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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 OSTI2023

24% Single-Junction GaAs Solar Cell Grown Directly on Growth-Planarized Facets Using Hydride Vapor Phase Epitaxy

A 24%-efficient single-junction GaAs solar cell grown directly on a faceted, spalled (100) GaAs substrate after in situ planarization growth by hydride vapor phase epitaxy (HVPE) is achieved. Controlled spalling, a promising low-cost substrate reuse technique, produces large facets in (100)-oriented GaAs substrates due to the orientation of the fracture planes used for lift-off. Planarization by HVPE offers a path toward direct use of these spalled substrates without costly polishing steps. In this report the growth rate anisotropy enabling planarization arising from diffusion and differences in the adsorption of growth species on {n11}B-type facets relative to (100) is determined. Consecutive planarization and device growth that results in a solar cell with a minimal performance difference relative to a control cell grown on an epitaxy-ready substrate are demonstrated. These results show that controlled spalling coupled with HVPE planarization is a viable pathway for lowering the cost of III-V photovoltaics.

14 SOLAR ENERGY↗
DOE OSTI2022

A continuum damage approach to spallation and the role of microinertia

Spall failure is of interest due to its prevalence in high strain rate problems in which the spallation is driven by the interaction of release waves. In this article, a porosity-based damage model that includes microinertial effects is used to examine spall failure. The model is successfully calibrated to plate impact-driven experiments and then used to evaluate experimental conditions producing more extreme strain rate conditions, such as those in laser-driven experiments. The incorporation of microinertia allows us to better understand the increase in apparent macroscopic spall strength seen at high strain rates. Correspondingly, we conclude that the incorporation of microinertial effects improves the model’s predictive capabilities. Microinertial effects result in more severe local tensile stresses that affect the damage evolution, and microinertia can play a significant role in the approach to the material’s ideal strength at extreme loading rates. Additionally, a preliminary parametric study is also carried out to investigate the role of microstructural aspects such as nucleation volume fraction and initial pore radius. One counter-intuitive result from the microinertial effects is that, for a given nucleation site volume fraction, having larger initial pore nucleation sites can lead to an improved macroscopic spall strength.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Scale Spallation During Coiling on the Electrochemical and Pickling Behavior of a Hot-Rolled Dual-Phase Steel

Tertiary oxide scale consists of magnetite and hematite, and in dual-phase steel strips were observed after the exit of final rolling stand in a thin slab casting rolling (TSCR) mill. Microscopic observation confirmed that these scales cracked and spalled off from many places of surface during coiling causing a non-uniform oxide layer on the steel surface. The present work discusses the synergistic effect of such non-uniform oxide layer and run-out-table cooling water on the electrochemical behavior of the dual-phase steel. The electrochemical response was assessed with the help of dynamic and linear polarization tests considering cooling water as electrolyte. The presence of non-uniform scale produced high cathodic (scaled zone) to anodic (spalled-off zone) area ratio that eventually led to extensive pitting corrosion in the present steel. Furthermore, the pickling behavior of the steel was also studied in detail. It was observed that the steel surface, with spalled-off area of about one-tenth of total surface area, corroded preferentially 3-4 times faster at spalled-off area than that of the uniformly pickled surface. The characterization study was performed using scanning electron microscopy, confocal laser 3D scanning microscopy, x-ray diffraction and Raman spectroscopy in order to establish the reasons for pitting corrosion due to the scale spallation.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Exceptionally high spallation strength for a high-entropy alloy demonstrated by experiments and simulations

High-entropy alloys are materials with an increasing number of technological applications. Amongst them, the Cantor alloy, FeMnCoCrNi, shows desirable mechanical properties at normal loading conditions. In this study we focus on the performance of the Cantor alloy at the ultra-high deformation rates of shock waves. We study shock-induced spallation using both experiments and atomistic simulations. Experimental loading is achieved using high power laser, with VISAR to obtain velocity profiles and spall strength, followed by transmission electron microscopy of the recovered samples. Molecular Dynamics (MD) simulations of shock-induced spallation are compared with experiments. Both experiments and simulations show a high spall strength which would be beneficial for certain applications, with experiments giving ~8 GPa at ~10 7 s -1 and MD giving almost ~30 GPa at ~10 9 s -1 . The difference between experiments and simulations can be explained by the difference in strain rate. Post-mortem analysis of the experimental samples shows nanotwins near the spall plane, while MD simulations show a highly disordered region giving rise to void nucleation and spall during loading.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effect of grain size on damage and failure in two-phase materials: Homogenized CuPb

