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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Optical Evidence of Compositional Fractioning between Plasma‐Condensed and Melt Pool Matter

Control of multicomponent alloys during welding is challenging because it lacks a real‐time understanding of composition. The optical emissions of plasma formed during laser‐induced metal welding correlate with the composition of particles ejected from the melt pool. Plasma emissions observed in this study contain large iron, manganese, chrome, and copper signatures, which match the composition of emitted particles. Particles recovered closest to the melt pool exhibit a core–shell morphology that is composed of iron‐manganese‐chrome intermetallic cores within copper shells. Particles collected farther from the melt pool, do not share this core–shell morphology, though similar elemental compositions are observed. The correlation between plasma optical emissions and particle composition can be used to predict the composition of the melt pool, allowing for real‐time welding and sintering control.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Hybrid of multi‐dimensional fillers for thermally enhanced polyamide 12 composites fabricated by selective laser sintering

Abstract Selective laser sintering (SLS) is an additive manufacturing technology that can provide a novel strategy to manufacture complex polymer‐based composites with tailored properties. In this study, polyamide 12 (PA12) composite powders based on Al 2 O 3 , boron nitride (BN), and carbon nanotubes (CNTs) were prepared via a two‐step mixing approach. Morphology characterization techniques indicated that the fillers were uniformly dispersed in the PA12 matrix as expected. Under the optimum 3D‐printing parameters, the fabrication of SLS parts with high filler loading could be obtained. With 40 wt% Al 2 O 3 , 8 wt% BN, and 2 wt% CNT hybrid fillers, the thermal conductivity of PA12 composites could reach 1.09 W/mK. It could be attributed to the synergistic effect of multi‐dimensional fillers to form dense and continuous thermal conduction paths. The factors influencing the performance of PA12 composites such as melting and crystallization behaviors, dielectric properties, and mechanical properties were also discussed. The results show that these composites have favorable dielectric and mechanical properties. Overall, the PA12 composites fabricated by SLS technology in this study exhibit excellent thermal management ability.

Yuan, Yue↗
DOE OSTI2023

Combinatorial Growth of Vertically Aligned Nanocomposite Thin Films for Accelerated Exploration in Composition Variation

Combinatorial growth is capable of creating a compositional gradient for thin film materials and thus has been adopted to explore composition variation mostly for metallic alloy thin films and some dopant concentrations for ceramic thin films. This study uses a combinatorial pulsed laser deposition method to successfully fabricate two‐phase oxide–oxide vertically aligned nanocomposite (VAN) thin films of La 0.7 Sr 0.3 MnO 3 (LSMO)‐NiO with variable composition across the film area. The LSMO‐NiO compositional gradient across the film alters the two‐phase morphology of the VAN through varying nanopillar size and density. Additionally, the magnetic anisotropy and magnetoresistance properties of the nanocomposite thin films increase with increasing NiO composition. This demonstration of a combinatorial method for VAN growth can increase the efficiency of nanocomposite thin film research by allowing all possible compositions of thin film materials to be explored in a single deposition.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Codesigning Alloy Compositions of CdSe y Te 1− y Absorbers and Mg x Zn 1− x O Contacts to Increase Solar Cell Efficiency

Thin‐film solar cells such as CdTe are a major commercial photovoltaic technology, with more than 25 GW installed worldwide and levelized costs of electricity competitive with fossil fuels. Further progress may result from integrating CdSe y Te 1− y absorbers with Mg x Zn 1− x O contacts, but the device efficiency is difficult to maximize due to coupled dependence on chemical composition of both alloys. Herein, a high‐throughput approach is demonstrated to codesign chemical compositions in alloyed Mg x Zn 1− x O/CdSe y Te 1− y thin‐film solar cells, using combinatorial libraries of PV devices with orthogonal composition gradients in CdSe y Te 1− y absorbers and Mg x Zn 1− x O contacts. It is found that the solar cell performance is a strong and coupled function of both elemental compositions, with efficiency up to 17.7% ( V OC = 836 mV, fill factor = 69%, J SC = 30.6 mA cm −2 ) at atomic compositions of Mg/(Mg + Zn) ≈18% and average Se/(Se + Te) ≈4%. These performance trends among >100 devices are explained by >100 ns lifetime of photoexcited charge carriers at the Mg x Zn 1− x O/CdSe y Te 1− y interface where strong Se accumulation is also observed. This study reports the optimal compositions of the commercially relevant Mg x Zn 1− x O/CdSe y Te 1− y solar cells and demonstrates a general approach to codesigning performance of alloyed thin‐film solar cells and other optoelectronic devices.

