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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
NASA NTRS2004

Interaction of Porosity with a Planar Solid/Liquid Interface

In this article, an investigation of the interaction between gas porosity and a planar solid/liquid (SL) interface is reported. A two-dimensional numerical model able to accurately track sharp SL interfaces during solidification of pure metals and alloys is proposed. The finite-difference method and a rectangular undeformed grid are used for computation. The SL interface is described through the points of intersection with the grid lines. Its motion is determined by the thermal and solute gradients at each particular point. Changes of the interface temperature because of capillarity or solute redistribution as well as any perturbation of the thermal and solute field produced by the presence of non-metallic inclusions can be computed. To validate the model, the dynamics of the interaction between a gas pore and a solidification front in metal alloys was observed using a state of the art X-ray transmission microscope (XTM). The experiments included observation of the distortion of the SL interface near a pore, real-time measurements of the growth rate, and the change in shape of the porosity during interaction with the SL interface in pure Al and Al-0.25 wt pct Au alloy. In addition, porosity-induced solute segregation patterns surrounding a pore were also quantified.

Catalina, Adrian V.↗
NASA NTRS2003

Fatigue Crack and Porosity Measurement in Composite Materials by Thermographic and Ultrasonic Methods

Contents include the following: 1. Purpose. Detect thermo-mechanically induced intra-ply fatigue microcracking and manufactured porosity in unlined composite pressure vessels. 2. Defect descriptions. Porosity, microcracking. 3. Thermography. Overview of technique. Strengths and Weaknesses. Examples of its use for porosity detection. 4. Resonant ultrasound spectroscopy. Overview of technique. Strengths and Weaknesses. Examples of its use for microcracking detection. Conclusions.

Walker, James L.↗
NASA NTRS2011

Correlation of Water Frost Porosity in Laminar Flow over Flat Surfaces

A dimensionless correlation has been proposed for water frost porosity expressing its dependence on frost surface temperature and Reynolds number for laminar forced flow over a flat surface. The correlation is presented in terms of a dimensionless frost surface temperature scaled with the cold plate temperature, and the freezing temperature. The flow Reynolds number is scaled with reference to the critical Reynolds number for laminar-turbulent transition. The proposed correlation agrees satisfactorily with the simultaneous measurements of frost density and frost surface temperature covering a range of plate temperature, ambient air velocity, humidity, and temperature. It is revealed that the frost porosity depends primarily on the frost surface and the plate temperatures and the flow Reynolds number, and is only weakly dependent on the relative humidity. The results also point out the general character of frost porosity displaying a decrease with an increase in flow Reynolds number.

Kandula, Max↗
NASA NTRS2018

Numerical and Experimental Study of Local Resin Pressure for the Manufacturing of Composite Structures and Their Effect on Porosity

Porosity can have significant impact on the mechanical performance of composite structures. The primary sources of voids during the cure of composites include air entrapped during lay-up, bag or tool leaks, and the off gassing of volatiles. Capturing the physics of void evolution during composite processing is a challenge due to the number of sources and changing phenomena that give rise to voids as the resin cures. Local changes in resin pressure due to geometric features or cure shrinkage have been experimentally linked to a higher likelihood of void formation. In this work, a preliminary model was developed to predict local resin pressure which can be used to identify regions more susceptible to porosity. Experiments were conducted to validate the model accuracy. Ultimately, this model can be used as a tool to minimize the likelihood of porosity by optimizing the material selection, part design, layup, and cure process.

Bedayat, Houman↗
NASA NTRS2020

Effect of Material Porosity on Residual Stress in an Additive Manufacturing Simulation using the Generalized Method of Cells

The effect of material porosity on final part distortion and residual stresses in a selective laser sintering manufacturing simulation is presented here. A time-dependent thermo-mechanical model is used with the open-source FEA software CalculiX. Effective homogenized material properties for Inconel 625 are precomputed using NASA’s Micromechanics Analysis Code with the Generalized Method of Cells. The evolving porosity of the material is estimated with each pass of the laser beam during simulation runtime. A comparison with a homogenous model and the evolving model shows that the model with evolving porosity predicts larger distortions with greater residual stresses.

Additive Manufactuirng↗
NASA NTRSDate not supplied

Assessment of Segmentation-Induced Deviations of Porosity Metrics in Powder Bed Fusion Additively Manufactured Components

Post processing X-ray computational tomography (CT) inspection data for additively manufactured (AM) components can induce deviations in defect quantification, affecting subsequent fatigue and failure predictions. To assess the influence and potential impact of segmentation-induced measurement deviations, this paper applies several segmentation techniques to X-ray CT data for powder bed fusion Ti-6Al-4V specimens exhibiting porosity conditions. X-ray CT reconstructions were segmented with varying techniques including Otsu’s thresholding, random forest, k-nearest neighbors, and the multilayer perceptron. Metrics such as pore size and global porosity were compared for internal validity. Then, top-down X-ray CT measurements of surface-breaking porosity were compared to optical profilometry for cross-validation.