It is well known that spall failure strongly depends on the microstructure of a material. There have been numerous studies to study the effect of grain size on the overall spall strength and the total amount of damage in single element metals like copper. However, such systematic studies remain rare in two-phase materials and alloys. In this work, two incipient spall experiments were performed on a Cu–1%Pb alloy to understand the effect of grain size on the damage and failure in a two-phase material. Overall, these results showed that even though the spall strength did not change as a function of grain size, there were significant differences in the total amount of damage as a function of grain size. A clear increase in the total damage present in the material was seen as the grain size was increased from 32 to either 70 or 75 μm in either of the experiments. Furthermore, this difference was attributed to variations in the void growth rate as the grain size was increased.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Hugoniot and Dynamic Strength in Polyurea

Polyurea is of interest for blast mitigation of structures, which requires a good understanding of the dynamic properties including the shock Hugoniot and dynamic spall and shear strength. In this study, reverse impact experiments were used to determine the shock Hugoniot, direct impact experiments were used to determine the spall strength, and lateral manganin gauge experiments were used to determine the dynamic shear strength. Reverse impact experiments revealed that the Hugoniot has a linear fit at low pressures and appears to be undergoing a reaction at higher pressures. The spall strength experiments in this study in combination with the literature data showed that the spall strength increases as a function of pressure, which is unusual in polymers and may be attributed to polyurea transforming to a glassy phase. In the shear strength experiments, the shear stress was shown to increase with increasing longitudinal stress in polyurea, similar to estane, another elastomer.

36 MATERIALS SCIENCE↗
NASA NTRS1978

The role of thermal shock in cyclic oxidation

The effect of thermal shock on the spalling of oxides from the surfaces of several commercial alloys was determined. The average cooling rate was varied from approximately 240 C/sec to less than 1.0 C/sec during cyclic oxidation tests in air. The tests consisted of one hundred cycles of one hour at the maximum temperature (1100 or 1200 C). The alloys were HOS-875, TD-Ni, TD-NiCrAl, IN-601, IN-702, and B-1900 plus Hf. Thermal shock resulted in deformation of the metal which in turn resulted, in most cases, in changing the oxide failure mode from compressive to tensile. Tensile failures were characterized by cracking of the oxide and little loss, while compressive failures were characterized by explosive loss of platelets of oxide. The thermally shocked oxides spalled less than the slow cooled samples with the exception of TD-NiCrAl. This material failed in a brittle manner rather than by plastic deformation. The HOS-875 and the TD-Ni did not spall during either type of cooling. Thus, the effect of thermal shock on spalling is determined, in large part, by the mechanical properties of the metal.

Lowell, C. E.↗
NASA NTRS1984

Performance of thermal barrier coatings in high heat flux environments

Thermal barrier coatings were exposed to the high temperature and high heat flux produced by a 30 kW plasma torch. Analysis of the specimen heating rates indicates that the temperature drop across the thickness of the 0.038 cm ceramic layer was about 1100 C after 0.5 sec in the flame. An as-sprayed ZrO2-8%Y2O3 specimens survived 3000 of the 0.5 sec cycles with failing. Surface spalling was observed when 2.5 sec cycles were employed but this was attributed to uneven heating caused by surface roughness. This surface spalling was prevented by smoothing the surface with silicon carbide paper or by laser glazing. A coated specimen with no surface modification but which was heat treated in argon also did not surface spall. Heat treatment in air led to spalling in as early as 2 cycle from heating stresses. Failures at edges were investigated and shown to be a minor source of concern. Ceramic coatings formed from ZrO2-12%Y2O3 or ZrO2-20%Y2O3 were shown to be unsuited for use under the high heat flux conditions of this study.