14 SOLAR ENERGY↗
DOE OSTI2024

Aluminum/SmCo 5 composites for structural and magnetic applications

Metal-bonded magnetic composites (MBMCs) present a promising alternative to dense sintered magnets, particularly for intricate components. Compared to polymer-based bonded magnets, MBMCs have wider applicability in harsh environments. In this paper, we demonstrate a solid-state shear-based manufacturing technique to introduce localized magnetization into a paramagnetic aluminum matrix by embedding SmCo5 permanent magnet particles. Our magnetic composites display hard magnetic behavior with a coercivity of 13 kOe and a remanent magnetization of 4.32 emu/g. In addition to magnetization, we also report a 9% improvement in Young’s modulus. Despite the local temperature rise during processing, the magnetic phases didn’t decompose into unwanted phases, preserving the composite's hard magnetic properties. Creation of an interfacial metallurgical bond with the matrix ensured the suitability of the composites for structural applications. Our study investigates the mechanical, and functional properties of composites, paving the way for lightweight structural magnetic composites with a transformative potential in the aerospace, nuclear, and automotive applications. This work underscores the potential for further optimization and development to drive innovations in magnet and equipment design.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Mechanical Characterization of High-Temperature Carbon Fiber-Polyphenylene Sulfide Composites for Large Area Extrusion Deposition Additive Manufacturing

Additive manufacturing (AM) is evolving from rapid prototyping to production of structural components. The widespread application of AM demands a high level of mechanical performance from these components, and it is therefore essential to improve feedstock material in order to meet these mechanical expectations. However, compared to traditional manufacturing techniques, the mechanical properties of AM materials and their resulting components are not well understood. In this study, we investigated the processability, microstructure, and mechanical performance of twin-screw compounded short carbon fiber reinforced polyphenylene sulfide (PPS) pellets as a feedstock material for big area AM (BAAM). The performance of the AM components was compared to that of traditional processing methods, namely injection molding (IM) and extrusion-compression molding (ECM). It was found that the AM composites exhibited 118% lower tensile strength and 55% lower tensile modulus when compared to traditional injection molding composite specimens; however, AM composites exhibited comparable properties to ECM composites. This response was attributed to highly aligned fibers in IM and AM samples. However, the AM composites contained porosity (15.5% volume), which reduced their mechanical properties in comparison to ECM composites. Finally, the IM process showed the maximum amount of fiber attrition with minimum porosity (0.007% volume), while the ECM process exhibited the least fiber attrition with 4.3% volume porosity.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Densification and oxidation behavior of spark plasma sintered Hafnium Diboride-Hafnium Carbide composite

This study reports on the sintering and oxidation behaviors of Hafnium Diboride (HfB 2 ) and Hafnium Carbide (HfC) based ultra-high temperature ceramic (UHTC) composites. Pure Hafnium Diboride, Hafnium Carbide, and HfB 2 -50 vol% HfC composite were consolidated using spark plasma sintering (SPS) without the use of sintering aids. HfB 2 -HfC composite displayed a high sintered density of 98% as compared to 87% density of pure HfB 2 . The increased density of the HfB 2 -HfC composite is attributed to the bimodal powder distribution, which allowed for the smaller HfC particle to occupy the voids between the larger HfB 2 particles resulting in improved packing efficiency. Moreover, the higher planar surface energy, for the (111) and the (200) planes for HfC, contributed to the smaller HfC particle being a significant driving force in the sintering process. Oxidation studies of each material were carried out by exposing them to a high-speed plasma jet in a temperature exceeding 2700 °C. The results of these studies show an improved oxidation resistance of HfB 2 -HfC composite by 54% and 70% over pure HfC and HfB 2 , respectively. The enhanced oxidation behavior is attributed to B 2 O 3 filling in the porosity between the HfO 2 scale and protecting the underlying material. This study provides a new alternative to improve the sinterability of UHTC diborides by introducing another UHTC (i.e., HfC) to form a fully dense composite without sintering aid and superior oxidation resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Enhanced ductility in in-layer glass-carbon fiber/epoxy hybrid composites produced via tailored fiber placement

