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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
DOE OSTI2023

Corrosion testing needs and considerations for additively manufactured materials in nuclear reactors

Metal additive manufacturing holds significant promise as an enabling technology for the 21st century nuclear energy industry. Metal additive manufacturing (MAM) can allow the fabrication of novel materials and innovative component designs that are not achievable through conventional manufacturing. Due to its very different fabrication methods, as-fabricated MAM components are characteristically different from conventionally manufactured components. MAM materials exhibit very different microstructures from conventional cast or wrought materials. For example, austenitic stainless steels fabricated by laser powder bed fusion exhibit columnar grain structures, dislocation cell structures, and melt pool fingerprints. In addition, MAM fabrication may result in defects such as porosity, incomplete processing of the feedstock (e.g., lack of fusion in melt-based methods), and oxide inclusions. Heat treatments may further evolve the microstructure, microsegregation, and stresses within the component. Furthermore, MAM components have a rough surface with feature sizes on the order of the feedstock material, as opposed to smooth surfaces resulting from conventional machining and forming operations. As a result, the corrosion behavior of MAM components will likely be significantly different from that of conventionally formed components. Corrosive environments for structural materials within advanced reactor environments include molten fluoride and chloride salts, liquid sodium and lead-bismuth, and high-temperature helium. The Advanced Materials and Manufacturing Technologies program within the Department of Nuclear Energy in the United States Department of Energy is assessing the unique concerns of MAM component corrosion and testing methodologies in advanced nuclear reactor environments. We discuss these concerns and testing strategies in this paper.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Fast, Accurate, and Reliable Thermal Metrology to Assess the Thermal Resistivity on Small Samples of Thermal Insulation

Developing new insulation materials having a thermal resistivity greater than 69 m K/W (10 hr ft2 °F/Btu/inch) can be appealing for building envelope retrofit and construction of new buildings. Multiple institutions are involved in the development of innovative insulation materials with high thermal resistivity. However, these projects have struggled in the development of new materials due to the difficulty associated with the measurement of small sections of high thermal resistivity materials. As new materials are being developed, the size of each test specimen impacts the cost of development. Given the lack of a reliable method to measure the thermal resistivity on small samples of such materials, we evaluated experimental techniques that can be improved to satisfy the need for testing small sections of high thermal resistivity materials and developed standardized test methods to enable the rapid thermal evaluation of advanced insulation materials. This paper presents the study results and potential techniques for fast, accurate, and reliable effective thermal resistivity measurement on small samples of insulation materials.

Desjarlais, Andre Omer↗
DOE OSTI2022

Temperature-Following Thermal Barrier Coatings for High Efficiency Engines (Final Report)

HRL Laboratories and General Motors (GM), pursued this effort to increase the efficiency of internal combustion engines (ICEs) by developing and implementing temperature-following thermal barrier coatings (TBCs) to decrease heat loss from the combustion chamber. HRL developed microsphere TBCs based on hollow high-temperature alloy spheres with average diameter of 50 μm and wall thickness ~1 μm (microspheres) that achieve unprecedented low thermal conductivity and heat capacity (10X lower than the state of the art) while offering exceptional environmental and mechanical resistance.> In current ICEs, approximately 29% of the fuel’s energy is lost to the cooling system and about 22% goes into moving the car. By limiting heat losses from the combustion chamber with insulating coatings, fuel energy can be redirected into additional piston work and into the exhaust stream. The additional energy that goes into the exhaust stream can be turned into useful work through the use of an exhaust energy recovery device, such as turbocompounding and/or through driving a turbocharger to increase the power density of the engine allowing downsizing. Insulating coatings for piston crowns have been pursued in the past, but previous materials—typically ceramics—exhibited low thermal conductivity but retained high heat capacity. Such materials reduce heat losses but stabilize at a high surface temperature. The high surface temperature heats the incoming gases, which lowers volumetric efficiency and increases propensity for knock, resulting in degraded engine performance. This program developed an innovative new material that combines low thermal conductivity with low heat capacity. These unique properties allow it to follow rapid changes in gas temperature during each combustion cycle. A metallic microsphere TBC has been demonstrated that exhibits increased surface temperature during the combustion period, resulting in reduced heat transfer losses, while still returning to a low surface temperature during the gas exchange period. A 10X lower thermal conductivity and heat capacity than state-of-the-art thermal barrier coatings has been demonstrated. These unprecedented thermal properties are achieved through the coating architecture, which consists of closed pores on the microscale and exhibits a total porosity of 90% to 95%. By selecting a high-temperature nickel alloy as the coating material, the ductility and strength of metals can be harnessed to achieve much better durability and damage tolerance than brittle ceramic coatings can achieve.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2019