Data fusion↗
DOE OSTI2023

Sintering inhibition enables hierarchical porosity with extreme resistance to degradation during redox cycling of Fe-Mo foams

High-temperature (800 ºC) steam-hydrogen redox cycling, relevant to grid-scale energy storage, is studied for iron-based freeze-cast lamellar foams. In contrast to previously studied Fe, Fe-Ni, and Fe-Co foams that rapidly degrade, Fe-25Mo foams feature a much-enhanced structural damage resistance. Utilizing in-situ x-ray diffraction, microscopy, and x-ray tomography, strong sintering inhibition is observed in Fe-Mo foams, creating a hierarchically porous lamellar structure. This leads to (i) wide channels between lamellae, enabling high macroscopic porosity (~78%) which can accommodate gas flow as well as volumetric expansion without lamellar contact, and (ii) microporosity within lamellae, providing additional free volume to accommodate expansion during oxidation, limiting both swelling of the lamellae and the formation of Kirkendall pores. Finally, these combined effects enable a near-complete reversibility of the microstructure during cycling, preventing damage produced via internal lamellar buckling, cracking, contacting and sintering, with a remarkably high porosity (65%) remaining after 50 consecutive redox cycles.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Hierarchical 3D Printed Porous Silicones with Porosity Derived from Printed Architecture and Silicone-Shell Microballoons

A method is reported to prepare siloxane microballoons that can be loaded into a direct ink write siloxane ink for 3D printing. The resulting structure is subjected to a solvent removal and supercritical drying process to provide a final printed siloxane having both macroscopic and microscopic porosity. Core-shell particles are generated by an emulsion template and phase separation process. Intra-strand closed-cell porosities can be achieved between 10 and 40 vol% thus facilitating additional compressive strain before lockup. Here short term compression set testing highlights the excellent shape retention properties of these elastomers, which have less than 8% relative compression set under load.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Layer size polydispersity in hydrated montmorillonite creates multiscale porosity networks

The aluminosilicate layers of the swelling clay mineral montmorillonite, and the saturated pores they delineate, control the mechanical properties and the transport of solutes in many natural and engineered environments. However, the structural basis of montmorillonite porosity remains poorly characterized due to the difficulty in visualizing hydrated samples in their native state. Here in this paper, we used cryogenic transmission electron microscopy (cryo-TEM) and cryo electron tomography (cryo-ET) to show that stacking defects within minimally altered, fully hydrated montmorillonite particles define multiscale porosity networks. Variations in layer lateral dimensions over tens to thousands of nanometers cause a range of topological and dynamic defects that generate pervasive curvature and introduce previously uncharacterized solute transport pathways. Observations of long-range rotational order between neighboring layers indicate that the layer-layer interactions that govern clay swelling involve three dimensional orienting forces that operate across nanoscale pores. These direct observations of the hierarchical structure of hydrated montmorillonite pore networks with nanoscale resolution reveal potentially general aspects of colloidal interactions in fluid-saturated clay minerals.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Anisotropic elastoplastic response of double-porosity media

Here we present a continuum framework to simulate fluid flow through anisotropic elastoplastic media with double porosity. Two effective stress measures σ' and δ" emerge from the thermodynamic formulation, which are energy-conjugate to the elastic and plastic components of strain, respectively. Both effective stress measures can be expressed as a combination of the total Cauchy stress σ and the average pore pressure $\bar{p}$ in the two pore scales. In the effective stress for elasticity, $\bar{p}$ is scaled with a rank-2 Biot tensor, whereas the effective stress for plasticity follows the Terzaghi form in which $\bar{p}$ is scaled by the Kronecker delta. The Biot tensor and storage coefficients are derived as functions of elasticity parameters and porosities. A mixed finite element formulation is introduced to discretize the domain and solve initial boundary-value problems. A stabilization scheme is employed on equal-order interpolation for both displacement and pressure fields throughout the entire range of drainage responses. Numerical simulations reproduce the hydromechanical response of Opalinus shale in one-dimensional consolidation tests throughout the range of primary and secondary consolidation under different external loads. Numerical simulations of the consolidation of a rectangular domain subjected to a strip load demonstrate the efficacy of the proposed stabilization scheme, as well as illustrate the impacts of stress history, mass transfer, and different pore systems on the hydromechanical response.

