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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 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Research Update: Towards designed functionalities in oxide-based electronic materials

One of the grand challenges facing materials-by-design approaches for complex oxide deployment in electronic devices is how to balance transformative first-principles based predictions with experimental feasibility. Here, we briefly review the functionality-driven approach (inverse design) for materials discovery, encapsulated in three modalities for materials discovery (m{sup 3}D) that integrate experimental feedback. We compare it to both traditional theoretical and high-throughput database-directed approaches aimed at advancing oxide-based materials into technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Characterization and nondestructive inspection of additively manufactured materials

Additively manufactured (AM) components often exhibit significant discontinuities and indications without a clear understanding of how they might affect the mechanical properties of a part during qualification and service. This uncertainty is unacceptable for the design and manufacturing of most aerospace components. Current research in both mechanical testing and nondestructive evaluation involves developing methods for characterizing and inspecting AM components as the use of such materials continues to rise. Although several AM manufacturing methods have been developed in recent decades, this paper focuses on AM production-ready processes for a direct metal laser sintering (DMLS) powder bed fusion machine and will provide background on Sandia National Laboratories’ research efforts in this area. Tensile bar samples manufactured using the DMLS powder bed fusion method were inspected in this study, and the results of ultrasonic spectroscopy for assessing internal flaws will be presented. A combination of material property evaluation, microstructural characterization, and nondestructive inspection techniques will also be described. Finally, the results obtained from these material evaluation methods assist in determining inspection limits and methods for qualifying AM materials.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Nuclear Material Characterization Using High-Energy X-rays at BNL Synchrotrons: From Reactor Steels and Molten Salts to Large Hadron Collider Novel Materials

New and improved materials, composites, and super-alloys capable of withstanding the anticipated extreme states of fusion reactors, fission reactors (i.e., high-temperature fast reactors) and multi-MW particle accelerators, with the latter facing similarly extreme states to reactors under energetic protons, are continuously sought. Materials structures like improved reactor steels, super-alloys, and novel composites are continuously being explored to help meet both the challenge of the higher-demand environments and longevity under extreme conditions. Greater fluxes of irradiating species (primarily fast neutrons and energetic protons), extreme temperatures, and aggressively corrosive environments make up the new cocktail of operating conditions these materials must withstand. A challenge in characterizing the effects under intense irradiation, high temperatures, and stresses is the establishment of the link between lattice-induced damage and phase transformation under particle irradiation and macroscopic physical properties, which ultimately determine performance in the real environment. With ever increasing irradiation fluxes, dramatic changes in the material properties are expected to occur stemming from the evolution or development of new microstructures.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Thermal, mechanical, and electrical properties of LSCo/mullite composite contact materials for solid oxide fuel cells

Lanthanum strontium cobaltite (LSCo) is considered as a good candidate cathode contact material for solid oxide fuel cells, due to high electrical conductivity. However, LSCo has a very large coefficient of thermal expansion (CTE) than the cells and metallic interconnects. As a result, poor mechanical stability is expected during thermal cycling. To minimize the CTE mismatch, we investigate a composite approach involving mixing LSCo with an inert material of low CTE, such as mullite at volume fractions from 0.1 to 0.4. Composite’s CTE shows a decreasing trend with increasing mullite volume fractions, and is consistent with model predictions. X-ray powder diffraction analysis of sintered LSCo/mullite composites exhibits no presence of other phases for samples aged for 500h at 800oC, indicating chemical compatibility. Electrical conductivity by a 4-pt method shows a decreasing trend with increasing mullite content. Contact strength of as-sintered and thermally cycled samples show that only the composite with 0.4 volume fraction has a measurable strength; the other composites have no strength. Overall, the composite approach is demonstrated in the LSCo/mullite system to lower the CTE and hence achieve thermal cycle stability. The addition of the inert phase to the LSCo matrix; however, also reduces the electrical conductivity.

