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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 OSTI2019

Integrated Simulation Framework for Additively Manufactured Ti-6Al-4V: Melt Pool Dynamics, Microstructure, Solid-State Phase Transformation, and Microelastic Response

In this work, to accelerate the establishment of fundamental understanding of the additive manufacturing (AM) process and its influence on microstructural evolution and related properties, we develop a multiphysics and multiscale modeling framework that integrates: (1) a high-fidelity powder-scale three-dimensional simulation of transient heat transfer and melt flow dynamics, (2) cellular automaton simulation of solidification grain structure and texture, (3) phase-field modeling of precipitation and dissolution of second-phase precipitate during repeated thermal cycles, and (4) microstructure-based micro- and mesoscopic elastic response calculation. Using Ti-6Al-4V as a model system, we demonstrate the application of the integrated framework to simulate complex microstructure evolution during a single-track laser powder bed fusion process and the associated mechanical response. Our modeling framework successfully captures the solidification β grain structure as a function of laser power and scanning speed, α precipitation upon subsequent cooling with different rates, and elastic response of the resulting (α + β) two-phase microstructure. The key features of solidification and second-phase precipitate microstructures, and their dependence on processing parameters, agree well with existing experimental observations. Finally, the established modeling framework is generally applicable to other metallic materials fabricated by AM.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Facet-dependent growth and dissolution of hematite resulting from autocatalytic interactions with Fe(II) and oxalic acid

The ability to simultaneously monitor the flux of iron atoms within the solution and solid phases can provide considerable insight into mechanisms of iron oxide mineral transformations. The autocatalytic interaction between hematite and Fe(II)-oxalate has long been of interest for its environmental and industrial relevance. In this study we take advantage of iron isotopic labelling and mass-sensitive imaging at the single particle scale to determine how changes in solution composition correlate with the morphologic evolution of faceted, micrometer-sized hematite platelets. Net dissolution is confirmed through analyses of aqueous iron chemistry, as well as by quantitative atomic force microscopy. Isotopic mapping techniques show that Fe(II) readily adsorbs to (001) and (012) surfaces in the absence of oxalate, but when oxalate is present selective dissolution of the (001) surface prevails and 57Fe deposition via recrystallization is not observed. Comparison between particle microtopographies following reaction with Fe(II), oxalate, and Fe(II)-oxalate show substantially different behavior, consistent with distinct mechanisms of interaction with hematite surfaces. The extensive characterization conducted on the coupled solution/solid dynamics in this system provides new insight for distinguishing crystal growth, dissolution, and recrystallization processes.

Taylor, Sandra D. [BATTELLE (PACIFIC NW LAB)]↗
DOE OSTI2019

Automated thermal extraction-desorption gas chromatography mass spectrometry: A multifunctional tool for comprehensive characterization of polymers and their degradation products

The TED-GC–MS analysis is a two-step method. A sample is first decomposed in a thermogravimetric analyzer (TGA) and the gaseous decomposition products are then trapped on a solid-phase adsorber. Subsequently, the solid-phase adsorber is analyzed with thermal desorption gas chromatography mass spectrometry (TDU-GC–MS). This method is ideally suited for the analysis of polymers and their degradation processes. A new entirely automated system is introduced which enables high sample throughput and reproducible automated fractioned collection of decomposition products. The fractionated collection together with low temperatures reduces the risk of contamination, improves instrumental stability and minimizes maintenance efforts. Through variation of the two main parameters (purge gas flow and heating rate) it is shown how the extraction process can be optimized. By measuring the decomposition products of polyethylene it is demonstrated that compounds with masses of up to 434 Da can be detected. This is achieved despite the low temperature (˜40 °C) of the solid-phase adsorber and the low thermal desorption temperature of 200 °C in the TDU unit. It is now shown that automated TED-GC–MS represents a new flexible multi-functional method for comprehensive polymer analyses. Comparable polymer characterization was previously only achievable through a combination of multiple independent analytical methods. This is demonstrated by three examples focused on practical challenges in materials analysis and identification: The first one is the analysis of wood plastic composites for which the decomposition processes of the polymer and the bio polymer (wood) could be clearly distinguished by fractionated collection using sequential adsorbers. Secondly, a fast quantitative application is shown by determining the weight concentrations of an unknown polyolefin blend through comparison with a reference material. Additionally, the determination of microplastic concentrations in environmental samples is becoming an increasingly important analytical necessity. It is demonstrated that with TED-GC–MS calibration curves showing good linearity for the most important precursors for microplastic, even complex matrix materials (suspended particulate matter) can be successfully analyzed.