CAMIEM: Compact Additively Manufactured Innovative Electric Motor

New manufacturing methods are needed to obtain innovative electric motor designs that have much higher power densities and/or efficiencies compared to the current state-of-the-art. Additive manufacturing offers the potential to radically change motor designs so that they have compact designs, multi-material components, innovative cooling, and optimally designed and manufactured components. New component designs enabled by additive manufacturing technologies have been designed and were fabricated to include the housing, rotors, stator cooling ring, a direct printed stator, and a wire embedded stator. The new components were integrated into the motor and tested evaluate the performance gains in comparison to the baseline electric motor configuration. Partners on the sub-project include NASA GRC, NASA LaRC, NASA AFRC, LaunchPoint Technologies, and the University of Texas El Paso.

Halbig, Michael C.↗
NASA NTRSDate not supplied

TPSAS-NF1676L-34884-DND

New manufacturing methods are needed to enable innovative electric motor designs that have much higher power densities and/or efficiencies compared to the current state-of-the-art. Additive manufacturing (AM) offers the potential to radically change motor designs so that they have compact designs, multi-material components, innovative cooling, and optimally designed and manufactured components.

Michael Halbig↗
DOE OSTI2026

The Art of Automation: Translating Electron Microscopy Workflows Into Automated Processes

Acquiring data using a scanning transmission electron microscope (STEM) is a complex, multi-step process. The intricacy of the process depends on the type of sample, composition of the material, desired results of the experiment, resolution requirement and other experimental factors. Each experiment presents unique complications, such as sample drift and contamination, that the microscopist must consider when acquiring data. All these challenges are handled fluidly and expertly by experienced microscopists, but to reach new levels of innovation in material development, including greater reproducibility, throughput, and precision, the automation of these workflows is essential. The initial phase of this work involved translating intuition-based workflows into discrete, programmable steps. Some common key stages in STEM workflows are the initial tuning, scanning the sample for areas of interest, and then acquiring the data. Each stage can be broken further into specific parameter adjustments, such as aberration correction and dwell time optimization, depending on the experiment. When deconstructing various experiments each step was assessed for automation feasibility based on the amount of real time operator decisions. There are steps that lend themselves to automation more readily than others, such as course focusing and sample screening, but there is potential for full automation of all stages with time. As an initial step, an automated montage routine was developed, allowing for the efficient acquisition of large portions of the sample without requiring continuous intervention from the operator. The automation of this small process of the procedure demonstrates the value of this capability. A major challenge in automation arises from discrepancies between commanded, reported and actual stage movements. Using systematic tests, stage movement was quantified. This error can be corrected algorithmically for more accurate workflows in the future. Expanding automation capabilities would result in larger, more efficient data acquisition which allows for more robust statistical analysis. Additionally, this work lays the groundwork for a closed loop system where machine learning algorithms would intake automatically acquired data and make real time decisions. By progressively automating this instrument, this work establishes the foundation for fully automated experimentation in transmission electron microscopy.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Characterization of coal extracts and their performances as binder for new carbon-based structural units

Coal production and usage have been declining in the past decade due to the transition to renewable energies, environmental regulations to reduce environmental pollution due to direct coal combustion from coal-fired power stations, and administrative policies. This downturn has created tremendous challenges for the coal industry, and many states rely on revenue from coal mining. Developing new valorization routes with high coal demand is essential and using coal-derived materials to make engineered products does offer an eco-friendly, attractive, and value-added use. This paper presents a brief introduction to the extraction process to derive coal deposits, extracts, and residuals (CDERs) and a comprehensive characterization analysis to determine the suitability of CDERs as binders to produce an innovative construction material named the carbon-based structural unit (CSU). CDERs are used to prepare the CSU with or without using mesophase pitch (MP) as binders and selected CDERs are heat-treated and pressure-heat-treated to improve their binding capabilities. The performances of the CSU specimens are evaluated based on compressive strength, density, and thermal conductivity. The CSU specimens mixed with distilled residue (DR) to pyrolysis char (PC) ratio of 1:2 achieve a compressive strength of 54.85 MPa, which is higher than the compressive strength of 30 MPa of normal concrete. The CSU specimens with deposit (De) and tetralin insoluble (TI) require the addition of MP to obtain compressive strengths greater than 30 MPa. Furthermore, these CSU specimens possess a relatively low density of about 1 g/cm 3 and low thermal conductivity of less than 0.25 W/m.K.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Scaling Innovative Approaches Within U.S. Department of Energy's Weatherization Assistance Program

