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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS2025

A Review of Direct Ink Writing of Polymer Derived Ceramics

With the growing demand for materials capable of withstanding extreme temperatures and pressures, ceramic components with exceptional corrosion resistance and reliable mechanical properties have experienced a significant surge in demand. However, traditional ceramic forming methods involve high-temperatures and energy-intensive processes that often struggle to produce complex parts or composites efficiently. Polymer-Derived Ceramics (PDCs) offer a transformative solution by using polymeric precursors that can be converted into a wide variety of silicon-based and non-silicon-based ceramics through heat treatment. The polymeric nature of PDC precursors enables the fabrication of geometrically intricate components using conventional polymer-forming techniques at significantly lower processing temperatures. Furthermore, PDCs are well-suited for additive manufacturing (AM), allowing the production of complex structural and functional components through cost-effective, low-temperature processes. By leveraging the diverse properties of PDC materials – each with unique advantages and limitations – manufacturers can optimise performance for specific applications. This review provides an overview of the types of PDCs developed to date and their broad range of applications. Specifically, it delves into the Direct Ink Writing (DIW) process, exploring its rheological requirements and the critical role of fillers in tailoring the rheological properties of polymeric precursors to meet the specific demands of DIW.

Victoria Bishop↗
DOE OSTI2023

Flux expulsion and material properties of Nb

Upcoming projects requiring high-Q ~650 MHz medium-to-high-! elliptical cavities drive a need to understand magnetic RF loss mechanisms and mitigations in greater detail. We explore the fastcooldown method, and high-temperature annealing (900°C) in 644- 650 MHz SRF cavities fabricated from two different niobium vendors: Tokyo-Denkai (TD), and Ningxia (NX). Using EBSD and PPMS methods, we aim to trace cavity flux expulsion efficiency to specific, measurable properties of the bulk niobium material, which, if identified, can lead to methods by which the flux expulsion properties of Nb material can be predicted prior to cavity fabrication.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

High Flux Microchannel Receiver Development (Final Report)

The opportunity addressed in this project was using microscale heat exchanger technology for improving solar thermal central receiver efficiency. This will result in smaller, less expensive components and reduce the levelized cost of electricity from concentrated solar thermal power. This micro-pin solar receiver (MSR) directly heats high pressure (25 MPa) supercritical carbon dioxide (sCO 2 ) from 550°C to 720°C with an incident flux of at least 120 W/cm 2 at a receiver efficiency of >90% (assuming availability of 95% absorptivity coating), and receiver cost target of less than $\$$150/kWt. Realization of the MSR required an understanding of thermal hydraulic performance of sCO 2 in micro-pin passages, mechanical behavior of high nickel alloys at high temperatures including joints, advanced fabrication methods of high nickel alloys (etching, machining, brazing, welding, diffusion bonding), and the cost implications of these when the concept is scaled to production volumes. The technology can be used with gases (sCO 2 , helium, etc.) or with liquids such as molten salt or liquid metal. Given the high pressure associated with sCO 2 , its use demonstrates a “worst case” scenario, and the successful development of the MSR for this application will result in the development of a technology also applicable to a range of other heat transfer fluids that will enable next generation CSP plants, including support of the Gen3CSP program.

14 SOLAR ENERGY↗
DOE OSTI2025

Summary Report Of The FY25 Computational Fluid Dynamics Verification And Validation Exercises In The Advanced Reactor Technologies - Gas-cooled Reactor Program

