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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

An efficient numerical model for predicting residual stress and strain in parts manufactured by laser powder bed fusion

Abstract Computational modeling of additively manufactured structures plays an increasingly important role in product design and optimization. For laser powder bed fusion processes, the accurate modeling of stress and distortion requires large amount of computational cost due to very localized heat input and evolving complex geometries. The current study takes advantage of a graphics processing unit accelerated explicit finite element analysis code and approximated heat conduction analysis to predict the macroscopic thermo-mechanical behavior in laser selective melting. Adjacent layers and tracks were lumped to reduce the number of time steps and elements in the finite element model. The effects of track and layer grouping on prediction accuracy and solution efficiency are investigated to provide a guidance for a cost-effective simulation. Thin-wall builds from Inconel alloy 625 (IN625) powders were simulated by applying the developed modeling approach to get the detailed residual stress and distortion at a computational speed 50 times higher than conventional approach. Under repeated heating and cooling cycles, a high tensile stress was produced near surfaces of a build due to a larger shrinkage on surface than that in central area. It is also shown that horizontal stresses concentrate near the root and top layers of the IN625 build. The predicted residual elastic strain distribution was validated by the experimental measurement using x-ray synchrotron diffraction.

36 MATERIALS SCIENCE↗
NASA NTRS2021

Evaluation and Applications of Multi-Instrument Boundary-Layer Thermodynamic Retrievals

Recent reports have highlighted the need for improved observations of the boundary layer. In this study, we explore the combination of ground-based active and passive remote sensors deployed for thermodynamic profiling to analyze various boundary-layer observation strategies. Optimal-estimation retrievals of thermodynamic profiles from Atmospheric Emitted Radiance Interferometer (AERI) observed spectral radiance are compared with and without the addition of active sensor observations from a May–June 2017 observation period at the Atmospheric Radiation Measurement–Southern Great Plains Site. In all, three separate thermodynamic retrievals are considered here: retrievals including AERI data only, retrievals including AERI data and Vaisala water vapour differential absorption lidar data, and retrievals including AERI data and Raman lidar data. First, the three retrievals are compared to each other and to reference radiosonde data over the full observation period to get a bulk understanding of their differences and characterize the impact of clouds on these retrieved profiles. These analyses show that the most significant differences are in the water vapour field, where the active sensors are better able to represent the moisture gradient in the entrainment zone near boundary layer top. We also explore how differences in retrievals may impact results of applied analyses including land–atmosphere coupling, convection indices, and severe storm environmental characterization. Overall, adding active sensors to the optimal-estimation retrieval showed some added information, particularly in the moisture field. Given the costs of such platforms, the value of that added information must be weighed for the application at hand.

boundary-layer observation↗
DOE OSTI2021

Evaluation and Applications of Multi-Instrument Boundary-Layer Thermodynamic Retrievals

Recent reports have highlighted the need for improved observations of the atmosphere boundary layer. In this study, we explore the combination of ground-based active and passive remote sensors deployed for thermodynamic profiling to analyze various boundary-layer observation strategies. Optimal-estimation retrievals of thermodynamic profiles from Atmospheric Emitted Radiance Interferometer (AERI) observed spectral radiance are compared with and without the addition of active sensor observations from a May–June 2017 observation period at the Atmospheric Radiation Measurement Southern Great Plains site. In all, three separate thermodynamic retrievals are considered here: retrievals including AERI data only, retrievals including AERI data and Vaisala water vapour differential-absorption lidar data, and retrievals including AERI data and Raman lidar data. First, the three retrievals are compared to each other and to reference radiosonde data over the full observation period to obtain a bulk understanding of their differences and characterize the impact of clouds on these retrieved profiles. These analyses show that the most significant differences are in the water vapour field, where the active sensors are better able to represent the moisture gradient in the entrainment zone near the boundary-layer top. Furthermore, we also explore how differences in retrievals may affect results of applied analyses including land–atmosphere coupling, convection indices, and severe storm environmental characterization. Overall, adding active sensors to the optimal-estimation retrieval shows some added information, particularly in the moisture field. Given the costs of such platforms, the value of that added information must be weighed for the application at hand.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Climatology of Melting Layer Heights Estimated From Cloud Radar Observations at Various Locations

