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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Additively-manufactured monocrystalline YBCO superconductor

Abstract Single-crystal microstructures enable high-performance YBa 2 Cu 3 O 7-x superconductors which are however limited to simple shapes due to their brittleness. Additive manufacturing can fabricate YBa 2 Cu 3 O 7-x superconductor with complex shapes, albeit with a polycrystalline microstructure. Here, we demonstrate a route to grow single-crystals from 3D-ink-printed, polycrystalline, sintered superconducting YBa 2 Cu 3 O 7-x (YBCO or Y123) + Y 2 BaCuO 5 (Y211), manufacturing objects with complex architectures displaying both high critical current density (J c =2.1 × 10 4 A . cm –2 , 77 K) and high critical temperature (T c = 88-89.5 K). An ink containing precursor powders (Y 2 O 3 , BaCO 3 , and CuO) is 3D-extruded into complex geometries and then reaction-sintered to obtain polycrystalline Y123 + Y211. A seed is then utilized to transform these 3D-printed parts from polycrystal to monocrystal via the melt growth method. The geometric details of 3D-printed parts survive the process without slumping, sagging or collapse, despite the long-term presence of liquid above the peritectic temperature. Origami structures can be created by sheet folding after 3D-printing. This additive approach enables the facile fabrication of superconducting devices with complex shapes and architectures, such as advanced undulator magnets to generate synchrotron radiation and microwave cavities for dark-matter axion search. This work highlights the potential of additive manufacturing for producing monocrystalline cuprate superconductors and opens the door to additive manufacturing of other monocrystalline functional ceramic or semiconductor materials.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2023

Spherical powders: Control over the size and morphology of powders for additive manufacturing and enriched stable isotope nuclear targets

Metal powders are a fundamental starting point for fabricating many types of nuclear targets. Elemental powder properties can differ drastically between batches, even when using the same method. Therefore, the variation in morphology and the size of metal powders can cause variable quality and produce inconsistent results with what are otherwise proven target manufacturing techniques. Additive manufacturing has additional requirements for higher quality and more uniform feedstock. The production of spheroidized powders with uniform, reproducible properties and a narrow size distribution represents unexplored opportunities for experiments. These opportunities include experimenting with solid metals that can now flow like liquids, new options for powder handling and dispensing, and new target fabrication methods using additive manufacturing. The Stable Isotope Materials and Chemistry Group at Oak Ridge National Laboratory obtained an AMAZEMET rePowder ultrasonic metal atomization tool for creating limited batches of fully dense, free flowing, spherical powders with a narrow size distribution of extremely rare materials. Early results are presented with materials that were produced. The team explores the anticipated limits of this instrument with extremely rare materials (e.g., enriched stable isotopes) and highlights research into new fabrication techniques that provide additional options benefitting the international nuclear target community.

Zach, Mike↗
DOE OSTI2023

Explosive fragmentation of additively manufactured stainless steel

Properties of fragmentation from an explosively driven 316L stainless steel spherical shell section fabricated by a laser powder bed additive manufacturing process with minimal surface finishing are investigated. This shell is driven by an insensitive high explosive, resulting in high strain rate deformation (>8 × 10 3 s –1 ) and failure of the stainless steel. Photonic Doppler velocimetry measures the expansion rate; dynamic radiography and high-speed imaging capture the fracture behavior of the stainless steel. The fracture response of the additively manufactured stainless steel shell is compared to published experimental results on additively manufactured 316L stainless steel and conventionally manufactured wrought 316L and 304 stainless steel shell fragmentation. Despite preferred crack orientation, suggesting the influence of surface grooves on fracture time, fragment size is identical to that measured in a similar experiment on wrought 304 stainless steel. Further analysis indicates that the 316L additively manufactured stainless steel shell exhibits comparable spall strength and fragmentation toughness to conventionally manufactured stainless steel yet lower failure strain due to surface stress concentrations.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Spall strength of additively repaired 304L stainless steel

Additive manufacturing has the potential to repair damaged parts, but the performance of additive materials under high strain rate loading is still uncertain—especially with the added complexity of an interface with an existing wrought material. In this work, 304L stainless steel samples were intentionally damaged and then repaired with wire-fed laser additive manufacturing. The samples were subjected to shock loading to generate incipient spall. Velocimetry and post-mortem metallography results show that when the additive repair process parameters are optimized to reduce porosity and match the equation of state of the original material, the influence of the repair region on the shock propagation is negligible. In conclusion, the free-surface velocity profile and internal damage morphology of the repaired sample are shown to be practically identical to the pristine material.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Tailoring additive manufacturing to optimize dynamic properties in 316L stainless steel

