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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 1,351 records · Page 75
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Deposit geometry and oxygen concentration spatial variations due to composition change in printed functionally graded components

Functionally graded materials (FGMs) with site specific chemical composition are commonly manufactured by directed energy deposition (DED). Although previous work fabricated an FGM with a compositional variation between a ferritic and austenitic alloy, difficulties arose due to variations in deposit shape with composition change. This problem also occurs for FGMs in literature; however, unlike other cases, the thermophysical properties of these two alloys were similar throughout the build. Here, we investigate the role of chemical composition and surface-active elements on deposit geometry during the manufacture of FGMs by laser DED. Single-track experiments for the relevant FGM compositions are analyzed with results from a well-tested, three-dimensional, transient numerical heat transfer and fluid flow model and thermodynamic calculations. Experiments showed deposit shape varied as a function of composition for constant laser power and scan speed. Thermodynamic analysis indicated that the oxygen solubility in the fusion zone varied significantly for each composition used for the FGM. Numerical modeling revealed that the change in fluid flow caused by Marangoni convection due to dissolved oxygen in the fusion zone were mainly responsible for the changes in deposit shape observed in experiments. Finally, because oxygen can be introduced into the fusion zone through the feedstock as well as the surrounding atmosphere, these findings elucidate a previously unconsidered aspect of process control during DED fabrication of FGMs.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Surface temperature: A key parameter to control the propanethiol plasma polymer chemistry

In this work, the influence of the substrate temperature (T{sub s}) on the chemical composition of propanethiol plasma polymers was investigated for a given set of plasma conditions. In a first study, a decrease in the atomic sulfur content (at. %S) with the deposition time (t{sub d}) was observed. This behavior is explained by the heating of the growing film during deposition process, limiting the incorporation of stable sulfur-based molecules produced in the plasma. Experiments carried out by controlling the substrate temperature support this hypothesis. On the other hand, an empirical law relating the T{sub s} and the at. %S was established. This allows for the formation of gradient layer presenting a heterogeneous chemical composition along the thickness, as determined by depth profile analysis combining X-ray photoelectron spectroscopy and C{sub 60} ion gun sputtering. The experimental data fit with the one predicted from our empiric description. The whole set of our results provide new insights in the relationship between the substrate temperature and the sulfur content in sulfur-based plasma polymers, essential for future developments.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Electrolytic Plasma Surface Polishing of Complex Components Produced by Selective Laser Melting

The applicability of electrolytic plasma surface polishing to complex components produced by selective laser melting (SLM) is analyzed. By electrolytic plasma polishing by electrolyte spraying, the surface quality of components produced by SLM may be improved. This technology is found to decrease the surface roughness from R{sub a} = 5.6 μm to 1.4 μm. The optimal pressure of the electrolyte jet is 0.02–0.05 MPa. At high pressures, the process becomes unstable. By electrolytic plasma polishing on the basis of electrolyte jets, uniform external and internal surface roughness of components produced by SLM may be ensured.

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

Reflective Fiber Temperature Probe Based on Localized Surface Plasmon Resonance towards Low-Cost and Wireless Interrogation

Reflection fiber temperature sensors functionalized with plasmonic nanocomposite material using intensity-based modulation are demonstrated for the first time. Characteristic temperature optical response of the reflective fiber sensor is experimentally tested using Au-incorporated nanocomposite thin films deposited on the fiber tip, and theoretically validated using a thin-film-optic-based optical waveguide model. By optimizing the Au concentration in a dielectric matrix, Au nanoparticles (NP) exhibit a localized surface plasmon resonance (LSPR) absorption band in a visible wavelength that shows a temperature sensitivity ~0.025%/°C as a result of electron–electron and electron–phonon scattering of Au NP and the surrounding matrix. Detailed optical material properties of the on-fiber sensor film are characterized using scanning electron microscopy (SEM) and focused-ion beam (FIB)-assisted transmission electron microscopy (TEM). Airy’s expression of transmission and reflection using complex optical constants of layered media is used to model the reflective optical waveguide. A low-cost wireless interrogator based on a photodiode transimpedance-amplifier (TIA) circuit with a low-pass filter is designed to integrate with the sensor. The converted analog voltage is wirelessly transmitted via 2.4 GHz Serial Peripheral Interface (SPI) protocols. Feasibility is demonstrated for portable, remotely interrogated next-generation fiber optic temperature sensors with future capability for monitoring additional parameters of interest.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