36 MATERIALS SCIENCE↗
DOE OSTI2014

NANO- AND MICROSTRUCTURES FOR THIN-FILM EVAPORATION-A REVIEW

Evaporation from thin films is a key feature of many processes, including energy conversion, microelectronics cooling, boiling, perspiration, and self-assembly operations. The phase change occurring in these systems is governed by transport processes at the contact line where liquid, vapor, and solid meet. Evidence suggests that altering the surface chemistry and surface topography on the micro-and the nanoscales can be used to dramatically enhance vaporization. The 2013 International Workshop on Micro- and Nanostructures for Phase-Change Heat Transfer brought together a group of experts to review the current state-of-the-art and discuss future research needs. This article is focused on the thin-film evaporation panel discussion and outlines some of the key principles and conclusions reached by that panel and the workshop attendees.

Plawsky, JL↗
DOE OSTI2023

Phase-Field Modeling of Materials Interfaces and Nanostructures

Nanostructured materials offer unique properties for a wide range of energy applications. Among various known processing methods, liquid metal dealloying (LMD)—the selective dissolution of a base alloy element into a metallic melt—has emerged as a powerful technique to produce a new class of nano-/meso-scale open porous and bicontinuous composite structures with ultra-high interfacial area. LMD has recently been complemented by the advent of vapor phase dealloying (VPD), a novel technique that exploits the selective evaporation of one element from a parent alloy containing elements with very different vapor pressures, thereby enabling to fabricate open nanoporous structures of various elements from less-noble metals to inorganic elements regardless of their chemical activity without requiring high LMD temperatures and chemical etching. Together LMD and VPD have greatly expanded the scope of dealloying techniques, limited by traditional electrochemical means to noble metals, and boosted the design of new functional and structural materials that combine a wide variety of elements. Topologically-connected open porous structures with ultra-high surface area allow mass transport within the structure while preserving structural integrity, enabling them to serve as catalysts, fuel cells, supercapacitors, or high-capacity battery materials. Bicontinuous composite structures in turn can display high strength and high ductility or superior radiation-damage resistance due to the ultra-high interface area between interpenetrating solid phases. This research program makes use of state-of-the-art computational methods to understand at a basic level the self-organizing dealloying process with main focus on dealloying kinetics and interfacial pattern formation at the dealloying front controlling initial structure size, topology, and phase compositions. Phase-field simulation studies of LMD focus on solid solutions, line compounds, and intermetallic systems that can form ternary composites by nucleation and growth of a new phase. Studies of VPD employ phase-field modeling and a hybrid method combining a kinetic Monte Carlo (KMC) model of evaporation and surface diffusion with molecular dynamics for vapor-phase transport inside nanopores. Simulations explore mechanisms of interface- and diffusion-controlled dealloying kinetics, both observed in VPD but not fundamentally understood. In addition, our newly developed multi-physics phase-field approach of large-volume-change phase transformations is being used to model novel 3D anode geometries based on dealloyed nanoporous structures including novel sandwiched graphene/Si/silica for highrate Li ion battery. Those studies are aimed at elucidating geometric design principles that improve mechanical stability. We expect this research to enhance the capability to tailor nano-/mesoscale structures for a wide range of energy-related materials applications and to yield further advances in computational methodologies that benefit a broad materials research community.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2026

Infrared triggered dwell and active cooling thermal control effects on microstructural uniformity in DED

Directed Energy Deposition (DED) offers rapid large scale fabrication, but difficulty in delivering consistent microstructures and properties hinders the use of DED fabricated components in safety or performance critical applications. Variability stems from the complex thermal cycles generated by the toolpath used to print the required geometry. Several practical methods have become established in DED to regulate overheating, such as active cooling of the baseplate structure or the use of an infrared camera to inject interlayer pauses to ensure the top layer of the component cools to a set temperature, which have been shown to affect microstructure. However, no critical assessment has been performed as to how effective these controls are in promoting microstructural uniformity in the context of complex layer timing commonly generated by non-prismatic geometries. Here we show how controls influence the thermal field, phase transformations, and dynamic annealing of a low-temperature transformation steel using infrared imaging and operando neutron diffraction. Counterintuitively, common thermal homogenization process controls can reduce microstructural uniformity because these approaches stabilize peak temperature while overlooking temperatures near the solid-state phase transformation fronts. Instead, the cyclic reheating induces spatially-variant dynamically annealed regions which can be modulated via control parameters. We show that these controls have spatially linked effects centimeters away from the active weld, which implies that microstructure control must co-optimize thermal input across many subsequent layers. In conclusion, our results demonstrate the pressing need for higher order controls that integrate predictive elements of simulation data to stabilize printed properties for future qualification of DED components.

