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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 217 records · Page 12

All sources NASA NTRS DOE OSTI

DOE OSTI2022

Soot and PAH formation in high pressure spray pyrolysis of gasoline and diesel fuels

Time-resolved soot and PAH formation from gasoline and diesel spray pyrolysis are visualized and quantified using diffuse back illumination (DBI) and laser induced fluorescence (LIF) at 355 nm, respectively, in a constant-volume vessel at 60 bar from 1400 to 1700 K for up to 30 ms. The delay, maximum formation rate, and yield of soot and PAHs are compared across fuels and temperatures and correlated with the yield sooting indices on either the mass or mole basis. The delays generally decrease with increasing temperature, and the formation rates of both PAHs and soot generally increase with temperature. The apparent PAH-LIF yield may decrease with temperature due to PAH growth and conversion into larger species, signal trapping, and thermal quneching. Soot yield generally increases with temperature. The mass-based YSI correlates reasonably well with soot delay, but YSI does not correlate well with soot yield. Here, the mass-based YSI is a more appropriate predictor of sooting propensity than the mole-based YSI.

42 ENGINEERING↗

DOE OSTI2020

High pressure/high temperature multiphase simulations of dodecane injection to nitrogen: Application on ECN Spray-A

The present work investigates the complex phenomena associated with pressure/high temperature dodecane injection for the Engine Combustion Network (ECN) Spray-A case, employing more elaborate thermodynamic closures, to avoid well known deficiencies concerning density and speed of sound prediction using traditional cubic models. A tabulated thermodynamic approach is proposed here, based on log 10 (p)-T tables, providing very high accuracy across a large range of pressures, spanning from 0 to 2500 bar, with only a small number of interpolation points. The tabulation approach is directly extensible to any thermodynamic model, existing or to be developed in the future. Here NIST REFPROP properties are used, combined with PC-SAFT Vapor-Liquid-Equilibrium to identify the liquid in mixtures penetration, hence avoiding the use of an arbitrary threshold for mass fraction. Identified liquid and vapour penetration are compared against experimental data from the ECN database showing a good agreement, within approximately 3–8% for axial penetration of liquid, 2% for vapor axial penetration and within experimental uncertainty for radial distribution of mass fraction. Analysis of the vortex evolution indicates that driving mechanisms behind the jet break-up are vortex tilting/stretching, then baroclinic torque, leading to Rayleigh-Taylor instabilities, closely followed by vortex dilation and finally viscous effects.

42 ENGINEERING↗

DOE OSTI2021

Corrosion behavior in aluminum/galvanized steel resistance spot welds and self-piercing riveting joints in salt spray environment

Here, this paper underlined the corrosion behavior of aluminum alloy/galvanized steel joints fabricated by resistance spot welding (RSW) and self-piercing riveting (SPR) exposed to different salt-spray cycles. It was found that the crevice generated by different joining methods has an important impact on corrosion behavior. Compared with the RSW joint, less corrosion happened on the coupled regions in SPR joints because of the higher local pH value resulted from the smaller crevice. The crevice, however, has less impact on the types of corrosion products. Galvanic corrosion happened in the coupled region for both RSW and SPR joints. The Pourbaix diagram explained the stable corrosion products of Al and Zn—Fe alloy, which are Al 2 O 3 , ZnO, and Fe 3 O 4 . Additional corrosion products observed from the experiment included α-Al(OH) 3 , Ca 4 Al 2 (CO 3 )(OH) 12 (H 2 O) 5 , Zn 5 (OH) 8 Cl 2 (H 2 O), Zn 5 (CO 3 ) 2 (OH) 6 , and Fe 2 (OH) 2 (CO 3 ), which can be understood by considering the metastable corrosion products, Pourbaix diagram, and possible chemical reactions.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Single particle impact explorations on the role of powder heat treatments in cold spray: Effects of strength and oxide structure

In cold spray, the optimization of the powder feedstock for improving the final properties of the coating and for improving the process itself are two different objectives. This paper explores the latter, studying the relationship between powder pre-heat treatment and the kinetic bonding between the individual particles and the substrate. Using a laser-induced particle impact test (LIPIT), we investigate the effect of different heat treatments on the critical adhesion velocity of Al 6061. Although heat treatments change the strength of the powders as well as the thickness of the native oxide layer each by as much as ∼50 %, the critical adhesion velocity remains constant to within only ∼10 %. A deeper analysis reveals that these two factors change in somewhat complementary ways for the heat treatments explored here, leading to counteracting effects. By quantitatively evaluating these two microstructural factors in tandem, we find that they are roughly equally important in determining the critical adhesion velocity. These observations thus provide insight for the development of new heat treatment regimens that might lower the adhesion velocity.