In this interactive workshop, attendees will hear from Grantees and Subgrantees of the U.S. Department of Energy's Weatherization Assistance Program (WAP), that have implemented innovative methods, materials and approaches in their weatherization program. Attendees will have the opportunity to exchange ideas and share their own stories and perspectives in breakout groups. Attendees will also learn how their state and agency may be able to work with the National Renewable Energy Lab and Oak Ridge National Lab on WAP-funded pilot projects to scale innovative methods throughout the WAP network.

ENERGY PLANNING, POLICY, AND ECONOMY,POWER TRANSMI↗
DOE OSTI2024

Mechanochromic Palettes of Cholesteric Liquid Crystal Elastomers for Visual Signaling

Mechanochromic photonic materials present promising prospects for enhancing diverse facets of human life. Cholesteric liquid crystal elastomers (CLCEs) present immediate mechanochromic properties, allowing their utility in various fields, including camouflages, textiles, and anticounterfeiting. Nonetheless, it is essential to provide differentiated color information corresponding to diverse types and degrees of deformation for practical use in real life. Herein, we investigate the mechanochromic responses of CLCEs using their optical rotation under compression and uniaxial stretching. The CLCEs exhibit the same reflection colors indistinguishable for compression and uniaxial stretching due to their contracted pitches. In contrast, the linearly polarized light passing through deformed CLCEs can be modulated by optical rotation, resulting in distinct transmission colors that can be discerned through mechanical deformations. We demonstrate a visual signaling system with color information derived from optical rotation. By comprehending and manipulating the mechanoresponsive behavior of CLCEs, we can advance these materials into innovative solutions with enhanced functionality and performance, thereby broadening their applications for human life enhancement.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Insights into Plastic Localization by Crystallographic Slip from Emerging Experimental and Numerical Approaches

Advanced experimental and numerical approaches are being developed to capture the localization of plasticity at the nanometer scale as a function of the multiscale and heterogeneous microstructure present in metallic materials. These innovative approaches promise new avenues to understand microstructural effects on mechanical properties, accelerate alloy design, and enable more accurate mechanical property prediction. This article provides an overview of emerging approaches with a focus on the localization of plasticity by crystallographic slip. New insights into the mechanisms and mechanics of strain localization are addressed. The consequences of the localization of plasticity by deformation slip for mechanical properties of metallic materials are also detailed.

36 MATERIALS SCIENCE↗
NASA NTRS1990

Unusual spacecraft materials

For particularly innovative space exploration missions, unusual requirements are levied on the structural components of the spacecraft. In many cases, the preferred solution is the utilization of unusual materials. This trend is forecast to continue. Several hypothetic examples are discussed.

Post, Jonathan V.↗
DOE OSTI2020

Highly Insulated Wall Systems with Exterior Insulation of Polyisocyanurate under Different Facer Materials: Material Characterization and Long-Term Hygrothermal Performance Assessment

The application of exterior insulation in both new construction and retrofits is a common practice to enhance the energy efficiency of buildings. In addition to increased thermal performance, the rigid insulation can serve to keep the sheathing board warm and serve as a water-resistive barrier to keep moisture-related problems due to condensation and wind-driven rain. Polyisocyanurate (PIR) rigid boards have a higher thermal resistance in comparison to other commonly used exterior insulation boards. However, because of its perceived lower permeance, its use as exterior insulation is not very common. In this study, the hygrothermal property of PIR boards with different facer types and thicknesses is characterized. The material data obtained through experimental test and extrapolation is used in a long term hygrothermal performance assessment of a wood frame wall with PIR boards as exterior insulation. Results show that PIR with no facer has the smallest accumulated moisture on the sheathing board in comparison to other insulation boards. Walls with a bigger thickness of exterior insulation perform better when no vapor barrier is used. The PIR exterior insulation supports the moisture control strategy well in colder climates in perfect wall scenarios, where there is no air leakage and moisture intrusion. In cases where there is trapped moisture, the sheathing board has a higher moisture content with PIR boards with both aluminum or fiberglass type facers. An innovative facer material development for PIR boards can help efforts targeting improved energy-efficient and durable wall systems.

