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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 1,333 records · Page 74
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Ion Exchange of Selected Group II Metals and Lead by Crystalline Silicotitanate and Competition for Cs Exchange Sites

A series of batch contact tests were conducted to evaluate the exchange behavior of Ba, Ca, Pb, and Sr onto crystalline silicotitanate (CST) in support of an expedited Cs removal and pretreatment system at the Hanford site. Binary Na/M 2+ and ternary Na/Cs/M 2+ isotherms were generated to understand selectivity, capacity, and competitive impact of each analyte on Cs uptake from a simple 1 M NaOH/4.6 M NaNO 3 simulant. Analyte loading from a 0.1 M NaOH/5.5 M NaNO 3 simulant was assessed to determine the effect of hydroxide concentration on binary Na/M 2+ isotherms. Finally, results from binary and ternary isotherms indicated that group II metals, and Pb do not impact CST performance toward CST at concentrations expected in Hanford tank waste supernate.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

A Study on the Interfacial Reaction Between Liquid Iron and MgO-Based Refractories Containing TiO{sub 2}

The interfacial reactions between liquid iron and MgO-based refractories were investigated based on the TiO{sub 2} concentration values. Substrates comprising MgO, MgO-TiO{sub 2} (MT), MgO-Al{sub 2}O{sub 3} (MA), and MgO-Al{sub 2}O{sub 3}, at loadings of 3, 6, 9, 12, and 15 wt pct TiO{sub 2} (MAT3-15), were reacted with liquid iron at 1823 K by using the sessile drop technique. Microscopic analysis by SEM/EDX and the associated thermochemical calculations by Factsage 7.0™ confirmed the reaction mechanisms of different refractory materials. MgO and MT showed higher resistance against liquid iron penetration compared with MA and MAT3-15, which was attributed to the formation of a magnesiowustite (MO (M = Fe, Mg)) layer formed at the interfaces. Increasing the levels of TiO{sub 2} up to 6 wt pct contributed to the denser microstructure of MA. However, the contact angle was lowest for 9 wt pct of TiO{sub 2} and then gradually increased up to 15 wt pct. Chemical reactions generating a liquid slag phase contributed to the fluctuations in contact angle with respect to TiO{sub 2}.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Boron Nitride-Driven Strengthening of Aluminum Composites via Friction Stir Processing

Friction stir welding and processing (FSW/P) has emerged as an effective solid-state joining technique for fabricating metal matrix composites (MMCs), offering improved mechanical properties through refined microstructural evolution. In this study, an aluminum-boron nitride nanoparticle (Al-BNNP) composite was synthesized via FSW, and its indentation-based mechanical properties were systematically evaluated. Microhardness mapping across the weld cross-section revealed a progressive increase in hardness toward the stir zone (SZ), attributed to severe plastic deformation, dynamic recrystallization (DRX), and the reinforcing effect of BNNPs. Profilometry-based indentation plastometry (PIP) inferred yield strength (YS) demonstrates a 47.8% increase compared to the base metal (BM) and a 75% improvement compared to FSP pure aluminum reported in literature. This enhancement is attributed to strengthening mechanisms, including grain boundary pinning, load transfer, and increased dislocation density. The strain rate sensitivity (SRS) measurements at the nanoscale demonstrated a substantial decrease in the SZ, correlated with ultrafine grain structures and strong BNNP-matrix interactions. Activation volume analysis revealed a significant reduction in the SZ, suggesting that dislocation motion is increasingly restricted by dislocation-dislocation and dislocation-particle interactions. These findings suggest that incorporating BNNPs in FSW/P enables tailoring the microstructure without thermal degradation of the secondary particles, thereby significantly enhancing the mechanical performance of aluminum composites, particularly for structural applications in aerospace and automotive industries.

