds its basis in Horstemeyer’s mechanical damage model, which includes three separate ISVs for damage nucleation, growth, and coalescence, as well as Walton’s inclusion of corrosion, which introduces five new ISVs for pit nucleation, growth, and coalescence, along with general corrosion and intergranular corrosion. While Walton’s corrosion ISVs are phenomenological in nature, herein we develop a multiscale physical basis for the corrosion ISVs. The parameters for the macroscale corrosion ISVs were garnered from the mesoscale Butler–Volmer equations. Pure magnesium with differing amounts of aluminum were used in corrosion tests to exemplify the different pitting, general corrosion, and intergranular corrosion rates, and the macroscale ISV model was calibrated with said data, in which the only inputs to the model are the volume percentages of the elements magnesium and aluminum. Although magnesium alloys were used to motivate and calibrate the model, the model is abstract enough to possibly capture other material systems as well.

Chemistry↗
NASA NTRS2014

A Technique for Mapping Characteristic Lengths to Preserve Energy Dissipated via Strain Softening in a Multiscale Analysis

It is often advantageous to account for the microstructure of the material directly using multiscale modeling. For computational tractability, an idealized repeating unit cell (RUC) is used to capture all of the pertinent features of the microstructure. Typically, the RUC is dimensionless and depends only on the relative volume fractions of the different phases in the material. This works well for non-linear and inelastic behavior exhibiting a positive-definite constitutive response. Although, once the material exhibits strain softening, or localization, a mesh objective failure theories, such as smeared fracture theories, nodal and element enrichment theories (XFEM), cohesive elements or virtual crack closure technique (VCCT), can be utilized at the microscale, but the dimensions of the RUC must then be defined. One major challenge in multiscale progressive damage modeling is relating the characteristic lengths across the scales in order to preserve the energy that is dissipated via localization at the microscale. If there is no effort to relate the size of the macroscale element to the microscale RUC, then the energy that is dissipated will remain mesh dependent at the macroscale, even if it is regularized at the microscale. Here, a technique for mapping characteristic lengths across the scales is proposed. The RUC will be modeled using the generalized method of cells (GMC) micromechanics theory, and local failure in the matrix constituent subcells will be modeled using the crack band theory. The subcell characteristic lengths used in the crack band calculations will be mapped to the macroscale finite element in order to regularize the local energy in a manner consistent with the global length scale. Examples will be provided with and without the regularization, and they will be compared to a baseline case where the size and shape of the element and RUC are coincident (ensuring energy is preserved across the scales).

softening↗
DOE OSTI2022

Anisotropic yield models for lattice unit cell structures exploiting orthotropic symmetry

We report numerical homogenization enables efficient computational analysis and design of multiscale structures made of micro-architected materials including lattice unit cells. However, predicting yield is nontrivial because it requires accurate and efficient predictions of the maximum stress inside the homogenized unit cells. To address this challenge, we develop a macroscale anisotropic yield function for micro-architected materials. The yield function depends on the three-dimensional macroscale stress state and the parameters describing a family of micro-architectures, such as the radii of the struts in a lattice unit cell. To ensure accuracy, we determine the maximum stress using three-dimensional continuum finite-element analysis. To ensure efficiency, we construct surrogate models from the aforementioned high-fidelity results for yield prediction. To reduce simulation costs and surrogate modeling complexity, we leverage orthotropic symmetry commonly found in lattice unit cells. In this paper, we provide a thorough presentation of group representations and the systematic procedure to exploit orthotropic domain symmetry in homogenization and surrogate modeling. We illustrate the use of linear homogenization results to predict yield in specific unit cells without further simulations. We furthermore show that surrogate modeling presents a viable option for anisotropic yield prediction in a continuously parametrized family of micro-architectures. More specifically, despite the dimensionality and degree of nonlinearity in the maximum micro von Mises stress within the unit cell, the surrogate models can predict it with less than 5% error at least 90% of the time. Moreover, the largest under-prediction error, which is more critical than the over-prediction error, is typically less than 10%.