Experimental mechanical property results of composite materials with hybrid reinforcements (commingled glass and carbon fibers) are detailed and compared with single-fiber composite properties. In-layer hybrid materials, with carbon and glass fiber tows laid side-by-side, were produced via tailored fiber placement (TFP) technology. Detailed experiments showed a phenomenon of “enhanced ductility” of carbon fiber in the hybrid composites of 12–24% relative to an all-carbon fiber composite and multiple stress–strain peaks were observed. Here, this enhanced ductility was hypothesized to be due to the glass fibers mitigating the shock waves arising from the initial failures of carbon fibers, and preventing the premature failure of the remaining carbon fibers. A novel way to engineer the stress–strain behavior of a hybrid composite to achieve a metal-like ductile response (plateau of stress–strain behavior, often termed “elastic–plastic deformation”) was demonstrated by carefully selecting the type and composition of carbon and glass fiber materials.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Economic competitiveness of pultruded fiber composites for wind turbine applications

Pultrusion manufacturing of fiber reinforced polymers has been shown to yield some of the highest mechanical properties for unidirectional composites, having a high degree of fiber alignment with consistent performance. Pultrusions offer a low-cost manufacturing approach for producing unidirectional composites with a constant cross-section and are used in many applications, including spar caps of wind turbine blades. However, as an intermediate processing step for wind blades, the additional cost of manufacturing pultrusions must be accompanied by sufficient increases in mechanical performance and system benefits. Wind turbine blades are manufactured using vacuum-assisted resin transfer molding with infused unidirectional fiberglass or carbon pultrusions for the spar cap. Infused fiberglass composites are among the most cost-effective structural materials available and replacing this material in the cost-driven wind industry has proven challenging, where infused fiberglass spar caps are still the predominant material system in use. To evaluate alternative material systems in a pultruded composite form, it is necessary to understand the costs for this additional manufacturing step which are shown to add 33%–55% on top of the material costs. A pultrusion cost model has been developed and used to quantify cost sensitivities to various processing parameters. The mechanical performance for pultruded composites is improved versus resin-infusion manufacturing with a 17% increase in design strength at a constant fiber volume fraction, but also enables higher achievable fiber volume fractions. The cost-specific mechanical performance is compared as a function of processing parameters for pultruded composites to identify the opportunities for alternative material and manufacturing approaches for wind turbine spar caps. Finally, four materials are compared in a representative wind turbine blade model to assess the performance of pultruded carbon fiber systems and pultruded fiberglass relative to infused fiberglass, where the pultruded systems produce lower weight blades with various cost distinctions.

42 ENGINEERING↗
DOE OSTI2023

Crashworthiness of recycled carbon fiber composite sinusoidal structures at dynamic rates

Fiber reinforced polymer composites are finding applications in the automotive space for structurally critical applications including crash management. The use of recycled carbon fiber reinforcement can greatly reduce carbon emissions. In this study, recycled carbon fiber composites were manufactured into a self-supporting geometry using three matrices: polyphenylene sulfide (PPS), acrylonitrile butadiene styrene (ABS), and a structural epoxy, and subsequently crushed between flat platens at dynamic rates ranging from 4.6 to 9.1 ms -1 at temperatures in a range of -40°C to 80°C. Load-displacement data was used to evaluate their specific energy absorption, crush efficiency, and steady-state crush stress. Further, the energy absorption of the ABS composites was strongly sensitive to temperature, while the PPS composites exhibited strong crush efficiency dependence with both rate and temperature. The epoxy composites exhibited stable crush behavior at dynamic crush rates but exhibited a dramatic reduction in crush efficiency relative to quasi-static tests. The results of this study indicate that recycled fiber composites can achieve very high energy absorption levels (50–80kJkg -1 at room temperature) that make them an excellent alternative to more expensive and less environmentally friendly continuous virgin fiber laminates.

42 ENGINEERING↗
DOE OSTI2024

Reassessing the proposed “CY chondrites”: Evidence for multiple meteorite types and parent bodies from Cr-Ti-H-C-N isotopes and bulk elemental compositions

Here, we report a coordinated bulk Cr-Ti-H-C-N isotopic and compositional study of six carbonaceous chondrites from Antarctica that are often considered to be related and termed Yamato-like carbonaceous (CY) chondrites. These meteorites are known to have undergone extensive aqueous alteration followed by different degrees of thermal alteration, to be similar to one another in regard to mineralogy, and share affinities with both the Ivuna-like carbonaceous (CI) and Mighei-like carbonaceous (CM) chondrites. While mineralogically similar, a key difference among these samples is that chondrules have been found in some of these samples, but not in others. The aim of this study is to evaluate the relationship of these meteorites to one another, and investigate how they relate to the CI and CM chondrite groups. We find that with the addition of the isotopic compositions of these ‘CY’ chondrites, there is now a continuum of isotopic compositions among the carbonaceous chondrites. The CI chondrites are no longer separate in O isotopic compositions from the other carbonaceous chondrite groups in plots of Cr-O and Ti-O. We also find that the ‘CY’ chondrites represent two distinct populations, which correlate with their heating stage. However, the peak temperatures experienced by each population can only explain the differences in H and C isotopes and abundances and N abundances between samples, and cannot have caused the differences in N, Cr, and Ti isotopes, or all the volatile element depletions of the sample’s bulk compositions. Instead, we conclude that the compositional and isotopic data of these two populations correlate with their known chondrule abundances, indicating distinct precursors for each population. We find it most likely that these samples originate from two distinct asteroids, implying that among the six samples studied here, there are not five related samples to constitute a new meteorite group. The chondrule-free heating Stage III samples are most likely heated CI chondrites, while the chondrule-bearing heating Stage IV samples could be heated CM chondrites.