Directed energy deposition↗
DOE OSTI2020

Optimization of Lithium Content and Sintering Additives in Tape Cast Lithium Garnet Electrolyte Sheets

The lithium garnet (LLZO) remains one of the most promising electrolyte materials for producing solid state batteries. Tape casting is one method for producing the thin ceramic electrolyte layer required for a high-performance solid state battery. Processing of LLZO is complicated by several factors including lithium volatilization, abnormal grain growth and phase instability. Many of these issues are exacerbated in tape cast sheets by the sheets' higher surface area to volume ratio, when compared to pellet processing methods. Here, we report on an environmentally friendly aqueous tape casting process for LLZO using methylcellulose as a binder and compare final sheet properties to other, solvent-based, options. Solids loading, binder content, dispersant composition, and wetting agent type are varied to improve ease of casting and enhance properties of the as-cast tape. Lithium content in sintered LLZO sheets is controlled by the inclusion of excess Li 2 CO 3 as lithium source in the ceramic tape itself and by a novel method of producing a lithium-saturated furnace atmosphere. Sintering time and temperature are optimized, and rapid thermal processing is investigated as a method of reducing lithium loss. Al 2 O 3 and MgO are examined for use as sintering additives. Characterization of LLZO sheets is performed with XRD, EIS and SEM. Li 2 CO 3 and sintering additive levels are optimized for ionic conductivity and density. The optimization effort improved the conductivity and density of 100µm thick sintered sheets to greater than 3x10 -4 S/cm conductivity and 90% density.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Lightweight TiC–(Fe–Al) ceramic–metal composites made in situ by pressureless melt infiltration

Lightweight ceramic–metal (cermet) composites combine stiffness and hardness with fracture toughness and ductility. TiC and Al are ideal pairs among lightweight cermet composites because of their relatively high strength-to-weight ratios, but these materials are difficult to process in solid state or with Al melt infiltration without making an aluminum carbide phase, which is detrimental to mechanical properties. Here, Fe is added to a TiC powder preform to reduce the activity of Al with TiC during Al melt infiltration and to aid in pressing TiC preforms, making a lightweight TiC–(Fe–Al) composite while avoiding other, unwanted phases. The composites are made by first pressing TiC powder mixed with Fe followed by Al melt infiltration; the result is a composite with high TiC content in a two-phase matrix, both of which are Fe–Al-based. The composite has low density, low porosity, high hardness, no detectable Al 4 C 3 phase with X-ray diffraction and retains shape well during infiltration.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Review of the impacts of leaking CO 2 gas and brine on groundwater quality

This review paper provides a synthetic view of the existing knowledge and summarizes data and findings of the recent literature on the subject of the potential leaking of CO2 from the deep subsurface storage reservoirs and the effects on aquifer quality. New ideas and concepts are developed and insights are also provided. The objectives of this paper are to: 1) present and discuss potential risks for groundwater degradation due to CO2 gas and brine exposure; 2) identify the set of geochemical data required to assess and predict aquifer responses to CO2 and brine leakage. Specifically, this paper will discuss the following issues: 1) Aquifer responses (such as changes in aqueous phase/groundwater chemical composition; changes in solid phase chemistry and mineralogy; changes in the extent and rate of reactions and processes and possible establishment of a new network of reactions and processes affecting or controlling overall mobility of major, minor, and trace elements; development of conceptual and reduced order models (ROMs) to describe and predict aquifer responses); 2) The degree of impact such as significant or insignificant changes in pH and major, minor, and trace element release that depend on the following controlling variables; the effect of leaking plume characteristics (gas composition, pure CO2 and/or CO2 -CH4 -H2S mixtures and brine concentration and composition (trace metals); aquifer properties [such as initial aqueous phase conditions and mineralogy: minerals controlling sediments’ response (e.g., calcite, Si bearing minerals, etc.)]; overview of relevant hydrogeological and geochemical processes related to the impact of CO2 gas and brine on groundwater quality; the fate of the elements released from sediments or transported with brine (such as precipitation/incorporation into minerals (calcite and other minerals), adsorption, electron transfer reactions, the role of natural attenuation; whether or not the release of metals following exposure to CO2 harmful (risk assessment).

