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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Applied Research and Development to Support Open Water Testing at PacWave – Task 5: Development of additively manufactured, functionally graded, corrosion resistant clads for wave energy applications

In this task, we focused on developing corrosion-resistant claddings for wave energy applications. Wave energy systems are exposed to saline conditions, which are corrosive to many metallic structural materials (e.g., carbon steel). Corrosion-resistant (stainless) steels are typically alloyed with >18% chromium (Cr) and >8% nickel (Ni), which dramatically raises material costs and can hinder the development of wave energy systems; thus, coatings are a necessary corrosion protection method for most. Non-metallic coatings (paint, epoxy) have shorter service lives, limited resistance to mechanical stress and wear, plus additional costs of inspection and eventual replacement. Therefore, overlay stainless steel (SS) claddings have a cost-effective use case for protecting components from corrosion, particularly for those that may be subject to mechanical stress / wear and with long service lives.

16 TIDAL AND WAVE POWER↗
NASA NTRS2003

Optimal Substrate Preheating Model for Thermal Spray Deposition of Thermosets onto Polymer Matrix Composites

High velocity oxy-fuel (HVOF) sprayed, functionally graded polyimide/WC-Co composite coatings on polymer matrix composites (PMC's) are being investigated for applications in turbine engine technologies. This requires that the polyimide, used as the matrix material, be fully crosslinked during deposition in order to maximize its engineering properties. The rapid heating and cooling nature of the HVOF spray process and the high heat flux through the coating into the substrate typically do not allow sufficient time at temperature for curing of the thermoset. It was hypothesized that external substrate preheating might enhance the deposition behavior and curing reaction during the thermal spraying of polyimide thermosets. A simple analytical process model for the deposition of thermosetting polyimide onto polymer matrix composites by HVOF thermal spray technology has been developed. The model incorporates various heat transfer mechanisms and enables surface temperature profiles of the coating to be simulated, primarily as a function of substrate preheating temperature. Four cases were modeled: (i) no substrate preheating; (ii) substrates electrically preheated from the rear; (iii) substrates preheated by hot air from the front face; and (iv) substrates electrically preheated from the rear and by hot air from the front.

Ivosevic, M.↗
DOE OSTI2022

Life-Cycle Inventory of Critical Materials: Nickel, Copper, Titanium, and Rare-Earth Elements

The United States has developed a list of critical minerals/materials whose sustained and reliable supply is pivotal to the robust functioning of critical industrial sectors. A key concern with these minerals is their environmental effects as a function of their production location. This requires material and energy flow details for their processing steps. This report provides a life-cycle inventory (LCI) for producing four critical minerals and/or material systems (nickel, copper, titanium, and rare-earth elements) incorporated in the updated GREET® (Greenhouse gases, Regulated Emissions, and Energy use in Technologies) model. For these systems, we provide an LCI as a function of production location – domestic (within the United States) and international (geographies from where the US imports these minerals). Our LCI also considers variations in ore grades for nickel and copper. This report also provides an LCI for all intermediate materials used to produce these critical materials.

58 GEOSCIENCES↗
DOE OSTI2020

Grid-assisted magnetron sputtering deposition of nitrogen graded TiN thin films

Titanium Nitride (TiN) films were obtained using the grid-assisted magnetron sputtering deposition technique on Al substrates in two conditions: under constant and variable nitrogen concentration along the thin solid film thickness. The formation of a film with variable N concentration (herein referred as graded film) was confirmed using energy filtered transmission electron microscopy, X-ray photoelectron spectroscopy and grazing incidence X-ray diffraction. The TiN thin films microstructures were also analysed using scanning and transmission electron microscopies (SEM and TEM). Finally, the viability of synthesizing TiN thin films with variable N concentration is herein proposed as an alternative method for tailoring the properties of such functional coating materials.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Thermal Aging Effects on the Yield and Tensile Strength of 9Cr-1Mo-V (Grade 91)