Aluminum↗
DOE OSTI2019

Butt Laser Welding–Brazing of AZ31 Mg to Nickel-Coated Ti-6Al-4V

Mg and Ti alloy are hard to be bonded due to their huge discrepancy in physical and metallurgical characteristics. As an intermediate element, Ni is feasible for joining of Mg and Ti. The interfacial microstructure and mechanical properties of laser-welded–brazed AZ31 Mg/Ti-6Al-4V joints in butt configuration were investigated with different thicknesses of electrodeposited Ni interlayer. The interfacial reaction products evolved from an ultra-thin Ti{sub 3}Al layer to Ti{sub 2}Ni layer mingled with Ti{sub 3}Al, and more Mg{sub 3}AlNi{sub 2} compounds were produced in the fusion zone (FZ) as Ni coating thickness increased. Slag inclusions and cracks were observed in interfacial layer when coating thickness exceeded 2.5 μm. The quantity of Mg{sub 3}AlNi{sub 2} and the thickness of interfacial layer decreased from the top to bottom of groove of the same joint owing to high thermal gradient during laser welding. The chemical potential of Al and Ni indicated that Al-Ti reaction product was produced more easily than Ni-Ti in 0.001Mg-(Ni-Al-Ti) system. The thermodynamic calculation results of Gibbs free energy suggested the preferential formation Ti-Al phase and Ti-Ni phase along the interface while the Mg-Al-Ni ternary phase in the FZ. Fracture loads of joints increased first followed by a decline with the increase in coating thickness. The joint fractured at the Mg base metal, reaching a maximum value of 3900 N with the Ni coating thickness of 1.5 μm. In the case of using thinner or thicker Ni coating, crack propagated along the interface due to the insufficient metallurgical bonding or defects existed in the interfacial layer. The characteristic of fracture surface changed from the tear ridges and terraces to river pattern when interfacial failure occurred.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Reducing Iridium Loading in Oxygen Evolution Reaction Electrocatalysts Using Core–Shell Particles with Nitride Cores

Here, the oxygen evolution reaction (OER) has broad applications in electrochemical devices, but it often requires expensive and scarce Ir-based catalysts in acid electrolyte. Presented here is a framework to reduce Ir loading by combining core–shell iridium/metal nitride morphologies using in situ experiments and density functional theory (DFT) calculations. Several group VIII transition metal (Fe, Co, and Ni) nitrides are studied as core materials, with Ir/Fe 4 N core–shell particles showing enhancement in both OER activity and stability. In situ X-ray absorption fine structure measurements are used to determine the structure and stability of the core–shell catalysts under OER conditions. DFT calculations are used to demonstrate adsorbate binding energies as descriptors of the observed activity trends.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Additively Manufactured Compliant Hybrid Gas Thrust Bearing for Supercritical Carbon Dioxide Turbomachinery: Experimental Evaluation and Fluid–Structure Model Predictions

This paper presents rotating test results and advances an analytical predictive fluid–structure model for a new type of gas-lubricated thrust bearing fabricated using direct metal laser melting. The bearing concept in this study is a compliant hybrid gas thrust bearing that uses external pressurization to increase load carrying capacity, where the testing campaign in this study was only focused on steady-state static performance. The need for the bearing concept comes from enabling highly efficient supercritical carbon dioxide (sCO2) turbomachinery by replacing oil-lubricated bearings with process gas lubrication. Leveraging the process gas of the turbomachine for bearing lubrication results in lowered bearing power loss, simplified mechanical design, and allows for novel oil-free hermetic drivetrains resulting in an efficient emission-free system. The new concept utilizes hydrostatic pressurization on individual tilting pads flexibly mounted with hermetic squeeze film dampers (HSFDs). This paper focuses on rotating tests of a 173 mm outer diameter gas thrust bearing in air up to 10 krpm and hydrostatic inlet pressures to 365 psi (2.52 MPa). The influence of thrust runner speed and bearing inlet pressure on force deflection characteristics and load carrying capability of the gas film were experimentally evaluated. This work also advances a predictive fluid–structure thrust bearing model using an isothermal ideal-gas-based compressible Reynolds flow equation directly coupled to a lumped stiffness element possessing axial and rotational degrees-of-freedom. The rotating testing demonstrated load capability of 1816 lbs (8.1 kN), which equates to a thrust bearing unit load of 67 psi (0.46 MPa). Gas film force–deflection curves reveal a nonlinear relationship between thrust load and film clearance. Comparison of film thickness values with the predictive model show good agreement under high load and inlet pressure, however deviate as load and pressure decrease. Load capability was shown to increase with increasing hydrostatic inlet pressure, while the increase in thrust runner speed revealed a small decrease in load capacity.

Engineering↗
DOE OSTI2022

Spectroscopic Investigation of Catalyst Inks and Thin Films Toward the Development of Ionomer Quality Control

As the production of polymer electrolyte fuel cells expands, novel quality control methods must be invented or adapted in order to support expected rates of production. Ensuring the quality of deposited catalyst layers is an essential step in the fuel cell manufacturing process, as the efficiency of a fuel cell is reliant on the catalyst layer being uniform at both the target platinum loading and the target ionomer content. Implementing a quality control method that is sensitive to these aspects is imperative, as wasting precious metals and other catalyst materials is expensive, and represents a potential barrier to entry into the field for manufacturers experimenting with novel deposition processes. In this work, we analyzed catalyst inks to determine if their ionomer content could be quantized spectroscopically. Attenuated total reflection (ATR) Fourier transform infrared spectroscopic technique was investigated producing a signal proportional to the ionomer content. ATR spectroscopy was able to quantitatively differentiate samples in which the ionomer to carbon mass ratio (I/C) varied between 0.9 and 3.0. The I/C ratio was correlated to the measured ATR signal near the CF 2 vibrational bands located between 1100 cm −1 and 1400 cm −1 . The experimental results obtained constitute a step toward the development of novel quality control methodologies for catalyst inks utilized by the fuel cell industry.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2019