42 ENGINEERING↗
DOE OSTI2023

Processing aluminum alloy with hybrid wire arc additive manufacturing and ultrasonic nanocrystalline surface modification to improve porosity, surface finish, and hardness

Here, in this paper, a novel hybrid wire arc additive manufacturing (WAAM) and ultrasonic nanocrystal surface modification (UNSM) on porosity manipulation and surface properties of aluminum 5356 alloys was studied. The goal is to improve the quality of the WAAM-built part by eliminating bigger pores and reducing its size, reducing surface roughness, and increasing surface hardness. The as-built WAAM and WAAM-UNSM-treated samples were quantitatively studied for porosity using an X-ray micro-computed tomography (μ-CT). The surface roughness was measured on the surface profile of the same samples before and after UNSM treatment. Followed by the Vickers micro-hardness tests to evaluate the hardness modified by the influence of the UNSM treatment. It was found that the bigger pores in the as-built WAAM samples were eliminated and the medium-sized pores were shrunk to almost half the size after the UNSM treatment. Further, the UNSM treatment showed a significant improvement in both surface roughness and hardness on the WAAM Al5356 samples. This experimental work demonstrates the critical advantages of hybrid WAAM-UNSM in improving the qualities of the WAAM processed parts.

Hardness↗
DOE OSTI2020

Correlating the influence of porosity, tortuosity, and mass loading on the energy density of LiNi 0.6 Mn 0.2 Co 0.2 O 2 cathodes under extreme fast charging (XFC) conditions

Extreme fast charging capabilities along with high energy density of Li-ion batteries are the key factors to increase the adoption of electric vehicles while eliminating the problem of range anxiety. The U.S Department of Energy has a goal of <12 min charging time with energy density of > 200 Wh kg -1 . A combined improvement in the electrode architecture, electrolyte properties, and separator membrane is necessary to achieve this goal. Cells with thin electrodes are capable of extreme fast charging at the expense of low energy density and high cost. Electrode engineering can maximize energy density. In this work, the influence of porosity, mass loading and charging protocols on capacity and energy density and electrode kinetics are investigated under extreme fast charging conditions. Increasing the mass loading from 11.5 mg cm -2 to 25 mg cm -2 compromises the rate performance due to the mass transport limitation and underutilization of thick electrodes. Furthermore, reducing the electrode porosity from 50% to 35% improves the rate performance ascribed to shorter Li ion diffusion length. Symmetric cells are cycled to verify the performance of the half cells, suggesting that Li metal plating is the rate limiting step under high current density.

25 ENERGY STORAGE↗
DOE OSTI2022

Porosity evolution under increasing tension in wire-arc additively manufactured aluminum using in-situ micro-computed tomography and convolutional neural network

Internal defects such as porosities are often formed in additively manufactured metal components. The pores nucleate, grow, and coalesce to form cracks under loads, leading to eventual catastrophic failure. Here, in this paper, the full-field porosity evolution, including pore growth and coalescence in a wire-arc additively manufactured (WAAM) aluminum alloy cylinder under tension is observed with in-situ X-ray micro-computed tomography (μCT). The pore size distribution, density, and tensile stress are calculated from the volumetric images analyzed by a convolutional neural network (CNN) algorithm, which provides rapid analysis of 12,950 slice images from μCT volumetric images at the reference state and 13 tensile strains. The results show the quantitative evolution of the growth and coalescence of macropores under tension. A strong correlation is found between the local pore volume fraction and the true tensile stress when the tensile strain is larger than 5%.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Unraveling the Effects of Hierarchical Bimodal Microscale Porosity on Thick Electrodes

The thick electrode design is preferential in high-energy lithium-ion batteries (LIBs) systems. However, the sluggish ionic transport in homogeneous porous thick electrodes severely limits the areal capacity at high charging/discharging rates. The hierarchical porous design is a promising approach to mitigate kinetic limitations because it can distribute mass effectively in natural systems. In this study, the effects of bimodal microscale pores are fully investigated in thick electrodes from both architectural and electrochemical perspectives. Notably, by introduction of the bimodal microscale porous structure, the rate capability improves remarkably in thick electrodes with a low porosity (39%). Herein, by combining experimental results with simulations, this work presents a rational design guideline for preparing thick electrodes with a porosity at the commercial level, as well as simultaneous high energy and power densities, which brings new insights into the advanced electrode architecture design in scalable high-energy and high-power energy storage systems for practical applications.