Qafoku, Nikolla P.↗
DOE OSTI2023

Insulator–metal transition in CrSiTe 3 triggered by structural distortion under pressure

van der Waals solids are well known to host remarkable phase diagrams with competing phases, unusual energy transfer processes, and elusive states of matter. Among this class of materials, chalcogenides have emerged as the most flexible and relevant platforms for unraveling charge–structure–function relationships. In order to explore the properties of complex chalcogenides under external stimuli, we measured the far infrared spectroscopic response of CrSiTe 3 under extreme pressure–temperature conditions. Analysis of the 368 cm –1 Si–Te stretching mode and the manner in which it is screened by the closure of the indirect gap reveals that the insulator–metal transition takes place immediately after the structural phase transition—once the mixed phase aspect of the lattice distortion is resolved. At the same time, the two-phase region associated with the structural transition widens with decreasing temperature, and the slope of the insulator–metal transition under pressure is consistent with increasing entropy. These trends completely revise the character of the temperature–pressure phase diagram as well as the relationship between the structural and insulator–metal transitions, leading to a critical nexus of activity that may hide a quantum critical point and allow superconductivity to emerge.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Quench process modeling & simulation in the heat-treatment of critical aerospace components

To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated temperatures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple)trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A Baseline CFD model is defined and its accuracy established to be comparable to(and which usually exceeds) the accuracy of existing HTC (heat-transfer coefficient) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled),generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.1

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2017

Subsurface injection of combustion power plant effluent as a solid-phase carbon dioxide storage strategy

Long-term geological storage of CO 2 may be essential for greenhouse gas mitigation, so a number of storage strategies have been developed that utilize a variety of physical processes. Recent work shows that injection of combustion power plant effluent, a mixture of CO 2 and N 2 , into CH 4 hydrate-bearing reservoirs blends CO 2 storage with simultaneous CH 4 production where the CO 2 is stored in hydrate, an immobile, solid compound. This strategy creates economic value from the CH 4 production, reduces the preinjection complexity since costly CO 2 distillation is circumvented, and limits leakage since hydrate is immobile. In this work, we explore the phase behavior of these types of injections and describe the individual roles of H 2 O, CO 2 , CH 4 , and N 2 as these components partition into aqueous, vapor, hydrate, and liquid CO 2 phases. Our results show that CO 2 storage in subpermafrost or submarine hydrate-forming reservoirs requires coinjection of N 2 to maintain two-phase flow and limit plugging.

58 GEOSCIENCES↗
DOE OSTI2014

Visible light activated photocatalytic behaviour of rare earth modified commercial TiO{sub 2}

Highlights: • RE gave more surface hydroxyl groups attached to the photocatalyst's surface. • RE gave the modified and fired samples a high specific surface area. • Photocatalytic activity was assessed in gas–solid phase under visible-light exposure. • Thermal treated RE-TiO{sub 2}s showed a superior visible-light photocatalytic activity. • La-TiO{sub 2} was the best performing photocatalyst. - Abstract: A commercial TiO{sub 2} nanopowder, Degussa P25, was modified with several rare earth (RE) elements in order to extend its photocatalytic activity into the visible range. The mixtures were prepared via solid-state reaction of the precursor oxides, and thermally treated at high temperature (900 and 1000 °C), with the aim of investigating the photocatalytic activity of the thermally treated samples. This thermal treatment was chosen for a prospective application as a surface layer in materials that need to be processed at high temperatures. The photocatalytic activity (PCA) of the samples was assessed in gas–solid phase – monitoring the degradation of isopropanol (IPA) – under visible-light irradiation. Results showed that the addition of the REs lanthanum, europium and yttrium to TiO{sub 2} greatly improved its photocatalytic activity, despite the thermal treatment, because of the presence of more surface hydroxyl groups attached to the photocatalyst's surface, together with a higher specific surface area (SSA) of the modified and thermally treated samples, with regard to the unmodified and thermally treated Degussa P25. The samples doped with La, Eu and Y all had excellent PCA under visible-light irradiation, even higher than the untreated Degussa P25 reference sample, despite their thermal treatment at 900 °C, with lanthanum producing the best results (i.e. the La-, Eu- and Y-TiO{sub 2} samples, thermally treated at 900 °C, had, respectively, a PCA equal to 26, 27 and 18 ppm h{sup −1} – in terms of acetone formation – versus 15 ppm h{sup −1} for the 900 °C thermally treated Degussa P25). On the other hand, Ce–TiO{sub 2}s had no significant photocatalytic activity.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Chemical Understanding of Actinide Separations