With the advent of additive manufacturing, manipulation of typical microstructural elements such as grain size, texture, and defect densities is now possible at a faster time scale. While the processing–structure–property relationship in additive manufactured metals has been well studied over the past decade, little work has been done in understanding how this process affects the dynamic behavior of materials. We postulate that additive manufacturing can be used to alter the material microstructure and used to enhance its dynamic strength. In this work, 316L stainless steel (SS) was manufactured via selected laser melting and its microstructure was altered through changing build parameters like laser power, speed, and hatch spacing systematically. These samples were then subjected to spall recovery experiments to measure the spall strength and quantify the amount of damage as a function of build parameters. By mapping the spall strength as a function of build parameters, this work demonstrated that indeed additive manufacturing can be used to tailor the spall strength of 316L SS. This work also determined the optimum build parameters (laser power=195W; scanning speed=1083mm/s; hatch spacing=0.09mm; layer thickness=0.02mm) to obtain the highest spall strength and the least amount of total damage in 316L SS. Microstructural characterization of the pre- and post-mortem samples revealed that increased grain average misorientation and textural index were the main driving force behind this higher spall strength. This work aims to enhance microstructural engineering techniques to design materials with greater resistance to dynamic shock loading.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Recent advances of two-dimensional material additives in hybrid perovskite solar cells

Perovskite solar cells (PSCs) have become one of the state-of-the-art photovoltaic technologies due to their facile solution-based fabrication processes combined with extremely high photovoltaic performance originating from excellent optoelectronic properties such as strong light absorption, high charge mobility, long free charge carrier diffusion length, and tunable direct bandgap. However, the poor intrinsic stability of hybrid perovskites under environmental stresses including light, heat, and moisture, which is often associated with high defect density in the perovskite, has limited the large-scale commercialization and deployment of PSCs. The use of process additives, which can be included in various subcomponent layers in the PSC, has been identified as one of the effective approaches that can address these issues and improve the photovoltaic performance. Among various additives that have been explored, two-dimensional (2D) materials have emerged recently due to their unique structures and properties that can enhance the photovoltaic performance and device stability by improving perovskite crystallization, defect passivation, and charge transport. In this work, we provide a review of the recent progresses in 2D material additives for improving the PSC performance based on key representative 2D material systems, including graphene and its derivatives, transitional metal dichalcogenides, and black phosphorous, providing a useful guideline for further exploiting unique nanomaterial additives for more efficient and stable PSCs in the near future.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2025

New Era Towards Autonomous Additive Manufacturing: A Review of Recent Trends and Future Perspectives

Abstract The Additive Manufacturing (AM) landscape has significantly transformed in alignment with Industry 4.0 principles, primarily driven by the integration of Artificial Intelligence (AI) and Digital Twin (DT). However, current Intelligent Additive Manufacturing (IAM) systems face limitations such as fragmented AI tool usage and suboptimal human-machine interaction (HMI). This paper reviews existing IAM solutions, emphasizing control, monitoring, process autonomy, and end-to-end integration, and identifies key limitations, such as the absence of a high-level controller for global decision-making. To address these gaps, we propose a transition from IAM to Autonomous Additive Manufacturing (AAM), featuring a hierarchical framework with four integrated layers: knowledge, generative solution, operational, and cognitive. In the cognitive layer, AI agents notably enable machines to independently observe, analyze, plan, and execute operations that traditionally require human intervention. These capabilities streamline production processes and expand the possibilities for innovation, particularly in sectors like in-space manufacturing (ISM). Additionally, this paper discusses the role of AI in self-optimization and lifelong learning, positing that the future of AM will be characterized by a symbiotic relationship between human expertise and advanced autonomy, fostering a more adaptive, resilient manufacturing ecosystem.