58 GEOSCIENCES↗
DOE OSTI2022

Quasi-static and dynamic response of a Cu/Nb composite following equal channel angular extrusion

The article presents a study of the plastic properties of a Cu–18%Nb composite following equal channel angular extrusion under both low- and high-strain rate loadings. The microstructures are characterized by optical and scanning electron microscopy as well as electron backscatter diffraction. Comparisons are also made with a Cu–50%Nb laminate made by accumulative roll bonding. Textures obtained within the respective phases in the extruded composite closely mimic those previously reported for the pure components alone (Cu, Nb). Grain sizes of the major phase (Cu) exhibit broad distributions, due largely to partial recrystallization during the extrusion process. Further re-crystallization is obtained within localized deformation bands produced at high strain rates (3 × 10 3 s –1 ). While the degree of anisotropy and the strain rate sensitivity of the composite response are similar to those of pure Cu after extrusion, the strength levels of the composite are somewhat greater, falling broadly between those obtained in the pure components after extrusion to comparable plastic strains. Furthermore, the implications for selection of composite composition and processing for achieving higher strengths are briefly discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Thermal mechanical assessment of a SiC-SiC-composite clad fuel pin concept in a light water reactor environment

Accident Tolerant Fuels (ATFs) are designed to increase coping time following an accident scenario while preserving or improving current steady state reactor operational performance. A potential ATF concept is SiC-SiC composite claddings. Fuel performance simulations were conducted on a SiC-SiC based cladding concept utilizing a multilayered approach for improved performance. This cladding concept referred to as the Duplex concept is a duplex structure composed of a monolithic SiC layer placed on the outside of a SiC-SiC composite. A liquid metal is added to fuel-cladding gap for improved heat dissipation from the fuel. The monolithic SiC layer is used to improve the coolant corrosion characteristics and protect the SiC-SiC composite layer from exposure to the coolant. The fuel performance code BISON was used to conduct fuel performance simulations on the cladding concepts. Comparisons are made with a current prototypic fuel rod design (UO 2 fuel enclosed in Zircaloy-4 cladding). Representative steady-state cases were considered for normal power and two cycle power histories. Additionally, a PCI ramp case was simulated to analyze potential anticipated operational occurrences. Transient response during a Loss of Coolant Accident and a Reactivity Initiated Accident were also simulated. This computational study demonstrated that for normal operating conditions, the SiC concept cladding performed as well as the baseline for the standard power cases evaluated. The ramping evaluations indicate potential fracturing of the SiC-SiC composite of the composite cladding compared to the Zircaloy-4 cladding due to the temperature gradient and the subsequent differential thermal conductivity degradation and swelling across the composite thickness. In conclusion, the rod fails early at low enthalpy for RIA but survives a LOCA with minimal material loss due to high temperature steam corrosion.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Improving ChemCam LIBS long-distance elemental compositions using empirical abundance trends

The ChemCam instrument on the Curiosity rover provides chemical compositions of Martian rocks and soils using remote laser-induced breakdown spectroscopy (LIBS). The elemental calibration is stable as a function of distance for Ti, Fe, Mg, and Ca. The calibration shows small, systematically increasing abundance trends as a function of distance for Al, Na, K, and to some extent, Si. The distance effect is known to be due to a dependence with distance on the relative strengths of atomic transition lines. Emission lines representing transitions from relatively low energy levels remain intense at longer distances while emission lines representing transitions from higher energy levels decrease in intensity more rapidly as a function of distance. The multivariate algorithms used to determine elemental compositions rely on a large number of emission lines in many cases, so rather than trying to correct all emission lines, a study was made of the predicted compositions as a function of distance, in order to determine an empirical correction. Abundance trends can be well approximated by a linear trend with distance within the ranges of abundances and distances observed up to ~6 m. Data from 11 distinct geological members and data groups of the Murray formation in Gale crater, Mars, were used to form the model, selecting the members and data groups yielding the best statistics. The model was tested using data from several targets observed from two different distances, and using data from the Kimberley formation, the composition of which is significantly different from the Murray formation, showing that the model works on other compositions beyond those used to build the model. For long-distance observations up to ~6 m, corrections can be made back to an equivalent composition at the median distance of ChemCam observations (2.6 m). Finally, the model has been validated up to 6.2 m, although ChemCam is able to observe bedrock targets to >7 m, and iron meteorites to distances of >9 m.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Mineral-hydrogel composites for mitigating harmful algal bloom and supplying phosphorous for photo-biorefineries

