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At least 19 records

All sources NASA NTRS DOE OSTI

NASA NTRS1995

Reactively Deposited Aluminum Oxide and Fluoropolymer Filled Aluminum Oxide Protective Coatings for Polymers

Reactive ion beam sputter deposition of aluminum simultaneous with low energy arrival of oxygen ions at the deposition surface enables the formation of highly transparent aluminum oxide films. Thick (12 200 A), adherent, low stress, reactively deposited aluminum oxide films were found to provide some abrasion resistance to polycarbonate substrates. The reactively deposited aluminum oxide films are also slightly more hydrophobic and more transmitting in the UV than aluminum oxide deposited from an aluminum oxide target. Simultaneous reactive sputter deposition of aluminum along with polytetrafluoroethylene (PTFE Teflon) produces fluoropolymer-filled aluminum oxide films which are lower in stress, about the same in transmittance, but more wetting than reactively deposited aluminum oxide films. Deposition properties, processes and potential applications for these coatings will be discussed.

Rutledge, Sharon K.↗

NASA NTRS1993

Calcium citrate without aluminum antacids does not cause aluminum retention in patients with functioning kidneys

It has been suggested that calcium citrate might enhance aluminum absorption from food, posing a threat of aluminum toxicity even in patients with normal renal function. We therefore measured serum and urinary aluminum before and following calcium citrate therapy in patients with moderate renal failure and in normal subjects maintained on constant metabolic diets with known aluminum content (967-1034 mumol/day, or 26.1-27.9 mg/day, in patients and either 834 or 1579 mumol/day, or 22.5 and 42.6 mg/day, in normal subjects). Seven patients with moderate renal failure (endogenous creatinine clearance of 43 ml/min) took 50 mmol (2 g) calcium/day as effervescent calcium citrate with meals for 17 days. Eight normal women received 25 mmol (1 g) calcium/day as tricalcium dicitrate tablets with meals for 7 days. In patients with moderate renal failure, serum and urinary aluminum were normal before treatment at 489 +/- 293 SD nmol/l (13.2 +/- 7.9 micrograms/l) and 767 +/- 497 nmol/day (20.7 +/- 13.4 micrograms/day), respectively. They remained within normal limits and did not change significantly during calcium citrate treatment (400 +/- 148 nmol/l and 600 +/- 441 nmol/day, respectively). Similarly, no significant change in serum and urinary aluminum was detected in normal women during calcium citrate administration (271 +/- 59 vs 293 +/- 85 nmol/l and 515 +/- 138 vs 615 +/- 170 nmol/day, respectively). In addition, skeletal bone aluminum content did not change significantly in 14 osteoporotic patients (endogenous creatinine clearance of 68.5 ml/min) treated for 24 months with calcium citrate, 10 mmol calcium twice/day separately from meals (29.3 +/- 13.9 ng/mg ash bone to 27.9 +/0- 10.4, P = 0.727). In them, histomorphometric examination did not show any evidence of mineralization defect. Thus, calcium citrate given alone without aluminum-containing drugs does not pose a risk of aluminum toxicity in subjects with normal or functioning kidneys, when it is administered on an empty stomach at a recommended dose of 20 mmol calcium/day.

Non-NASA Center↗

DOE OSTI2021

High-Field One-Dimensional and Two-Dimensional 27Al Magic-Angle Spinning Nuclear Magnetic Resonance Study of ?-, d-, and ?-Al2O3 Dominated Aluminum Oxides: Toward Understanding the Al Sites in ?-Al2O3

