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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

A Phase-Field Model for In-Space Manufacturing of Binary Alloys

The integrity of the final printed components is mostly dictated by the adhesion between the particles and phases that form upon solidification, which is a major problem in printing metallic parts using available In-Space Manufacturing (ISM) technologies based on the Fused Deposition Modeling (FDM) methodology. Understanding the melting/solidification process helps increase particle adherence and allows to produce components with greater mechanical integrity. We developed a phase-field model of solidification for binary alloys. The phase-field approach is unique in capturing the microstructure with computationally tractable costs. The developed phase-field model of solidification of binary alloys satisfies the stability conditions at all temperatures. The suggested model is tuned for Ni-Cu alloy feedstocks. We derived the Ginzburg-Landau equations governing the phase transformation kinetics and solved them analytically for the dilute solution. We calculated the concentration profile as a function of interface velocity for a one-dimensional steady-state diffuse interface neglecting elasticity and obtained the partition coefficient, k, as a function of interface velocity. Numerical simulations for the diluted solution are used to study the interface velocity as a function of undercooling for the classic sharp interface model, partitionless solidification, and thin interface.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Elevated temperature mechanical properties of Inconel 617 surface oxide using nanoindentation

Inconel 617 is a principal candidate material for helium gas cooled very-high-temperature reactors with outlet temperatures of 700–950 °C. Recent findings showed that this alloy develops unique surface oxide layers especially at high temperature (HT) helium environment with distinctive wear, friction and contact properties. This study investigates the elevated temperature mechanical properties of Inconel 617 top surface layers aged in HT helium environment. Nanoindentation technique is used to obtain load-displacement graphs of the alloy top surface oxide in temperatures ranging from 25 °C up to 600 °C. In addition, using finite element analysis along with an iterative regression technique, a semi-numerical method is developed to further measure and quantify the material parameters and, in particular, time-independent and creep characteristics of the oxide. Although Young's modulus of the oxide is found to be relatively close to the bulk for the tested temperatures, the yield strength and hardness, in comparison to the bulk material, increase significantly as the material is oxidized after aging. The oxide exhibits significant softening as the temperature increases to 600 °C. Unlike the bulk material, diffusion through the grains is found to be the dominant creep mechanism for the oxide. Considerable difference between the mechanical properties of the oxide and the bulk material shows the need for accurate measurements of near surface mechanical properties, if reliable predictive contact and tribological models are sought at elevated temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Molecular Dynamics Simulations of Water Structure and Diffusion in a 1 nm Diameter Silica Nanopore as a Function of Surface Charge and Alkali Metal Counterion Identity

Water confined in nanopores-particularly in pores narrower than 2 nm-displays distinct physicochemical properties that remain incompletely examined despite their importance in nanofluidics, molecular biology, geology, and materials sciences. In this study, we use molecular dynamics simulations to investigate the coordination structure and mobility of water and alkali metals (Li, Na, K, Cs) inside a 1 nm diameter cylindrical silica nanopore as a function of surface charge density, a model system particularly relevant to the alteration kinetics of silicate glasses and minerals in geologic formations. We find that the presence of a negative surface charge and adsorbed counterions within the pore strongly impacts water structure and dynamics. In particular, it significantly orients water O-H bonds toward the surface and slows water diffusion by almost 1 order of magnitude. Ion crowding in the charged nanopore enhances the tendency of counterions to coordinate closely with the silica surface, which moderates the impact of ions on water dynamics. Co-ions are strongly excluded from the nanopore at all surface charges, suggesting that the 1 nm diameter cylindrical silica nanopores likely exhibit nearly ideal semipermeable membrane transport properties.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Heat pulse propagation and anomalous electron heat transport measurements on the optimized stellarator W7-X