36 MATERIALS SCIENCE↗
NASA NTRS1999

Composite Nozzle/Thrust Chambers Analyzed for Low-Cost Boosters

The Low Cost Booster Technology Program is an initiative to minimize the cost of future liquid engines by using advanced materials and innovative designs, and by reducing engine complexity. NASA Marshall Space Flight Center s 60K FASTRAC Engine is one example where these design philosophies have been put into practice. This engine burns a liquid kerosene/oxygen mixture. It uses a one-piece, polymer composite thrust chamber/nozzle that is constructed of a tape-wrapped silica phenolic liner, a metallic injector interface ring, and a filament-wound epoxy overwrap. A cooperative effort between NASA Lewis Research Center s Structures Division and Marshall is underway to perform a finite element analysis of the FASTRAC chamber/nozzle under all the loading and environmental conditions that it will experience during its lifetime. The chamber/nozzle is a complex composite structure. Of its three different materials, the two composite components have distinctly different fiber architectures and, consequently, require separate material model descriptions. Since the liner is tape wrapped, it is orthotropic in the nozzle global coordinates; and since the overwrap is filament wound, it is treated as a monoclinic material. Furthermore, the wind angle on the overwrap varies continuously along the length of the chamber/nozzle.

Sullivan, Roy M.↗
NASA NTRSDate not supplied

Additive Manufacturing: Disrupting Global Supply Chains and Enabling Sustainable Development

The integration of new materials and innovative manufacturing technologies into product supply chains are critically needed to address human and societal needs and to promote sustainable development and economic competitiveness. Recently, there has been tremendous growth in the additive manufacturing (AM) landscape with the introduction of high- end machines suitable for industrial applications. In addition, availability of desktop 3-D printers as well as open source printers and platforms have also facilitated the large scale growth of distributed manufacturing. The paradigm shift in thinking, where one can turn their design into product on demand, is leading to new business models and challenging traditional models of product development and distribution. In this presentation, an overview of different AM technologies will be provided along with technical challenges and opportunities. Various examples of materials (polymers, ceramics, metals, hybrids, and multi material systems) and structures achieved from utilizing a wide variety of additive manufacturing approaches will be provided. Technical challenges and opportunities for the utilization of additive manufacturing as a powerful enabler for sustainable development and disruptive technological threat to global supply chains for different materials and systems will be presented.

Additive Manufacturing↗
NASA NTRS2001

Materials Overview

The Materials and Structures for High Performance project has made excellent progress in the development of advanced high-temperature materials and computational materials science tools to enable high-performance, hgh-efficiency, and environmentally compatible propulsion systems. Ceramic matrix composite (CMC) systems with 2700 O F temperature capability are initially being developed for low NO, combustor liners and turbine vanes. The feasibility of pushing CMC technologies to 3000 O F through revolutionary concepts is also being pursued. Achieving fuel savings of 8 to 15 percent requires higher turbine inlet temperatures as well as reductions in engine weight. An advanced disk alloy has been evaluated for application in future engines. Advanced thermal barrier coatings (TBC s) will enable 3200 O F turbine rotor inlet temperature capability. Advanced alloy development and the development of computational tools for the design of these future alloys will further enable attainment of these goals. Innovative lightweight materials, and structural and nozzle aerodynamic concepts are also being developed to reduce the weight of engine static structures to contribute toward overall fuel savings. Rig tests will demonstrate long-term durability of CMC linersand vanes and advanced turbine airfoil alloy systems, as well as fabricability of components with the highest payoff potential using the lightweight materials and structures concepts being developed.