The long-term exposure of 9Cr-1Mo-V (Grade 91) steel to elevated temperature can have a significant effect on reducing its yield and tensile strength. The yield and tensile strength changes, in turn, have potential implications to the assurance of the integrity of components constructed with this material over their design or intended lifetime. The ASME Boiler & Pressure Vessel Code (BPVC), Section III, Division 5 (III-5, high temperature reactors) provides tabulated reduction factors for Grade 91 yield and tensile strength as a function of exposure temperature and time up to 300,000 h. ASME BPVC III-5 s intent to extend these factors to an exposure duration of 500,000 h, the lack of available historic information to support the existing factors, and the recent development of a physics-based prediction model for ASME BPVC application are prime motivation for this study. This work describes results of the conventional time-temperature Hollomon–Jaffe parameter, strength reduction ratio prediction method using an updated, extensive Grade 91 unaged and related aged material strength database. The method, previously used by Oak Ridge National Laboratory in its evaluation of Grade 91 and likely used in development of the existing BPVC III-5 reduction factors, provides strength reduction ratio predictions useful for general component fitness-for-service assessments and for computing BPVC III-5 reduction factors as defined. Specific reduction factors to 500,000 h at 650 °C applicable to ASME BPVC III-5 are computed from the strength reduction ratios.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Beyond the Toolpath: Site-Specific Melt Pool Size Control Enables Printing of Extra-Toolpath Geometry in Laser Wire-Based Directed Energy Deposition

A variety of techniques have been utilized in metal additive manufacturing (AM) for melt pool size management, including modeling and feed-forward approaches. In a few cases, closed-loop control has been demonstrated. In this research, closed-loop melt pool size control for large-scale, laser wire-based directed energy deposition is demonstrated with a novel modification, i.e., site-specific changes to the controller setpoint were commanded at trigger points, the locations of which were generated by the projection of a secondary geometry onto the primary three-dimensional (3D) printed component geometry. The present work shows that, through this technique, it is possible to print a specific geometry that occurs beyond the actual toolpath of the print head. This is denoted as extra-toolpath geometry and is fundamentally different from other methods of generating component features in metal AM. A proof-of-principle experiment is presented in which a complex oak leaf geometry was embossed on an otherwise ordinary double-bead wall made from Ti-6Al-4V. The process is introduced and characterized primarily from a controls perspective with reports on the performance of the control system, the melt pool size response, and the resulting geometry. The implications of this capability, which extend beyond localized control of bead geometry to the potential mitigations of defects and functional grading of component properties, are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Capsule and Specimen Geometries for HFIR Irradiation Testing Supporting the Transformational Challenge Reactor

This report provides a summary of irradiation capsule design and analysis for the three main categories of materials to be used in the Transformational Challenge Reactor (TCR) core. These materials are yttrium hydride as the moderator, silicon carbide, and Grade 316L austenitic stainless steel. No neutron irradiation data exists on the former and the latter two are derived from advanced manufacturing techniques and therefor need to undergo rigorous testing to assess their behavior as function of dose and temperature. The detailed design and analysis summarized in this report is the critical step to facilitate safe and relevant irradiation of these materials to be conducted at ORNL’s High Flux Isotope Reactor. These irradiations will ultimately yield critical materials properties data for reactor design and licensing purposes.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2008

A Versatile Lifting Device for Lunar Surface Payload Handling, Inspection and Regolith Transport Operations

Devices for lifting and transporting payloads and material are critical for efficient Earth-based construction operations. Devices with similar functionality will be needed to support lunar-outpost construction, servicing, inspection, regolith excavation, grading and payload placement. Past studies have proposed that only a few carefully selected devices are required for a lunar outpost. One particular set of operations involves lifting and manipulating payloads in the 100 kg to 3,000 kg range, which are too large or massive to be handled by unassisted astronauts. This paper will review historical devices used for payload handling in space and on earth to derive a set of desirable features for a device that can be used on planetary surfaces. Next, an innovative concept for a lifting device is introduced, which includes many of the desirable features. The versatility of the device is discussed, including its application to lander unloading, servicing, inspection, regolith excavation and site preparation. Approximate rules, which can be used to size the device for specific payload mass and reach requirements, are provided. Finally, details of a test-bed implementation of the innovative concept, which will be used to validate the structural design and develop operational procedures, is provided.

