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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 OSTI2023

In-situ and ex-situ characterization of ion-irradiated AM materials

Additive manufacturing (AM) has attracted increasing attention in recent years as a new way of making high-quality components for nuclear reactors. While AM materials are compositionally similar to their conventionally produced counterparts, they do possess different microstructures, such as dislocation cells and chemical inhomogeneity, that can lead to different mechanical properties and performance behavior. In this study, the irradiation response of AM materials was investigated. In-situ and ex-situ ion irradiations were performed on AM316L and AM316H stainless steels (SS) at 300 and 600°C. The influence of the dislocation cell structure on the evolution of irradiation-induced dislocation loops was evident at 600ºC, but was much weaker at 300ºC. No voids were observed with the in-situ ion irradiation up to 10 dpa at both temperatures. Post-irradiation energy dispersive spectroscopy showed radiation-induced segregation (RIS) near grain boundaries and the formation of Cr-rich oxides throughout the matrix. The extent of segregation at dislocation cell walls varies with dose. Nanoindentation tests performed on the AM316L SS irradiated at 600ºC showed a complex dose dependence with softening at low doses and hardening at high doses.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Process-Microstructure-Property Relationships in Low Heat Input Wire-Arc Additive Manufacturing (WAAM) of Ni-Based Superalloy Haynes 282

Conference presentation on WAAM process optimization on Ni-based superalloy Haynes® 282®. This alloy is targeted for advanced power generation systems for its superior high temperature mechanical properties. Wire-arc additive manufacturing (WAAM) offers attractive cost and materials savings with high deposition rates. Based on initial build process optimization, WAAM blocks were made, and screened for defects using high-throughput CT scanning. The microstructural evolution in arc energy range of 250-700 J/mm was characterized in the as-built and aged conditions, using electron microscopy. Results showed self-consistent microstructure across conditions, with grain size dependence on arc energy, MC and M6C carbides in as-built, and blocky grain boundary M23C6 in as-heat-treated condition. Further reductions in as-built porosity were explored through 20+ combinations of H2 and CO2 additions to shielding gas. Initial results show improved wetting behavior, and bead overlap with up to 1% H2 and up to 0.25% CO2. Combination of experimentally determined datasets provided comprehensive understanding of process-structure-property relationships in WAAM Haynes 282.

Haynes 282↗
DOE OSTI2023

Comparison of metagenomes from fermentation of various agroindustrial residues suggests a common model of community organization

The liquid residue resulting from various agroindustrial processes is both rich in organic material and an attractive source to produce a variety of chemicals. Using microbial communities to produce chemicals from these liquid residues is an active area of research, but it is unclear how to deploy microbial communities to produce specific products from the different agroindustrial residues. To address this, we fed anaerobic bioreactors one of several agroindustrial residues (carbohydrate-rich lignocellulosic fermentation conversion residue, xylose, dairy manure hydrolysate, ultra-filtered milk permeate, and thin stillage from a starch bioethanol plant) and inoculated them with a microbial community from an acid-phase digester operated at the wastewater treatment plant in Madison, WI, United States. The bioreactors were monitored over a period of months and sampled to assess microbial community composition and extracellular fermentation products. We obtained metagenome assembled genomes (MAGs) from the microbial communities in each bioreactor and performed comparative genomic analyses to identify common microorganisms, as well as any community members that were unique to each reactor. Collectively, we obtained a dataset of 217 non-redundant MAGs from these bioreactors. This metagenome assembled genome dataset was used to evaluate whether a specific microbial ecology model in which medium chain fatty acids (MCFAs) are simultaneously produced from intermediate products (e.g., lactic acid) and carbohydrates could be applicable to all fermentation systems, regardless of the feedstock. MAGs were classified using a multiclass classification machine learning algorithm into three groups, organisms fermenting the carbohydrates to intermediate products, organisms utilizing the intermediate products to produce MCFAs, and organisms producing MCFAs directly from carbohydrates. This analysis revealed common biological functions among the microbial communities in different bioreactors, and although different microorganisms were enriched depending on the agroindustrial residue tested, the results supported the conclusion that the microbial ecology model tested was appropriate to explain the MCFA production potential from all agricultural residues.