Herein, a detailed analysis was carried out using high-field (19.9 T) 27Al magic-angle spinning (MAS) nuclear magnetic resonance (NMR) on three specially prepared aluminum oxide samples where the ?-, d-, and ?-Al2O3 phases are dominantly expressed through careful control of the synthesis conditions. Specifically, two-dimensional (2D) multiquantum (MQ) MAS 27Al was used to obtain high spectral resolution, which provided a guide for analyzing quantitative 1D 27Al NMR spectra. Six aluminum sites were resolved in the 2D MQ MAS NMR spectra, and seven aluminum sites were required to fit the 1D spectra. A set of octahedral and tetrahedral peaks with well-defined quadrupolar line shapes was observed in the ?-phase dominant sample and was unambiguously assigned to the ?-Al2O3 phase. The distinct line shapes related to the ?-Al2O3 phase provided an opportunity for effectively deconvoluting the more complex spectrum obtained from the d-Al2O3 dominant sample, allowing the peaks/quadrupolar parameters related to the d-Al2O3 phase to be extracted. The results show that the d-Al2O3 phase contains three distinct AlO sites and three distinct AlT sites. This detailed Al site structural information offers a powerful way of analyzing the most complex ?-Al2O3 spectrum. It is found that the ?-Al2O3 phase consists of Al sites with local structures similar to those found in the d-Al2O3 and ?-Al2O3 phases albeit with less ordering. Spin–lattice relaxation time measurement further confirms the disordering of the lattice. Collectively, this study uniquely assigns 27Al features in transition aluminas, offering a simplified method to quantify complex mixtures of aluminum sites in transition alumina samples.

Xu, Suochang↗

DOE OSTI2026

Impact of Molten Gallium on the Microstructure and Corrosion Behavior of Aluminum and Uranium-Aluminum Alloys for Used Nuclear Fuel Reprocessing

Test reactors around the world utilize highly enriched uranium fuel to achieve high neutron fluxes for materials testing. Once spent, the remaining uranium is a valuable resource for subsequent fuel fabrication. However, some of these test reactor cores consist of curved plate-type fuel elements, fabricated using aluminum alloy 6061 (AA6061) cladding to encapsulate a uranium-aluminum alloy (UAlx) fuel matrix. These assemblies require non-standard reprocessing approaches for uranium recovery, as aluminum dissolves readily in acidic solutions, generating large volumes of waste and complicating downstream chemical separations. In this work, we investigate a novel chemical decladding strategy based on the interaction between AA6061/UAlx and molten gallium (Ga). Ga is known to induce severe degradation of aluminum metal through liquid metal embrittlement (LME), even at relatively low Ga concentrations. By penetrating the aluminum crystal lattice, Ga disrupts grain cohesion and facilitates fracture or dissolution of the aluminum matrix. Thermodynamic analysis of the Al–Ga binary phase diagram suggests that Ga may offer a viable pathway to selectively weaken or dissolve the AA6061 cladding, and potentially the aluminum component of the UAlx fuel matrix within. To this end, parametric experiments were performed at 50 °C and 100 °C across a range of Al–Ga atomic fractions. At lower Al fractions, the AA6061 was completely molten after 2 hours of exposure to the Ga metal. In contrast, samples with higher Al fractions (0.9 Al, 0.1 Ga) contained residual solids after 2 hours, which were characterized by microstructural examination using electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM). These Al-Ga compositions were also evaluated using FactSage thermodynamic modeling to further elucidate the relationship between phase diagram behavior and LME.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

A Sobering Examination of the Feasibility of Aqueous Aluminum Batteries

Recent reports on aqueous aluminum (Al) batteries boast encouraging metrics including high energy density, nonflammability, and low raw material cost. However, the poorly understood solvation environment around the trivalent aluminum ions (Al3+) raises uncertainty regarding their feasibility. Furthermore, the corrosiveness of the acidic solutions and degree of hydration of aluminum trifluoromethanesulfonate (Al(OTf)3) salt is routinely mischaracterized. This study provides a rigorous examination of aqueous Al electrolytes, with the first compelling evidence for a dynamic octahedral solvation structure around Al3+ dominated by labile water and OH-, without Al-OTf contact ion pairs, at high concentrations. This solvation behavior and the concomitant electrostatic hydrolysis differs greatly from previously reported water-in-salt electrolytes, and occurs due to the high charge density of the Lewis acidic Al3+. Nuclear magnetic resonance spectroscopy and other physicochemical measurements quantitatively reveal how species activity evolves with concentration. The high proton activity observed in transport and electrochemical measurements constitutes a prohibitive barrier to the feasibility of rechargeable aluminum batteries with aqueous electrolyte.