Doggett, William R.↗
DOE OSTI2019

FTIR and Raman Spectroscopy of Reduced Graphene Oxide Carbon Nanoribbons and Graphene Oxide on Copper (Cu)

In the past couple of decades, carbon nanomaterials produced from graphene and graphite have emerged as one of the more important recently discovered substances. These carbon nanomaterials have been found to exhibit high levels of mechanical strength, thermal resistance, and electrical conductivity, thus having a multitude of applications. Therefore, it is important to identify and analyze their traits in order to maximize their effectiveness. Two spectroscopic techniques employed for such analyses of these materials are Fourier-Transform Infrared (FTIR) and Raman Spectroscopy. The advantages of FTIR and Raman include nondestructive analysis, relatively quick measurements under normal atmospheric conditions, and enhanced sensitivity with high resolution capacity. FTIR Spectroscopy was used in this research project to determine the effects of thermal exfoliation and photoreduction on the functionality groups of a carbon nanomaterial. Raman Spectroscopy was used in this research project to determine the effects of thermal exfoliation and photoreduction on the intensity of the disorder peak, which is greater in intensity if the carbon nanomaterial exhibits greater amounts of functionalities or defects in the graphitic material. There were two sample types which were analyzed with both FTIR and Raman Spectroscopy for the research project: graphene nanoribbons and graphene oxide. The m-grade graphene nanoribbons (GNRs) were produced from m-grade carbon nanotubes (CNTs) via Tour's method. The graphene oxide (GO) was produced from graphene via Tour's method, sonicated and centrifuged, dip-coated onto Copper (Cu) foil, and then photoreduced under a UV light source. FTIR measurements and analyses were conducted using a Jasco FTIR Spectrometer. Raman measurements and analyses were conducted using a Jasco Laser Raman Spectrometer. Tasks and techniques for this project included photoreduction, dip-coating, corrosion testing, FTIR and Raman data collection and analysis, and improvement of data collection for the Raman Spectrometer. GNRs exfoliated and reduced (deoxygenation) at 270 deg. C in air showed a significant decrease in O functionalities according to FTIR. However, Raman revealed that a large increase in graphene planar and edge defects are present as indicated by the disorder band at 1340 cm-1. Further optimization could be performed by thermal exfoliation at lower temperatures assuming a need for fewer structural defects. Graphene oxide coatings showed clear reduction with an increase with photoreduction time. Raman revealed that the reduced graphene oxide films had less disruption in the planar phonon lattice vibrations which indicates that the structure is returning to sp2 hybridization of pristine graphene without adding structural defects.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Controlling microstructure and B2 ordering kinetics in Fe–Al system through additive manufacturing

Multi-material fabrication between steel and aluminum is challenging because of the formation of several intermetallic phases. Embrittling B2 ordered intermetallics form in the steel rich side and are stable till about 60% of Al dilution in steel. In this work by using multi-length scale characterization coupled with integrated computational process and thermokinetic modeling, we show that the ordered B2 intermetallics in the steel rich side of the Fe–Al system forms via a nucleation and growth mechanism. The extent of B2 ordered intermetallics can be controlled by modifying the directed energy deposition-additive manufacturing (DED-AM) process parameters. Our findings lay the foundation for enabling fabrication of crack-free functionally graded compositions between the two alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Energy Conversion from Heat to Electricity by Highly Reversible Phase-Transforming Ferroelectrics