Liquified SO 2 induced solid/cathode electrolyte interphase for lithium ion batteries

Formation of robust solid/cathode electrolyte interphases (S/CEI) is vital for long-term stability and high-performance operation of lithium-ion batteries (LIBs), particularly under high voltage regimes. However, engineering electrochemically stable S/CEIs that effectively suppress interfacial side reactions remains a key challenge. Herein, we introduce a liquefied sulfur dioxide (SO 2 )– ionic liquid complex as a fluorine-free multifunctional electrolyte additive for the first time that significantly improves the formation of sulfate/sulfite-rich S/CEI layers at both graphite and NMC811 interfaces. The unique SO 2 -N coordination with a 1,2,4-triazolide-based ionic liquid enables homogeneous SO 2 dissolution, resulting in controlled SO 2 decomposition during the initial electrochemical cycle. This decomposition yields sulfur-rich interphase species that stabilize the electrolyte-electrode interface, reduce impedance growth, and lessen electrolyte decomposition. Electrochemical tests show significantly improved cycle life, reduced polarization, and increased Coulombic efficiency for both anodes and cathodes. XPS confirms the presence of SO 2 -derived surface species that contribute to interfacial stability. In conclusion, this approach highlights a new direction for interphase engineering using liquefied gas additives and opens pathways for sulfur-based S/CEI chemistry in advanced battery systems.

Graphite↗
DOE OSTI2025

Rotation of electrothermal-instability-driven overheating structure due to helically oriented surface magnetic field on a high-current-density aluminum rod

Experiments on the 1-MA, 100-ns-rise-time Mykonos Facility demonstrate rotation of electrothermal instability (ETI)-driven overheating structure on 1.00-mm-diameter, 10-nm-surface roughness, 99.999%-pure aluminum rods, which are pulsed with helically polarized surface magnetic field. Rods are machined to include pairs of 10-micron-scale quasi-hemispherical voids or “engineered defects (ED)” which provide the dominant current density perturbation from which ETI grows most rapidly. Experiments include an axial magnetic field component through the addition of a helically wound return-current electrode or “helical return can (HRC).” For a given HRC design, azimuthal field (B ɵ ) and axial field (B z ) components rise at a prescribed and fixed ratio, driving an increasing magnetic field of constant polarization at the rod's surface; most experiments generated surface magnetic field at a 15-degree field polarization angle (from horizontal) defined as ɸ B = arctan(B z /B ɵ ). ETI-driven emission patterns from individual ED are observed to rotate along ɸ B , while emission patterns from dielectric-coated ED pairs are shown to elongate and preferentially merge along ɸ B , in qualitative agreement with 3D-magnetohydrodynamic simulations. These data strongly support that for a randomized distribution of current density perturbations on a high-current density conductor, nearby perturbations will favorably merge about ɸ B , with the degree of merging increasing with current. Such observations offer fundamental new understanding of the seeding mechanisms of the helical magneto-Rayleigh Taylor (MRT) instabilities observed from axially magnetized magnetically driven imploding liners.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2017

Defect engineering in atomically-thin bismuth oxychloride towards photocatalytic oxygen evolution

Photocatalytic solar energy conversion is a clean technology for producing renewable energy sources, but its efficiency is greatly hindered by the kinetically sluggish oxygen evolution reaction. Herein, confined defects in atomically-thin BiOCl nanosheets were created to serve as a remarkable platform to explore the relationship between defects and photocatalytic activity. Surface defects can be clearly observed on atomically-thin BiOCl nanosheets from scanning transmission electron microscopy images. Theoretical/experimental results suggest that defect engineering increased states of density and narrowed the band gap. With combined effects from defect induced shortened hole migratory paths and creation of coordination-unsaturated active atoms with dangling bonds, defect-rich BiOCl nanosheets displayed 3 and 8 times higher photocatalytic activity towards oxygen evolution compared with atomically-thin BiOCl nanosheets and bulk BiOCl, respectively. As a result, this successful application of defect engineering will pave a new pathway for improving photocatalytic oxygen evolution activity of other materials.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Combined wet and dry cleaning of SiGe(001)