Miller, R. A.↗
NASA NTRS1984

Impact ejection, spallation, and the origin of meteorites

A model for the ejection of material from an impact crater which links ejection velocity, fragment size, and shock pressure through a simplified stress-wave propagation and reflection scheme is presented. It is shown that a small amount of material (0.01 to 0.05 projectile mass) may be ejected at high velocity without suffering petrologically detectable shock pressures. The largest fragments ejected at any velocity are spalls that originate from the target planet's surface. The spall size is proportional to the radius of the primary impactor and the target tensile strength and inversely proportional to ejection velocity. The shock level in the spalls is low, typically half of the dynamic crushing strength of the rock. The model also predicts the aspect ratio of the spalled fragments, the angle of ejection, and the sizes and shock level of other fragments originating deeper in the target. Comparison with observational and experimental data shows generally good agreement.

Melosh, H. J.↗
NASA NTRS1984

Performance of thermal barrier coatings in high heat flux environments

Thermal barrier coatings were exposed to the high temperature and high heat flux produced by a 30 kW plasma torch. Analysis of the specimen heating rates indicates that the temperature drop across the thickness of the 0.038 cm ceramic layer was about 1100 C after 0.5 sec in the flame. An as-sprayed ZrO2-8 percent Y2O3 specimens survived 3000 of the 0.5 sec cycles with falling. Surface spalling was observed when 2.5 sec cycles were employed but this was attributed to uneven heating caused by surface roughness. This surface spalling was prevented by smoothing the surface with silicon carbide paper or by laser glazing. A coated specimen with no surface modification but which was heat treated in argon also did not surface spall. Heat treatment in air led to spalling in as early as 1 cycle from heating stresses. Failures at edges were investigated and shown to be a minor source of concern. Ceramic coatings formed from ZrO2-12 percent Y2O3 or ZrO2-2O percent Y2O3 were shown to be unsuited for use under the high heat flux conditions of this study.

Miller, R. A.↗
NASA NTRS1984

Performance of thermal barrier coatings in high heat flux environments

Thermal barrier coatings were exposed to the high temperature and high heat flux produced by a 30 kW plasma torch. Analysis of the specimen heating rates indicates that the temperature drop across the thickness of the 0.038 cm ceramic layer was about 1100 C after 0.5 sec in the flame. An as-sprayed ZrO2-8 percent Y203 specimens survived 3000 of the 0.5 sec cycles with failing. Surface spalling was observed when 2.5 sec cycles were employed but this was attributed to uneven heating caused by surface roughness. This surface spalling was prevented by smoothing the surface with silicon carbide paper or by laser glazing. A coated specimen with no surface modification but which was heat treated in argon also did not surface spall. Heat treatment in air led to spalling in as early as 2 cycle from heating stresses. Failures at edges were investigated and shown to be a minor source of concern. Ceramic coatings formed from ZrO2-12 percent Y2O3 or ZrO2-20 percent Y2O3 were shown to be unsuited for use under the high heat flux conditions of this study.

Miller, R. A.↗
NASA NTRS1991

COSP - A computer model of cyclic oxidation

A computer model useful in predicting the cyclic oxidation behavior of alloys is presented. The model considers the oxygen uptake due to scale formation during the heating cycle and the loss of oxide due to spalling during the cooling cycle. The balance between scale formation and scale loss is modeled and used to predict weight change and metal loss kinetics. A simple uniform spalling model is compared to a more complex random spall site model. In nearly all cases, the simpler uniform spall model gave predictions as accurate as the more complex model. The model has been applied to several nickel-base alloys which, depending upon composition, form Al2O3 or Cr2O3 during oxidation. The model has been validated by several experimental approaches. Versions of the model that run on a personal computer are available.