The optimized stellarator Wendelstein 7-X (W7-X) is designed to have an approximately quasi-isodynamic magnetic configuration with reduced neoclassical transport in comparison to a classical stellarator, and turbulent transport is expected to be a significant source of anomalous heat transport across the plasma minor radius. The ion temperature gradient driven mode and the trapped electron mode (TEM) are thought to be responsible for the ion-scale turbulence in W7-X plasmas with volume averaged pressure below 1%. In this work, the electron temperature gradient driven turbulence is shown to be a good candidate for the explanation of the observed electron heat flux, in the inner plasma region where the density gradient is weak (in the outer region, a relatively stronger density gradient would drive additional TEM turbulence). Further, the experimental electron heat transport measured during electron cyclotron resonant heating power and plasma density scans is compared to neoclassical predictions, and the stiffness in the electron heat transport measured during transient transport experiments is presented in three common magnetic configurations of W7-X. In low-(β) plasma discharges, the stiffness in the electron heat flux, quantified by the ratio of the heat pulse to power balance diffusivity, ${\chi }_{\mathrm{e}}^{\mathrm{H}\mathrm{P}}/{\chi }_{\mathrm{e}}^{\mathrm{P}\mathrm{B}}$, is measured to be less than 2, and trend downwards with increasing collisionality.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2018

On the Steel–Aluminum Hybrid Casting by Sand Casting

Hybrid casting is a well-known technology to join steel inserts and aluminum. In order to achieve a high-performance material-based joining between steel and aluminum, a new PVD Al-Si-(Fe) coating, which consists of two sub-layers, has been successfully developed for high-pressure die casting. This coating system has been investigated further in this work for the sand casting process. By extending the sand casting process to the plaster casting process with preheating possibilities for the coated steel inserts, a material-based connection between steel and aluminum with a tensile shear strength of 7.7 MPa could be created. The ductility of this connection is decreased comparing with the connection manufactured by die casting. SEM and EDS analysis and diffusion experiments show that the difference of mechanical properties between plaster and die casting is caused by the extensive diffusion and the corresponding layer growth at plaster casting. The edge separation in plaster casting is a result of the edge stresses due to the different thermal expansion of steel and aluminum which can be suppressed at high-pressure die casting. To improve the joining properties at sand casting, it is necessary to control the layer diffusion by adding other alloy elements such as Mn into the Al-Si-(Fe) coating layer.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Theoretical model of dielectrophoretic water vapor condensation during multiphase flow of electrically charged water droplets in air

Water droplet growth in air, influenced by vapor diffusion and electrical charging, has significant implications for indoor air quality, cloud formation, and aerosol dynamics. Here, this study presents a comprehensive theoretical model that describes the growth dynamics of electrically charged water droplets under external electric fields, incorporating diffusion, electrostatic, and dielectrophoretic forces to enhance understanding and practical applications in air dehumidification and environmental control. A theoretical model was established to analyze the growth dynamics of the charged water droplets. The approach extended the thermodynamic framework of the Modified Kelvin-Thomson equation by integrating electrostatic and dielectrophoretic effects, enabling a comprehensive evaluation of vapor concentration near the surface of charged droplets. A sensitivity analysis was performed to assess the roles of droplet size, electric field intensity, surface charge, and vapor concentration on condensation rates. The study progressed beyond the classical diffusion-limited growth of neutral droplets, addressing the behavior of charged droplets in electrohydrodynamic environments. The model highlighted the significance of dielectrophoretic drift flux for dipolar vapor molecules, especially in micron-sized droplets ranging from 10 to 100 µm. Findings demonstrated that, for smaller droplets subjected to elevated electrical charge, average growth rates varied from 0.3 to 1.6 µm/s if the air relative humidity increased from 50 to 100 %. Analytical results are corroborated by numerical simulations, which exhibited strong concordance, thereby validating the proposed theoretical approach. This research introduced an innovative and scalable analytical methodology for electric field-enhanced droplet growth, offering valuable insights into the advancement of energy-efficient air dehumidification, water desalination, and atmospheric water harvesting technologies.