Verification and Validation (V&V) of numerical tools is critical for ensuring reasonable predictions during design, safety analysis, and licensing. Recent work in the Advanced Reactor Technologies - Gas-cooled Reactor (ART-GCR) program has focused on V&V of common Computational Fluid Dynamics (CFD) tools that are used within the Untied States. This report presents an update on these CFD V&V activities. These Generation IV Forum (GIF) Very High Temperature Reactor (VHTR) Computational Methods, Validation, and Benchmarking (CMVB) is an international organization dedicated to the verification and validation of High Temperature Gas-Cooled Reactor (HTGR) simulation tools. Participation in the CMVB provides additional value to the V&V activities, as it allows for access to a wider range of data, and provides valuable benchmarking exercises. Three HTGR phenomena are targeted: Reactor Cavity Cooling System (RCCS) performance, core bypass flow, and lower plenum mixing. Simulations of the University of Wisconsin-Madison (UW-Madison) RCCS facilities are performed with Reynolds Averaged Navier-Stokes (RANS) in StarCCM+. Results are compared for both forced and natural convection conditions, with both exhibiting good agreement with experimental measurements. The Idaho National Laboratory (INL) matched index of refraction (MIR) and Korean Atomic Energy Research Institute (KAERI) bypass flow expeirments are used to validation CFD predictions of bypass flow. Simulations are performed with RANS in StarCCM+ and with Large Eddy Simulation (LES) in NekRS. Finally, preliminary simulations of the Institute of Nuclear and New Energy Technology (INET) lower plenum mixing facilities are presented. Initial work has developed models with LES, RANS, and porous media models. These preliminary models are presented and compared to each other to gauge differences in predictions with each of the three methods.

and Benchmarking (CMVB)↗
NASA NTRS1983

Development of a simplified analytical method for representing material cyclic response

Development of a simplified method for estimating structural inelastic stress and strain response to cyclic thermal loading is presented. The method assumes that high temperature structural response is the sum of time independent plastic and time dependent elastic/creep components. The local structural stress and strain response predicted by linear elastic analysis is modified by the simplified method to predict the inelastic response. The results with simulations by a nonlinear finite element analysis and used time independent plasticity and unified time dependent material model are compared.

Moreno, V.↗
DOE OSTI2024

A Method for Dynamic Kolsky Bar Compression at High Temperatures: Application to Ti-6Al-4V

Abstract An experimental apparatus for measuring the dynamic behavior of materials subjected to strain rates on the order of 10 $$^3$$ 3 s $$^{-1}$$ - 1 and temperatures up to 800°C with a unique triple actuation system is developed in this work. This system is based on the traditional Kolsky (or split-Hopkinson pressure) bar design, with the addition of an external furnace used to heat the specimen to the desired temperature. A synchronized triple pneumatic actuation system is used to control the motion and timing of the the sample, incident, and transmitted bars. The cold contact time (CCT), or the time during which the heated sample is in contact with the room temperature bars before compression, is measured experimentally and carefully controlled to minimize the development of a temperature gradient across the sample and avoid heating of the bars. Experiments are performed in conjunction with ultra high speed imaging and 2D digital image correlation (DIC), as well as high speed thermal imaging. To verify the viability of the proposed system, experiments were conducted on Ti-6Al-4V (wt.%) at temperatures from 25°C up to and 800°C at an average strain rate of approximately 1200 s $$^{-1}$$ - 1 .

36 MATERIALS SCIENCE↗
NASA NTRS1973

Apparatus and method for generating large mass flow of high temperature air at hypersonic speeds

A description is given of tests performed in the Mach number 8 to 10 regime to generate high temperature air at hypersonic speeds. The test flow was obtained by pressuring a ceramic lined storage tank with air to a pressure of about 100 to 200 atm. The air is heated to temperatures of 7,000 R to 8,000 R prior to introduction into the tank by passing air through an electric arc heater. The air cools to 5,500 R to 6,000 R while in the tank and then it is rapidly released through a Mach number 8 to 10 nozzle. Cold air or hot driver gas under pressure is injected simultaneously with the release of pressurized hot air and regulated to enter the tank at the same rate the hot air is leaving. This holds pressure in the tank constant during the test. Alternatively, the driver gas is introduced into the tank prior to the discharge of the hot air to increase the pressure in the tank and permit tests at higher pressures than can be handled by the arc heater.