Al 6061↗

DOE OSTI2021

Semi-integral LOCA test of cold-spray chromium coated zircaloy-4 accident tolerant fuel cladding

Enhancing the accident tolerance of PWRs came under serious consideration following the 2011 Fukushima Daiichi nuclear power plant events. While the current nuclear fuels are based on mature technology and have an excellent operational record, further enhancing their strength through accident tolerant fuel (ATF) research and development continues to be of interest. Particularly, the chromium coated clad ATF technology represents an evolutionary change to improve the high temperature performance of existing Zircaloy claddings. Additionally, despite several years of investigation of coated cladding, the integral loss of coolant accident (LOCA) performance of chromium coated cladding has had little attention. In this work, cold-spray chromium coated zircaloy-4 claddings are evaluated using EDF's semi-integral LOCA test facility. Results show that the chromium coating induces a reduced ballooning and burst and an increased burst temperature in the investigated conditions. However, these tests exhibit limited benefits concerning the post-quench behavior of the coated specimens which occurs in the last stage of a prototypical LOCA scenario.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Multi-technique characterization of spray coated and roll-to-roll coated gas diffusion fuel cell electrodes

Here this work reports the characterization of catalyst layer (CL) structure and composition for a set of gas-diffusion electrodes (GDEs) fabricated by different coating methods with the goal of developing a better understanding of CL processing-structure-property-performance relationships. The CL coating techniques used in this study were ultrasonic spray coating, and two roll-to-roll (R2R) methods - gravure and slot die. Scanning transmission electron microscopy (STEM) coupled with X-ray energy dispersive spectroscopy (EDS) analysis of GDE cross-sections provided bulk information, while scanning electron microscopy (SEM) with EDS and X-ray photoelectron spectroscopy (XPS) were used to investigate the near surface and surface composition of the CLs that will be in direct contact with the membrane once the membrane electrode assembly (MEA) is constructed. This study demonstrates that common quantification parameters, namely the F:Pt ratio extracted from cross-sectional STEM-EDS maps and top-down CL measurements with SEM and XPS, along with roughness parameters quantified from SEM micrographs are useful parameters in explaining and potentially predicting performance trends. Additionally, it highlights the importance of understanding key CL surface properties for advancing the manufacturability of high-performance components for polymer electrolyte membrane (PEM) technologies.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

A sui generis whipping-instability-based self-sequencing multi-monodisperse 2D spray from an anisotropic microfluidic liquid jet device

Well-defined aerosols pave the way for versatile basic and applied research. Here, we demonstrate a unique whipping instability that generates from a high-aspect-ratio microfluidic device resulting in a unique steady-state gas-focused whipping jet (WJ) without any need for electrification. This WJ device emanates a multi-monodisperse whipping spray jet with a two-dimensional (2D) profile. We demonstrate this phenomenon based on various fluidic parameters theoretically and experimentally. The 2D WJ’s unique behavior is derived using analytical fluid dynamics to explain jet diameter, whipping regime, and spreading angle. The phenomenon is further characterized experimentally by measuring the angle with respect to the flow rate, the distances between droplets, the droplet shapes, and the reproducibility of these parameters. We also explain the precise fabrication of such inexpensive devices. Lastly, we highlight these devices’ potential use as sample environments in versatile applications ranging from cryoelectron microscopy over mass spectrometry to drug formulation and structural studies at X-ray free-electron lasers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Spray Mechanism of Contained-Electrospray Ionization

Analytical characteristics of contained electrospray ionization (ESI) are summarized in terms of its potential to modify the analyte solution during the stages of droplet formation to provide opportunities to generate native versus denatured biomolecular gas-phase ions, without the need for bulk-phase analyte modifications. The real-time modification of the charged microdroplets occurs in a cavity that is included in the outlet of the contained-ESI ion source. Close examination of the inside of the cavity using a high-speed camera revealed the formation of discrete droplets as well as thin liquid films in the droplets wake. When operated at 20 psi N2 pressure, the droplets were observed to move at an average speed of 8 mm/s providing ~1 s mixing time in a 10 mm cavity length. Evidence is provided for the presence of highly reactive charged droplets based on myoglobin charge state distribution, apo-myoglobin contents, and ion mobility drift time profiles under different spray conditions. Mechanistic insights for the capture of vapor-phase reagents and droplet dynamics as influenced by different operational modes are also described.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Real-Time Screening for Uranium Enrichment by Paper Spray Ionization Mass Spectrometry for Field Applications