The search for performant multiferroic materials has attracted general research interest in energy science as they have been increasingly exploited as the conversion media among thermal, electric, magnetic, and mechanical energies by using their temperature-dependent ferroic properties. Here we report a material development strategy that guides us to discover a reversible phase-transforming ferroelectric material exhibiting enduring energy harvesting from small temperature differences. The material satisfies the crystallographic compatibility condition between polar and nonpolar phases, which shows only 2.5°C thermal hysteresis and a high figure of merit. It stably generates 15μA of electricity in consecutive thermodynamic cycles in the absence of any bias fields. We demonstrate our device to consistently generate 6μA/cm 2 current density near 100°C over 540 complete phase transformation cycles without any electric and functional degradation. The energy-conversion device can light up an LED directly without attaching an external power source. Furthermore, this promising material candidate brings the low-grade waste-heat harvesting closer to a practical realization, e.g., small temperature fluctuations around the water boiling point can be considered as a clean energy source.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Property-Graded Stainless Steel 316L by Selective Laser Melting: Characterization & Design

Abstract The purpose of this research work is to characterize and inform the design of (mechanical) property-graded bulk structures made from a single metallic alloy via a laser powder bed fusion (LPBF) process, with an end goal of creating repeatable/reproducible functionally-graded additively manufactured (FGAM) parts. This paper specifically investigates the manufacture of stainless steel (SS) 316L structures via a pulsed selective laser melting (SLM) process, and the underlying causes of property variations (within a functionally-acceptable range) through various material characterization techniques. For this, a design of experiments spanning the volumetric energy density (VED) based process parameter design space was utilized to investigate the range of functionally-acceptable physical/mechanical properties achievable in SS 316L. Five sample conditions (made via different process parameter combinations) were down-selected for in-depth microstructure analysis and mechanical/physical property characterization; these were suitably selected to impart a wide and controllable property range (209–318 HV hardness, 90–99.9% relative density, and 154–211 GPa modulus). It was observed that property variations resulted from combinations of porosity types/amounts, martensitic phase fractions, and grain sizes. Based on these findings, property-graded standard test specimens were designed and manufactured for further investigation—tensile specimens having a monotonic hardness change along its gauge length, four-point bending specimens with varying elastic moduli as a function of the distance from the neutral axis, and Moore’s rotating beam fatigue specimens with moduli variations based on the distance from the center. Altogether, this work lays the foundation for understanding and designing the local and global mechanical performance of FGAM bulk structures.

Engineering↗
DOE OSTI2023

High temperature annealing of irradiated nuclear grade graphite

Previous work has shown that the material properties of nuclear grade graphite are substantially affected by the atomic and microstructural changes that occur during neutron-irradiation. The parameters that play a role in these changes are irradiation dose, temperature, graphite composition and the initial microstructure of the graphite. Understanding the details of how these material changes occur and exactly what the changes consists of will enable the prediction of the material property changes as a function of these variables. Other work has shown these atomic level and microstructural changes can be healed or annealed out by raising the irradiated graphite above its irradiation temperature. Here in this work, experiments were carried out to investigate how the properties of irradiated graphite recover when heated. By showing property recovery as a function of annealing temperature or energy, insight is provided into the type of damage that occurred during neutron-irradiation. The data presented here shows recovery of thermal diffusivity, coefficient of thermal expansion, Young's modulus and electrical resistivity between annealing temperatures of 500 °C and 2380 °C. Graphite grades NBG-18, IG-110 and PCEA are considered that were both stressed and unstressed during irradiation.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Development and Performance of Tungsten-Coated Graphitic Foam for Plasma-Facing Components

High-density graphitic foam is an ideal low-Z plasma-facing material for deuterium-deuterium plasma experiments where tritium codeposition is not an issue. However, like all carbon, graphitic foam suffers from a precipitous drop in thermal conductivity at high temperatures, >600°C. To mitigate these problems, functionally graded layers of tungsten can be deposited to a thickness of 2 to 4 mm onto the plasma side of the foam using chemical vapor deposition. The graphitic foam then acts as a high-conductivity heat sink at temperatures below 600°C for the thin high-Z armor coating. The overall component weighs 18 times less than a comparable volume of tungsten and lacks the coefficient of thermal expansion joining issues between the CuCrZr tubing and the tungsten. This paper discusses the coating development and characterization and presents the results of recent plasma exposures in W7-X. It also reports on computational fluid dynamics heat transfer modeling and preparations for high heat flux testing of mock-ups. This hybrid plasma-facing component (PFC) consisting of innovative engineered materials may be a cost-effective, actively cooled solution for the divertors and other PFCs in long-pulse machines like W7-X and WEST.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1993