60 APPLIED LIFE SCIENCES↗
NASA NTRS1978

Fabrication of composite shell structure for advanced space transportation

It is pointed out that future space missions, such as those involving spacecraft and structural assemblies to be used in geosynchronous orbits, will require ultralightweight composite structures to achieve maximum payloads. Of equal importance is the requirement to provide designs that are cost-competitive with metal designs. For space structures that must resist buckling, graphite-epoxy materials offer an attractive potential for providing lightweight, low-cost structural components that will meet future space mission requirements. A description is presented of a program which was conducted to evaluate the merits of graphite-epoxy cylindrical shells and to continue the development of a design data base for ultralightweight structures. An objective of the program was to design, fabricate, and test a corrugated graphite-epoxy cylinder 10 ft in diameter and 10 ft long.

Penton, A. P.↗
NASA NTRS1980

Overview of a stirling engine test project

Tests were conducted on three Stirling engines ranging in size from 1.33 to 53 horsepower (1 to 40 kW). The tests were directed toward developing alternative, backup component concepts to improve engine efficiency and performance or to reduce costs. Some of the activities included investigating attractive concepts and materials for cooler-regenerator units, installing a jet impingement device on a Stirling engine to determine its potential for improved engine performance, and presenting performance maps for initial characterization of Stirling engines. The experiment results of the tests are presented along with predictions of results of future tests to be conducted on the Stirling engines.

Slaby, J. G.↗
NASA NTRS1985

Advanced latent heat of fusion thermal energy storage for solar power systems

The use of solar thermal power systems coupled with thermal energy storage (TES) is being studied for both terrestrial and space applications. In the case of terrestrial applications, it was found that one or two hours of TES could shift the insolation peak (solar noon) to coincide with user peak loads. The use of a phase change material (PCM) is attractive because of the higher energy storage density which can be achieved. However, the use of PCM has also certain disadvantages which must be addressed. Proof of concept testing was undertaken to evaluate corrosive effects and thermal ratcheting effects in a slurry system. It is concluded that the considered alkali metal/alkali salt slurry approach to TES appears to be very viable, taking into account an elimination of thermal ratcheting in storage systems and the reduction of corrosive effects. The approach appears to be useful for an employment involving temperatures applicable to Brayton or Stirling cycles.

Phillips, W. M.↗
NASA NTRS1998

Modal Acoustic Emission of Damage Accumulation in Woven SiC/SiC at Elevated Temperatures

Ceramic matrix composites exhibit significant nonlinear stress-strain behavior that makes them attractive as potential materials for many high temperature applications. The mechanisms for this nonlinear stress-strain behavior are all associated with various types of damage in the composites, e.g. transverse matrix cracks and individual fiber failures. Modal acoustic emission has been employed to aid in discerning the damage accumulation that occurs during elevated temperature tensile stress-rupture of woven Hi-Nicalon fiber, BN interphase, SiC matrix composites. It is shown that modal acoustic emission is an effective monitor of the relative damage accumulation in the composites and locator of the damage and failure events as a function of strain (stress), time at temperature, and temperature gradients along the length of the elevated temperature test specimen.

Morscher, G. N.↗
NASA NTRS2002

Characterization of C/SiC Ceramic Matrix Composites (CMCs) with Novel Interface Fiber Coatings

Ceramic Matrix Composites (CMCs) are attractive candidate aerospace materials due to their high specific strength, low density and high temperature capabilities. The National Aeronautics and Space Administration (NASA) is pursuing the use of CMC components in advanced Reusable Launch Vehicle (RLV) propulsion applications. Carbon fiber-reinforced silicon carbide (C/SiC) is the primary material of interest for a variety of RLV propulsion applications. These composites consist of high-strength carbon fibers and a high modulus, oxidation resistant matrix. For RLV propulsion applications, environmental durability will be critical. Two types of carbon fibers were processed with both standard (pyrolytic carbon) and novel (multilayer and pseudoporous) types of interface coatings as part of a study investigating various combinations of constituents. The benefit of protecting the composites with a surface sealant was also investigated. The strengths, durability in oxidizing environments, and microstructures of these developmental composite materials are presented. The novel interface coatings and the surface sealant show promise for protecting the carbon fibers from the oxidizing environment.