A rapid isotope ratio screening technique for uranium enrichment is demonstrated by utilizing paper spray ionization (PSI) high-resolution mass spectrometry (HRMS). Measurements were conducted using an ambient ionization mass spectrometer coupled to a custom-made JEOL PSI attachment apparatus, with de minimus sample preparation requirements. The current method detection limit for individual isotopes (e.g., 235 U and 238 U) is approximately 50 pg, with subsequent optimization expected to further improve U isotopic sensitivity. The PSI analytical method described herein can support rapid analysis (both in-field and in-lab screening) of isotopes-of-interest, as demonstrated by empirical differentiation of depleted uranium (DU) and low enriched uranium (LEU) analytical aliquots. Furthermore, this analytical workflow holds promise for applications in nuclear forensics, international nuclear safeguards, and nonproliferation missions.

Anions↗

DOE OSTI2024

Conductive Spray Paint Fabricated Cylindrical Coplanar Waveguide for Noncontact Liquid-Level Sensing

A noncontact liquid-level sensor using a cylindrical coplanar waveguide (CCPW) is proposed. The concept is demonstrated using a prototype device made by directly spraying conductive paint on the outer surface of a glass cylinder. The position of the air–liquid interface is measured using the time-domain reflection (TDR) signal from the CCPW. The geometric parameters of the prototype sensor were optimized using a full-wave simulation tool. The experimental results show that the prototype CCPW-based liquid-level sensor has a resolution of 29.8μm over a range of 210 mm at the sweeping frequency bandwidth of 500 MHz–4 GHz. The tradeoff between the resolution and the measurement range was discussed. The proposed sensor provides a low-cost, easy-to-fabricate, and noncontact method for liquid-level measurement, which has potential applications in fuel storage, chemical production, and wastewater treatment.

42 ENGINEERING↗

DOE OSTI2025

Shoreline wave breaking strongly enhances the coastal sea spray aerosol population: Climate and air quality implications

Sea spray aerosol (SSA) emission is a major source of atmospheric aerosols, influencing global climate and coastal air quality. Much of our knowledge about SSA derives from coastal observations near shorelines, but whether and when these observations accurately represent open oceans remain unclear. Here, we show that strong nearshore SSA production during high-wave periods greatly enhances downwind cloud condensation nuclei (CCN) and aerosol mass concentrations. Strong shoreline wave breaking is widespread globally, and swell waves, which are decoupled from local winds, play a dominant role in many coastal regions. Therefore, extrapolating results based on coastal measurements to open oceans may significantly overestimate SSA concentration and its contribution to CCN and, by extension, the impact of SSA on clouds and climate. Additionally, the strong enhancement of coastal aerosol population by shoreline wave breaking and its environmental impact on coastal communities cannot be captured by current regional models, which do not parameterize nearshore SSA generation using wave energy or completely neglect it.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Degradation Mechanisms in Advanced MEAs for PEM Water Electrolyzers Fabricated by Reactive Spray Deposition Technology

Proton exchange membrane water electrolyzers (PEMWEs) have demonstrated enormous potential as the next generation hydrogen production technology. The main challenges that the state-of-the-art PEMWEs are currently facing are excessive cost and poor durability. Understanding the failure modes in PEMWEs is a key factor for improving their durability, lowering the precious metal loading, and hence cost reduction. Here, reactive spray deposition technology (RSDT) has been used to fabricate a membrane electrode assembly (MEA) with one order of magnitude lower Pt and Ir catalyst loadings (0.2–0.3 mg PGM cm –2 ) in comparison to the precious metal loadings in the stat-of-the-art commercial MEAs (2–3 mg PGM cm –2 ). As fabricated MEA with an active area of 86 cm 2 , has been tested for over 5000 h at steady-state conditions that are typical for an industrial hydrogen production system. Herein, we present and discuss the results from a comprehensive post-test analysis of the MEA of interest. The main degradation mechanisms, governing the performance loss in the RSDT fabricated MEA with ultra-low precious metal loadings, have been identified and discussed in detail. All failure modes are critically compared and the main degradation mechanism with the highest impact on the MEA performance loss among the others is identified.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

LT-LiNi 1/3 Mn 1/3 Co 1/3 O 2 : A Partially-Disordered, Composite Rock Salt Cathode Prepared by Flame Spray Pyrolysis for Li-Ion Batteries