Combined wet and dry cleaning via hydrofluoric acid (HF) and atomic hydrogen on Si{sub 0.6}Ge{sub 0.4}(001) surface was studied at the atomic level using ultrahigh vacuum scanning tunneling microscopy (STM), scanning tunneling spectroscopy (STS), and x-ray photoelectron spectroscopy to understand the chemical transformations of the surface. Aqueous HF removes native oxide, but residual carbon and oxygen are still observed on Si{sub 0.6}Ge{sub 0.4}(001) due to hydrocarbon contamination from post HF exposure to ambient. The oxygen contamination can be eliminated by shielding the sample from ambient via covering the sample in the HF cleaning solution until the sample is introduced to the vacuum chamber or by transferring the sample in an inert environment; however, both processes still leave carbon contaminant. Dry in-situ atomic hydrogen cleaning above 330 °C removes the carbon contamination on the surface consistent with a thermally activated atomic hydrogen reaction with surface hydrocarbon. A postdeposition anneal at 550 °C induces formation of an atomically flat and ordered SiGe surface observed by STM. STS verifies that the wet and dry cleaned surface has an unpinned Fermi level with no states between the conduction and valence band edge comparable to sputter cleaned SiGe surfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Methods and apparatus for radially compliant component mounting

Methods and apparatus for a mounting assembly for a liner of a gas turbine engine combustor are provided. The combustor includes a combustor liner and a radially outer annular flow sleeve. The mounting assembly includes an inner ring surrounding a radially outer surface of the liner and including a plurality of axially extending fingers. The mounting assembly also includes a radially outer ring coupled to the inner ring through a plurality of spacers that extend radially from a radially outer surface of the inner ring to the outer ring.

42 ENGINEERING↗
DOE OSTI2017

PPPL ST-FNSF Engineering Design Details

One of the goals of the PPPL Spherical Tokamak (ST) Fusion Nuclear Science Facility (FNSF) study was to generate a self-consistent conceptual design of an STFNSF device with sufficient physics and engineering details to evaluate the advantages and disadvantages of different designs and to assess various ST-FNSF missions. This included striving to achieve tritium self-sufficiency; the ability to provide shielding protection of vital components and to develop maintenance strategies that could be used to maintain the in-vessel components (divertors, breeding blankets, shield modules and services) and characterize design upgrade potentials to expanded mission evolutions. With the conceptual design of a 2.2 m ST pilot plant design already completed emphasis was placed on evaluating a range of ST machine sizes looking at a major radius of 1m and a mid-range device size between 1 m and 2.2 m. This paper will present an engineering summary of the design details developed from this study, expanding on earlier progress reports presented at earlier conferences that focused on a mid-size 1.7 m device. Further development has been made by physics in defining a Super-X divertor arrangement that provides an expanded divertor surface area and places all PF coils outside the TF coil inner bore, in regions that improve the device maintenance characteristics. Physics, engineering design and neutronics analysis for both the 1.7 m and 1 m device have been enhanced. In conclusion, the engineering results of the PPPL ST-FNSF study will be presented along with comments on possible future directions.

42 ENGINEERING↗
DOE OSTI2023

Neutral Silicon Vacancy Centers in Undoped Diamond via Surface Control

Neutral silicon vacancy centers (SiV 0 ) in diamond are promising candidates for quantum applications; however, stabilizing SiV 0 requires high-purity, boron-doped diamond, which is not a readily available material. Here, we demonstrate an alternative approach via chemical control of the diamond surface. We use low-damage chemical processing and annealing in a hydrogen environment to realize reversible and highly stable charge state tuning in undoped diamond. The resulting SiV 0 centers display optically detected magnetic resonance and bulklike optical properties. Controlling the charge state tuning via surface termination offers a route for scalable technologies based on SiV 0 centers, as well as charge state engineering of other defects.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2026

Surface Energy Modulated Self‐Assembly of Percolative Gallium Nanodroplet Films for Stretchable Electronics