42 ENGINEERING↗
DOE OSTI2010

A Coupling Methodology for Mesoscale-informed Nuclear Fuel Performance Codes

This study proposes an approach for capturing the effect of microstructural evolution on reactor fuel performance by coupling a mesoscale irradiated microstructure model with a finite element fuel performance code. To achieve this, the macroscale system is solved in a parallel, fully coupled, fully-implicit manner using the preconditioned Jacobian-free Newton Krylov (JFNK) method. Within the JFNK solution algorithm, microstructure-influenced material parameters are calculated by the mesoscale model and passed back to the macroscale calculation. Due to the stochastic nature of the mesoscale model, a dynamic fitting technique is implemented to smooth roughness in the calculated material parameters. The proposed methodology is demonstrated on a simple model of a reactor fuel pellet. In the model, INL’s BISON fuel performance code calculates the steady-state temperature profile in a fuel pellet and the microstructure-influenced thermal conductivity is determined with a phase field model of irradiated microstructures. This simple multiscale model demonstrates good nonlinear convergence and near ideal parallel scalability. By capturing the formation of large mesoscale voids in the pellet interior, the multiscale model predicted the irradiation-induced reduction in the thermal conductivity commonly observed in reactors.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Synergetic Effects of Soil Organic Matter Components During Interactions with Minerals

Mineral-associated soil organic matter (SOM) is critical for stabilizing organic carbon and mitigating climate change. However, mineral-SOM interactions at the molecular scale, particularly synergetic adsorption through organic-organic interaction on the mineral surface known as organic multilayering, remain poorly understood. This study investigates the impact of organic multilayering on mineral-SOM interactions, by integrating macroscale experiments and molecular-scale simulations that assess the individual and sequential adsorption of major SOM compounds – lauric acid (lipid), pentaglycine (amino acid), trehalose (carbohydrate), and lignin onto soil minerals. Ferrihydrite, Al-hydroxide, and calcite are exposed to SOM compounds to determine adsorption affinities and binding energies. Results show that lauric acid has 20-40 times higher K d than pentaglycine, following the order K d (ferrihydrite) > K d (Al-hydroxide) >> K d (calcite). Molecular-scale simulations confirm that lauric acid has a higher binding energy (30.8 kcal/mol) on ferrihydrite than pentaglycine (6.0 kcal/mol), attributed to lipid hydrophobicity. The lower binding energy of pentaglycine results from its hydrophilic amide groups, facilitating partitioning into water. Sequential experiments examine how the first layer of lipid or amino acid affects the adsorption of carbohydrate/lignin, which show little or no individual adsorption affinities. Macroscale results reveal that lipid and amino acid adsorption induce ferrihydrite particle repulsion increasing reactive surface area and enhancing carbohydrate/lignin adsorption independently and synergistically through organic multilayering. Molecular-scale results reveal that amino acid adsorbed on ferrihydrite interacts more readily with lignin macroaggregates (preformed in solution) than with individual lignin units, indicating organic multilayering via H-bonding. Further, these findings reveal the molecular mechanisms of SOM-mineral interactions, crucial for enhancing soil carbon stabilization.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2019

Procedure for the Transfer of Polymer Films Onto Porous Substrates with Minimized Defects