Fan, Haolin↗
DOE OSTI2024

Joint inference of multiplicative and additive systematics in galaxy density fluctuations and clustering measurements

Galaxy clustering measurements are a key probe of the matter density field in the Universe. With the era of precision cosmology upon us, surveys rely on precise measurements of the clustering signal for meaningful cosmological analysis. However, the presence of systematic contaminants can bias the observed galaxy number density, and thereby bias the galaxy two-point statistics. As the statistical uncertainties get smaller, correcting for these systematic contaminants becomes increasingly important for unbiased cosmological analysis. We present and validate a new method for understanding and mitigating both additive and multiplicative systematics in galaxy clustering measurements (two-point function) by joint inference of contaminants in the galaxy overdensity field (one-point function) using a maximum-likelihood estimator (MLE). We test this methodology with Kilo-Degree Survey-like mock galaxy catalogues and synthetic systematic template maps. We estimate the cosmological impact of such mitigation by quantifying uncertainties and possible biases in the inferred relationship between the observed and the true galaxy clustering signal. Our method robustly corrects the clustering signal to the sub-percent level and reduces numerous additive and multiplicative systematics from 1.5σ to less than 0.1σ for the scenarios we tested. In addition, we provide an empirical approach to identifying the functional form (additive, multiplicative, or other) by which specific systematics contaminate the galaxy number density. Even though this approach is tested and geared towards systematics contaminating the galaxy number density, the methods can be extended to systematics mitigation for other two-point correlation measurements.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2020

Additive and Subtractive Manufacturing Augmented Reality Interface (ASMARI)

Industry 4.0 represents the next evolution of industrial technology. Some of the key characteristics of Industry 4.0 include augmented reality and additive manufacturing. In support of this evolution, researchers at Oak Ridge National Lab created a prototype augmented reality (AR) interface, ASMARI. This prototype acts as a common interface for both industrial additive and subtractive machines. Additionally, in the changing industrial workspace of Industry 4.0, the role of humans will also change. This interface focuses on increasing productivity and situational awareness, while providing new interaction modalities for interacting with hardware. The prototype was also evaluated by multiple users who provided positive feedback on the system. Ultimately, the prototype represents a first step towards significant integration between augmented reality and additive manufacturing.

Borish, Michael↗
DOE OSTI2019

Long-term nitrogen addition modifies microbial composition and functions for slow carbon cycling and increased sequestration in tropical forest soil

Nitrogen (N) deposition is a component of global change that has considerable impact on belowground carbon (C) dynamics. Plant growth stimulation and alterations of fungal community composition and functions are the main mechanisms driving soil C gains following N deposition in N-limited temperate forests. In N-rich tropical forests, however, N deposition generally has minor effects on plant growth; consequently, C storage in soil may strongly depend on the microbial processes that drive litter and soil organic matter decomposition. Here, we investigated how microbial functions in old-growth tropical forest soil responded to 13 years of N addition at four rates: 0 (Control), 50 (Low-N), 100 (Medium-N), and 150 (High-N) kg N ha -1 year -1 . Soil organic carbon (SOC) content increased under High-N, corresponding to a 33% decrease in CO 2 efflux, and reductions in relative abundances of bacteria as well as genes responsible for cellulose and chitin degradation. A 113% increase in N 2 O emission was positively correlated with soil acidification and an increase in the relative abundances of denitrification genes (narG and norB). Soil acidification induced by N addition decreased available P concentrations, and was associated with reductions in the relative abundance of phytase. The decreased relative abundance of bacteria and key functional gene groups for C degradation were related to slower SOC decomposition, indicating the key mechanisms driving SOC accumulation in the tropical forest soil subjected to High-N addition. However, changes in microbial functional groups associated with N and P cycling led to coincidentally large increases in N 2 O emissions, and exacerbated soil P deficiency. These two factors partially offset the perceived beneficial effects of N addition on SOC storage in tropical forest soils. Finally, these findings suggest a potential to incorporate microbial community and functions into Earth system models considering their effects on greenhouse gas emission, biogeochemical processes, and biodiversity of tropical ecosystems.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Impacts of the Additive Manufacturing Process on the Roughness of Engine Scale Vanes and Cooling Channels

Abstract By leveraging the additive manufacturing (AM) platform, development time and costs for turbine component testing can be reduced relative to traditional investment casting. Surface roughness is a key characteristic of the additive manufacturing process that can impact flow, heat transfer, and mechanical integrity of printed components. There are multiple design and build considerations that result in variability in surface roughness, especially when additively fabricating complicated three-dimensional vanes and internal cooling passages. This study characterizes the surface roughness of internal cooling passages, vanes, and flat external surface samples made using additive manufacturing, specifically the direct metal laser sintering process. The samples were manufactured with various wall thicknesses, layer thicknesses, build locations, build directions, and on different AM machines. A combination of computed tomography scanning and optical profilometry was used to evaluate surface roughness levels. The data indicate that the dominant factors in roughness for a given layer thickness are a function of wall thickness, build location, and build direction.