Petko, Jeanne F.↗
NASA NTRS2004

Boron Nitride Nanotubes Synthesized by Pressurized Reactive Milling Process

Nanotubes, because of their very high strength, are attractive as reinforcement materials for ceramic matrix composites (CMCs). Recently there has been considerable interest in developing and applying carbon nanotubes for both electronic and structural applications. Although carbon nanotubes can be used to reinforce composites, they oxidize at high temperatures and, therefore, may not be suitable for ceramic composites. Boron nitride, because it has a higher oxidation resistance than carbon, could be a potential reinforcement material for ceramic composites. Although boron nitride nanotubes (BNnT) are known to be structurally similar to carbon nanotubes, they have not undergone the same extensive scrutiny that carbon nanotubes have experienced in recent years. This has been due to the difficulty in synthesizing this material rather than lack of interest in the material. We expect that BNnTs will maintain the high strength of carbon nanotubes while offering superior performance for the high-temperature and/or corrosive applications of interest to NASA. At the NASA Glenn Research of preparing BN-nTs were investigated and compared. These include the arc jet process, the reactive milling process, and chemical vapor deposition. The most successful was a pressurized reactive milling process that synthesizes BN-nTs of reasonable quantities.

Hurst, Janet B.↗
NASA NTRSDate not supplied

TPSAS-NF1676L-35020-DND

Low dimensionality materials continue to gain interest in the research community due to a combination of unique optical, electronic transport, and structural properties. Carbon Nanotubes and graphene are two such materials that are attractive for structural health monitoring applications. Single layer graphene is transparent, conductive, strong, flexible, and amenable to deposition by inkjet printing techniques. Carbon nanotubes are extremely strong and lightweight, and available in forms that can be printed, stitched or applied as a sensory patch on a structure. In this work the flexibility, conductivity, and processing capabilities of these low dimensionality carbon structures are coupled to produce directly printed strain sensors. Experimental results from coupon testing through full-scale flight tests are presented and a path toward structural systems with inherent health monitoring discussed.

Buzz Wincheski↗
NASA NTRSDate not supplied

Reduced Cost NiTi-Alloy Bearings Made Via Near Net Shape Powder Metallurgy Processes

NiTi alloys are emerging as an attractive bearing race material for bearings exposed to high static loads and highly corrosive environments. One obstacle yet to be overcome is the intrinsically high relative cost of these materials compared to traditional bearing steels. Traditional net-shape powder metallurgy methods, such as cold-press and sinter, are not applicable to NiTi alloys because they require hot isostatic pressing (HIP) to achieve full density, flaw free microstructures. Recently, innovative powder metallurgy processing has been successful in forming bearing ring blank shapes through the use of geometrically tailored HIP containers. Microstructural evaluations show that ring blanks made from this process are comparable to material made using conventional HIP containers while substantially reducing material usage.

bearings↗
DOE OSTI2020

Graphene reinforced materials and related methods of manufacture

Graphene reinforced materials and related methods of manufacture are provided. The graphene reinforced materials include graphene sheet or scroll, graphene-polymer sheet or scroll, and graphene-carbon sheet or scroll, each having material properties that are attractive across a broad range of applications and industries. The graphene reinforced materials generally include monolayer or multilayer graphene that is synthesized by annealing a catalyst substrate within a CVD chamber, introducing a hydrocarbon gas as a carbon source with the CVD chamber to form a layer of graphene on the catalyst substrate, detaching the catalyst substrate from the layer of graphene, and rolling the layer of graphene onto itself to form a scroll, optionally with the addition of a polymer layer or carbonized layer on the graphene layer.