Effect of thermal processing practices on the properties of superplastic Al-Li alloys

The effect of thermal processing on the mechanical properties of superplastically formed structural components fabricated from three aluminum-lithium alloys was evaluated. The starting materials consisted of 8090, 2090, and X2095 (Weldalite(TM) 049), in the form of commercial-grade superplastic sheet. The experimental test matrix was designed to assess the impact on mechanical properties of eliminating solution heat treatment and/or cold water quenching from post-forming thermal processing. The extensive hardness and tensile property data compiled are presented as a function of aging temperature, superplastic strain and temper/quench rate for each alloy. The tensile properties of the materials following superplastic forming in two T5-type tempers are compared with the baseline T6 temper. The implications for simplifying thermal processing without degradation in properties are discussed on the basis of the results.

Hales, Stephen J.↗
DOE OSTI2025

Evaluating design safety margins in the American Society of Mechanical Engineers graphite core components design-by-analysis assessments

Graphite is an important material being used for core components in next-generation high-temperature gas-cooled nuclear reactors. The selection of graphite grade for a specific Designer is a complex task, dependent on reactor conditions, component functionality, and required reliability. The American Society of Mechanical Engineers (ASME) provides two semi-probabilistic design-by-analysis assessments to evaluate graphite core components against design reliability targets. The simplified assessment uses a 2-parameter Weibull distribution to describe the graphite grade’s tensile-strength distribution to establish component stress limits. The full assessment uses the 3-parameter Weibull distribution and a modified Weakest-Link Theory approach to calculate a component design probability of failure. The paper defines recommended assessment rules, which are the as-written simplified assessment and the full assessment with parameter lower bounds, the modulus update with threshold reduction, and the 2027 grouping rules. Code rules are applied to three grades: 2114, IG-110, and NBG-18. The baseline margin calculation is developed using the experimental tensile dogbone specimen. Percent margin is defined as the percent reduction in the median experimental load to obtain the allowable load per ASME assessments. Under the recommended rules, the SRC–1 margin in the simplified assessment ranged from 40.2 % to 52.7 % among the grades in this study and from 36.1 % to 49.8 % in the full assessment. The full assessment only decreases the margins by 2.5–4.5 % for the SRC-1 components and 0–1.5 % for the SRC-2 components for this baseline case. Margin is inversely related to material median strength (i.e., the strongest grade, 2114, has the lowest margin).

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2011

Properties and Performance Attributes of Novel Co-Extruded Polyolefin Battery Separator Materials: Mechanical Properties - Part 1

As NASA prepares for its next era of manned spaceflight missions, advanced energy storage technologies are being developed and evaluated to address future mission needs and technical requirements and to provide new mission-enabling technologies. Cell-level components for advanced lithium-ion batteries possessing higher energy, more reliable performance and enhanced, inherent safety characteristics are actively under development within the NASA infrastructure. A key component for safe and reliable cell performance is the cell separator, which separates the two energetic electrodes and functions to prevent the occurrence of an internal short-circuit while enabling ionic transport. Recently, a new generation of co-extruded separator films has been developed by ExxonMobil Chemical and introduced into their battery separator product portfolio. Several grades of this new separator material have been evaluated with respect to dynamic mechanical properties and safety-related performance attributes. This paper presents the results of these evaluations in comparison to a current state-ofthe-practice separator material. The results are discussed with respect to potential opportunities to enhance the inherent safety characteristics and reliability of future, advanced lithium-ion cell chemistries.

Baldwin, Richard S.↗