Lowell, Carl E.↗
NASA NTRS2007

RDS-21 Face-Gear Surface Durability Tests

Experimental fatigue tests were performed to determine the surface durability life of a face gear in mesh with a tapered spur involute pinion. Twenty-four sets of gears were tested at three load levels: 7200, 8185, and 9075 lb-in face gear torque, and 2190 to 3280 rpm face gear speed. The gears were carburized and ground, shot-peened and vibro-honed, and made from VIM-VAR Pyrowear 53 steel per AMS 6308. The tests produced 17 gear tooth spalling failures and 7 suspensions. For all the failed sets, spalling occurred on at least one tooth of all the pinions. In some cases, the spalling initiated a crack in the pinion teeth which progressed to tooth fracture. Also, spalling occurred on some face gear teeth. The AGMA endurance allowable stress for a tapered spur involute pinion in mesh with a face gear was determined to be 275 ksi for the material tested. For the application of a tapered spur involute pinion in mesh with a face gear, proper face gear shim controlled the desired gear tooth contact pattern while proper pinion shim was an effective way of adjusting backlash without severely affecting the contact pattern.

Lewicki, David G.↗
NASA NTRS2010

Discontinuous Inter-Granular Separations (DIGS) in the Gas Nitride Layer of ISS Race Rings

The starboard solar alpha rotary joint (SARJ) race ring on the International space station (ISS) failed due to severe spalling of the outer diameter, 45 degree (outer canted) nitrided surface. Subsequent analysis at NASA-KSC revealed that almost all of the debris generated due to the failure was nitrided 15-5 stainless steel. Subsequent analysis of the nitride control coupons (NCC) at NASA-JSC revealed the presence of discontinuous inter-granular separations (DIGS) in the gas nitride layer. These DIGS were present in the inter-granular networking located in the top 2 mils of the nitride layer. The manufacturer's specification requires the maximum white structure to be 0.0003 inches and intergranular networking below the allowable white structure depth to be cause for rejection; a requirement that the NCCs did not meet. Subsequent testing and analysis revealed that lower DIGS content significantly lowered the probability of nitride spalling in simulated, dry condition runs. One batch of nitride samples with DIGS content similar to the port SARJ (did not fail on orbit) which exhibited almost no nitride spalling after being run on one test rig. Another batch of nitride samples with DIGS content levels similar to the starboard SARJ exhibited significant nitride spalling on the same test rig with the same load under dry conditions. Although DIGS were not the root cause of starboard race ring failure, testing indicates that increased DIGS reduced the robustness of the gas nitride layer under dry operating conditions.

Figert, John↗
NASA NTRS2004

Windows(Registered Trademark)-Based Software Models Cyclic Oxidation Behavior

Oxidation of high-temperature aerospace materials is a universal issue for combustion-path components in turbine or rocket engines. In addition to the question of the consumption of material due to growth of protective scale at use temperatures, there is also the question of cyclic effects and spallation of scale on cooldown. The spallation results in the removal of part of the protective oxide in a discontinuous step and thereby opens the way for more rapid oxidation upon reheating. In experiments, cyclic oxidation behavior is most commonly characterized by measuring changes in weight during extended time intervals that include hundreds or thousands of heating and cooling cycles. Weight gains occurring during isothermal scale-growth processes have been well characterized as being parabolic or nearly parabolic functions of time because diffusion controls reaction rates. In contrast, the net weight change in cyclic oxidation is the sum of the effects of the growth and spallation of scale. Typically, the net weight gain in cyclic oxidation is determined only empirically (that is, by measurement), with no unique or straightforward mathematical connection to either the rate of growth or the amount of metal consumed. Thus, there is a need for mathematical modeling to infer spallation mechanisms. COSP is a computer program that models the growth and spallation processes of cyclic oxidation on the basis of a few elementary assumptions that were discussed in COSP: A Computer Model of Cyclic Oxidation, Oxidation of Metals, vol. 36, numbers 1 and 2, 1991, pages 81-112. Inputs to the model include the selection of an oxidation-growth law and a spalling geometry, plus oxide-phase, growth-rate, cycle-duration, and spall-constant parameters. (The spalling fraction is often shown to be a constant factor times the existing amount of scale.) The output of COSP includes the net change in weight, the amounts of retained and spalled oxide, the total amounts of oxygen and metal consumed, and the terminal rates of weight loss and metal consumption.

