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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 19 records

An experimental investigation of silicon wafer surface roughness and its effect on the pull-strength of plated metals

Plated silicon wafers with surface roughness ranging from 0.4 to 130 microinches, subjected to tensile pull-strength tests, were analyzed. Results show that the measured pull-strength of plated metals decrease with increasing silicon surface roughness, effecting a weakening of the cohesive strength of the wafer, possibly caused by microcracks or 'etch pits' in the silicon surface. The mean value of pull-strength for all wafers plated with the Ni-Cu-Cu sequence exceeded the required 450 g/0.02 sq cm, and at Ra = 0.4 microinches, the mean pull-strength for the Ni-Cu-Cu and Ni-Cu wafers were 2290 and 850 g/0.02 sq cm, respectively. The development of standardized methods for measuring contact pull-strength is suggested. These results may have some bearing on solar cell arrays problems.

Spiers, G. D.↗

An experimental investigation of silicon wafer surface roughness and its effect on the full strength of plated metals

Plated silicon wafers with surface roughness ranging from 0.4 to 130 microinches were subjected to tensile pull strength tests. Electroless Ni/electroless Cu/electroplated Cu and electroless Ni/electroplated Cu were the two types of plate contacts tested. It was found that smoother surfaces had higher pull strength than rougher, chemically etched surfaces. The presence of the electroless Cu layer was found to be important to adhesion. The mode of fracture of the contact as it left the silicon was studied, and it was found that in almost all cases separation was due to fracture of the bulk silicon phase. The correlation between surface roughness and mode of contact failure is presented and interpreted.

Spiers, G. D.↗

Delayed Critical and Subcritical Experiments with Polyethylene Moderated Unreflected Thin 15 in. Diameter HEU Metal Plates

The thin ~15 in. diameter highly enriched uranium (HEU) metal plates were assembled to delayed criticality at the Oak Ridge Critical Experiments Facility (ORCEF) in 1969 with various thicknesses of polyethylene (varying from 1/16 to 2$\frac{3}{8}$ inches) between uranium metal plates. The average 235 U enrichment was 93.27 wt. %. These unreflected critical configurations contained 4$\frac{2}{3}$ to 20$\frac{5}{6}$ thin 15 in. diameter HEU metal plates (on loan from Los Alamos National Laboratory [LANL] and shipped to Oak Ridge National Laboratory [ORNL] on June 3, 1969). Depending on the thickness of polyethylene, the enriched uranium masses varying from 28,053 to 135,148 grams. Fractional plate sections consisted of the appropriate number of 60° pie sections. In addition to the measurement at delayed criticality, subcritical measurements were also performed by the inverse kinetic rod drop method. Prompt neutron decay constant measurements were also performed by the Rossi alpha and randomly pulsed neutron method using a time-tagged spontaneous fission californium neutron source; these are briefly reported here. At the time of these measurements in 1969, the thin HEU metal plates were in near-pristine condition with extremely little oxidation, allowing better descriptions of the uranium plates than the use of these plates in a heavily oxidized and deteriorated condition in recent reflected benchmark experiments at the LANL facility at the Nevada Test Site with these same thin highly enriched uranium metal plates. This report documents the experimental information for the measurements performed so that later researchers can perform the required uncertainty and calculational analyses and documentation to use these data for an International Nuclear Criticality Safety Benchmark Evaluation Program (ICSBEP) or a Nuclear Energy Agency (NEA) benchmark. Data from the experiments described should be acceptable for use as criticality safety benchmark experiments for the ICSBEP and the NEA nuclear criticality safety benchmark program once the uncertainty analysis on the measured neutron multiplication factors is completed. Additional data—such as the dimensional inspection reports, uranium isotopic information, and other relevant particulars—should be retrieved from the Y-12 Plant or LANL and incorporated in the final ICSBEP benchmark. Based on previous ICSBEP benchmarks with this enriched uranium metal at ORCEF, the uncertainties in $k_{eff}$ could be as low as ± 0.0002 for some configurations. Other experiments with smaller-diameter than 15 in. diameter HEU metal plates have been benchmarked in HEU-METFAST-001. The prompt neutron time decay measurements could be the basis for an International Reactor Physics Benchmark Program. Preparation of the present report is part of an effort at ORNL to document more than 15 undocumented critical and subcritical experiments enumerated in ORNL/TM-2019/18 and performed by ORNL at ORCEF and other US Department of Energy critical experiments facilities using more than 500 operational days of critical facility time. This work for this report publication was supported by the Nuclear Criticality, Radiation Transport and Safety NCSP Program at ORNL.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Metals plated on fluorocarbon polymers