Harmful algal blooms (HAB) are a major environmental concern in eutrophic aquatic systems. To mitigate HABs and recover the phosphorus that drives algal growth, this study developed hydrogel composites seeded with calcium phosphate and wollastonite particles, which first adsorb phosphate (P) and then precipitate it as calcium phosphate. Using a fast-growing cyanobacterium, Synechococcus elongatus 2973, as a model microalga, we found that the mineral-hydrogel composites reduced dissolved P in BG11 media from 5.1 mg/L to 0.31 mg/L, initially reducing the biomass growth rate by up to 73 % and ultimately reducing the total biomass concentration by 75 %. When applied to municipal wastewater and agricultural run-off, the composites removed 96 % and 91 % of the dissolved P, respectively. Moreover, when the recovered P-enriched composites were reused as a slow-release bio-compatible fertilizer in a photobioreactor, they effectively supported algal growth without blocking light and interfering with photosynthesis. The P-enriched composites could tune the P concentration in the culture medium and significantly promote algal lipid accumulation. Finally, this study demonstrates the mineral-hydrogel composites' potential to treat point sources of P pollution and subsequently facilitate photoautotrophic biofuel production as a nutrient, effectively recycling the captured P.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Hydrogen sensing in different hydrogen-carrying gases using composites of PdSnO 2 and halloysite nanotubes

Here, in this work, we developed composites of palladium-decorated tin dioxide (PdSnO 2 ) and halloysite nanotubes (HNTs) by adding different amounts of HNTs as additives into PdSnO 2 , and investigated how the different amounts of HNTs in the composites and the different hydrogen (H 2 ) carrying gases (air and helium (He)) could affect the H 2 sensing performance of such composites (PdSnO 2 -HNT). Through the sensing-performance characterization using H 2 carried by air, it was found that PdSnO 2 with an appropriate small amount of HNTs (i.e., 2 % of PdSnO 2 mass) can improve the sensing performance with respect to limit of detection (LOD) and response/recovery time. Further, the optimal PdSnO2-HNT composite as a sensor was tested to detect H 2 in He. The testing results indicated that the composite can detect H 2 in He, but its performance parameters (i.e., the profile of calibration curve, LOD, and response time) are different from those of such a sensor in detecting H 2 in air. Moreover, the composite still presented better sensing performance than PdSnO 2 without HNTs in detecting H 2 in He. Possible reasons for the effects of HNT and H 2 -carrying gas on the sensing performance of PdSnO 2 -HNT-based sensors were discussed. We believe that this study provides valuable insights into the functionality and the adaptability of PdSnO 2 -HNT-based H 2 sensors in diverse operational conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Tribological behavior of hybrid Aluminum-TiB 2 metal matrix composites for brake rotor applications

Here, this research investigates the feasibility of hybrid aluminum metal matrix composites (MMC) incorporating TiB 2 particles for brake rotor applications. The composites were produced by incorporating both in-situ, submicron-sized TiB 2 particles and regular micron-sized TiB 2 powders via stir and squeeze casting techniques into A206 aluminum alloy matrix. Systematic adjustments in the fractions of in-situ and ex-situ TiB 2 particles were conducted to evaluate their impact on wear behavior and mechanisms. Combination of both particle types allowed composites with up to 10 vol% of reinforcements. Composites with higher proportions of ex-situ particles demonstrated increased wear resistance compared to those solely composed of in-situ particles, control specimens without TiB 2 , and conventional cast iron counterparts. The lowest wear rate for the hybrid composites sliding against phenolic brake pads was 1.1 × 10 -5 mm 3 /Nm, signifying a 3-fold reduction relative to cast iron sliding against the same pads. Wear analysis elucidated distinctive mechanisms within the hybrid composites, characterized by mild fragmented abrasive wear, adhesive wear, and plastic deformation, accompanied by the formation of an intermixed tribo-oxide layer.

42 ENGINEERING↗