Advancements in soft robotics and wearable technologies have led to an increased need for flexible and stretchable electronic systems. Liquid metals like Gallium (Ga) and its alloys offer high potential in the field of stretchable electronics and photonics due to their inherent high conductivity and malleability. However, their high surface tension and native oxide formation hinder uniform wetting and continuous film formation to get conducting films. Here, we report a fabrication strategy to realize electrically conductive Ga thin films with effective thicknesses around 100 nm on polymeric and elastomeric substrates. By enhancing the surface energy of the elastomer, we create uniform Ga nanodroplets capable of sustaining stretchability up to 200% strain. Our devices exhibit electronic conduction primarily through tunneling and display strain tunable piezoresistive characteristics, which are explained using Kirchhoff's resistive network and Simmon's analytical tunneling current model. To showcase the device's capability in fields of stretchable electronics, we demonstrate several functional prototypes, including flexible devices integrated with Light Emitting Diodes (LEDs), curvature and pressure sensors, and soft robotic grippers capable of sensing object curvature. The demonstrated devices highlight the potential of this approach for scalable integration of stretchable electronics in soft robotic and wearable platforms.

42 ENGINEERING↗
DOE OSTI2022

Optical Imaging for Understanding of Thermal Barrier Coated Piston Engine Performance

Thermal barrier coatings (TBC) applied to pistons have been a recently renewed research topic in the field of internal combustion engines. Single cylinder testing of a conventional C15™ Tier 4 final pro-duction steel piston and a TBC coated piston showed that the Yttrium stabilized Zirconia (YSZ) TBC did not significantly alter engine performance, with the TBC piston having slower combustion rates and higher criteria emissions. For deeper understanding, research continued by studying 3D-piston sections optically in a constant pressure vessel using photodiodes, four high-speed cameras (natural luminosity, CH*, and OH*), and visualization of the flame from two orthogonal directions. Particle Im-aging Velocimetry (PIV) algorithms were adapted to perform Combustion Imaging Velocimetry (CIV) to aid in quantification of the observed visual combustion flow field differences. The optical work showed that the TBC piston flame development is slower, spatially different, with lower mixing energy for the TBC variant. Geometric profiles of engine pistons and optical vessel 3D-piston sections were measured using a Coordinate Measurement Machine (CMM), and surface roughness was measured with a stylus surface profilometer. CMM results showed that the TBC piston bowl had reasonable macroscopic accuracy, but the rim had a larger radius with less reentrancy. A discussion of the results and analyses in relation to future TBC effort and direction concludes the work.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

A machine learning pipeline for identifying infiltration managed aquifer recharge locations from satellite imagery in the San Joaquin Valley, California

This study focuses on an agricultural region in California’s Central Valley, USA, where Managed Aquifer Recharge (MAR) is widely implemented to mitigate groundwater depletion under increasing water demand and climate variability. A deep learning and machine learning framework was developed to identify infiltration-MAR locations using satellite imagery and environmental data. The framework integrates surface water detection from Sentinel-2 imagery, geospatial delineation of water bodies, spatiotemporal tracking of water body dynamics, and supervised classification using meteorological, environmental, and topographic variables. The framework was applied to a 2379 km² study area southwest of Fresno, where 765 water bodies were detected, including 139 identified MAR sites based on publicly available datasets and expert knowledge. The classification model achieved an accuracy of 0.94 and an F1 score of 0.85. Feature importance analysis indicates that cropland, normalized difference vegetation index (NDVI), and evaporation are among the most influential predictors for infiltration-MAR. Notably, the framework suggests that engineered water management in infiltration-MAR systems can disrupt or even reverse the expected positive correlation between surface water extent and precipitation. These findings provide physically interpretable insights into the characteristics of existing infiltration-MAR facilities and demonstrate the potential of the proposed framework as a reproducible, interpretable, and potentially transferable tool for data-driven infiltration-MAR identification and inventory development under growing climatic and hydrological uncertainty.

Classification↗
DOE OSTI2020

Parametrically designed surface topography on CAD models of additively manufactured lattice structures for improved design validation