A melting layer (ML) detection algorithm for cloud radar with polarimetric capability was developed and applied to the cloud radar data collected from five different sites around the world for several years. The retrieved melting layer top height (MLH) showed a very good correspondence with the ECMWF Reanalysis 5 zero degree level data for all five sites. The ML characteristics were distinctively different for different sites, revealing climatological characteristics of ML forming clouds in different regions. Generally, ML tended to occur more frequently in summer than in winter except for a maritime site, where low stratiform clouds formed frequently in summer, the top of which might be lower than the freezing level. In contrast, at two Arctic sites, ML occurred almost exclusively in summer because it was too cold to have an ML in the other seasons. The MLH also varied significantly from site to site but generally was higher during warmer seasons. Based on MLH, two new indices, bulk temperature lapse rate (BLR) and relative depth (RD) of liquid cloud below MLH (RD) were developed, which were useful to explain the environmental characteristics of the five sites. BLR generally increased with the surface temperature at all sites except at the marine site that showed an opposite trend, where a unique synoptic pattern in winter generated high BLR in this cold season. Finally, these findings confirm that studies on thermodynamic structures using cloud radars can be broadened, taking advantage of BLR and RD information, as these indices can represent environmental thermodynamic characteristics of the clouds that have ML.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2003

Collaboration of the NASA Glenn Research Center and Rolls-Royce Developed Thin Film Multilayered Dielectrics for Harsh Environments

The use of thin films to electrically insulate thin film sensors on engine components minimizes the intrusiveness of the sensors and allows a more accurate measurement of the environment. A variety of insulating films were investigated for preventing electrical shorting caused by insulator failure between the sensor and the component. By alternating layers of sputtered high-temperature ceramics, a sequence of insulating layers was devised that (1) prevents pinholes from forming completely through the insulator and (2) maintains high electrical resistivity at high temperatures. The total thickness is only a fraction of that needed for conventional insulating techniques. The Sensors and Electronics Technology Branch of the NASA Glenn Research Center has an in-house effort to develop thin film sensors for surface measurement in propulsion system research. Thin film sensors do not require special machining of the components on which they are mounted, and they are considerably thinner (less than 10 mm thick) than wire or foil sensors. The thin film sensors are thus much less disturbing to the operating environment and have a minimal impact on the physical characteristics of the supporting component. To further this research, NASA Glenn and Rolls-Royce (Derby, UK), with assistance from the Ohio Aerospace Institute (OAI) and the Akima Corporation, pursued a joint investigation using multilayered thin film dielectrics as a reliable insulator in harsh environments. The use of a multilayered scheme is thought to be promising for the fabrication of electrically insulating thin films. A major cause of conduction in thin film dielectrics is the presence of defects, such as pinholes, that propagate through the film to the underlying substrate surface. By alternating the insulating material, each new growth pattern would deviate from the previous one, eliminating direct pathways for conduction to the substrate. The film depositions and testing were conducted in the Instrument Research Laboratory at Glenn. The multilayered insulator test samples were made from alumina and stainless steel shims that were first covered with a sputtered underlayer of either yttria-stabilized zirconia or chromium carbide, and then overcoated with a sputtered top layer of alumina. An example of a test sample is shown in the following photograph. Each multilayered insulator sample was 5 mm thick, at least an order of magnitude thinner than conventional insulators. The insulating properties of the samples were tested in a high-temperature air oven to determine their suitability. The multilayer insulators tested showed a stabilized film at temperatures in excess of 800 C (1472 F). The underlying materials in these multilayers allow thermal expansion stresses produced during the heating to be graded. The chromium carbide-alumina multilayer had the best adhesion at high temperatures, presumably from the induced chemical bonding between the substrate and the chromium carbide underlayer. However, the zirconia-alumina multilayer proved to have slightly better insulating properties when adhering. The application of the zirconia-alumina insulator has been demonstrated on a nickel-alloy fan blade, as shown. The insulators using thin film sensors still need to be tested in a relevant high-temperature combustion environment.