Engineering↗
DOE OSTI2023

Printability and Overall Cooling Performance of Additively Manufactured Holes With Inlet and Exit Rounding

Abstract To improve cooling effectiveness of gas turbine hardware, various film cooling hole shapes have previously been researched. Unique design modifications have recently been made possible through the design freedom allotted by additive manufacturing (AM). As one example, creating a rounded inlet for a film-cooling hole can mitigate separation at the inlet. This study explores various geometric features by exploiting the uses of additive manufacturing for shaped film cooling holes at engine scale. Both printability and cooling performance were evaluated. Resulting from this study, additively manufactured holes with hole inlet and exit rounding were printed with some variations from the design intent (DI). The largest deviations from the design intent occurred from dross roughness features located on the leeward side of the hole inlet. The measured overall effectiveness indicated that an as-built inlet fillet decreased in-hole convection as well as decreased jet mixing compared to the as-built sharp inlet. Including an exit fillet, which prevented an overbuilt diffuser exit, was also found to decrease jet mixing. A particular insight gained from this study is the importance of the convective cooling within the hole to the overall cooling performance. In-hole roughness, which is a result of additive manufacturing, increased convective cooling within the holes but also increased jet mixing as the coolant exited the hole. The increased jet mixing caused low overall effectiveness downstream of injection.

Engineering↗
DOE OSTI2023

Experimental and Numerical Investigation of Flow Boiling in Additive Manufactured Foam Structures With Vapor Pathways

Abstract The unique properties of metal foams make them potential candidates for a range of applications, including microsystem thermal management. Using additive manufacturing to create foam-type structures can improve upon prior thermal solutions by eliminating thermal interface materials and allowing for customization/local control of parameters. In the present investigation, flow boiling in additive-manufactured metal foams is investigated both experimentally and numerically. Two test samples, one with uniform structure and the other with pathways for vapor removal, are compared both experimentally and numerically. A conjugate computational fluid dynamics and heat transfer (CFD-HT) model utilizing a three-dimensional volume of fluid (VOF) model with accompanying evaporation/condensation model provided in-depth visualization of the boiling flow phenomena. The experiments generated the thermohydraulic performance over a range of heat fluxes, demonstrating that the sample incorporating dedicated vapor pathways performed better in both pressure and heat transfer performance metrics compared to the uniform foam. Additionally, negative system-level effects (i.e., hydraulic oscillations) were shown to be abated using the vapor removal structures. The numerical model yielded further insight into the factors contributing to the improved performance. Results indicated the pathways functioned as vapor removal channels, allowing the generated vapor to vent from the foam structure into the lanes. Further computational investigations demonstrated changes in flow regimes, where the addition of vapor channels caused the flow to change from churn to annular. Bubble behavior unique to the vapor pathway structure was studied, showing stagnant regions that eject vapor into the channel.

Engineering↗
DOE OSTI2020

Construction-Scale Concrete Additive Manufacturing and its Application in Infrastructure Energy Storage

Construction is filled with labor intensive, hazardous, and often wasteful processes. It is also an enormous industry, so improvements in efficiency could have a tremendous economic impact. Construction-scale additive manufacturing is one path toward achieving those improvements. In this paper, a construction-scale additive manufacturing system, called Sky-BAAM, is presented. In addition to possibly leading to more energy-efficient construction practices, leveraging additive manufacturing in construction opens the solution space to more energy efficient building design. One such design, the EMPOWER wall, is also presented in this paper. The exterior of the wall is shaped to maximize heat transfer, while acting as form work for an internal energy-storage system. This allows energy to be stored in the wall during off-peak times and retrieved during peak periods.