Boatright, W. B.↗
NASA NTRS1973

Apparatus and method for generating large mass flow of high temperature air at hypersonic speeds

High temperature, high mass air flow and a high Reynolds number test air flow in the Mach number 8-10 regime of adequate test flow duration is attained by pressurizing a ceramic-lined storage tank with air to a pressure of about 100 to 200 atmospheres. The air is heated to temperatures of 7,000 to 8,000 R prior to introduction into the tank by passing the air over an electric arc heater means. The air cools to 5,500 to 6,000 R while in the tank. A decomposable gas such as nitrous oxide or a combustible gas such as propane is injected into the tank after pressurization and the heated pressurized air in the tank is rapidly released through a Mach number 8-10 nozzle. The injected gas medium upon contact with the heated pressurized air effects an exothermic reaction which maintains the pressure and temperature of the pressurized air during the rapid release.

Sabol, A. P.↗
DOE OSTI2023

Multi-core high-temperature, irradiation-resistant thermocouple, and related methods

A multi-core thermocouple includes a plurality of wires, an insulation core surrounding the plurality of wires, a sheath surrounding the insulation core, and a plurality of electrical junctions. The plurality of electrical junctions may include a first electrical junction formed between a first wire of the plurality of wires and the sheath at a first axial mid-section of the multi-core thermocouple, the first electrical junction including a first swaged axial mid-section of the sheath and a second electrical junction formed between a second wire of the plurality of wires and the sheath at a second, different axial mid-section of the multi-core thermocouple, the second electrical junction including a second swaged axial mid-section of the sheath.

Skifton, Richard S.↗
DOE OSTI2025

Spinel-Structured High Entropy Oxides: Low Temperature Synthesis, Characterization, and Potential Applications

High entropy oxides (HEOs) have recently attracted increasing attention due to their remarkable properties and relatively low cost. Herein we report a simple, highly scalable, and low temperature method for synthesizing spinel (FeNiCoCuZn) 3 O 4 (HEO). We heated an aqueous solution containing divalent cations in high alkali environments to temperatures of 25 - 95 °C for 24 h under atmospheric pressure. The HEO, synthesized at 95 °C for 24 h in 1 M KOH, was paramagnetic at room temperature, with a magnetic mass susceptibility of χ = (7.5 ± 0.2) × 10 –7 m 3 ·kg –1 . It demonstrated stable electrochemical lithium storage performance, with a gravimetric capacity of ∼300 mAh·g –1 at 100 mA·g –1 . It was also active in the electrocatalytic oxygen evolution reaction with an overpotential of 460 mV in alkaline media. The band gap energies were in the range of 2.4 eV. Our advancement in the synthesis and processing of transition metal-based HEOs will undoubtedly render them a viable solution for next generation materials for energy production and storage.

diffraction↗
NASA NTRS2009

Advances in Non-contact Measurement of Creep Properties

Our team has developed a novel approach to measuring creep at extremely high temperatures using electrostatic levitation (ESL). This method has been demonstrated on niobium up to 2300 C, while ESL has melted tungsten (3400 C). High-precision machined spheres of the sample are levitated in the NASA MSFC ESL, a national user facility, and heated with a laser. The laser is aligned off-center so that the absorbed photons transfer their momentum to the sample, causing it to rotate at up to 250,000+ RPM. The rapid rotation loads the sample through centripetal acceleration, causing it to deform. The deformation of the sample is captured on high-speed video, which is analyzed by machine-vision software from the University of Massachusetts. The deformations are compared to finite element models to determine the constitutive constants in the creep relation. Furthermore, the noncontact method exploits stress gradients within the sample to determine the stress exponent in a single test. This method was validated in collaboration with the University of Tennessee for niobium at 1985 C, with agreement within the uncertainty of the conventional measurements. A similar method is being employed on Ultra-High-Temperature ZrB2- SiC composites, which may see application in rocket nozzles and sharp leading edges for hypersonic vehicles.