Electroplating lead on fluorocarbon polymer parts is accomplished by etching the parts to be plated with sodium, followed by successive depositions of silver and lead from ultrasonically agitated plating solutions. Metals other than lead may be electroplated on the silvered parts.

Ford, H.↗

Understanding ion-selective Li/Na metal plating behavior in hybrid Li-Na battery

This study investigates ion-selective Li/Na metal plating behavior in hybrid Li-Na battery systems, revealing the critical role of electrolyte solvents in these processes. Using a hybrid battery design with a LiFePO 4 cathode, Na metal anode, and NaPF 6 -based electrolytes, we observed contrasting effects of carbonate- and ether-based electrolyte solvents. While ether-based electrolytes showed expected Na plating/stripping, carbonate-based electrolytes surprisingly favored a Li-dominant plating/stripping reaction despite the Na-rich environment. X-ray photoelectron spectroscopy revealed that this selectivity is linked to the composition of the solid electrolyte interphase (SEI) layer, with carbonate electrolytes forming Li-based inorganic-rich SEI layers that facilitate Li-ion diffusion while screening Na ions. In conclusion, these findings challenge the conventional understanding of metal plating in multi-ion environments and offer insights for designing future hybrid battery systems.

25 ENERGY STORAGE↗

Transient Adjustments for Metal-Sheathed Thermocouples on Metal Plates (Shrouds)

This report provides guidance on how to adjust temperature measurements from mineral-insulated, metal-sheathed (MIMS) thermocouples (TCs) mounted on metal plates to correct for slow transient response. This information is needed so that more accurate transient temperature measurements can be made. These more accurate temperature measurements are of benefit for both qualification of hardware and as data sets for model validation. The approach was to use a relatively simple first order adjustment to the MIMS TC reading, as compared to a more accurate metal plate temperature measurement. MIMS TCs are used to improve reliability. Results from four data sets were analyzed to determine the time constraint; an overall average of 5.0 s was obtained.

42 ENGINEERING↗

The Pd2Si - /Pd/ - Ni - solder plated metallization system for silicon solar cells

The rationale and application of a plated metal system, Pd2Si Pd - Ni - solder, is presented. This metallization system is particularly useful on shallow p-n junction solar cells. The advantages of such plated solar cell contacts are discussed. A process sequence for applying the metallization system is outlined. A specific example is presented, including chemical plating solution formulations and detailed process step descriptions. Electrical test data for solar cells metallized with the palladium-nickel-solder system are provided.

Coleman, M. G.↗

Detection and characterization of fatigue cracks in thin metal plates by low frequency resonant model analysis

Low-frequency resonant model analysis, a technique for the detection and characterization of fatigue cracks in thin metal plates, which could be adapted to rapid scan or large area testing, is considered. Experimental data displaying a direct correlation between fatigue crack geometry and resonance frequency for the second vibrational plate mode are presented. FEM is used to calculate the mechanical behavior of the plates, and provides a comparison basis for the experimentally determined resonance frequency values. The waveform of the acoustic emission generated at the resonant frequency is examined; it provides the basis for a model of the interaction of fatigue crack faces during plate vibration.