Characterization and CST Batch Contact Equilibrium Testing of Aged TCCR Tank 10H Batch 1A and 2 Process Supernate Samples

The Tank Closure Cesium Removal (TCCR) system uses ion exchange columns filled with Crystalline Silicotitanate (CST) media to process radioactive waste solutions for the removal of Cs-137. TCCR currently focuses on dissolving Savannah River Site (SRS) Tank 10H waste (primarily sodium saltcake solids) within the tank followed by at-tank ion exchange column treatment. Previous equilibrium batch contact tests conducted in the SRNL Shielded Cells laboratory and associated analyses indicated that CST cesium removal performance was lower than predicted by ZAM modeling for TCCR Tank 10H Production Supernate Batch 1A. An average cesium distribution coefficient of 1,948 mL/g which corresponds to 94.1% Cs + removal was observed for Batch 1A supernate at 38 °C in January of 2019 using laboratory pretreated IONSIV™ R9120-B a CST from Lot #209900034 (predominant TCCR CST batch) at a phase ratio of 122 mL/g. This cesium loading was approximately 32% lower than model predictions, presumably due to ion exchange competition or fouling associated with alkaline earth or transition metals present in the solutions at low levels. The current testing was designed to: 1) evaluate whether supernate compositional changes during storage would result in improved cesium removal performance with CST, and 2) assist in media selection and handling protocols for future TCCR columns by evaluating several CST manufacturer batches as well as samples of one CST batch which had been pretreated using two different methods (field and laboratory methods).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Additive Manufacturing Flaw Assessment Methodology

An evolution fatigue data and flaw tolerance of components produced using the Powder Bed Fusion (PBF) Additive Manufacturing (AM) process is documented in this report. Initial differences in fatigue data for AM components compared to smooth bar fatigue data indicated a need for a more detailed analysis of AM data available in technical literature. The investigation was initiated to support the development of a fatigue analysis methodology for AM components to support the of codification of AM technology for pressure equipment. The project was initiated to collect and analyze stainless steel 304L and 316L AM fatigue test data and corresponding process and quality information to develop S-N and E-N based fatigue data representation. Additional AM fatigue test data including Inconel Ti-6-4 and aluminum alloys were also considered for comparison purposes Metallic AM parts tend to contain various forms of defects distributed throughout the part. If an AM part is subjected to fatigue loading in service, a fatigue analysis needs to be performed during the design process to ensure an acceptable service life for the part. Post-process machining and polishing do not to improve fatigue resistance in any significant degree. The low cycle fatigue regime is of particular interest to this project in support of flaw acceptance criteria currently under development by ASME’s BPTCS/BNCS. Internal defects become exposed as external surface defects during machining for the machining of the AM part to final dimensions. This implies that as long as inherent AM defects are within a controlled limit in terms of both size and distribution characteristics, the corresponding fatigue test data in terms of either S-N (stress life) or E-N (strain life) can be investigated and characterized to establish fatigue properties of AM parts for design and fatigue evaluation purposes. The resulting S-N or E-N curves and their scatter bands can be used to derive fatigue design allowable stress values by capturing the effects of distributed discontinuities within an acceptable limit.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Fracture and crack growth resistance studies of 304 stainless steel weldments relating to retesting of cryogenic vessels

Fracture and crack growth resistance characteristics of 304 stainless steel alloy weldments as relating to retesting of cryogenic vessels were examined. Welding procedures were typical of those used in full scale vessel fabrication. Fracture resistance survey tests were conducted in room temperature air, liquid nitrogen and liquid hydrogen. In air, both surface-flawed and center-cracked panels containing cracks in weld metal, fusion line, heat-affected zone, or parent metal were tested. In liquid nitrogen and liquid hydrogen, tests were conducted using center-cracked panels containing weld centerline cracks. Load-unload, sustained load, and cyclic load tests were performed in air or hydrogen gas, liquid nitrogen, and liquid hydrogen using surface-flawed specimens containing weld centerline cracks. Results were used to evaluate the effectiveness of periodic proof overloads in assuring safe and reliable operation of over-the-road cryogenic dewars.

Hall, L. R.↗
NASA NTRS1978

Automated space fabrication of structural elements

A description is presented of an automated space fabrication technique for basic structural elements, taking into account as representative the design loads and requirements of the solar power satellite structure. Roll forming for continuous cap and brace members is applicable for all proposed metallic materials. Spot-welding, electron beam welding, ultrasonic welding, laser welding, cold welding, and various mechanical fastening techniques are applicable for the automated fabrication process. Termination of the formed cap and brace members can be accomplished by sawing, shearing, punching, and laser cutting. The most cost effective materials were found to be the aluminum alloys. Selected for further study were AL20224T3 and AL2219-T62. In the area of fiber composites, thermoplastic matrix materials with graphite fibers were selected for future studies.

