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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 OSTI2024

Insight into the interfacial microstructure and chemistry of hot isostatically pressed AA6061-AA6061 bonds for U-10Mo fuel cladding application

Here, in the present study, hot isostatic pressing (HIP) bonding was carried out using AA6061-AA6061 plates for U-10Mo monolithic fuel cladding application. HIP was performed at 560°C with an applied isostatic pressure of 103 MPa for 90 min. Interfacial microstructure characterizations were performed using scanning electron microscopy (SEM) combined with electron backscatter diffraction (EBSD) to quantify precipitate fractions and study recrystallization, grain growth, and orientation relationships across the interface. EBSD results confirmed that no interfacial grain growth occurred during the HIP process. Transmission electron microscopy (TEM) was also employed to quantify composition and identify phases of various precipitates and an oxide layer that formed at the interface during HIP bonding. Microstructural analyses revealed the formation of a large fraction of Mg 2 Si precipitate and a ~50 nm thick Mg-oxide layer at the interface. Further TEM analysis confirmed that the oxide layer was not continuous, and Mg 2 Al 2 O 5 oxide particles with an average size of 18 nm were present in the oxide layer. Finite element modeling analysis was performed to study the stress distribution at the interface during HIP processing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

Effects of alpha-zirconium phosphate on thermal degradation and flame retardancy of transparent intumescent fire protective coating

Graphical abstract: - Highlights: • A transparent intumescent fire protective coating was obtained by UV-cured technology. • OZrP could enhance the thermal stability and anti-oxidation of the coating. • OZrP could reduce the combustion properties of the coatings. - Abstract: Organophilic alpha-zirconium phosphate (OZrP) was used to improve the thermal and fire retardant behaviors of the phenyl di(acryloyloxyethyl)phosphate (PDHA)-triglycidyl isocyanurate acrylate (TGICA)-2-phenoxyethyl acrylate (PHEA) (PDHA-TGICA-PHEA) coating. The morphology of nanocomposite coating was characterized by X-ray diffraction (XRD) and transmission electron microscopy (TEM). The effect of OZrP on the flame retardancy, thermal stability, fireproofing time and char formation of the coatings was investigated by microscale combustion calorimeter (MCC), thermogravimetric analysis (TGA), X-ray photoelectron spectroscopy (XPS), laser Raman spectroscopy (LRS) and scanning electric microscope (SEM). The results showed that by adding OZrP, the peak heat release rate and total heat of combustion were significantly reduced. The highest improvement was achieved with 0.5 wt% OZrP. XPS analysis indicated that the performance of anti-oxidation of the coating was improved with the addition of OZrP, and SEM images showed that a good synergistic effect was obtained through a ceramic-like layer produced by OZrP covered on the surface of char.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Structural and thermal characterization of CaO-MgO-SiO2-P2O5-CaF2 glasses

The paper presents the influence of varying CaO/MgO ratio on the structure and thermal properties of CaO-MgO-SiO2-P2O5-CaF2 glasses. A series of eight glass compositions in the glass forming region of diopside (CaMgSi2O6) - fluorapatite [Ca5(PO4)3F] - wollastonite (CaSiO3) ternary system have been designed and synthesized by varying diopside/wollastonite ratio in glasses. The as prepared melt-quenched glasses have been characterized for their structure by infrared spectroscopy (FTIR) and magic angle spinning (MAS)-nuclear magnetic resonance (NMR) spectroscopy. Silicon is predominantly present as Q2 (Si) species, while phosphorus tends to coordinate in orthophosphate environment in all the investigated glasses. The change in CaO/MgO ratio had an insignificant affect on the structure of glasses. The thermal sintering and crystallization parameters for the studied glasses have been obtained from differential thermal analysis (DTA) while crystalline phase fractions in the sintered glass-ceramics have been analyzed by X-ray diffraction adjoined with Rietveld refinement. Diopside, fluorapatite, wollastonite and pseudowollastonite have crystallized as the main crystalline phases in all the glass-ceramics with their content varying with respect to variation in CaO/MgO ratio in glasses. Scanning electron microscopy (SEM) has been used to shed light on the microstructure of glass-ceramics. The possible implications of structure and sintering behaviour of glasses on their bioactivity have been discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2021