Vlassiouk, Ivan V.↗
DOE OSTI2024

Development & Experimental Validation of a Generalized Resistance-Capacitance Model for Numerical Simulation of Phase-Change Material Embedded Heat Exchangers

Latent heat thermal energy storage (LHTES) using phase change material (PCM) has attracted increased attention as a viable solution for overcoming the mismatch between energy supply and demand for renewable energy-based systems. PCM-embedded heat exchangers (PCM-HX) have the potential to significantly improve thermal performance due to high storage capacity and low temperature variation during the phase change process. Most models for simulating LHTES heat transfer use Computational Fluid Dynamics (CFD) simulations, which have high computational costs resulting from considering the complex and time-dependent physics relevant to PCM-HXs. In this paper, a Generalized Resistance Capacitance-based Model (GRCM) was developed to predict the thermal performance of arbitrary PCM-HXs in a computationally efficient manner without compromising modeling accuracy. The GRCM is exercised for three case studies: (i) verification for a single-slabbed finned PCM-HX, (ii) verification and validation for a copper foam/paraffin composite PCM-HX, and (iii) validation for a straight tube annular finned PCM-HX. The copper foam PCM-HX uses an electric heater at the top of HX, while the other two configurations utilize water as heat transfer fluid. For the single-slabbed finned PCM-HX melting case, the mean deviation in average PCM temperature predicted by the GRCM compared to the CFD model was between 0.56 – 0.73 K, with maximum temperature deviation of 2.68 K. For the HTF outlet temperature, the validation results showed that GRCM prediction matches very well with experimental data, with mean temperature deviation of 0.24 K during melting case, while for solidification case was 0.34 K. These results showcase the GRCM’s capability for accurately reproducing the thermal characteristics of PCM-HXs with considerably lower computational effort.

42 ENGINEERING↗
NASA NTRS2001

Novel High Efficient Organic Photovoltaic Materials

In man's mission to the outer space or a remote site, the most abundant, renewable, nonpolluting, and unlimited external energy source is light. Photovoltaic (PV) materials can convert light into electrical power. In order to generate appreciable electrical power in space or on the Earth, it is necessary to collect sunlight from large areas due to the low density of sunlight, and this would be very costly using current commercially available inorganic solar cells. Future organic or polymer based solar cells seemed very attractive due to several reasons. These include lightweight, flexible shape, ultra-fast optoelectronic response time (this also makes organic PV materials attractive for developing ultra-fast photo detectors), tunability of energy band-gaps via molecular design, versatile materials synthesis and device fabrication schemes, and much lower cost on large-scale industrial production. It has been predicted that nano-phase separated block copolymer systems containing electron rich donor blocks and electron deficient acceptor blocks will facilitate the charge separation and migration due to improved electronic ultrastructure and morphology in comparison to current polymer composite photovoltaic system. This presentation will describe our recent progress in the design, synthesis and characterization of a novel donor-bridge-acceptor block copolymer system for potential high-efficient organic optoelectronic applications. Specifically, the donor block contains an electron donating alkyloxy derivatized polyphenylenevinylene, the acceptor block contains an electron withdrawing alkyl-sulfone derivatized polyphenylenevinylene, and the bridge block contains an electronically neutral non-conjugated aliphatic hydrocarbon chain. The key synthetic strategy includes the synthesis of each individual block first, then couple the blocks together. While the donor block stabilizes the holes, the acceptor block stabilizes the electrons. The bridge block is designed to hinder the electron-hole recombination. Thus, improved charge separation is expected. In addition, charge migration will also be facilitated due to the expected nano-phase separated and highly ordered block copolymer ultrastructural. The combination of all these factors will result in significant overall enhancement of photovoltaic power conversion efficiency.