Contact materials, LSCo, mullite, CTE, electrical ↗
DOE OSTI2016

Theoretical Considerations for Improving the Pulse Power of a Battery through the Addition of a Second Electrochemically Active Material

Here, porous electrode theory is used to conduct case studies for when the addition of a second electrochemically active material can improve the pulse-power performance of an electrode. Case studies are conducted for the positive electrode of a sodium metal-halide battery and the graphite negative electrode of a lithium “rocking chair” battery. The replacement of a fraction of the nickel chloride capacity with iron chloride in a sodium metal-halide electrode and the replacement of a fraction of the graphite capacity with carbon black in a lithium-ion negative electrode were both predicted to increase the maximum pulse power by up to 40%. In general, whether or not a second electrochemically active material increases the pulse power depends on the relative importance of ohmic-to-charge transfer resistances within the porous structure, the capacity fraction of the second electrochemically active material, and the kinetic and thermodynamic parameters of the two active materials.

25 ENERGY STORAGE↗
DOE OSTI2017

Materials for Energy Conversion: Materials for Energy Conversion and Storage

The main objective of this collaborative research project was to identify a formulation and develop a catalyst for electro-oxidation of ethanol. Ethanol is one of the most mass-produced biofuels, and such catalysts will enable the development of Direct Ethanol Fuel Cell technology and through it, will interconnect fuel cells with biofuels. Several catalysts for direct electrochemical oxidation of ethanol have been selected on the principles of rational desig from the knowledge build in studying aqueous oxidation of ethanol. The program involved fundamental study of ethanol oxidation in liquid media, and particularly in alakine solutions. The lessons learned from the heterogeneous catalysis of ethanol thermal oxidation have been applied to the design of an electrocatalyst for direct ethanol fuel cells. The successful chemical compositions are based on PdZn and NiZn allows. The studies reveled the role of the transition metal oxide phase as a co-catalyst and the role of the active support material. To complete the set of materials for ethanol fuel cell, this program also invested n the development of ctalysts for oxygen reduction that are selective against alcohol oxidation. Non-platinum ctalysts based on pyrolyzed macrocycles or similar composites have been studied. This program included also the development of stuctured supports as an integral part of the catalyst development. A new family of materials has been designed based on mesoporous silica templating with synthetic carbon resulting in hierarchicaly porous structure. Structure-to-property relationship of catalysis and catalysts has been the center of this program. This have been engaged in both surface and bulk level and pursued with the tools avialble at the academic institutions and at LANSCE at LANL. The structural studies have been built in interaction with a computational effort on the basis of DFT approach to materials structure and reactivity.

08 HYDROGEN↗
DOE OSTI2018

Material Model Testing in the DYNA3D Code: Material Models 1 through 5

This report is the first volume in an effort to study the material model implementations in DYNA3D, using the latest developmental version of the code. Input files were derived from a template supplied by Jerry Lin to perform an equation-of-state study. Most of the simulations use 10 cubes, each 1 cm on a side with a density of 8.03 (steel). Each of the cubes tests a different aspect of the material model. The first three cubes are testing normal stresses and normal strains (uniaxial stresses and strains) placed on the cube parallel to the x-axis, y-axis and z-axis, respectively. The x (or y or z) = 1 face of the cube is moved along the x-axis (or y-axis or z-axis) to test the model, while the opposite side remains in the x (or y or z) = 0 plane. For some of the tests, the nodes are free to move perpendicular to the applied strain to allow the cross-sectional area of the cube to change in response to being placed under pressure or tension (to test Poisson’s Ratio), while in others the nodes are frozen to eliminate dynamic effects resulting from the code. The cube is placed in tension along the axis being tested and then released, followed by a cycle of compression and release. This tension/compression cycle is repeated 3 more times. The additional cycles allow for the model to be tested under different loads. For these calculations, the amount by which the cube is stretched and compressed is varied from cycle to cycle to allow testing of model features. Cubes number 4 and 5 are intended to test xy shear stresses/strains. This is done by sliding one face of the cube in its plane parallel to the axis of interest. For example, for cube 4, the upper face of the cube is slid in the y=1 plane in a direction parallel to the x-axis (so there are no changes in the y and z coordinates of the points in the plane) and then returned to its starting position. This preserves the volume of the cube, so there is no change in density or pressure. The cycle is repeated 8 times. For cube 5, the plane of the cube satisfying x=1 is slid in this plane in a direction parallel to the y-axis and then returned to its starting position. This preserves the volume of the cube, so there is no change in density or pressure. The cycle is repeated 8 times. Cubes number 6 through 9 repeat these tests for yz shear stresses/strains (Cubes 6 and 7) and zx shear stresses and strains (Cubes 8 and 9). For reasons discussed in the next paragraph, it is unclear if these tests represent a state of pure shear stress and shear strain in the code. Application of shear stresses and strains should not, in general, result in the appearance of normal stresses and strains in Cubes 4 - 9. In the infinitesimal limit, this result might be obtained. However, DYNA3D is a finite deformation code and in the real deformations used in the code, this result is not achieved and the individual components of the normal stresses and strains are non-zero during the cycling. However, the sums of the normal strains are zero in these tests and, except in the case of thermally dependent models, so are the sums of the normal stresses. Cube 10 tests the response of the material model to a hydrostatic loading of the cube. The load curve used for the first three tests is used again and applied to each of the 8 nodes in a manner causing the cube to be either compressed or expanded. This compression/tension cycle is repeated 4 times. The additional cycles allow for the model to be tested under different loads. The amount by which the cube is stretched and compressed is varied from cycle to cycle to allow testing of model features. This document will discuss the testing of Material Models 1 through 5. Relevant results from the test cubes will be discussed. A discussion of the results from all 10 test cubes will be presented only if necessary.