Pastel, Glenn R.↗

NASA NTRS1998

Properties Data for Adhesion and Surface Chemistry of Aluminum: Sapphire-Aluminum, Single-Crystal Couple

An investigation was conducted to examine the adhesion and surface chemistry of single-crystal aluminum in contact with single-crystal sapphire (alumina). Pull-off force (adhesion) measurements were conducted under loads of 0. I to I mN in a vacuum of 10(exp -1) to 10(exp -9) Pa (approx. 10(exp -10) to 10(exp -11) torr) at room temperature. An Auger electron spectroscopy analyzer incorporated directly into an adhesion-measuring vacuum system was primarily used to define the chemical nature of the surfaces before and after adhesion measurements. The surfaces were cleaned by argon ion sputtering. With a clean aluminum-clean -sapphire couple the mean value and standard deviation of pull-off forces required to separate the surfaces were 3015 and 298 micro-N, respectively. With a contaminated aluminum-clean sapphire couple these values were 231 and 241 micro-N. The presence of a contaminant film on the aluminum surface reduced adhesion by a factor of 13. Therefore, surfaces cleanliness, particularly aluminum cleanliness, played an important role in the adhesion of the aluminum-sapphire couples. Pressures on the order of 10(exp -8) to 10(exp -9) Pa (approx. 10(exp -10) to 10(exp -11) torr) maintained a clean aluminum surface for only a short time (less then 1 hr) but maintained a clean sapphire surface, once it was achieved, for a much longer time.

Miyoshi, Kazuhisa↗

DOE OSTI2021

On the interactions between molten aluminum and high entropy alloy particles during aluminum matrix composite processing

The feasibility of adding AlCrTiV high entropy alloy (HEA) particles to molten aluminum to make metal matrix composites was studied. Equiatomic AlCrTiV HEA particles, produced by a solid state reduction process, were dispersed into pure aluminum and 7075 alloy (Al-5.8Zn-2.3Mg-1.4Cu, all weight %) melt and by a ultrasonic dispenser. It was found that the AlCrTiV particles reacted with molten aluminum, leading to the formation of Al 45 (Cr,V) 7 and Al 3 Ti intermetallic phases in the aluminum matrix composites. Although the AlCrTiV HEA particles did not survive in molten aluminum during composite processing, the final composite materials showed significantly improved mechanical properties, due to grain refinement and dispersion strengthening. Finally, the research suggests that the interactions between matrix aluminum alloys and the particles are key in controlling the final microstructure and properties of the composites.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Evaluation of Radiolysis Data for Hydrogen Gas Generation During Gamma Irradiation of Pre-Corroded and Pristine Aluminum Samples - An Aluminum SNF Dry Storage Study Interim Report

Information and data from radiolysis testing to measure hydrogen (H₂) generated from hydrated oxides on aluminum exposed to ⁶⁰Co radiation were reviewed to evaluate hydrogen generation with radiation dose. Hydrogen generation rate is a primary input to the coupled thermal-chemical system model of the performance of aluminum-clad spent nuclear fuel in a dry storage canister (ASNF-in-canister) over its storage life. Hydrogen generation data and hydrogen generation rate (hydrogen generated per absorbed radiation dose, $\Delta$(H₂)/$\Delta$(dose)) were reported in two reports for radiolysis testing [1, 2]. The testing involved first-time data¹ for radiolytic yield of hydrogen from hydrated-oxides-on-aluminum substrates, and from pristine (non-corroded) aluminum substrates. The laboratory-grown hydrated-oxides-on-aluminum substrates contained a ~ 5 μm film consisting of the trihydroxide bayerite (Al(OH)₃) with amounts of the oxyhydroxide boehmite (AlOOH). These specimens were assumed to also contain physisorbed water (unquantified). The pristine substrates were flat coupons of aluminum that were ground to a 600-grit finish but were not immersed in water to grow a hydrated oxide. The pristine substrates were tested as companion specimens to provide information on hydrogen generation from material without chemisorbed water and were assumed to contain physisorbed water (unquantified).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1990