The fabrication of devices containing thin film structures necessitate the transfer of these films onto the surfaces of arbitrary support substrates. Accomplishing this transfer in a highly controlled, mechanized, and reproducible manner would eliminate the creation of macroscale defect structures (e.g. tears, cracks, and wrinkles) within the thin film that would otherwise have a negative impact on ultimate device performance. In this work, we describe a general protocol for the highly controlled and mechanized transfer of a polymeric thin film onto an arbitrary porous support substrate for eventual use as a water filtration membrane device. Specifically, we fabricate a block copolymer (BCP) thin film on top of a sacrificial, water-soluble poly(acrylic acid) (PAA) layer and silicon wafer substrate. We then utilize a custom-designed, 3D-printed transfer tool and drain chamber system to deposit, lift-off, and transfer the BCP thin film onto the center of a porous anodized aluminum oxide (AAO) support disc. The transferred BCP thin film is shown to be consistently placed onto the center of the support surface due to the guidance of the meniscus. Additionally, we compare our mechanized transfer-processed thin films to those that have been transferred by other commonly used techniques, such as by hand with the use of tweezers. Optical inspection and image analysis of the transferred thin films from the mechanized process confirm that little-to-no macroscale inhomogeneities or plastic deformations are produced, as compared to the multitude of tears and wrinkles produced from manual transfer by hand. Our findings indicate that the proposed strategy for thin film transfer can reduce defects when compared to other methods across many systems and applications.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Invariant soil water potential at zero microbial respiration explained by hydrological discontinuity in dry soils

We report that soil microbial respiration rates decrease with soil drying, ceasing below water potentials around -15 MPa. A proposed mechanism for this pattern is that under dry conditions, microbes are substrate limited because solute diffusivity is halted due to breaking of water film continuity. However, pore connectivity estimated from hydraulic conductivity and solute diffusivity (at Darcy's scale) is typically interrupted at much less negative water potentials than microbial respiration (-0.1 to -1 MPa). It is hypothesized here that the more negative respiration thresholds than at the Darcy's scale emerge because microbial activity is restricted to microscale soil patches that retain some hydrological connectivity even when it is lost at the macroscale. This hypothesis is explored using results from percolation theory and meta-analyses of respiration-water potential curves and hydrological percolation points. Lastly, when reducing the spatial scale from macroscale to microscale, hydrological and respiration thresholds become consistent, supporting the proposed hypothesis.

58 GEOSCIENCES↗
DOE OSTI2019

Ultrastiff, Strong, and Highly Thermally Conductive Crystalline Graphitic Films with Mixed Stacking Order

A macroscopic film (2.5 cm × 2.5 cm) made by layer-by-layer assembly of 100 single-layer polycrystalline graphene films is reported. The graphene layers are transferred and stacked one by one using a wet process that leads to layer defects and interstitial contamination. Heat-treatment of the sample up to 2800 °C results in the removal of interstitial contaminants and the healing of graphene layer defects. The resulting stacked graphene sample is a freestanding film with near-perfect in-plane crystallinity but a mixed stacking order through the thickness, which separates it from all existing carbon materials. Macroscale tensile tests yields maximum values of 62 GPa for the Young's modulus and 0.70 GPa for the fracture strength, significantly higher than has been reported for any other macroscale carbon films; microscale tensile tests yield maximum values of 290 GPa for the Young's modulus and 5.8 GPa for the fracture strength. The measured in-plane thermal conductivity is exceptionally high, 2292 ± 159 W m -1 K -1 while in-plane electrical conductivity is 2.2 × 10 5 S m -1 . Finally, the high performance of these films is attributed to the combination of the high in-plane crystalline order and unique stacking configuration through the thickness.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Carbon Additive Manufacturing with a Near-Replica “Green-to-Brown” Transformation

Nanocomposites containing nanoscale materials offer exciting opportunities to encode nanoscale features into macroscale dimensions, which produces unprecedented impact in material design and application. However, conventional methods cannot process nanocomposites with a high particle loading, as well as nanocomposites with the ability to be tailored at multiple scales. A composite architected mesoscale process strategy that brings particle loading nanoscale materials combined with multiscale features including nanoscale manipulation, mesoscale architecture, and macroscale formation to create spatially programmed nanocomposites with high particle loading and multiscale tailorability is reported. The process features a low-shrinking (<10%) “green-to-brown” transformation, making a near-geometric replica of the 3D design to produce a “brown” part with full nanomaterials to allow further matrix infill. Here, this demonstration includes additively manufactured carbon nanocomposites containing carbon nanotubes (CNTs) and thermoset epoxy, leading to multiscale CNTs tailorability, performance improvement, and 3D complex geometry feasibility. The process can produce nanomaterial-assembled architectures with 3D geometry and multiscale features and can incorporate a wide range of matrix materials, such as polymers, metals, and ceramics, to fabricate nanocomposites for new device structures and applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Customized Nanostructured Ceramics via Microphase Separation 3D Printing