Draper, Robert↗
NASA NTRS2005

Improved Method of Manufacturing SiC Devices

The phrase, "common-layered architecture for semiconductor silicon carbide" ("CLASSiC") denotes a method of batch fabrication of microelectromechanical and semiconductor devices from bulk silicon carbide. CLASSiC is the latest in a series of related methods developed in recent years in continuing efforts to standardize SiC-fabrication processes. CLASSiC encompasses both institutional and technological innovations that can be exploited separately or in combination to make the manufacture of SiC devices more economical. Examples of such devices are piezoresistive pressure sensors, strain gauges, vibration sensors, and turbulence-intensity sensors for use in harsh environments (e.g., high-temperature, high-pressure, corrosive atmospheres). The institutional innovation is to manufacture devices for different customers (individuals, companies, and/or other entities) simultaneously in the same batch. This innovation is based on utilization of the capability for fabrication, on the same substrate, of multiple SiC devices having different functionalities (see figure). Multiple customers can purchase shares of the area on the same substrate, each customer s share being apportioned according to the customer s production-volume requirement. This makes it possible for multiple customers to share costs in a common foundry, so that the capital equipment cost per customer in the inherently low-volume SiC-product market can be reduced significantly. One of the technological innovations is a five-mask process that is based on an established set of process design rules. The rules provide for standardization of the fabrication process, yet are flexible enough to enable multiple customers to lay out masks for their portions of the SiC substrate to provide for simultaneous batch fabrication of their various devices. In a related prior method, denoted multi-user fabrication in silicon carbide (MUSiC), the fabrication process is based largely on surface micromachining of poly SiC. However, in MUSiC one cannot exploit the superior sensing, thermomechanical, and electrical properties of single-crystal 6H-SiC or 4H-SiC. As a complement to MUSiC, the CLASSiC five-mask process can be utilized to fabricate multiple devices in bulk single-crystal SiC of any polytype. The five-mask process makes fabrication less complex because it eliminates the need for large-area deposition and removal of sacrificial material. Other innovations in CLASSiC pertain to selective etching of indium tin oxide and aluminum in connection with multilayer metallization. One major characteristic of bulk micromachined microelectromechanical devices is the presence of three-dimensional (3D) structures. Any 3D recesses that already exist at a given step in a fabrication process usually make it difficult to apply a planar coat of photoresist for metallization and other subsequent process steps. To overcome this difficulty, the CLASSiC process includes a reversal of part of the conventional flow: Metallization is performed before the recesses are etched.

Okojie, Robert S.↗
DOE OSTI2021

Advanced Manufacturing of Alpha Double Prime Iron Nitride (ADPIN): An Innovative Rare Earth Element (REE) Free Ultra-High Performance Permanent Magnet for Clean Energy Applications

Iron nitride magnets offer the potential for large magnetic remanence magnets absent any rare earth materials [1]. This project was submitted in response to the funding opportunity announcement (FOA) from the Advanced Manufacturing Office (AMO) of the Office of Energy Efficiency & Renewable Energy (EERE) of the Department of Energy (DOE): DE-FOA-0001465: Advanced Manufacturing Projects for Emerging Research Exploration; Topic Area 1: Advanced Materials; Subtopic 1.1: Innovative Advanced Materials Manufacturing for Clean Energy to explore nitriding iron powder using a fluidized bed technique which if successful would accomplish nitriding the iron powder with reduce industrial energy intensity. Of particular concern when using metal powders at high temperatures in a fluidized bed reactor is the defluidization temperature of the bed, also known as the ‘bed collapse’ temperature. Above the defluidization temperature the metal powders can no longer fluidize and instead become an undesirable packed powder bed. Using the published results from the Institute of Process Engineering at the Chinese Academy of Sciences in Beijing, China, FeNix Magnetics was able to develop a spreadsheet calculation that allowed predictive guidelines for the defluidization temperature of iron powder based on the type of carrier gas, flow rate of the carrier gas, and the iron powder diameter. FeNix Magnetics was not able to conclude whether the temperatures to avoid bed defluidization that were achievable in a fluidized bed reactor actually resulted in nitriding the iron powder to the required level. In order to measure the amount of nitrogen in the iron powder, FeNix Magnetics contracted with the DOE sponsored Advanced Photon Source (APS) at Argonne National Laboratory to conduct X-Ray diffraction measurements. Unfortunately, due to COVID-19 restrictions, the DOE sponsored APS was closed and unable to provide X-Ray Diffraction measurements during this program.

36 MATERIALS SCIENCE↗