X-ray photoelectron spectroscopy study of catalyzed aluminum carbide formation at aluminum-carbon interfaces

Aluminum carbide may form at aluminum-graphite interfaces during the high-temperature processing of graphite fiber-reinforced aluminum metal matrix composites. The chemical interactions leading to the formation of the aluminum carbide in the solid state involve the breaking of the carbon-carbon bonds within the graphite, the transport of the carbon atoms across the interface, and the reaction with the aluminum to form Al4C3. The aluminum carbide formation process has been followed using X-ray photoelectron spectroscopy of model, thin-film, reaction couples. The overall reaction is shown to be catalyzed by the presence of water vapor. Water at the interface increases reaction kinetics by apparently weakening the bonds between the surface carbon atoms and their substrate. This result is in general agreement with what is known to occur during the oxidation of graphite in air.

Rabenberg, L.↗

NASA NTRS2013

Investigation of Methods for Selectively Reinforcing Aluminum and Aluminum-Lithium Materials

Several studies have indicated that selective reinforcement offers the potential to significantly improve the performance of metallic structures for aerospace applications. Applying high-strength, high-stiffness fibers to the high-stress regions of aluminum-based structures can increase the structural load-carrying capability and inhibit fatigue crack initiation and growth. This paper discusses an investigation into potential methods for applying reinforcing fibers onto the surface of aluminum and aluminum-lithium plate. Commercially-available alumina-fiber reinforced aluminum alloy tapes were used as the reinforcing material. Vacuum hot pressing was used to bond the reinforcing tape to aluminum alloy 2219 and aluminum-lithium alloy 2195 base plates. Static and cyclic three-point bend testing and metallurgical analysis were used to evaluate the enhancement of mechanical performance and the integrity of the bond between the tape and the base plate. The tests demonstrated an increase in specific bending stiffness. In addition, no issues with debonding of the reinforcing tape from the base plate during bend testing were observed. The increase in specific stiffness indicates that selectively-reinforced structures could be designed with the same performance capabilities as a conventional unreinforced structure but with lower mass.

Bird, R. Keith↗

DOE OSTI2023

Model for Humidity-Mediated Diffusion on Aluminum Surfaces and Its Role in Accelerating Atmospheric Aluminum Corrosion

Bare aluminum metal surfaces are highly reactive, which leads to the spontaneous formation of a protective oxide surface layer. Because many subsequent corrosive processes are mediated by water, the structure and dynamics of water at the oxide interface are anticipated to influence corrosion kinetics. Here, using molecular dynamics simulations with a reactive force field, we model the behavior of aqueous aluminum metal ions in water adsorbed onto aluminum oxide surfaces across a range of ion concentrations and water film thicknesses corresponding to increasing relative humidity. We find that the structure and diffusivity of both the water and the metal ions depend strongly on the humidity of the environment and the relative height within the adsorbed water film. Aqueous aluminum ion diffusion rates in water films corresponding to a typical indoor relative humidity of 30% are found to be more than 2 orders of magnitude slower than self-diffusion of water in the bulk limit. Connections between metal ion diffusivity and corrosion reaction kinetics are assessed parametrically with a reductionist model based on a 1D continuum reaction–diffusion equation. Our results highlight the importance of incorporating the properties specific to interfacial water in predictive models of aluminum corrosion.