36 MATERIALS SCIENCE↗
DOE OSTI2019

First Annual Report on Pulsed Thermal Tomography Nondestructive Evaluation of Additively Manufactured Reactor Materials and Components: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Additive manufacturing (AM, or 3D printing) for commercial nuclear energy applications is an emerging method for cost-efficient manufacturing aimed at replacing aging nuclear reactor parts and reducing costs for new construction. Because of the geometry of metallic structures of interest for nuclear applications, which consist of planar primitives with no symmetry of revolution, limited options are available for nondestructive evaluation (NDE), either during or post manufacturing. Known material flaws in AM include low-density regions consisting of non-sintered powder, which have to be detected to ensure the safety of long-term performance nuclear reactor components. As a solution to NDE of AM, we are developing pulsed thermal tomography (PTT) models and depth inversion algorithms for 3D imaging. PTT has many advantages because the method is non-contact and allows for in-service, NDE of AM nuclear reactor parts. By analyzing transients of surface temperature response due to internal thermal resistances, one can obtain 3D reconstructions of material effusivity using a unique inversion algorithm developed at Argonne. This report provides results of preliminary performance evaluation of PTT capability in detection of flaws in metallic structures, as well imaging complex geometry AM structures. Performance of PTT was investigated through modeling and experiments, Computer models of PTT were developed using COMSOL Heat Transfer module. Defects were modeled as cylindrical flat bottom holes (FBH), which is a common model of calibrated material flaws in thermal tomography experiments. Materials considered in this study include stainless steel 316 (SS316), stainless steel 304 (SS304), and Inconel 718. Theoretical analyses were conducted to validate inversion of simulated PTT data with COMSOL for a plate. Subsequently, 3D reconstructions were performed on COMSOL simulations for FBH, revealing a decrease in spatial resolution over depth due to thermal diffusion. The results of this study show that the performance of the inversion algorithm for detecting smaller defects depends strongly on the depth of the defect as well as the incident heat flux. The size of detectable defect was estimated by fitting a Gaussian function to surface temperature profile. The criteria for detectability was taken as 20mK noise equivalent temperature difference (NETD), which is currently the sensitivity limit of high-performance infrared cameras. It was determined through computer simulations that the smallest detectable FBH in SS316 has a 50µm diameter and is located 0.5mm below the plate surface. Preliminary experimental studies were performed to evaluate PTT performance in detecting calibrated flaws using metallic specimens with AM defects simulated as drilled-in FBH’s. High strength Stainless Steel 316 and Inconel 718 alloys were considered, as well as lower grade Stainless Steel 304, Nickel 200, and Hastelloy C276. Specimens investigated in this report consisted of approximately 1/4in-thick plates made out of these alloys using conventional manufacturing methods. The diameters of FBH’s varied from 1mm to 8mm, and their depths below the plate flat surface varied between 1mm and 6mm. The size of the smallest FBH was limited to 1mm because conventional mechanical drills were used for creating the holes. PTT imaging results have shown that 1mm-diameter FBH located 1mm and 2mm below the surface were detectable. Larger size FBH were detectable at greater depth. For example, 6mm-diameter FBH could be detected at 8mm depth. Image contrast varied slightly between the specimens, with the best reconstructions obtained in SS316 and C276 plates. Finally, PTT capability in imaging several AM structures fabricated from Inconel 718 (IN718) powder feedstock was investigated. The AM structures have complex geometry, but do not have calibrated internal defects. The objective is to determine PTT settings, such as the total integration time, for imaging of representative AM structures. A new FLIR X8500sc IR camera with higher spatial resolution (1280x1024 at 181Hz frame rate) was integrated into the PTT laboratory setup. Software tools were developed to ensure compatibility of new camera files with legacy effusivity reconstruction codes. The new camera was used to obtain 3-D reconstructions of AM IN718 nozzle plate and a particle filter plate. It was shown that PTT can scan through 2/3in-thick Inconel 718 plates in approximately 15s. Several modes of 3-D data visualization were explored, including using ImageJ and MATLAB software packages. The results demonstrate the capability of PTT in 3-D imaging of complex geometry AM structures. Intermediate results demonstrated in this report will be developed further to investigate detection of flaws in AM specimens.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Securing Critical Materials for the U.S. Electric Vehicle Industry: A Landscape Assessment of Domestic and International Supply Chains for Five Key Battery Materials