Wincheski, B.↗

Pristine or Highly Defective? Understanding the Role of Graphene Structure for Stable Lithium Metal Plating

The role of graphene host structure/chemistry in plating–stripping in lithium metal anodes employed for lithium metal batteries is first examined in this study. Structural and chemical defects are bad, since highly defective graphene promotes unstable solid electrolyte interphase (SEI) growth. This consumes the fluoroethylene carbonate (FEC) additive in the carbonate electrolyte and is correlated with rapid decay in Coulombic efficiency (CE) and formation of filament-like Li dendrites. A unique flow-aided sonication exfoliation method is employed to synthesize “defect-free” graphene (df-G), allowing for a direct performance comparison with conventional reduced graphene oxide (r-GO). At cycle 1, the r-GO is better electrochemically wetted by Li than df-G, indicating that initially it is more lithiophilic. With cycling, the nucleation overpotential with r-GO becomes higher than with df-G, indicating less facile plating reactions. The df-G yields state-of-the-art electrochemical performance, with the post cycled metal surface being relatively smooth and dendrite-free. Conversely, r-GO templates have CE rapidly degrade from the onset, with extensive dendrites after cycling. Severe SEI growth and associated FEC depletion with r-GO are further confirmed by electrochemical impedance analysis and surface science methods. Finally, a new design rule is provided for Li metal templates: An ideal host must be noncatalytic toward SEI formation.

36 MATERIALS SCIENCE↗

Empirical Formula for Puncture Energy of Flat Metal Plates by a Cylindrical Flat Punch

Impact problems of plate-like parts by punch-like objects with relatively large mass moving at slow speeds of a few feet per second constitute a subset of impact problems of interest at Sandia. This is in contrast to small objects moving in the range of hundreds or thousands of feet per second or higher. The objective of this work is to develop a simple formula that can be used to estimate a lower bound for the puncture energy of metal plates impacted by cylindrical, essentially rigid punches of circular cross-section and at nose. Such geometry is used as a basis in the design of puncture mitigation barriers or procedures. This was accomplished by deriving an expression using non-dimensional analysis and then calibrating it based on tests results in the range of speeds of interest. Lower bounds can then be determined based on confidence intervals or factors of safety.

36 MATERIALS SCIENCE↗

Electromagnetic Scattering From a Polygonal Thin Metallic Plate Using Quadrilateral Meshing

The problem of electromagnetic (EM) scattering from irregularly shaped, thin, metallic flat plates in free space is solved using the electric field integral equation (EFIE) approach in conjunction with the method of moments (MoM) with quadrilateral meshing. An irregularly shaped thin plate is discretized into quadrilateral patches and the unknown electric surface current over the plate is expressed in terms of proper basis functions over these patches. The basis functions for the electric surface current density that satisfy the proper boundary conditions on these quadrilateral patches are derived. The unknown surface current density on these quadrilateral patches is determined by setting up and solving the electric field integral equation by the application of the MoM. From the knowledge of the surface current density, the EM scattering from various irregularly shaped plates is determined and compared with the earlier published results. The novelty in the present approach is the use of quadrilateral patches instead of well known and often used triangular patches. The numerical results obtained using the quadrilateral patches compare favorably with measured results.

Deshpande, Manohar D.↗

Forming Weld Lands On Metal Plates

Forming shoe pounds edge of newly inserted plate workpiece. After many passes of shoe and advances of plate, thick land builds up at edge. Workpiece heated to enable metal to flow without strain hardening. Proposed upset-forming process replaces relatively expensive, time-consuming, and wasteful process in which integral weld lands created by machining metal away from plates everywhere except at lands.

Weddendorf, Bruce↗

Thermal conductance of gold plated metallic contacts at liquid helium temperatures

The thermal conductance of gold plated OFHC copper, 6061-T6 aluminum, free-machining brass, and 304 stainless steel contacts has been measured over the temperature range of 1.6 to 4.2 K, with applied forces from 22 N to 670 N. The contact surfaces were prepared with a 0.8 micron lapped finish prior to gold coating. It was found that for all materials, except stainless steel, the thermal conductance was significantly improved as the result of gold coating the contact surfaces.

Kittel, Peter↗