Atkins, Celeste↗
DOE OSTI2020

Effects of O 2 addition on in-plasma photo-assisted etching of Si with chlorine

Addition of oxygen was used to control the in-plasma photo-assisted etching (PAE) of p-type Si(100) and poly-Si in a high density, inductively coupled, Faraday-shielded, Ar/Cl 2 (225/25 SCCM), 60 mTorr plasma. After etching, samples were transferred under vacuum to an UHV x-ray photoelectron spectroscopy chamber for surface analysis. Samples etched under PAE conditions (ion energies below the ionassisted etching, IAE, threshold) had a thicker surface oxide and lower [Cl] surface concentration, when compared to samples etched under IAE conditions (ion energies above the IAE threshold). PAE was found not to be affected by 0.1 or 0.25 SCCM O 2 addition, while etching stopped with more than 0.5 SCCM O 2 addition. IAE with RF power on the sample stage, resulting in -65 V self-bias, was not affected by up to 2 SCCM of oxygen addition but decreased rapidly when more than 5 SCCM O 2 was added to the plasma. These results imply that PAE may be completely suppressed, while IAE occurs unobstructed. The implications of these findings are discussed in view of applications involving continuous wave and pulsed-plasma processes.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Performance Improvement of Lithium Metal Batteries Enabled By LiBF 3 CN as a New Electrolyte Additive

A newly synthesized electrolyte additive, lithium trifluoro(cyano) borate (LiBF 3 CN), has been investigated for electrochemical performance improvement of lithium metal batteries. The LiBF 3 CN has a structure where one fluorine atom of BF 4 – is substituted with a cyano group (–CN) prepared by the reaction of boron trifluoride etherate with lithium cyanide. The electrochemical performance in symmetric Li/Li cells and NCM523/Li cells is significantly improved upon the incorporation of LiBF 3 CN as an electrolyte additive into a carbonate-based electrolyte. Extensive characterization of the deposited lithium metal reveals that a thin (≈20 nm) and robust SEI composed of LiN x O y , Li 3 N and Li 2 O is formed by the reductive decomposition of the LiBF 3 CN additive, which plays an important role in decreasing the resistance and stabilizing lithium deposition/stripping. The insight into the substitution effect of a functional group obtained from this work provides guidance for the design of new electrolyte additives.

25 ENERGY STORAGE↗
DOE OSTI2024

Impact of Electrolyte Additives on the Lifetime of High Voltage NMC Lithium-Ion Pouch Cells

This work involves improving the lifetime of lithium-ion cells during high voltage cycling using electrolyte additives. Three generations of electrolyte additives were investigated and screened in NMC442/graphite pouch cells using a 24 h voltage-hold protocol at 40 degrees C to accelerate oxidative reactions occurring at 4.4 V. Once promising additives and combinations were identified, they were then tested in cobalt-free NMC640/graphite cells for long-term cycling to upper cutoff voltages of 4.3, 4.4, and 4.5 V at temperatures of 20, 40, and 55 degrees C. Degradation mechanisms were probed using dV/dQ analysis, micro-X-ray fluorescence spectroscopy, and electrochemical impedance spectroscopy. The primary failure mode of cells held at high voltages is due to increase in cell impedance, which is correlated to the dissolution of transition metals, specifically manganese, originating from the positive electrode. We believe this dissolution is presumably due to the formation of a high impedance rock salt surface layer on the NMC positive electrode particles. Such deleterious outcomes can be limited by selecting an appropriate electrolyte additive package. It is hoped that this paper can provide a starting point for developing NMC Li-ion cells that can operate to voltages as high as 4.4 V and still display long lifetimes.

Azam, Saad↗
DOE OSTI2019

Lipophilic Additives for Highly Concentrated Electrolytes in Lithium-Sulfur Batteries

The use of concentrated electrolytes in batteries has been impeded in part by the lack of compatible electrolyte additives for protection of electrodes. Herein, a lipophilic additive tetrabutylammonium iodide (TBAI = [Bu4N]I) was introduced to concentrated electrolyte (CH3CN)(2)LiTFSI/TTE (TTE = 1,1,2,2-tetrafluoroethyl 2,2,3,3-tetrafluoropropyl ether) for Li-S batteries. Electrochemical and SEM/EDS analyses showed that the additive provided short-term capacity retention via removal of S deposits by in situ generated I-2. These results strongly suggest lipophilic salts as viable candidates for additives in concentrated electrolytes. (c) 2019 The Electrochemical Society.

Lau, Ka-Cheong↗