Wrbanek, John D.↗
DOE OSTI2023

Microstructural Insights into Performance Loss of High-Voltage Spinel Cathodes for Lithium-ion Batteries

Spinel-structured LiNi x Mn 2-x O 4 (LNMO), with low-cost earth-abundant constituents, is a promising high-voltage cathode material for lithium-ion batteries. Even though extensive electrochemical investigations have been conducted on these materials, few studies have explored correlations between their loss in performance and associated changes in microstructure. Here, down to the atomic scale, the structural evolution of these materials is investigated upon the progressive cycling of lithium-ion cells. Transgranular cracking is revealed to be a key feature during cycling; this cracking is initiated at the particle surface and leads to the penetration of electrolytes along the crack path, thereby increasing particle exposure to the electrolyte. The lattice structure on the crack surface shows spatial variances, featuring a top layer of rock-salt, a sublayer of a Mn 3 O 4 -like arrangement, and then a mixed-cation region adjacent to the bulk lattice. The transgranular cracking, along with the emergence of local lattice distortion, becomes more evident with extended cycling. Further, phase transformation at primary particle surfaces and void formation through vacancy condensation is found in the cycled samples. All these features collectively contribute to the performance degradation of the battery cells during electrochemical cycling.

25 ENERGY STORAGE↗
DOE OSTI2021

Avoiding surface instability and slurry jamming in simultaneous multilayer coating of structured particulate films

Simultaneous multilayer coating techniques are widely known, but their industrial application remains limited to narrow market sectors. One barrier to adoption may be the mismatch between industries that are familiar with such processes but have no need, and industries that have need but are not familiar. Moreover, there are application-specific technical challenges to developing multilayer-coating processes. In this article, we describe our resolution of two specific issues in simultaneous multilayer coating of all aqueous highly loaded slurries for new and emerging energy applications. The first issue is particle jamming (associated with Shear-thickening) of the highly loaded slurries in the die internals, which we alleviated by adding small amounts of viscosity modifiers without reducing the solid loading. The second issue is a Marangoni-driven surface instability that resembles top layer de-wetting, which we solved by carefully selecting surfactants to tune the dynamic surface tensions of each slurry. Both issues were resolved early in a step-wise development, saving significant development cost which in our case was driven by expensive materials.

08 HYDROGEN↗
DOE OSTI2023

Using Multiple Geophysical Methods to Refine a Stratigraphic Conceptual Site Model at a Nuclear Waste Site

At contaminated sites, there is a critical reliance on conceptual site models of which a key component is the geologic framework model (GFM), which is used to build predictive fate and transport modeling in support of remediation goals. Here, we detail an ongoing study at a nuclear waste site (Hanford Site, Washington, USA) where surface geophysical methods were used to complement existing borehole information and to help site new boreholes to update and refine the GFM. Ground-based electrical resistivity tomography (ERT), time-domain electromagnetics (TEM), and seismic data was acquired on the Hanford Site’s Central Plateau, where the presence of a hydraulically transmissive subsurface feature, or paleochannel, was suspected but uncertain based on contaminant concentrations at sparsely located boreholes. To assess and compare ERT, TEM, and seismic geophysical datasets, co-located data was acquired in an area where the existing GFM was more certain. Surrounding the suspected paleochannel, ERT and seismic refraction tomography showed similar subsurface structures consistent with a channelized feature. While TEM interpretation was limited in the suspected paleochannel area due to a thick resistive top layer and high electromagnetic noise, TEM showed greater utility in a different area where these factors were less prevalent. Based on the results of quasi-3D ERT inversions, we propose updates to the GFM, including identifying a paleochannel. Further, we evaluate the utility of geophysical methods and examine lessons learned that will be used as a basis for continued characterization efforts to support site management decisions and implementation efforts.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Infrared triggered dwell and active cooling thermal control effects on microstructural uniformity in DED