Engler, E. E.↗
NASA NTRS1981

Effects of geometric variables on rub characteristics of Ti-6Al-4V

Experiments simulating rub interactions between Ti-6Al-4V blade tips and various seal materials were conducted. The number of blade tips and the blade tip geometry were varied to determine their effects on rub forces and on wear phenomena. Contact was found to be quite unsteady for all blade tip geometries except for those incorporating deliberately rounded blade tips. The unsteady contact was characterized by long periods of rubbing contact and increasing blade tip that terminated in sudden rapid metal removal, sometimes accompanied by tearing and disruption of porous seal material under the rub surface. A model describing the blade tip loading is proposed and is based on the propagation of an elastic stress wave through the seal material as the seal material is dynamically compressed by the blade tip leading edge.

Bill, R. C.↗
NASA NTRS1992

Shock-treated Lunar Soil Simulant: Preliminary Assessment as a Construction Material

In an effort to examine the feasibility of applying dynamic compaction techniques to fabricate construction materials from lunar regolith, preliminary explosive shock-loading experiments on lunar soil simulants were carried out. Analysis of our shock-treated samples suggests that binding additives, such as metallic aluminum powder, may provide the necessary characteristics to fabricate a strong and durable building material (lunar adobe) that takes advantage of a cheap base material available in abundance: lunar regolith.

Boslough, Mark B.↗
NASA NTRS1993

Metal Matrix Laminate Tailoring (MMLT) code: User's manual

The User's Manual for the Metal Matrix Laminate Tailoring (MMLT) program is presented. The code is capable of tailoring the fabrication process, constituent characteristics, and laminate parameters (individually or concurrently) for a wide variety of metal matrix composite (MMC) materials, to improve the performance and identify trends or behavior of MMC's under different thermo-mechanical loading conditions. This document is meant to serve as a guide in the use of the MMLT code. Detailed explanations of the composite mechanics and tailoring analysis are beyond the scope of this document, and may be found in the references. MMLT was developed by the Structural Mechanics Branch at NASA Lewis Research Center (LeRC).

Murthy, P. L. N.↗
NASA NTRS1998

A Progressive Damage Methodology for Residual Strength Predictions of Notched Composite Panels

The translaminate fracture behavior of carbon/epoxy structural laminates with through-penetration notches was investigated to develop a residual strength prediction methodology for composite structures. An experimental characterization of several composite materials systems revealed a fracture resistance behavior that was very similar to the R-curve behavior exhibited by ductile metals. Fractographic examinations led to the postulate that the damage growth resistance was primarily due to fractured fibers in the principal load-carrying plies being bridged by intact fibers of the adjacent plies. The load transfer associated with this bridging mechanism suggests that a progressive damage analysis methodology will be appropriate for predicting the residual strength of laminates with through-penetration notches. A progressive damage methodology developed by the authors was used to predict the initiation and growth of matrix cracks and fiber fracture. Most of the residual strength predictions for different panel widths, notch lengths, and material systems were within about 10% of the experimental failure loads.

Coats, Timothy W.↗
NASA NTRS2009

Advances in Non-Contact Measurement of Creep Properties

As the required service temperatures for superalloys increases, so do the demands on testing for development of these alloys. Non-contact measurement of creep of refractory metals using electrostatic levitation has been demonstrated at temperatures up to 2300 C using samples of only 20-40 mg. These measurements load the spherical specimen by inertial forces due to rapid rotation. However, the first measurements relied on photon pressure to accelerate the samples to the high rotational rates of thousands of rotations per second, limiting the applicability to low stresses and high temperatures. Recent advances in this area extend this measurement to higher stresses and lower-temperatures through the use of an induction motor to drive the sample to such high rotational speeds. Preliminary results on new measurements on new materials will be presented.

Hyers, Robert↗
DOE OSTI2019

High velocity impact of an Fe/Cr/Mn/Ni high entropy alloy

A series of shock loading experiments were conducted on High Entropy Alloy (HEA) samples consisting of Fe/Cr/Mn/Ni in weight percentages of 25.2/23.5/24.8/26.5. Characterizing this transition metal alloy is a first step in understanding the shock compression response of this relatively new class of alloy. A single stage light gas gun was used to conduct a series of flyer plate symmetric impact experiments to obtain fundamental dynamic properties. Photonic Doppler Velocimetry (PDV) diagnostics were employed to measure the free surface velocity on the back of each target during dynamic compression. These experiments yielded four data points that are in reasonable agreement with an estimated Hugoniot for the material.

36 MATERIALS SCIENCE↗