25 ENERGY STORAGE↗
DOE OSTI2024

Groundwater and Surface Water Flow (GSFLOW) model files to explore bedrock circulation depth and porosity in Copper Creek, Colorado

This data package contains integrated hydrological model input and output files for Copper Creek, Colorado (24 km2), a tributary of the East River located in the headwaters of the Upper Colorado River Basin. The model code is the U.S. Geological Survey (USGS) Groundwater and Surface Water Flow (GSFLOW) model. The model contains a 100-m grid resolution and a daily timestep. The land surface model is dynamically linked to a three-dimensional groundwater flow model that allows for streamflow gaining and losing conditions. The groundwater model contains 12 model layers and extends 400 m below land surface. The original Copper Creek model was modified to contain geologic layers representing saprolite, shallow bedrock, and deep bedrock. Endmember depth versus hydraulic conductivity relationships and porosity values for fractured crystalline rock are simulated. For the shallow case, median flow depths occur in the shallow saprolite at depths <8 m, while the deep case promotes a median groundwater flow depth of 100 m. With this modeling framework we compare streamflow response to a plausible worst-case drought lasting up to five years. Streamflow metrics of analysis include average streamflow, fraction of stream network that is dry, no-flow duration, average groundwater flow to streams and time to recovery following the drought. Results and implications are presented in a paper submitted to Geophysical Research Letters titled, "The role of bedrock circulation depth and porosity in mountain streamflow response to prolonged drought" by Rosemary WH. Carroll, Andrew H. Manning and Kenneth H Williams. A Readme.txt file provides instructions on how to download all model files and execute each model scenario. In addition to the GSFLOW output/prms/copper_drought.csv file containing daily basin water stores and fluxes (refer to GSFLOW manual) and the output/prms/copper_drought_statvar.dat file with output defined in the gsflow3.control file (refer to GSFLOW Manual), output files also include spatially distributed daily values of total evapotranspiration, canopy evaporation, precipitation, snowfall, infiltration, snow water equivalent, potential evapotranspiration, recharge, sublimation, soil moisture, contributing interflow, water table elevations, changes in groundwater storage, groundwater evapotranspiration, interbasin groundwater flow (limited to the alluvium below the stream outlet), and surface-groundwater exchanges within the river system.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Predicting Fracture Porosity Evolution in Sandstone

To better understand the porosity, strength, chemical reactivity, and patterns of fractures in the subsurface, we used evidence from mineral deposits in open fractures to unravel how fracture growth and diagenesis interact to create and destroy fracture porosity. Quartz cement textures and associated fluid inclusions and thermal histories provided data used to infer the duration and rates at which fractures open.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2017

Modeling the Relationship Between Porosity and Permeability During Oxidation of Ablative Materials

The ablative materials used in thermal protection systems (TPS) undergo oxidation during atmospheric entry which leads to an in-depth change in both permeability and porosity. These properties have a significant affect on heat transfer in a TPS during entry. X-ray micro-tomography has provided 3D images capturing the micro-structure of TPS materials. In this study, we use micro-tomography based simulations to create high-fidelity models relating permeability to porosity during oxidation of FiberForm, the carbon fiber preform of the Phenolic Impregnated Carbon Ablator (PICA) often used as a TPS material. The goal of this study is to inform full-scale models and reduce uncertainty in TPS modeling.

Ablativ↗
DOE OSTI2024

Multivariate Machine Learning Models of Nanoscale Porosity from Ultrafast NMR Relaxometry

Abstract Nanoporous materials are of great interest in many applications, such as catalysis, separation, and energy storage. The performance of these materials is closely related to their pore sizes, which are inefficient to determine through the conventional measurement of gas adsorption isotherms. Nuclear magnetic resonance (NMR) relaxometry has emerged as a technique highly sensitive to porosity in such materials. Nonetheless, streamlined methods to estimate pore size from NMR relaxometry remain elusive. Previous attempts have been hindered by inverting a time domain signal to relaxation rate distribution, and dealing with resulting parameters that vary in number, location, and magnitude. Here we invoke well‐established machine learning techniques to directly correlate time domain signals to BET surface areas for a set of metal‐organic frameworks (MOFs) imbibed with solvent at varied concentrations. We employ this series of MOFs to establish a correlation between NMR signal and surface area via partial least squares (PLS), following screening with principal component analysis, and apply the PLS model to predict surface area of various nanoporous materials. This approach offers a high‐throughput, non‐destructive way to assess porosity in c.a. one minute. We anticipate this work will contribute to the development of new materials with optimized pore sizes for various applications.

Fricke, Sophia N.↗