The onset of alloying in Cu-Ni powders under high-shear consolidation

Friction consolidation (FC) is a solid phase processing methodology that densifies a material through high-shear deformation and pressure at elevated temperature. The method has garnered interest in the scientific community because of its ability to produce extremely refined and homogeneous microstructures, off-axis texture development, and improved material properties. This manuscript presents an investigation of Cu and Ni material mixing via evaluation of morphological evolution, grain boundary characterization, and compositional analysis to provide insights on the operational alloying mechanisms occurring under high shear and elevated temperature. Using correlative microscopy techniques, we show alloying progresses via a combination of grain boundary diffusion and interfacial roughening at heterophane boundaries. Evidence supporting Cu infiltration along Ni-Ni grain boundaries along with asymmetric diffusion of Cu into Ni grains is highlighted. The resultant, consolidated microstructure was produced directly from a powder compact in ~30 s and exhibited a submicron, equiaxed grain size.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Effect of KCl, NaCl and CaCl{sub 2} mixture on volume combustion synthesis of TiB{sub 2} nanoparticles

Highlights: {yields} A low melting diluent lowers the ignition temperature in combustion synthesis. {yields} Deagglomerated synthesized products are formed as the result of diluent addition. {yields} Addition of 45% salt mixture resulted in formation of 70 nm TiB{sub 2} nanoparticles. {yields} Thermodynamically unstable Mg{sub 2}TiO{sub 4} and Mg{sub 3}B{sub 2}O{sub 6} by-products were formed. {yields} Small change in particle size was observed with addition of salt mixture. -- Abstract: Preparation of titanium diboride (TiB{sub 2}) nanoparticles was carried out by volume combustion synthesis. TiO{sub 2}, B{sub 2}O{sub 3} and elemental Mg were mixed with 0-60% salt mixture of KCl, NaCl and CaCl{sub 2} with increment of 15% as a low melting temperature diluent. Compressed samples were synthesized in a tubular furnace at a constant heating rate under argon atmosphere. Thermal analysis of the process showed that the addition of the low melting temperature salts mixture led to a significant decrease in ignition and combustion temperatures. Synthesized samples were then leached by nitric and hydrochloric acids to remove impurities. The samples were examined by XRD, SEM and DLS analysis. The results showed the formation of fine deagglomerated particles with the addition of the salts mixture. The results revealed that 45% salts mixture had the smallest average particle size of about 90 nm.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Fabrication of flower-like Ni{sub 3}(NO{sub 3}){sub 2}(OH){sub 4} and their electrochemical properties evaluation

Graphical abstract: Ni{sub 3}(NO{sub 3}){sub 2}(OH){sub 4} nano-flakes materials, which have a flower-like structure, were successfully synthesized by a facile solvothermal method without adding any surfactant. The as-prepared Ni{sub 3}(NO{sub 3}){sub 2}(OH){sub 4} possesses a maximum specific capacitance of 2212.5 F g{sup −1} at the current density of 5 mA, suggesting its potential application in electrode material for secondary batteries and electrochemical capacitors. Highlights: ► Flower-like Ni{sub 3}(NO{sub 3}){sub 2}(OH){sub 4} materials were fabricated in a simple method. ► High specific capacitance of 2212.5 F g{sup −1} has been achieved. ► For the first time the effects of concentration and temperature on its specific capacitance has been studied. -- Abstract: Flower-like Ni{sub 3}(NO{sub 3}){sub 2}(OH){sub 4} was successfully synthesized by a facile solvothermal method. The microstructure and surface morphology of prepared Ni{sub 3}(NO{sub 3}){sub 2}(OH){sub 4} were physically characterized by X-ray diffraction (XRD) analysis, scanning electron microscopy (SEM) and transmission electron microscope (TEM). The electrochemical properties studies were carried out using cyclic voltammetry (CV), chronopotentiometry technology and AC impedance spectroscopy, respectively. The results indicate that the flower-like structure has a profound impact on electrode performance at high discharge capacitance. A maximum specific capacitance of 2212.5 F g{sup −1} at the current density of 5 mA could be achieved, suggesting its potential application in electrode material for secondary batteries and electrochemical capacitors. Furthermore, the effects of Ni(NO{sub 3}){sub 2}·6H{sub 2}O concentration and temperature on the microstructure and specific capacitance of prepared Ni{sub 3}(NO{sub 3}){sub 2}(OH){sub 4} have also been systematically studied. The results show that flower-like structure can be formed when the concentration is appropriate, while the temperature has just little effect on its electrochemical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Microstructure of V-based ohmic contacts to AlGaN/GaN heterostructures at a reduced annealing temperature