42 ENGINEERING↗
DOE OSTI2020

Deciphering atomistic mechanisms of the gas-solid interfacial reaction during alloy oxidation

Gas-solid interfacial reaction is critical to many technological applications from heterogeneous catalysis to stress corrosion cracking. A prominent question that remains unclear is how gas and solid interact beyond chemisorption to form a stable interphase for bridging subsequent gas-solid reactions. Here, we report real-time atomic-scale observations of Ni-Al alloy oxidation reaction from initial surface adsorption to interfacial reaction into the bulk. We found distinct atomistic mechanisms for oxide growth in O 2 and H 2 O vapor, featuring a “step-edge” mechanism with severe interfacial strain in O 2 , and a “subsurface” one in H 2 O. Ab initio density functional theory simulations rationalize the H 2 O dissociation to favor the formation of a disordered oxide, which promotes ion diffusion to the oxide-metal interface and leads to an eased interfacial strain, therefore enhancing inward oxidation. Our findings depict a complete pathway for the Ni-Al surface oxidation reaction and delineate the delicate coupling of chemomechanical effect on gas-solid interactions.

36 MATERIALS SCIENCE↗
DOE OSTI2020

UO 2 + 5 vol% ZrB 2 nano composite nuclear fuels with full boron retention and enhanced oxidation resistance

The boron isotope ( 10 B) can be used as a neutron absorber in UO 2 to control the reactivity of nuclear fuel pellets, however, the boron source can react with oxygen source in UO 2 to form B 2 O 3 that vaporize readily at temperatures above 1200 °C. Unfortunately, the sintering of UO 2 fuel requires hours holding at high temperature (>1700 °C), resulting in an inevitable B loss during sintering and unpredictable B concentration in final product. It is challenging to incorporate boron through a conventional sintering method. In this work, we demonstrated that spark plasma sintering (SPS), a field assisted sintering technology, can effectively densify UO 2 + 5 vol% ZrB 2 composite fuel pellets by rapid consolidation at 1600 °C for a short duration of 5 min under an applied pressure of 40 MPa. Further, thermogravimetric analysis (TGA) measurements confirm that ZrB 2 is fully retained inside the composite fuel pellets. Inside the composite fuel pellets, nano sized ZrB 2 particles are uniformly distributed along the grain boundaries of the UO 2 matrix. The ZrB 2 particle transforms to a glassy B 2 O 3 phase covering the sample surface and grain boundaries of UO 2 matrix after a simple post-sintering annealing at 1000 °C in flowing Argon gas for 4 h. The formed glassy B 2 O 3 slows down the diffusion of oxygen ions and postpones the onset temperature for oxidation of UO 2 from 400 °C to 550 °C. This study demonstrates the capability of SPS, an advanced fuel manufacturing technique, to achieve a full retention of ZrB 2 in UO 2 oxide fuel and increase oxidation resistance through a simple post-sintering annealing. The reported work holds great engineering potential for development of advanced oxide fuel for nuclear application.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Challenges and future perspectives on sodium and potassium ion batteries for grid-scale energy storage

The energy crisis and environmental pollution require the advancement of large-scale energy storage techniques. Among the various commercialized technologies, batteries have attracted enormous attention due to their relatively high energy density and long cycle life. Nevertheless, the limited supply and uneven distribution of lithium minerals, as well as their high cost, has greatly hindered the application of lithium-ion batteries in large-scale energy storage. Therefore, building next-generation alternative rechargeable batteries that feature low cost, long service life, and high safety is of the utmost importance. Over the past several years, we have witnessed many successful research outcomes for sodium and potassium ion batteries (SIBs and PIBs) in regard to electrode and electrolyte materials. In this Perspective, we summarize the current developments on SIBs/PIBs and their challenges when facing practical applications, including their cost, energy density, ion diffusivity in solids/electrolytes/interphases, cycle life, and safety concerns. Furthermore, we provide an overview of strategies to overcome the remaining challenges for achieving better electrochemical performance. Finally, we outline several possible directions for the future development of these two battery chemistries, with the hope of aiding the transition from the laboratory to next-generation practical applications for SIBs/PIBs batteries in grid-scale energy storage.