To date, the restricted capability to fabricate ceramics with independently tailored nano- and macroscopic features has hindered their implementation in a wide range of crucial technological areas, including aeronautics, defense, and microelectronics. In this study, a novel approach that combines self- and digital assembly to create polymer-derived ceramics with highly controlled structures spanning from the nano- to macroscale is introduced. Polymerization-induced microphase separation of a resin during digital light processing generates materials with nanoscale morphologies, with the distinct phases consisting of either a preceramic precursor or a sacrificial polymer. By precisely controlling the molecular weight of the sacrificial polymer, the domain size of the resulting material phases can be finely tuned. Pyrolysis of the printed objects yields ceramics with complex macroscale geometries and nanoscale porosity, which display excellent thermal and oxidation resistance, and morphology-dependent thermal conduction properties. This method offers a valuable technological platform for the simplified fabrication of nanostructured ceramics with complex shapes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Hierarchically Templated Synthesis of 3D‐Printed Crosslinked Cyclodextrins for Lycopene Harvesting

Abstract Plants produce a wide range of bioactive phytochemicals, such as antioxidants and vitamins, which play crucial roles in aging prevention, inflammation reduction, and reducing the risk of cancer. Selectively harvesting these phytochemicals, such as lycopene, from tomatoes through the adsorption method is cost‐effective and energy efficient. In this work, a templated synthesis of 3D‐printed crosslinked cyclodextrin polymers featuring nanotubular structures for highly selective lycopene harvesting is reported. Polypseudorotaxanes formed by triethoxysilane‐based telechelic polyethylene glycols and α‐cyclodextrins (α‐CDs) are designed as the template to (1) synthetically access urethane‐based nanotubular structures at the molecular level, and (2) construct 3D‐printed architectures with designed macroscale voids. The polypseudorotaxane hydrogels showed good rheological properties for direct ink writing, and the 3D‐printed hydrogels were converted to the desired α‐CD polymer network through a three‐step postprinting transformation. The obtained urethane‐crosslinked α‐CD monoliths possess nanotubular structures and 3D‐printed voids. They selectively adsorb lycopene from raw tomato juice, protecting lycopene from photo‐ or thermo‐degradations. This work highlights the hierarchically templated synthesis approach in developing functional 3D‐printing materials by connecting the bottom‐up molecular assembly and synthesis with the top‐down 3D architecture control and fabrication.

Chemistry↗
DOE OSTI2022

Generalized thermo-mechanical framework for heterogeneous materials through asymptotic homogenization

Abstract A fundamental understanding of the interaction between microstructure and underlying physical mechanisms is essential, especially for developing more accurate multi-physics models for heterogeneous materials. Effects of microstructure on the material response at the macroscale are modeled by using the generalized thermomechanics. In this study, strain gradient theory is employed as a higher-order theory on the macroscale with thermodynamics modeled as a first-order theory on the microscale. Hence, energy depends only on the temperature such that we circumvent an extension of Fourier’s law and analyze the “simplest” thermo-mechanical model in strain gradient elasticity. Developing multiphysics models for heterogeneous materials is indeed a challenge and even this “simplest” model in generalized thermomechanics creates dozens of parameters to be determined. We develop a thermo-mechanical framework, in which microstructure is modeled as a periodic structure and through asymptotic homogenization approach, higher-order parameters at macroscopic scale are calculated. To illustrate the importance of higher-order parameters in overall thermo-mechanical response of a heterogeneous materials, finite element method (FEM) is employed with the aid of open-source codes (FEniCS). Verification example of a bulk system and several case studies of porous structures demonstrate how such numerical framework can be beneficial in the design of materials with tailored microstructures.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