Ohmic contacts with V/Al/Ni/Au and V/Ni/Au metalization schemes were deposited on AlGaN/GaN heterostructures. The dependence of the specific contact resistance on the annealing conditions and the V:Al thickness ratio was shown. For an optimized electrode stack, a low specific contact resistance of 8.9 × 10{sup −6} Ω cm{sup 2} was achieved at an annealing temperature of 650 °C. Compared to the conventional Ti/Al/Ni/Au contact, this is a reduction of 150 K. The microstructure and contact formation at the AlGaN/metal interface were investigated by transmission electron microscopy including high-resolution micrographs and energy dispersive X-ray analysis. It was shown that for low-resistive contacts, the resistivity of the metalization has to be taken into account. The V:Al thickness ratio has an impact on the formation of different intermetallic phases and thus is crucial for establishing ohmic contacts at reduced annealing temperatures.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2013

Direct visualization of β phase causing intergranular forms of corrosion in Al–Mg alloys

For a more effective examination of microstructure in Al–Mg alloys, a new etching solution has been developed; dissolved ammonium persulfate in water. It is demonstrated how β phase (Al{sub 3}Mg{sub 2}) in Al–Mg alloys respond to this solution using samples of a binary Al–Mg alloy and a commercial 5083 aluminum alloy. Nanometer sized β phase is clearly visualized for the first time using scanning electron microscopy (SEM) instead of transmission electron microscopy (TEM). It is anticipated that direct and unambiguous visualization of β phase will greatly augment intergranular corrosion research in 5xxx series aluminum alloys. - Highlights: • Nanometer sized β phase in Al-10% Mg is first clearly visualized with SEM. • Nanometer sized β phase in wrought alloy 5083 is first clearly visualized with SEM. • Grain boundary decorating β phase and isolated sponge-like β phase are shown. • This phase is confirmed to be β phase using composition analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Utilizing Oxygen Redox in Layered Cathode Materials from Multiscale Perspective

We report in high-capacity layered oxide cathode materials, utilization of lattice oxygen as a redox center is considered to be one of the most promising approaches to overcome the capacity limitation set by conventional transition metal redox centers. However, rapid material degradation is often associated with oxygen oxidation, leading to formidable challenges in utilizing oxygen redox. Further mechanistic understanding of the oxygen activities thus becomes critical to better control oxygen redox reactions. This review summarizes recent advances for investigating oxygen redox reactions in cathode materials from a multiscale perspective, i.e., from the atomistic level to the microstructure regime. First the mechanistic aspects of oxygen redox and the consequences of this reaction on various electrode degradation pathways during battery operation (e.g., oxygen loss, transition metal migration, irreversible phase transition), relating structural changes at the crystallographic scale to those at the macro scale, are discussed. Then recent developments based on atomic and microstructure modifications that are promising for improving the reversibility of oxygen redox reaction or mitigating the harmful processes arising from oxidation of the oxygen centers under high operating voltage are recounted. The analysis is concluded with a commentary on further research directions toward optimizing the oxygen activity for high-capacity charge storage.

25 ENERGY STORAGE↗
DOE OSTI2014

Resolving microstructures in Z pinches with intensity interferometry

Nearly 60 years ago, Hanbury Brown and Twiss [R. Hanbury Brown and R. Q. Twiss, Nature 178, 1046 (1956)] succeeded in measuring the 30 nrad angular diameter of Sirius using a new type of interferometry that exploited the interference of photons independently emitted from different regions of the stellar disk. Its basis was the measurement of intensity correlations as a function of detector spacing, with no beam splitting or preservation of phase information needed. Applied to Z pinches, X pinches, or laser-produced plasmas, this method could potentially provide spatial resolution under one micron. A quantitative analysis based on the work of Purcell [E. M. Purcell, Nature 178, 1449 (1956)] reveals that obtaining adequate statistics from x-ray interferometry of a Z-pinch microstructure would require using the highest-current generators available. However, using visible light interferometry would reduce the needed photon count and could enable its use on sub-MA machines.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2013

Thermal Conductivity of Wood-Derived Graphite and Copper-Graphite

The thermal conductivity of wood-derived graphite and graphite/copper composites was studied both experimentally and using finite element analysis. The unique, naturally-derived, anisotropic porosity inherent to wood-derived carbon makes standard porosity-based approximations for thermal conductivity poor estimators. For this reason, a finite element technique which uses sample microstructure as model input was utilized to determine the conductivity of the carbon phase independent of porosity. Similar modeling techniques were also applied to carbon/copper composite microstructures and predicted conductivities were compared to those determined via experiment.