Additively Manufactured (AM) lattice structures of the laser powder bed fusion (LPBF) process generally have different surface geometries depending on the overhang angle and location. This means that the design validation stage is often challenging, considering it is based on an ideal Computer Aided Design (CAD) model that is not truly representative, since the AM part will be different in terms of dimensional accuracy and surface finish. Previous studies have relied on the design of surface textures that are independent of the overhang angle, or techniques based on directly using X-ray Computed Tomography (XCT) data. In this paper, a new technique for designing surface texture on the CAD of lattices has been investigated and correlated with areal surface roughness parameters. After extracting areal surface parameters from the XCT data of the lattice, the method allowed for the design of this surface texture on the part CAD taking in consideration if its up skin or down skin, without using XCT data as the main input. By applying this method, it is possible to obtain a lattice CAD model with a designed surface texture and geometry that is more representative of the actual AM lattice. The mean deviation between the CAD model with the designed surface and the XCT was a third of the one between the XCT and the initial CAD. The proposed method allows for designing and replicating LPBF AM surfaces on the CAD of a lattice, taking into consideration the dimensional deviation caused by AM surfaces, especially on overhangs. Assuming that an LPBF AM process is stable and produces approximately the same AM surface, this method can be used to predict the geometry of a lattice, providing a cost-effective and efficient methodology that minimizes the time needed for design validation.

42 ENGINEERING↗
DOE OSTI2024

Optimizing the quality factor of InP nanobeam cavities using atomic layer deposition

Photonic crystal nanobeam cavities are valued for their small mode volume, CMOS compatibility, and high coupling efficiency-crucial features for various low-power photonic applications and quantum information processing. However, despite their potential, nanobeam cavities often suffer from low quality factors due to fabrication imperfections that create surface states and optical absorption. In this work, we demonstrate InP nanobeam cavities with up to 140% higher quality factors by applying a coating of Al 2 O 3 via atomic layer deposition to terminate dangling bonds and reduce surface absorption. Additionally, changing the deposition thickness allows precise tuning of the cavity mode wavelength without compromising the quality factor. This Al 2 O 3 atomic layer deposition approach holds great promise for optimizing nanobeam cavities that are well-suited for integration with a wide range of photonic applications.

42 ENGINEERING↗
DOE OSTI2022

Machine learning-informed and synthetic biology-enabled semi-continuous algal cultivation to unleash renewable fuel productivity

Abstract Algal biofuel is regarded as one of the ultimate solutions for renewable energy, but its commercialization is hindered by growth limitations caused by mutual shading and high harvest costs. We overcome these challenges by advancing machine learning to inform the design of a semi-continuous algal cultivation (SAC) to sustain optimal cell growth and minimize mutual shading. An aggregation-based sedimentation (ABS) strategy is then designed to achieve low-cost biomass harvesting and economical SAC. The ABS is achieved by engineering a fast-growing strain, Synechococcus elongatus UTEX 2973, to produce limonene, which increases cyanobacterial cell surface hydrophobicity and enables efficient cell aggregation and sedimentation. SAC unleashes cyanobacterial growth potential with 0.1 g/L/hour biomass productivity and 0.2 mg/L/hour limonene productivity over a sustained period in photobioreactors. Scaling-up the SAC with an outdoor pond system achieves a biomass yield of 43.3 g/m 2 /day, bringing the minimum biomass selling price down to approximately $281 per ton.

09 BIOMASS FUELS↗
DOE OSTI2017

High-temperature annealing of macroporous silicon in an inert-gas flow

Interest in the sintering of macroporous silicon is due to the possibility of purposefully modifying its structure. The annealing of macroporous structures in an atmosphere of Ar, instead of H{sub 2}, simplifies the requirements to equipment and safety engineering. The sintering of macroporous silicon as result of annealing at T = 1000–1280°C in a horizontal tube purged with high-purity gases: Ar or Ar + 3%H{sub 2} is examined. Experiments were conducted with layers having deep cylindrical macropores produced by the electrochemical etching of samples with seed pits on their surface (ordered pores) and without seeds (random pores). The morphology of the porous structure and the changes in this structure upon annealing are studied with electron and optical microscopes. It is shown that, depending on the pore diameter and treatment temperature, the following transformation occurs: the pore surface is smoothed, pores are closed and a surface crust is formed, cylindrical pores are spheroidized and decompose into isolated hollow spheres, and a fine structure and faceting are formed. It is shown that the (111) planes have the minimal surface energy. It is found that the annealing of macroporous silicon in an inert gas leads to strong thermal etching, which is manifested in the fact that the porosity increases or even the porous layer at the sample edge fully disappears. Moreover, an oxide layer appears as a film, beads, or long filaments forming a glass wool upon annealing, especially at low temperatures. These features can be attributed to the presence of trace amounts of an oxidizing agent in the inert gas, which causes the formation of highly volatile SiO and products formed in the reaction involving this compound.

36 MATERIALS SCIENCE↗