36 MATERIALS SCIENCE↗

NASA NTRS1972

Time exposure studies on stress corrosion cracking of aluminum 2014-T6, aluminum 7075-T651, and titanium 6Al-4V

The effect of a constant applied stress in crack initiation of aluminum 2014-T6, 7075-T651 and titanium 6A1-4V has been investigated. Aluminum c-ring specimens (1-inch diameter) and u-band titanium samples were exposed continuously to a 3.5% NaCl solution (pH 6) and organic fluids of ethyl, methyl, and iso-propyl alcohol (reagent purity). Corrosive action was observed to begin during the first and second day of constant exposure as evidenced by accumulation of hydrogen bubbles on the surface of stressed aluminum samples. However, a similar observation was not noted for titanium stressed specimens. Results of this investigation seems to suggest that aluminum 2014-T6, aluminum 7075-T651 are susceptible to stress corrosion cracking in chloride solution (NaCl); while they (both alloys) seem to resist stress corrosion cracking in methyl alcohol, ethyl alcohol, iso-propyl alcohol, and demineralized distilled water. Titanium 6A1-4V showed some evidence of susceptibility to SCC in methanol, while no such susceptibility was exhibited in ethanol, iso-propyl alcohol and demineralized distilled water.

Terrell, J.↗

NASA NTRS1979

Wear of aluminum and hypoeutectic aluminum-silicon alloys in boundary-lubricated pin-on disk sliding

The friction and wear of pure aluminum and a number of hypoeutectic aluminum-silicon alloys (with 3 to 12 wt %Si) were studied with a pin-on-disk apparatus. The contacts were lubricated with mineral oil and sliding was in the boundary-lubrication regime at 2.6 cm/sec. Surfaces were analyzed with photomicrographs, scanning electron microscopy, X-ray dispersive analysis, and diamond pyramid hardness measurements. There were two wear regimes for the alloys - high and low - whereas pure aluminum exhibited a high wear rate throughout the test period. Wear rate decreased and the transition stress from high to low wear increased with increasing hardness. There was no correlation between friction coefficient and hardness. A least squares curve fit indicated a wear-rate dependence greater than the inverse first power of hardness. The lower wear rates of the alloys may be due to the composites of silicon platelets in aluminum resulting in increased hardness and thus impairing the shear of the aluminum.

Ferrante, J.↗

NASA NTRS1984

Aluminum chloride formation on Space Shuttle aluminum oxide

Samples of particulates collected from the exhaust of Space Shuttle launches STS-1, -4, -5, -6, and -7 were analyzed. Scanning electron microscopy and X-ray diffractometry of these samples indicated that the particulates were spherical and predominantly composed of aluminum oxide. The water-soluble weight fraction, pH, acid-soluble weight fraction, and insoluble weight fraction were determined for each sample. Water-soluble weight fractions averaged about 7 percent of the total sample weight, were generally very acidic, and contained significantly elevated concentrations of chloride and aluminum (III) ion. The high concentrations of soluble aluminum (III) and chloride ions observed suggested that aluminum chlorides and/or oxychlorides had formed on the surface of the alumina particulates. More than 72 percent by weight of each sample was insoluble in either water or strong mineral acid, and was identified as alpha-Al2O3. The results from these analyses suggest that the surface of Space Shuttle exhaust alumina particulates will be highly acidic and heavily chlorided, and that a substantial amount of the surface chloride may be chemically associated with aluminum (III) ions rather than just physically adsorbed as HCl.

Cofer, W. R., III↗

NASA NTRS1990

Chemical interactions in the aluminum-carbon and aluminum-silicon carbide systems

XPS was used to investigate the influence of O2 and H2O on the formation of aluminum carbide at Al-C and Al-SiC interfaces. It was determined that dosing the interfaces with H2O catalyzed the formation of aluminum carbide in both systems. This result is consistent with the oxidation model of carbide formation (developed to understand the kinetics of aluminum carbide formation at graphite-aluminum interfaces). These results imply that the formation of aluminum carbide in graphite- and SiC-reinforced metal-matrix composites, which severely degrades the composite mechanical properties by degrading the fiber and interface strength is catalyzed.