A unique composite cathode structure for Li-ion batteries, designated LT-LiNi 1/3 Mn 1/3 Co 1/3 O 2 (or LT-NMC111), has been prepared by flame spray pyrolysis and subsequent annealing between 400 and 650 °C. It is composed predominantly of structurally-integrated and partially-disordered lithiated-spinel and layered components, both of which can be broadly described as partially-disordered rock salt constituents. The paper describes the evolution of the LT-NMC111 structure as a function of the synthesis method, annealing temperature, and electrochemical properties in the context of other recently reported “low-temperature” (LT) materials, such as LT-LiCo 1−x Al x O 2 and LT-LiMn 0.5 Ni 0.5 O 2 or, in spinel notation, LT-Li 2 Co 2–2x Al 2x O 4 and LT-Li 2 MnNiO 4 , respectively.

25 ENERGY STORAGE↗

DOE OSTI2025

Ink-sprayed transparent ceramic multilayer planar waveguides for ribbon lasers

Multilayer transparent ceramic planar waveguides were fabricated using a newly developed particle-loaded ink spraying method, characterized, and lased. Waveguides with five Yb:YAG gain regions and four Lu:YAG index-matched regions were produced for application as a “ribbon laser,” as well as a homogeneous Yb:YAG waveguide. Elemental mapping revealed that the waveguide thicknesses varied from 40 to 69 μm, comprised of layers of less than 10 µm. The Yb concentration profiles were fit to a diffusion profile. The homogeneous and multilayer waveguides were tested in a laser cavity and produced similar slope efficiencies, with a maximum of 31% achieved. In conclusion, their beam profiles provided evidence of the ribbon structure affecting the preferred mode.

Osborne, Ross [Lawrence Livermore National Laborat↗

DOE OSTI2022

DEMONSTRATION OF TWICE REDUCED LORENTZ FORCE DETUNING IN SRF CAVITY BY COPPER COLD SPRAYING

Superconducting RF (SRF) cavities usually are made of thin-wall high RRR Niobium that is susceptible to Lorentz Force Detuning (LFD) ? cavity deformation phenomena caused by high magnitude RF fields. This type of deformation can be mitigated by using an additional copper layer deposited on the outer surface of the cavity. In this paper, we present both modeling results and experimental data of high gradient test of an SRF cavity at cryogenic temperatures. It was demonstrated that LFD can be significantly reduced (factor of two) by the copper cold spray reinforcement without sacrificing cavity flexibility for tuning. We also present a finite-element model that allows us to confirm our experimental results and optimize the cavity geometry for LFD reduction with incorporated coupled RF, structural and thermal modules.

Kostin, R.↗

DOE OSTI2021

Electrical and Thermal Properties of Cold-Sprayed Bulk Copper and Copper-Tungsten Samples at Cryogenic Temperatures

The development of high thermal conductivity coatings with pure copper or copper-tungsten alloy could be beneficial to improve the heat transfer of bulk Nb cavities for conduction cooling applications and to increase the stiffness of bulk Nb cavities cooled by liquid helium. Cold-spray is an additive manufacturing technique suitable to grow thick coatings of either Cu or CuW on a Nb substrate. Bulk (~5 mm thick) coatings of Cu and CuW were deposited on standard 3 mm thick, high-purity Nb samples and smaller samples with 2 mm x 2 mm cross section were cut for measuring the thermal conductivity and the residual resistivity ratio. The samples were subjected to annealing at different temperatures and a maximum RRR of ~130 and ~40 were measured for the Cu samples and CuW samples, respectively.

Pokhrel, H.↗

DOE OSTI2020

Characterizing Novel Cold Spray Materials at High Strain Rates

Researchers at Sandia National Laboratories have recently conducted a series of experiments on novel cold spray deposited materials to understand dynamic material properties at high strain rates.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Impact Response of Cold Spray Deposited Materials

Solid-state cold spraying (CS) of metals and respective blends is becoming increasingly attractive compared to conventional high temperature processes due to the unique properties such as increased yield strength, low ductility, and differences in tensile and compressive strengths that result from microstructural features due to the CS process. Here we report the results of plate impact experiments applied to CS deposits of tantalum (Ta), niobium (Nb), and a tantalum- niobium blend (TaNb). These methods allowed for definition of the Hugoniot for each material type and allowed for assessment of the Hugoniot Elastic Limit (HEL). Scanning electron microscopy was used on recovered samples to characterize the fracture mechanism during spallation.

36 MATERIALS SCIENCE↗