B. Porosity↗
DOE OSTI2020

Effect of heat treatment on microstructural evolution and hardness homogeneity in laser powder bed fusion of alloy 718

The thermal history developed in laser powder bed fusion (LPBF) processes has been shown to be complex resulting in equally complex microstructures and mechanical properties. Microscopic observations and Vickers micro-hardness mapping measurements were carried out on diff ;erent section planes of LPBF alloy 718 cuboids. Three-dimensional finite element analysis was used to simulate thermal history and to predict the residual stress distribution in the as-built material. Computational thermodynamics was used to predict the micro-segregation and nucleation driving force of various phases in the bulk and in segregated regions. Varied heat-treatments such as simulated hot isostatic pressing, and double aging were applied. Their influence on the microstructure, microsegregation, precipitate formation, and micro-hardness variations of LPBF alloy 718 were investigated. Hardness map results showed heterogeneous micro-hardness on the xy- and xz-planes of the as-built parts where the bottom plane and center regions had larger hardness of ~315 HV 0.5 while the top plane and contours showed hardness of ~300 HV 0.5 . It was found that the aging treatment increased the overall hardness of the as-built condition from ~310 HV 0.5 to 470 HV 0.5 but also increased the hardness gradient throughout the coupon. After simulated hot isostatic pressing process (i.e., without applied pressure) at 1020 °C for 4 h followed by water quench (HIPWQ), the hardness gradient and hardness was minimized (~210 HV 0.5 ) as the microstructure transitioned from heterogeneous columnar grains in the as-built condition to more uniform recrystallized grains. A double aging treatment was applied to enhance hardness from ~210 HV 0.5 to ~440 HV 0.5 . Finally, HIPWQ followed by double aging produced a homogeneous microstructure and more uniform hardness map with enhanced mechanical properties in LPBF alloy 718 coupons.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Novel preparation of Al-5%Cu / BN and Si3N4 composites with analyzing microstructure, thermal and mechanical properties

Highlights: • The novel MMCs Al5Cu-Si{sub 3}N{sub 4}/BN successfully produced by squeeze casting techniques • Squeeze casting technique improves the wettability between the matrix and nitrides. • XRD analysis showing the presence of new AlN and AlB{sub 2} phases • The hardness curves of the MMCs exhibited the increasing trend till reaching peak. • BN reinforcements significantly accelerate precipitation behavior of Al-5%Cu alloy. - Abstract: The purpose of this research is to develop and characterize composites of Al-5%Cu alloy reinforced by silicon and boron nitride (Si{sub 3}N{sub 4}, BN). The developing of this type of composites gives a new trend of metal matrix composite synthesizing, especially in the case of boron nitride. The stir cast composites showed large areas of porosity and agglomeration. On the other hand, the squeezed cast composites exhibited a fairly uniform particles distribution throughout the matrix alloy. The microstructure and XRD results of the composites confirmed a reaction occurred at the interface between the particles and alloy. AlN and AlB{sub 2} phases were identified in Al5%Cu-Si{sub 3}N{sub 4} and Al5%Cu-BN composites respectively. The ageing results showed that the time to reach peak hardness decreased with addition of the particles. Also, the ageing kinetics was significantly accelerated due to the presence of BN particulates. The coefficient of thermal expansion (CTE) results of the matrix alloy and its composites were practically and theoretically determined. Difference between experimental and calculated values of CTE was less than 8%. Increasing the concentration of Si{sub 3}N{sub 4} increased YS from 215 MPa in the matrix alloy to 285 MPa in the Al-5%Cu-7%Si{sub 3}N{sub 4} composites at a testing temperature of 20 °C.

36 MATERIALS SCIENCE↗
DOE OSTI2022

An analysis of fluff formation in metallic fuel via data analyzes from EBR-II experiments and BISON fuel code modeling

During the operation of EBR-II, it was found that a highly porous structure (over 40% area fraction) formed at the top of several fuel columns. Previous work has shown that this structure, designated fluff in this paper, contains a significant fraction of fuel elements (e.g., U and Pu) which could potentially impact neutronics. This work aims in analyzing the formation mechanism of this microstructure so its impact can be incorporated into future metallic fuel modeling codes and algorithms. This paper details a preliminary examination into the formation mechanisms of fluff by performing qualitative and statistical analysis of EBR-II experimental data. Additionally, the operating conditions that have the greatest impact on fluff formation were determined based on this data set. Also, BISON fuel code simulations were used to help postulate potential fluff formation mechanisms. From this analysis it was found that the largest contributors to fluff formation were fuel burnup and composition, with fluff formation exhibiting a roughly linear positive correlation with increasing burnup and a negative correlation with increasing Pu content. It was also found that higher pin operating temperatures decreased fluff formation but only for U-10Zr fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Three-dimensional morphology of an ultrafine Al-Si eutectic produced via laser rapid solidification