Maruyama, Benji↗

DOE OSTI2020

Effect of Aluminum Oxide on the Performance of Ionic Liquid-Based Aluminum–Air Battery

The aluminum–air (or oxygen) battery has received intense attention in the past because of its excellent benefits such as low cost and high energy density, but due to the challenging issues such as hydrogen evolution and inactive oxide film formation on the Al surface, it could not be fully applied. In this study, 1-Ethyl 3-Methyl Imidazolium Chloride ([EmIm]Cl) and aluminum chloride (AlCl3) are applied to resolve the aforementioned issues. Ex situ component-level and in situ cell-level open circuit voltage (OCV) tests combined with the physics-based model analyses were conducted to investigate the electrochemical reaction behaviors of the Al–air cell. Especially, the effect of aluminum oxide formation on the anode- and cathode-side reactions were analyzed in detail. The oxide film formed at the Al surface strongly was found to significantly impede the electrochemical reaction at the surface, and the film growth was controlled by decreasing the surface tension by aggressive anions. In the cathode side, the aluminum oxide precipitated in the porous cathode electrode was found to decrease the porous reaction area and block reactant access into the reaction sites. The effects of O2 solubility in the electrolyte, initial porosity and thickness of the porous electrode are compared in detailed, and optimal thickness is suggested.

25 ENERGY STORAGE↗

NASA NTRS1995

Structural Damage Prediction and Analysis for Hypervelocity Impact: Properties of Largest Fragment Produced by Hypervelocity Impact of Aluminum Spheres with Thin Aluminum Sheets

Results of a series of hypervelocity impact tests are presented. In these tests, 1.275-g, 9.53-mm-diameter, 2017-T4 aluminum spheres were fired at normal incidence at eight thicknesses of 6061-T6 aluminum sheet. Bumper thickness to projectile diameter (t/D) ratio ranged from 0.026 to 0.424. Nominal impact velocity was 6.7 km/s. Results of five tests using 6.35, 9.53, and 12.70-mm-diameter aluminum spheres and other aluminum alloy bumpers are also given. A large chunky fragment of projectile was observed at the center of the debris clouds produced by the impacts. The equivalent diameter of this large fragment ranged from 5.5 mm for the lowest t/D ratio to a minimum of 0.6 mm for the case where maximum breakup of the projectile occurred (t/D approximately 0.2 to 0.3). When the t/D ratio was 0.42, numerous large flaky fragments were evenly distributed in the external bubble of bumper debris. Velocity of the large central fragments decreased continuously with increasing t/D ratio, ranging from about 99 percent to less than 80 percent of the impact velocity. The change in the velocity of small fragments spalling from the rear of the projectile was used to obtain a relationship showing a linear increase in the size of the central projectile fragment with decrease in the shock-induced stress in the projectile.

Piekutowski, Andrew J.↗

NASA NTRS2003

Effects of Forged Stock and Pure Aluminum Coating on Cryogenic Performance of Heat Treated Aluminum Mirrors

In spite of its baseline mechanical stress relief, aluminum 6061-T651 harbors some residual stress that may relieve and distort mirror figure to unacceptable levels at cryogenic operating temperatures unless relieved during fabrication. Cryogenic instruments using aluminum mirrors for both ground-based and space IR astronomy have employed a variety of heat treatment formulae, with mixed results. We present the results of an on-going test program designed to empirically determine the effects of different stress relief procedures for aluminum mirrors. Earlier test results identified a preferred heat treatment for flat and spherical mirrors diamond turned from blanks cut out of Al6061-T651 plate stock. Further tests have been performed on mirrors from forged stock and one set from plate stock coated with Alumiplate(TM) aluminum coating to measure the effect of these variables on cryogenic performance. The mirrors are tested for figure error and radius of curvature at room temperature and at 80 K for three thermal cycles. We correlate the results of our optical testing with heat treatment and metallographic data.

Toland, Ronald↗