Energy Storage↗
DOE OSTI2025

Chemical Redox Agent-Driven Noncorrosive Formation of Nanoporous Mg Structures for Advanced Hydrogen Storage

Light metal-based nanomaterials are widely used for energy storage due to their high energy density and surface-to-volume ratio. However, their high reactivity is paradoxically both the source of advantageous properties and a hurdle to the fabrication of stable nanostructures. Here, in this study, we demonstrate the formation of nanoporous Mg via chemical redox agent-driven dealloying, which ensures minimized surface passivation and results in fine nanostructures with <50 nm of interconnected metallic ligament despite the labile chemical properties of Mg. The thin passivation layer protects the metallic ligaments from severe coarsening by suppressing surface diffusion. The hydrogen storage performance of nanoporous Mg is investigated as an exemplar for energy applications, and the hydrogen ab/desorption kinetics is substantially enhanced compared to other nano-Mg with similar dimensions. Mesoscale simulations highlight the significance of the bicontinuous structure compared to the particle-like counterpart. This work offers valuable insights into the unexplored realm of reactive metal-based nanoporous structures, highlighting their potential for sustainable energy storage and carrier media.

08 HYDROGEN↗
DOE OSTI2022

Causes of fuel–ablator mix inferred from modeling of monochromatic time-gated radiography of OMEGA cryogenic implosions

Here, we present evidence, in the context of OMEGA cryogenic target implosions, that laser imprint, known to be capable of degrading laser-direct-drive target performance, plays a major role in generating fuel–ablator mix. OMEGA cryogenic target implosions show a performance boundary correlated with acceleration-phase shell stability; for sufficiently low adiabats (where the adiabat is the ratio of the pressure to the Fermi pressure) and high in-flight aspect ratios (IFAR's), the neutron-weighted shell areal density and neutron yield relative to the clean simulated values sharply decline. Direct evidence of Rayleigh–Taylor fuel–ablator mixing was previously obtained using a Si Heα backlighter driven by an ~20-ps short pulse generated by OMEGA EP. The shadow cast by the shell shortly prior to stagnation, as diagnosed using backlit radiographs, shows a softening near the limb, which is evidence of an ablator–fuel mix region for a low-adiabat implosion (α ~ 1.9, IFAR = 14) but not for a moderate adiabat implosion (α ~ 2.5, IFAR = 10). We find good agreement between experimental and synthetic radiographs in simulations that model laser imprint and account for uncertainty in the initial ablator thickness. Furthermore, we further explore the role of other mechanisms such as classical instability growth at the fuel–ablator interface, species concentration diffusion, and long-wavelength drive and target asymmetries.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

Axisymmetric benchmarks of impurity dynamics in extended-magnetohydrodynamic simulations

A verification benchmark has been carried out between the M3D-C1 and NIMROD extended-magnetohydrodynamics (xMHD) codes for simulations of impurity-induced disruption mitigation. Disruptions are a significant concern for future tokamaks, and high-fidelity simulations are required in order to ensure the success of disruption-mitigation techniques (e.g., shattered-pellet injection) in large-scale fusion reactors. Both MHD codes have been coupled to the KPRAD code for impurity dynamics. The codes show excellent agreement in four axisymmetric, nonlinear simulations, particularly during the thermal quench. This agreement is seen in the time histories of global plasma quantities such as thermal energy, radiated power, and total number of electrons, as well as 2D contours of temperature and current density. The simulations predict that, given the same number of atoms injected, argon quenches the plasma two-to-three times as fast as neon. Furthermore, the inclusion of temperature-dependent Spitzer resistivity causes the current to diffuse and to decay, inducing axisymmetric MHD instabilities that result in a current quench. As a result, this work represents an important verification of the coupled impurity and MHD models implemented in M3D-C1 and NIMROD, giving greater confidence in the ability of both codes to perform more sophisticated disruption-mitigation simulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Assessment of the Performance of Hydrofluoroolefins, Hydrochlorofluoroolefins, and Halogen-Free Foam Blowing Agents in Cellular Plastic Foams