Sun, Sam↗
NASA NTRS1993

Performance of ceramic superconductors in magnetic bearings

Magnetic bearings are large-scale applications of magnet technology, quite similar in certain ways to synchronous machinery. They require substantial flux density over relatively large volumes of space. Large flux density is required to have satisfactory force density. Satisfactory dynamic response requires that magnetic circuit permeances not be too large, implying large air gaps. Superconductors, which offer large magnetomotive forces and high flux density in low permeance circuits, appear to be desirable in these situations. Flux densities substantially in excess of those possible with iron can be produced, and no ferromagnetic material is required. Thus the inductance of active coils can be made low, indicating good dynamic response of the bearing system. The principal difficulty in using superconductors is, of course, the deep cryogenic temperatures at which they must operate. Because of the difficulties in working with liquid helium, the possibility of superconductors which can be operated in liquid nitrogen is thought to extend the number and range of applications of superconductivity. Critical temperatures of about 98 degrees Kelvin were demonstrated in a class of materials which are, in fact, ceramics. Quite a bit of public attention was attracted to these new materials. There is a difficulty with the ceramic superconducting materials which were developed to date. Current densities sufficient for use in large-scale applications have not been demonstrated. In order to be useful, superconductors must be capable of carrying substantial currents in the presence of large magnetic fields. The possible use of ceramic superconductors in magnetic bearings is investigated and discussed and requirements that must be achieved by superconductors operating at liquid nitrogen temperatures to make their use comparable with niobium-titanium superconductors operating at liquid helium temperatures are identified.

Kirtley, James L., Jr.↗
NASA NTRS1996

NASA-UVa Light Aerospace Alloy and Structures Technology Program: Aluminum-Based Materials for High Speed Aircraft

This report is concerned with 'Aluminum-Based Materials for High Speed Aircraft' which was initiated to identify the technology needs associated with advanced, low-cost aluminum base materials for use as primary structural materials. Using a reference baseline aircraft, these materials concept will be further developed and evaluated both technically and economically to determine the most attractive combinations of designs, materials, and manufacturing techniques for major structural sections of an HSCT. Once this has been accomplished, the baseline aircraft will be resized, if applicable, and performance objectives and economic evaluations made to determine aircraft operating costs. The two primary objectives of this study are: (1) to identify the most promising aluminum-based materials with respect to major structural use on the HSCT and to further develop those materials, and (2) to assess these materials through detailed trade and evaluation studies with respect to their structural efficiency on the HSCT.

Starke, E. A., Jr.↗
DOE OSTI2021

Kinetics of Hydrogen Desorption from Yttrium Hydride: The Development of Material Characterization Methods

Yttrium hydride possesses attractive neutronic and thermal properties for moderator applications as a high-temperature moderator material in advanced thermal neutron spectrum reactors that require small core volumes. For safe operation of the nuclear reactors, it is critical to understand the kinetics of H desorption from yttrium hydride at elevated temperatures. In previous studies, the H desorption flux as a function of temperature was measured by thermal desorption spectroscopy. To fully understand the H desorption kinetics, the amount of H within the specimen must be locally evaluated, especially if this uniformity strongly affects the thermomechanical properties and irradiation resistance of the bulk material.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Understanding the Beneficial Role of Transition-Metal Layer Na + Substitution on the Structure and Electrochemical Properties of the P2-Layered Cathode Na 2+ x Ni 2– x /2 TeO 6

Layered Na x MO 2 sodium oxide positive electrode materials have experienced renewed interest owing to the current commercial attention on sodium-ion batteries. Although there are many attractive qualities of these materials, they suffer from serious shortcomings owing to Na + ordering and transition-metal layer gliding that cause a plethora of voltage plateaus during cycling. The P2-layered Na 2+x Ni 2–x/2 TeO 6 (0 ≤ x ≤ 0.5) system provides a framework for investigating the effect of dual Na + substitution into the sodium layer and the transition-metal layer of the structure and its effects on the electrochemical properties of the materials. A careful investigation into the synthesis and properties of these materials reveals that the sodium content used during material preparation has a drastic effect on the composition and electrochemical profile of these materials. The sodium substitution disrupts ordering within the transition-metal layer, thereby disrupting Na + ordering in the adjacent sodium layers. Beyond a critical sodium concentration, the layer stacking shifts, and all voltage plateaus of the P2-Na 2 Ni 2 TeO 6 material are no longer observed at 4.4 V versus Na + /Na. These results also question the common belief that additional sodium precursor is required when preparing layered sodium oxide cathodes, providing new guidelines for material synthesis and characterization.

36 MATERIALS SCIENCE↗