Directed Energy Deposition (DED) offers rapid large scale fabrication, but difficulty in delivering consistent microstructures and properties hinders the use of DED fabricated components in safety or performance critical applications. Variability stems from the complex thermal cycles generated by the toolpath used to print the required geometry. Several practical methods have become established in DED to regulate overheating, such as active cooling of the baseplate structure or the use of an infrared camera to inject interlayer pauses to ensure the top layer of the component cools to a set temperature, which have been shown to affect microstructure. However, no critical assessment has been performed as to how effective these controls are in promoting microstructural uniformity in the context of complex layer timing commonly generated by non-prismatic geometries. Here we show how controls influence the thermal field, phase transformations, and dynamic annealing of a low-temperature transformation steel using infrared imaging and operando neutron diffraction. Counterintuitively, common thermal homogenization process controls can reduce microstructural uniformity because these approaches stabilize peak temperature while overlooking temperatures near the solid-state phase transformation fronts. Instead, the cyclic reheating induces spatially-variant dynamically annealed regions which can be modulated via control parameters. We show that these controls have spatially linked effects centimeters away from the active weld, which implies that microstructure control must co-optimize thermal input across many subsequent layers. In conclusion, our results demonstrate the pressing need for higher order controls that integrate predictive elements of simulation data to stabilize printed properties for future qualification of DED components.

Directed energy deposition↗
DOE OSTI2020

Enhanced NO, CO and C 3 H 6 conversion on Pt/Pd catalysts: Impact of oxygen storage material and catalyst architecture

Simultaneous conversion of NO, CO and C 3 H 6 under stoichiometric conditions was carried out on washcoated monoliths containing oxygen storage material (OSM)-promoted mixed Platinum group metals (PGM: Pt(95 %)/Pd(5 %)), to evaluate OSM promotion and to identify the best architecture. The studied OSMs include ceria-zirconia (Ce 0.3 Zr 0.7 O 2 ; CZO) and mixed metal oxide spinel (Mn 0.5 Fe 2.5 O 4 ; MFO). PGM supported directly on the OSM was found to be the best design for CZO, leading to a ~70 °C simultaneous decrease in the light-off temperature (T 80 ; feed temperature giving 80 % conversion) for NO, CO and C 3 H 6 conversion compared to the alumina-supported PGM. Close coupling between the PGM and CZO is responsible for the activity promotion. In contrast, a dual-layer architecture (top PGM layer, bottom MFO layer) outperformed the MFO-supported PGM catalyst. The dual-layer PGM-MFO catalyst decreased the T 80 by ~50 °C for NO, CO and C 3 H 6 conversion compared to the PGM-only catalyst. Enhancement obtained with the dual-layer PGM-MFO architecture relies on a direct catalytic contribution from the spinel. During lean/rich modulation the addition of CZO or spinel helps to mitigate the detrimental impact of modulation on NO, CO and C 3 H 6 conversion above 400 °C. The data suggest that both CZO and MFO can buffer lean/rich modulation but exhibit preference to different reductants; CZO-supported PGM and dual-layer PGM-MFO show no conversion decrease during modulation for CO or C 3 H 6 modulation, respectively. Dynamic oxygen storage capacity (DOSC) measurements show that the spinel exhibits ~10 times higher DOSC than CZO for both CO and C 3 H 6 reductants. Both CO and C 3 H 6 are equally effective reductants for the MFO but CO is better for CZO and PGM-deposited CZO. The study provides useful insight into benefits of OSM and provides guidance for optimization of the multi-component PGM + OSM catalyst composition and architecture.