This study explores the prospective supply of upstream critical materials, providing insights into the U.S.'s capacity to meet its Electric Vehicle (EV) and Energy Storage System (ESS) deployment targets for 2035. It evaluates the proportion of critical materials demand that can be met by domestic upstream sources and the amount that will require non-U.S. sources. The analysis considers geological resources and current international development activities, contributing to the understanding of mineral supply security as the global community strives for net-zero emissions by 2050. The study focuses on five materials assessed in the 2023 DOE Critical Materials Assessment – Lithium, Nickel, Cobalt, Graphite, and Manganese.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Development Results on Replacement Materials for Current Scarce or High Supply Chain Risk Materials

In September 2020, the U.S. government issued an executive order to address the threat to the domestic supply chain from its reliance on critical minerals (CMs) from foreign competitors and to support the domestic mining and processing industry. The Advanced Materials and Manufacturing Technology (AMMT) program is addressing this executive order by evaluating advanced manufacturing (AM) and its impact on the demands of CMs for energy production in general and how the deployment of AM in nuclear energy will support the projected goals of the Paris Accord and further a net-zero carbon economy (NZE) by 2050. Three strategic reports were previously prepared by the AMMT program to date and identified two areas for more detailed exploration: (1) the replacement of high-risk CMs such as cobalt and niobium by more abundant minerals and (2) the minimization and utilization of CM waste streams. The design of nuclear materials without critical elements as alloying elements, is a part of the nuclear materials strategy to overcome the critical minerals scarcity. In this report, two approaches are evaluated namely (1) replacement of critical elements as alloying elements in nuclear materials, and (2) the design of a new alloys that does not contain critical minerals as an alloying element.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Development of Computational Materials Workflows for Additively Manufactured Metallic Materials to Enable Accelerated Prediction of Fatigue Performance

The maturation of computational materials approaches for fatigue performance prediction in a qualification and certification process is stifled by the ability to validate complex, microstructure-based simulations. Such a validation strategy bears immediate challenges including generating accurate virtual microstructures, efficiently solving physics-based mechanical simulations over relevant spatial and temporal scales, and acquiring high-fidelity calibration and validation data at the appropriate length scale. This presentation will overview these common challenges and present a case study to demonstrate a computational materials workflow for additively manufactured metallic materials. In this study, process-specific defects are characterized using segmented X-Ray micro-computed tomography measurements and overlaid on virtual microstructures. Accelerated crystal plasticity-based fatigue simulations are performed to demonstrate cyclic evolution and localization of mechanical fields in the vicinity of defects in response to their precise spatial configuration. An example of how this computational materials workflow may support next-generation qualification is discussed.