Hyers, Robert W.↗
DOE OSTI2021

Modeling of High-Temperature Corrosion of Zirconium Alloys Using the eXtended Finite Element Method (X-FEM)

Oxidation modeling in modern nuclear fuel performance codes is currently limited by the lack of coupling with mechanics, thus preventing proper description of how high-temperature oxidation impacts mechanical properties. This is mostly due to the fact that the finite difference formalism adopted in corrosion models is incompatible with the direct coupling with mechanics in the finite element modeling employed in modern nuclear fuel performance codes. In this study, a physically based zirconium alloy corrosion model called the Coupled-Current Charge Compensation (C4) model, which was initially developed for operating temperature conditions, has been updated to include high-temperature corrosion in order to provide additional critical information (e.g., oxygen concentration profile) under loss-of-coolant accident (LOCA) conditions—information lacking in existing empirical models. The C4 model was implemented in the MOOSE finite-element framework developed at Idaho National Laboratory, enabling it to be used in the BISON nuclear fuel performance code based on the MOOSE framework. To precisely track the different interfaces at a relatively low computational cost, the eXtended Finite Element Method (X-FEM) was applied in MOOSE. The model’s results were compared to those of existing empirical models as well as metallographic analysis of high-temperature oxidized Zircaloy-4 coupons. Oxygen diffusivities in the a and ß phases resulting from this comparison closely agree with those found in the literature. The C4 model implemented with X-FEM in MOOSE now has the capability to accurately predict oxide, oxygen-stabilized a, and prior ß phase layer growth kinetics under isothermal exposure at high temperature (1000–1500°C). Furthermore, in contrast with the empirical models, the C4 model accounts for the finite thickness of the fuel cladding. It can predict the oxygen concentration profile evolution through the whole cladding, enabling evaluation of the remaining ductile thickness—a crucial variable for modeling the mechanical behavior of the fuel cladding under LOCA. Furthermore, this implementation allows direct coupling with mechanics, at a low computing cost, using finite-element-based nuclear fuel performance codes such as BISON.

36 MATERIALS SCIENCE↗
DOE OSTI2024

NDMAS Portal Updates

Overview of current ART-GCR Data, including fuel fabrication, irradiation monitoring, fuel and graphite, post-irradiation examination, graphite characterization, high temperature metals mechanical tests, methods validation data (including: HTTR, NSTF, and HTTF), addition of AGR fuel data, other GCR and related data, updated high temperature metals, ongoing and upcoming work, users guide, and the link to those interested in access to NDMAS.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Ba 6 (Cu x Z y )Sn 4 S 16 (Z = Mg, Mn, Zn, Cd, In, Bi, Sn): High Chemical Flexibility Resulting in Good Nonlinear-Optical Properties

Seven acentric sulfides Ba 6 (Cu x Z y )Sn 4 S 16 (Z = Mg, Mn, Zn, Cd, In, Bi, Sn) were grown by a high-temperature salt flux method. The crystal structures of the Ba 6 (Cu x Z y )Sn 4 S 16 (Z = Mg, Mn, Zn, Cd, In, Bi, Sn) compounds were determined by single-crystal X-ray diffraction with the aid of solid-state NMR spectroscopy. The Ba 6 (Cu x Z y )Sn 4 S 16 (Z = Mg, Mn, Zn, Cd, In, Bi) compounds are isostructural and crystallize in the Ba 6 Ag 4 Sn 4 S 16 structure type. The Sn-containing compound exhibits high structural similarity to Ba 6 (Cu x Z y )Sn 4 S 16 (Z = Mg, Mn, Zn, Cd, In, Bi) with the presence of an interstitial atomic position partially occupied by Sn atoms. The chemical bonding characteristics of Ba 6 (Cu 2.9 Sn 0.4 )Sn 4 S 16 were understood with electron localization function calculations coupled with crystal orbital Hamilton population calculations. The Ba–S and Cu–S interactions are dominantly ionic, but the Sn–S interactions consist of strong covalent bonding characteristics in Ba 6 (Cu 2.9 Sn 0.4 )Sn 4 S 16 . The monovalent Cu atoms, mixed with certain metals with various oxidation states, significantly shift the optical properties of the Ba 6 (Cu x Z y )Sn 4 S 16 (Z = Mg, Mn, Zn, Cd, In, Bi) compounds. This results in a good balance between the second-harmonic-generation (SHG) response and laser damage threshold (LDT). Ba 6 (Cu 1.9 Zn 1.1 )Sn 4 S 16 possesses a high SHG response and a high LDT of 2.8 × AGS and 3 × AGS, respectively. Here, a density functional theory calculation revealed that CuS 4 and SnS 4 tetrahedra significantly contribute to the SHG response in Ba 6 (Cu 2 Mg)Sn 4 S 16 , which also confirmed that CuS 4 tetrahedra are crucial for the stability and optical properties of the Ba 6 (Cu x Z y )Sn 4 S 16 (Z = Mg, Mn, Zn, Cd, In, Bi, Sn) compounds revealed by electronic structure analysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2018