This work provides a broad overview of the separation processes used to isolate actinides and the experimentally and computationally determined chemical characteristics that define those separations. The redox chemistry of the actinides plays a pivotal role in both aqueous and pyrochemical processing separations. The near-overlapping energies of the 6d and 5f orbitals in the light actinides allow for facile adjustment of actinide oxidation states, which is used in many established separation methods. In contrast, the stable, generally 3+ oxidation states of the mid- and heavy actinides can make it difficult to separate them from the similarly lanthanides(III). In aqueous separations, the tendency of the actinides to form anionic and neutral aqueous complexes with a variety of complexants (especially soft donors) is used to achieve high separation factors between chemically similar elements in both solid–liquid separations and liquid–liquid extraction. This selectivity can be further tuned through the use of specialized organic or solid-phase ligands. Pyroprocessing separations utilize the unique redox behavior of the actinides to adjust their distribution between a molten salt electrolyte and either a solid electrode or molten metal phase. Atomic-level insights into the mechanisms underlying actinide separation processes, with the ultimate goal of predicting separation behavior, can be provided by electronic structure and statistical mechanical-based calculation methods.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Polymorphism of ScBO{sub 3} at the Solid Phase Synthesis from Amorphous Precursors

Detailed X-ray studies of changes in the structure of the scandium orthoborate ScBO{sub 3} in the process of serial isothermal annealing of the initial charge in the form of amorphous precursor were carried out. It was shown that upon successive annealing of the amorphous precursor, the crystalline phase first forms at an annealing temperature of 710°C, the positions of the reflections of which do not coincide with the positions that of the known calcite structure. This phase exists in a very narrow temperature range (≈30°C) and, when the annealing temperature is increased to 750°C, it completely transfers to the known rhombohedral phase of calcite. Using the ENDEAVOR software, the cell parameters, atom positions in the cell, and the spatial symmetry group of the new phase were determined. It turned out that the new phase corresponds to the hexagonal structure of the faterite (S.G. P63/mmc), known for other orthoborates of rare-earth elements (REE).

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2015

Recycling process for recovery of gallium from GaN an e-waste of LED industry through ball milling, annealing and leaching

Waste dust generated during manufacturing of LED contains significant amounts of gallium and indium, needs suitable treatment and can be an important resource for recovery. The LED industry waste dust contains primarily gallium as GaN. Leaching followed by purification technology is the green and clean technology. To develop treatment and recycling technology of these GaN bearing e-waste, leaching is the primary stage. In our current investigation possible process for treatment and quantitative leaching of gallium and indium from the GaN bearing e-waste or waste of LED industry dust has been developed. To recycle the waste and quantitative leaching of gallium, two different process flow sheets have been proposed. In one, process first the GaN of the waste the LED industry dust was leached at the optimum condition. Subsequently, the leach residue was mixed with Na{sub 2}CO{sub 3}, ball milled followed by annealing, again leached to recover gallium. In the second process, the waste LED industry dust was mixed with Na{sub 2}CO{sub 3}, after ball milling and annealing, followed acidic leaching. Without pretreatment, the gallium leaching was only 4.91 w/w % using 4 M HCl, 100 °C and pulp density of 20 g/L. After mechano-chemical processing, both these processes achieved 73.68 w/w % of gallium leaching at their optimum condition. The developed process can treat and recycle any e-waste containing GaN through ball milling, annealing and leaching. - Highlights: • Simplest process for treatment of GaN an LED industry waste developed. • The process developed recovers gallium from waste LED waste dust. • Thermal analysis and phase properties of GaN to Ga{sub 2}O{sub 3} and GaN to NaGaO{sub 2} revealed. • Solid-state chemistry involved in this process reported. • Quantitative leaching of the GaN was achieved.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Continuous recovery of high-purity Kraft lignin from black liquor via simultaneous, liquid-phase acidification and purification

Here, a key advantage of the Sequential Liquid-Lignin Recovery and Purification (SLRP) process for the recovery of lignin from Kraft black liquor is the precipitation of a solvated, “liquid-lignin” phase (vs. the typical solid) during the CO 2 acidification step. Here, we have discovered that this lignin can also be maintained in a solvated state during the H 2 SO 4 acidification step if aqueous acetic acid from the Aqueous Lignin Purification with Hot Agents (ALPHA) process is incorporated into the H 2 SO 4 solution. As the liquid-lignin is converted from its salt form at pH = 9.5 to its acid form at pH = 2.5, the lignin initially solvated with water becomes solvated and thus liquefied with the organic–water solution. Maintaining the lignin in a solvated liquid state has two advantages: (1) the entire SLRP + ALPHA process, from starting black liquor to final lignin product, can be operated continuously; and (2) mass transfer of metals impurities out of the liquid-lignin phase is significantly enhanced, resulting in both a cleaner Kraft lignin product (~2000 ppm Na and 0.5-1.0 % ash) and reduced water washing.

09 BIOMASS FUELS↗