Al-Si alloys processed by laser rapid solidification yield eutectic microstructures with ultrafine and interconnected fibers. Such fibrous structures have long been thought to bear resemblance to those formed in impurity-doped alloys upon conventional casting. Here, we show that any similarity is purely superficial. By harnessing high-throughput characterization and computer vision techniques, we perform a three-dimensional analysis of the branching behavior of the ultrafine eutectic and compare it against an impurity-modified eutectic as well as a random fractal (as a benchmark). Differences in the branching statistics point to different microstructural origins of the impurity- and quench-modified eutectic. Finally, our quantitative approach is not limited to the data presented here but can be used to extract abstract information from other volumetric datasets, without customization.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Discovering mechanisms for materials microstructure optimization via reinforcement learning of a generative model

Abstract The design of materials structure for optimizing functional properties and potentially, the discovery of novel behaviors is a keystone problem in materials science. In many cases microstructural models underpinning materials functionality are available and well understood. However, optimization of average properties via microstructural engineering often leads to combinatorically intractable problems. Here, we explore the use of the reinforcement learning (RL) for microstructure optimization targeting the discovery of the physical mechanisms behind enhanced functionalities. We illustrate that RL can provide insights into the mechanisms driving properties of interest in a 2D discrete Landau ferroelectrics simulator. Intriguingly, we find that non-trivial phenomena emerge if the rewards are assigned to favor physically impossible tasks, which we illustrate through rewarding RL agents to rotate polarization vectors to energetically unfavorable positions. We further find that strategies to induce polarization curl can be non-intuitive, based on analysis of learned agent policies. This study suggests that RL is a promising machine learning method for material design optimization tasks, and for better understanding the dynamics of microstructural simulations.

36 MATERIALS SCIENCE↗
DOE OSTI2019

The Mechanical and Corrosion Properties of Hot-Rolled TiB{sub 2}/Ni Composites

To quickly prepare TiB{sub 2}/Ni composites at low temperatures, a method combining spark plasma sintering and hot rolling was used. This paper presents the preparation, microstructural and mechanical properties, strengthening mechanism and corrosion properties of TiB{sub 2}/Ni composites in detail. X-ray diffraction analysis shows that the texture degree of the TiB{sub 2}/Ni composites after hot rolling greatly differed from that of the as-rolled pure Ni samples. The addition of TiB{sub 2} particles limited grain growth in the Ni matrix and led to grain refinement. Dislocation strengthening, grain refinement strengthening and load transfer strengthening contributed to a 30% increase in the tensile strength compared to that of the as-rolled pure Ni. In addition, the strengthening mechanism of the mechanical property reinforcement was analyzed. The electrochemical test results demonstrate that the as-rolled pure Ni exhibited a lower corrosion current density and corrosion resistance than the other as-rolled TiB{sub 2}/Ni composites fabricated in this paper. This work demonstrates a new approach for fabricating composites in less time at lower preparation temperatures than conventional methods.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Optimizing the TiO{sub 2} Content to Obtain the Highest Corrosion Resistance in Ir-Ru-Ta-Based Mixed Metal Oxide Coating in Oxygen Evolution Reaction Application

In this article, the role of TiO{sub 2} on deactivation and corrosion mechanism of a MMO coating was assessed in 1 M Na{sub 2}SO{sub 4} solution. The Ti/40IrO{sub 2} + 30RuO{sub 2} + (30 − x)Ta{sub 2}O{sub 5} + (x)TiO{sub 2} anodes were prepared by thermal decomposition method. Surface morphology and microstructure of the coatings were characterized by scanning electron microscopy, energy-dispersive spectroscopy and grazing incidence x-ray diffraction analysis. The electrochemical properties and corrosion behavior of these coatings were performed by accelerated lifetime test, investigation of active surface area (q*) and electrochemical impedance spectroscopy. The results showed that the uniform dissolution of the active surface layers was the main reason behind the anode deactivation. Furthermore, addition of titanium oxide up to 15% to the above-mentioned composition improved the performance of the anode and increased its working life up to 200 h.

36 MATERIALS SCIENCE↗