Oak Ridge National Laboratory has conducted a literature search to identify relevant information available on alternative materials and technologies that are proposed for foam blowing agents applications. For comparison, similar information was collected for available hydrofluorocarbons (HFC), hydrofluoroolefin (HFO), and hydrochlorofluoroolefins (HCFO) materials. The publicly available literature was analyzed and assessed for technical accuracy for each alternative, and a gap analysis was conducted to understand if additional studies are required to fully assess the viability of an alternative. In assessing these alternatives, this project focused on relevant performance and safety attributes. The performance attributes collected include insulation value per unit thickness, which impacts energy usage of buildings and insulated equipment such as refrigerators. We also assessed the impact of blowing agents on foam mechanical properties and flammability characteristics, and the ability of current processing equipment and techniques to utilize these alternatives. Diffusion of blowing agents through foam cells and its impact on foam aging was also examined. The applications covered in this study are spray foam, boardstock, panels, and appliances. Some of the most relevant findings are summarized below.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Inference of Experimental Radial Impurity Transport on Alcator C-Mod: Bayesian Parameter Estimation and Model Selection.

We present a fully Bayesian approach for the inference of radial profiles of impurity transport coefficients and compare its results to neoclassical, gyrofluid and gyrokinetic modeling. Using nested sampling, the Bayesian Impurity Transport InferencE (BITE) framework can handle complex parameter spaces with multiple possible solutions, offering great advantages in interpretative power and reliability with respect to previously demonstrated methods. BITE employs a forward model based on the pySTRAHL package, built on the success of the well-known STRAHL code [Dux, IPP Report, 2004], to simulate impurity transport in magnetically-confined plasmas. In this paper, we focus on calcium (Ca, Z=20) Laser Blow-Off injections into Alcator C-Mod plasmas. Multiple Ca atomic lines are diagnosed via high-resolution X-ray Imaging Crystal Spectroscopy and Vacuum Ultra-Violet measurements. We analyze a sawtoothing I-mode discharge for which neoclassical and turbulent (quasilinear and nonlinear) predictions are also obtained. We find good agreement in diffusion across the entire radial extent, while turbulent convection and density profile peaking are estimated to be larger in experiment than suggested by theory. Efforts and challenges associated with the inference of experimental pedestal impurity transport are discussed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2002

Membrane Separation Processes at Low Temperatures

The primary focus of Kennedy Space Center's gas separation activities has been for carbon dioxide, nitrogen, and argon used in oxygen production technologies for Martian in-situ resource utilization (ISRU) projects. Recently, these studies were expanded to include oxygen for regenerative life support systems. Since commercial membrane systems have been developed for separation of carbon dioxide, nitrogen, and oxygen, initially the studies focused on these membrane systems, but at lower operating temperatures and pressures. Current investigations art examining immobilized liquids and solid sorbents that have the potential for higher selectivity and lower operating temperatures. The gas separation studies reported here use hollow fiber membranes to separate carbon dioxide, nitrogen, and argon in the temperature range from 230 to 300 K. Four commercial membrane materials were used to obtain data at low feed and permeate pressures. These data were used with a commercial solution-diffusion modeling tool to design a system to prepare a buffer gas from the byproduct of a process to capture Martian carbon dioxide. The system was designed to operate, at 230 K with a production rate 0.1 sLpm; Feed composition 30% CO2, 44% N2, and 26% Ar; Feed pressure 104 kPa (780); and Permeate pressure 1 kPa (6 torr); Product concentration 600 ppm CO2. This new system was compared with a similar system designed to operate at ambient temperatures (298 K). The systems described above, along with data, test apparatus, and models are presented.