Smialek, J. L.↗
DOE OSTI2023

Design of Planarizing Growth Conditions on Unpolished and Faceted (100)-Oriented GaAs Substrates Using Hydride Vapor Phase Epitaxy

Here we performed a design of experiments (DoE) analysis to determine the effect of various growth parameters on in situ planarizing overgrowth of rough substrates using hydride vapor phase epitaxy (HVPE). We used two types of rough (100)-oriented GaAs substrates to compare the effect of the initial morphology on the epitaxial growth behavior: an irregular, as-cut surface resultant from cutting the wafer from a GaAs boule and a regularly faceted surface produced by controlled spalling. The DoE analysis identified trends in the overgrowth behavior with changing growth conditions, and we used these trends to design favorable planarization growth conditions for each surface type. These favorable conditions enabled full planarization of a spalled surface with >2.5 um facet height within 10.8 min of growth. The root mean squared (RMS) surface roughness of the resulting (100) surface was 24.5 nm over a 286 um x 215 um area. Our results show that planarization growth by HVPE is a promising technique to enable device growth directly on rough substrates, and the trends revealed through DoE analysis indicate a path toward further optimization of planarization growth conditions for as-cut and spalled surfaces.

14 SOLAR ENERGY↗
DOE OSTI2019

Thermally Assisted Adhesion Enhancement in High-Phosphorous Electroless Nickel Plating

High-phosphorus electroless nickel is a widely recognized protective plating for oilfield metallic parts subject to corrosion and wear. In the present investigation, thermally activated diffusion treatment was applied to enhance electroless nickel (10-13 wt.% P) plating adhesion on low-alloy steel (UNS G41400) and reduce the risks of spalling. High-phosphorus electroless nickel (10-13 wt.% P) was applied to a variety of UNS G41400 low-alloy steel test samples as per ASTM B733 that were subsequently heat-treated in air for four distinct temperatures, i.e., 510, 540, 570, and 600 °C for 2-10 h. Following post-plating diffusion heat treatments, the initial amorphous electroless nickel was replaced by Ni{sub 3}P precipitates dispersed in a crystalline nickel-rich phase, with an average hardness improvement from 500 to 700 HK. An increased atomic interdiffusion (from 400 to 3.5 µm) was observed at plating–substrate interfaces, resulting in enhanced adhesion and reduced susceptibility toward spalling. This improvement in adhesion was measured repeatedly through post-bending crack analyses and subsequently validated by interface microindentation. Along with diffusion across plating–substrate interface, nickel oxide formation on surface by oxidation was observed to grow at quasi-parabolic rate with no detrimental impact on spalling. In all cases, plating adhesion was improved by heat treatments due to the diffusion-controlled formation of a seemingly ductile layer.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Structure/property (constitutive and spallation response) of additively manufactured 316L stainless steel

For additive manufacturing (AM) of metallic materials, the certification and qualification paradigm needs to evolve as there is currently no broadly accepted “ASTM- or DIN-type” additive manufacturing certification process or AM-produced material specifications. Accordingly, design, manufacture, and subsequent implementation and insertion of AM materials to meet engineering applications requires detailed quantification of the constitutive (strength and damage) properties of these evolving materials, across the spectrum of metallic AM methods, in comparison/contrast to conventionally-manufactured metals and alloys. For this paper, cylindrical samples of 316L SS were produced using a LENS MR-7 laser additive manufacturing system from Optomec (Albuquerque, NM) equipped with a 1 kW Yb-fiber laser. The microstructure of the AM-316L SS was characterized in both the “as-built” AM state and following a heat-treatment designed to obtain full recrystallization to facilitate comparison with annealed wrought 316L SS. The constitutive behavior as a function of strain rate and temperature was characterized and is compared to that of annealed wrought 316L SS plate material. The dynamic shock-loading-induced damage evolution and failure response of all three 316L SS materials was quantified using flyer-plate impact driven spallation experiments at peak stresses of 4.7 and 6.5 GPa. The spall strength of AM-produced 316L SS and the recrystallized-AM-316L SS were found to decrease with increasing peak shock stress while the annealed wrought 316L SS spall strength remained essentially constant. Finally, the damage evolution, characterized using optical metallography and electron-backscatter diffraction (EBSD), was found to vary significantly across the three 316L SS microstructures while the three samples loaded to a peak shock stress of 6.5 GPa displayed only ~12% differences in spall strength.

316L SS↗