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

Automatic voltage regulation application for PV inverters in low-voltage distribution grids – A digital twin approach

This paper proposes a hierarchical coordinated control strategy for PV inverters to keep voltages in low-voltage (LV) distribution grids within specified limits. The top layer of the proposed architecture consists of the designed automatic voltage regulation (AVR) application, which has access to voltage measurements and grid parameters from the LV distribution grid, both current and historical. The AVR application solves a constrained optimization problem, which provides a set of local control set-points that bring the voltage across the grid within bounds. The middle layer consists of a local Volt/VAR controller, which is adjusted by the AVR app, while the bottom layer is the inner-loop controller of the PV inverter. The proposed method not only improves the voltage quality in the grid but also manages the reactive power outputs of PV inverters efficiently. Further, a digital twin of the cyber-physical system has also been employed that interacts with the control system to ensure its appropriate operation. The effectiveness of the proposed methodology is demonstrated on a representative low-voltage feeder located in Denmark.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Tetrapodal textured Janus textiles for accessible menstrual health

Menstruating individuals without access to adequate hygiene products often improvise with alternatives that pose health risks and limit their participation in society. We describe here a menstrual hygiene product based on low-cost materials, which are integrated onto fabrics to imbue unidirectional permeability. A body-facing "Janus" fabric top layer comprising ZnO tetrapods spray-coated onto polyester mosquito netting imparts hierarchical texturation, augmenting the micron-scale texturation derived from the weave of the underlying fabric. The asymmetric coating establishes a gradient in wettability, which underpins flash spreading and unidirectional permeability. The hygiene product accommodates a variety of absorptive media, which are sandwiched between the Janus layer and a second outward-facing coated densely woven fabric. An assembled prototype demonstrates outstanding ability to wick saline solutions and a menstrual fluid simulant while outperforming a variety of commercially alternatives. The results demonstrate a versatile menstrual health product that provides a combination of dryness, discretion, washability, and safety.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2021

Impact of organic acids and sulfate on the biogeochemical properties of soil from urban subsurface environments

Urban subsurface environments are often different from undisturbed subsurface environments due to the impacts of human activities. For example, deterioration of underground infrastructure can introduce elevated levels of Ca, Fe, and heavy metals into subsurface soils and groundwater. Likewise, leakage from sewer systems can lead to contamination by organic C, N, S, and P. However, the impact of these organic and inorganic compounds on biogeochemical processes including microbial redox reactions, mineral transformations, and microbial community transitions in urban subsurface environments is poorly understood. Here we conducted a microcosm experiment with soil samples from an urban construction site to investigate the possible biotic and abiotic processes impacted when sulfate and acetate or lactate were introduced into an urban subsurface environment. In the top-layer soil (0-0.3 m) microcosms, which were highly alkaline (pH > 10), the major impact was on abiotic processes such as secondary mineral precipitation. In the mid-layer (2-3 m) soil microcosms, the rate of Fe(III)-reduction and the amount of Fe(II) produced were greatly impacted by the specific organic acid added, and sulfate-reduction was not observed until after Fe(III)-reduction was complete. Near the end of the incubation, some genera related to syntrophic acetate oxidation and methanogenesis were observed in the lactateamended microcosms. In the bottom-layer (7-8 m) soil microcosms, the rate of Fe(III)-reduction and the amount of Fe(II) produced were affected by the concentration of amended sulfate. Sulfate-reduction was concurrent with Fe(III)-reduction, suggesting that Fe(II) production was likely due to abiotic reduction of Fe(III) by sulfide produced by microbial sulfate reduction. The slightly acidic initial pH (~5.8) of the mid-soil system was a major factor controlling sequential microbial Fe(III) and sulfate reduction versus parallel Fe(III) and sulfate reduction in the bottom soil system, which had a neutral initial pH (~7.2). Finally, 16S rRNA gene-based community analysis revealed a variety of indigenous microbial groups including alkaliphiles, dissimilatory iron and sulfate reducers, syntrophes, and methanogens tightly coupled with, and impacted by, these complex abiotic and biogeochemical processes occurring in urban subsurface environments.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Toward Hot Carrier Extraction in Intervalley Photovoltaic Devices

InGaAs heterostructures have demonstrated the means to maintain hot carrier behavior under practical operating conditions via valley photovoltaics. However, enhancing the extraction to create a fully operational hot carrier solar cell requires an enhanced understanding of the barriers inside such devices. A set of four InGaAs heterostructures altering the n + top layer of the structure has been produced to enable comparative analysis of the current density-voltage characterization and the relationship to the band and valley alignments.