Parrish, Clyde↗
DOE OSTI2022

Overcoming Anode Instability in Solid‐State Batteries through Control of the Lithium Metal Microstructure

Abstract Enabling the lithium metal anode (LMA) in solid‐state batteries (SSBs) is the key to developing high energy density battery technologies. However, maintaining a stable electrode–electrolyte interface presents a critical challenge to high cycling rate and prolonged cycle life. One such issue is the interfacial pore formation in LMA during stripping. To overcome this, either higher stack pressure or binary lithium alloy anodes are used. Herein, it is shown that fine‐grained ( d = 20 µm) polycrystalline LMA can avoid pore formation by exploiting the microstructural dependence of the creep rates. In a symmetric cell set‐up, i.e., LiǀLi 6.25 Al 0.25 La 3 Zr 2 O 12 (LLZO)ǀLi, fine‐grained LMA achieves > 11.0 mAh cm −2 compared to ≈ 3.6 mAh cm −2 for coarse‐grained LMA ( d = 295 µm) at 0.1 mA cm −2 and at moderate stress of 2.0 MPa. Smaller diffusion lengths (≈ 20 µm) and higher diffusivity pathway along dislocations ( D d ≈ 10 −7 cm 2 s −1 ), generated during cell fabrication, result in enhanced viscoplastic deformation in fine‐grained polycrystalline LMA. The electrochemical performances corroborate well with estimated creep rates. Thus, microstructural control of LMA can significantly reduce the required stack pressure during stripping. These results are particularly relevant for “anode‐free” SSBs wherein both the microstructure and the mechanical state of the lithium are critical parameters.

25 ENERGY STORAGE↗
DOE OSTI2025

Polyethylene Upcycling to Diacids Using Acid-Only Activation

There is a pressing need to develop plastic recycling technologies. Chemical upcycling converts low-value waste plastics into higher-value products. Here, polyethylene (PE) upcycling is accomplished by using acid-only activation of PE (PEAA), thus eliminating costly and toxic organic solvents. Acid mixtures of chlorosulfuric acid (CSA) and sulfuric acid (SA) were used to effectively sulfonate PE, allowing for subsequent facile depolymerization. Molecular deconstruction of sulfonated PE using H 2 O 2 in the presence of an Fe(III) catalyst achieved molar yields of C 2 –C 4 diacids exceeding 40% (based on estimates of acids generated from sulfonates). The sulfonation step using PEAA is hypothesized to follow a shrinking core mechanism (SCM), in which PE particles quickly reach a saturated state in the outer sulfonated layer as CSA diffuses radially inward. This proposed mechanism is supported by the fact that, regardless of the extent of sulfonation, similar molar yields of products and ratios of liberated carbon to sulfur are observed. Modeling and experimentation show that deviations from the SCM occur by lowering the Damköhler number (Da) or increasing CSA solubility in PE. In both cases, CSA diffusion is enhanced, which favors kinetically limited sulfonation.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Resolving electron and hole transport properties in semiconductor materials by constant light-induced magneto transport

The knowledge of minority and majority charge carrier properties enables controlling the performance of solar cells, transistors, detectors, sensors, and LEDs. Here, we developed the constant light induced magneto transport method which resolves electron and hole mobility, lifetime, diffusion coefficient and length, and quasi-Fermi level splitting. We demonstrate the implication of the constant light induced magneto transport for silicon and metal halide perovskite films. We resolve the transport properties of electrons and holes predicting the material’s effectiveness for solar cell application without making the full device. The accessibility of fourteen material parameters paves the way for in-depth exploration of causal mechanisms limiting the efficiency and functionality of material structures. To demonstrate broad applicability, we further characterized twelve materials with drift mobilities spanning from 10 –3 to 10 3 cm 2 V –1 s –1 and lifetimes varying between 10 –9 and 10 –3 seconds. The universality of our method its potential to advance optoelectronic devices in various technological fields.

14 SOLAR ENERGY↗