computational materials↗
DOE OSTI2017

Electrode material comprising graphene-composite materials in a graphite network

A durable electrode material suitable for use in Li ion batteries is provided. The material is comprised of a continuous network of graphite regions integrated with, and in good electrical contact with a composite comprising graphene sheets and an electrically active material, such as silicon, wherein the electrically active material is dispersed between, and supported by, the graphene sheets.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Energetic potting materials, electronic devices potted with the energetic potting materials, and related methods

A potted electronic device comprises an electronic device at least partially encapsulated by an energetic potting material. The energetic potting material comprises a halogenated urethane binder and a metal fuel dispersed within the halogenated urethane binder. Related energetic potting materials and methods of forming electronic devices at least partially encapsulated with the energetic potting materials are also disclosed.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Electrode material comprising graphene-composite materials in a graphite network

A durable electrode material suitable for use in Li ion batteries is provided. The material is comprised of a continuous network of graphite regions integrated with, and in good electrical contact with a composite comprising graphene sheets and an electrically active material, such as silicon, wherein the electrically active material is dispersed between, and supported by, the graphene sheets.

25 ENERGY STORAGE↗
DOE OSTI2019

Structure and chemical stability in perovskite–polymer hybrid photovoltaic materials

Adding polymers to methylammonium lead iodide perovskite solar cell active layers has been previously shown to increase their chemical stability, but stabilization mechanisms in these hybrid materials are poorly understood. We report here on a structural and spectroscopic analysis in a number of perovskite–polymer hybrid materials and compare their stability. We observed that perovskite crystallite sizes decrease with the addition of polymers (polyethylene glycol, polyethyleneimine, poly(acrylic acid) and polyvinylpyrrolidone), and through the use of nanomechanical AFM showed phase contrast in the perovskite–polymer mixture. NMR and single-crystal growth experiments reveal that acid–base interactions, as well as facet-dependent interfacial interactions between perovskite and polymer, contribute to differences in stabilities of these hybrid materials. The polymers investigated tend to suppress the formation of a hydrate crystal phase that accelerates the degradation reaction, and we report that adding poly(acrylic acid) increases significantly the stability of perovskite films under humid air and ambient illumination. Under these controlled degradation conditions, perovskite–poly(acrylic acid) hybrid solar cells maintain stable efficiency for the first 3 days and then slowly degrade over the next 6 days under humid air and illumination, whereas control perovskite solar cells degrade entirely within the first 2 days. Furthermore, these results highlight the importance of choosing suitable functional groups in the polymer phase of perovskite hybrid solar cells to prolong their device lifetime.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Silk Flexible Electronics: From Bombyx mori Silk Ag Nanoclusters Hybrid Materials to Mesoscopic Memristors and Synaptic Emulators

Functionalization of flexible materials based on mesoscopic reconstruction is a key strategy in fabricating biocompatible flexible electronics. This work is to acquire new mesoscopic bioelectronic hybrid materials of silk fibroin (SF)-Ag nanoclusters (AgNCs@BSA; BSA: bovine serum albumin), which enhance significantly the performance of silk memristors. It is to build AgNCs@BSA into SF mesoscopic networks by templated ß-crystallization. Atomic force microscopy potential probing indicates that AgNCs@BSA serve as electronic potential wells that change completely the transport behavior of charge particles within the SF films. This leads to significant enhancement in the switching speed (˜10 ns), very good switching stability, extremely low set/reset voltages (0.3/-0.18 V) of SF meso-hybrid memristors, compared with the original and other organic memristors, and displays unique synapse characteristics and the capability of synapse learning. Classical density functional theory Poisson–Nernst–Planck simulations indicate that the enhanced performance is subject to the low potential paths interconnecting the AgNCs@BSA, which guide charges' transport (Ag+) and deposition in SF films.

Shi, Chenyang↗