14 SOLAR ENERGY↗
DOE OSTI2026

Charged Defects in UO 2 Bulk and Surface: A First-Principles Study

Uranium dioxide (UO 2 ) is the primary fuel used in nuclear reactors. Under the extreme heat and radiation inside a reactor, this material inevitably develops defects in its crystal structure. To investigate the nature and behavior of these defects, DFT+U calculations were employed to investigate charged point defects in both bulk UO 2 and its most stable surface, the (111) plane. The formation of defects and their impact on the electronic structure were systematically examined. The results reveal that these defects introduce localized electronic states, alter magnetic behavior, and modify the structural properties. In general, such defects act as deep traps capable of capturing and retaining charge carriers. The stability of these defects depends strongly on the chemical environment and the position of the Fermi level. Surface defect calculations reveal that oxygen vacancies form more readily at the surface than in the bulk over a wide range of electron chemical potential, with subsurface oxygen vacancies being more stable than those in the top layer. Overall, the findings demonstrate how charged defects influence magnetism, transport, and stability in UO 2 , providing insights that may guide improvements in the safety and efficiency of nuclear fuel.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Mild and Selective Hydrogenation of Nitrate to Ammonia in the Absence of Noble Metals

Motivated by increased awareness about nitrate contamination of surface waters and its deleterious effects in human and animal health, we sought an alternative, non-noble metal catalyst for the chemical degradation of nitrate. First row transition metal phosphides recently emerged as excellent alternatives for hydrogen evolution and hydrotreating reactions. We demonstrate that a key member of this family, Ni 2 P, readily hydrogenates nitrate (NO 3 – ) to ammonia (NH 3 ) near ambient conditions with very high selectivity (96%). One of the few non-precious metal-based catalysts for this transformation, and among ca. 1% of catalysts with NH 3 selectivity, Ni 2 P can be recycled multiple times with limited loss of activity. Both nitrite (NO 2 – ) and nitric oxide (NO) intermediates are also hydrogenated. Density functional theory (DFT) indicates that—in the absence of a catalyst—nitrite hydrogenation is the reaction bottleneck. A variety of adsorbates (H, O, N, NO) induce surface reconstruction with top-layer Ni-rich surface stoichiometry. Critically, H saturation coverage on Ni 2 P(001) is only ca. 3 nm –2 , significantly less than that on Pd(111) and Ni(111) of ca. 15–18 nm –2 , which may play a key role in allowing coadsorption of NO x – . Here the ability of Earth-abundant, binary metal phosphides such as Ni 2 P to catalyze nitrate hydrogenation could transform and help us to better understand the basic science behind catalytic hydrogenation and, in turn, advance the next generation of oxyanion removal technologies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Uncovering the Effects of Metal Contacts on Monolayer MoS 2

Metal contacts are a key limiter to the electronic performance of two-dimensional (2D) semiconductor devices. In this work, we present a comprehensive study of contact interfaces between seven metals (Y, Sc, Ag, Al, Ti, Au, Ni, with work functions from 3.1 to 5.2 eV) and monolayer MoS 2 grown by chemical vapor deposition. We evaporate thin metal films onto MoS 2 and study the interfaces by Raman spectroscopy, X-ray photoelectron spectroscopy, X-ray diffraction, transmission electron microscopy, and electrical characterization. We uncover that (1) ultrathin oxidized Al dopes MoS 2 n-type (>2 × 1012 cm –2 ) without degrading its mobility, (2) Ag, Au, and Ni deposition causes varying levels of damage to MoS 2 (e.g. broadening Raman E' peak from <3 to >6 cm –1 ), and (3) Ti, Sc, and Y react with MoS 2 . Reactive metals must be avoided in contacts to monolayer MoS 2 , but control studies reveal the reaction is mostly limited to the top layer of multilayer films. Finally, we find that (4) thin metals do not significantly strain MoS 2 , as confirmed by X-ray diffraction. These are important findings for metal contacts to MoS 2 and broadly applicable to many other 2D semiconductors.

2D materials↗