Single Crystal Rhombohedral Epitaxy of Sige on Sapphire at 450.Degree. C.-500.Degree. C. Substrate Temperatures

Various embodiments may provide a low temperature (i.e., less than 850° C.) method of Silicon-Germanium (SiGe) on sapphire (Al2O3) (SiGe/sapphire) growth that may produce a single crystal film with less thermal loading effort to the substrate than conventional high temperature (i.e., temperatures above 850° C.) methods. The various embodiments may alleviate the thermal loading requirement of the substrate, which in conventional high temperature (i.e., temperatures above 850° C.) methods had surface temperatures within the range of 850° C.-900° C. The various embodiments may provide a new thermal loading requirement of the sapphire substrate for growing single crystal SiGe on the sapphire substrate in the range of about 450° C. to about 500° C.

Choi, Sang Hyouk↗
NASA NTRS1983

High-temperature fatigue in metals - A brief review of life prediction methods developed at the Lewis Research Center of NASA

The presentation focuses primarily on the progress we at NASA Lewis Research Center have made. The understanding of the phenomenological processes of high temperature fatigue of metals for the purpose of calculating lives of turbine engine hot section components is discussed. Improved understanding resulted in the development of accurate and physically correct life prediction methods such as Strain-Range partitioning for calculating creep fatigue interactions and the Double Linear Damage Rule for predicting potentially severe interactions between high and low cycle fatigue. Examples of other life prediction methods are also discussed. Previously announced in STAR as A83-12159

Halford, G. R.↗
NASA NTRS2010

Microwave Plasma Hydrogen Recovery System

A microwave plasma reactor was developed for the recovery of hydrogen contained within waste methane produced by Carbon Dioxide Reduction Assembly (CRA), which reclaims oxygen from CO2. Since half of the H2 reductant used by the CRA is lost as CH4, the ability to reclaim this valuable resource will simplify supply logistics for longterm manned missions. Microwave plasmas provide an extreme thermal environment within a very small and precisely controlled region of space, resulting in very high energy densities at low overall power, and thus can drive high-temperature reactions using equipment that is smaller, lighter, and less power-consuming than traditional fixed-bed and fluidized-bed catalytic reactors. The high energy density provides an economical means to conduct endothermic reactions that become thermodynamically favorable only at very high temperatures. Microwave plasma methods were developed for the effective recovery of H2 using two primary reaction schemes: (1) methane pyrolysis to H2 and solid-phase carbon, and (2) methane oligomerization to H2 and acetylene. While the carbon problem is substantially reduced using plasma methods, it is not completely eliminated. For this reason, advanced methods were developed to promote CH4 oligomerization, which recovers a maximum of 75 percent of the H2 content of methane in a single reactor pass, and virtually eliminates the carbon problem. These methods were embodied in a prototype H2 recovery system capable of sustained high-efficiency operation. NASA can incorporate the innovation into flight hardware systems for deployment in support of future long-duration exploration objectives such as a Space Station retrofit, Lunar outpost, Mars transit, or Mars base. The primary application will be for the recovery of hydrogen lost in the Sabatier process for CO2 reduction to produce water in Exploration Life Support systems. Secondarily, this process may also be used in conjunction with a Sabatier reactor employed to stockpile life-support oxygen as well as propellant and fuel production from Martian atmospheric CO2

Atwater, James↗