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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 OSTI2024

Controlling Bond Scission Pathways of Isopropanol on Fe- and Pt-Modified Mo 2 N Model Surfaces and Powder Catalysts

Biomass valorization can be used to produce value-added chemicals and fuels from renewable biomass resources by upgrading them via selective bond scission while retaining certain functional groups. Specifically, upgrading biomass through the dehydrogenation of alcohols to carbonyl compounds has gained interest as a method of utilizing biomass-derived alcohols while additionally producing H 2 . In this work, isopropanol was used as a probe molecule to control bond scission selectivity over Fe- and Pt-modified molybdenum nitride (Mo 2 N) model surfaces and powder catalysts. Trends in the selectivity toward dehydration and dehydrogenation were dependent on both the type and coverage of the metal overlayer on model surfaces. These results were then extended to the corresponding powder catalysts to demonstrate how model surface studies can inform the design of supported catalysts. Density functional theory calculations provided insights into controlling the dehydration and dehydrogenation pathways. In conclusion, this work shows that a fundamental understanding of the reactivity and intermediates on Mo 2 N-based model surfaces can be applied to understand the catalytic performance of metal-modified Mo 2 N powder catalysts, and also demonstrates that Mo 2 N-based catalysts are potentially promising materials for upgrading biomass-derived oxygenates.

09 BIOMASS FUELS↗
DOE OSTI2025

Controlling Selective C–O and C–H Bond Scission of Methanol by Supporting Pt on TiN and Mo 2 N Model Surfaces and Powder Catalysts

Transition metal nitrides (TMNs) have been explored as effective supports for Pt due to their Pt-like electronic properties. However, there is a lack of fundamental understanding regarding the behavior of Pt on different TMNs (Pt/TMN). Herein two TMNs, Mo 2 N and TiN, were modified with Pt and compared using methanol decomposition as a probe reaction via both ultrahigh vacuum (UHV) studies on thin films and ambient-pressure batch reactor studies of powder catalysts. Temperature-programmed desorption (TPD) and high-resolution electron energy loss spectroscopy (HREELS) measurements were conducted under UHV conditions with Mo 2 N and TiN thin films. Mo 2 N was shown to favor C–H bond scission to form CO with a 56.2% selectivity, while TiN favored C–O bond scission to form CH 4 with a 74.5% selectivity. The addition of 0.9 monolayers (MLs) of Pt increased C–H bond scission selectivity to 89.7% and 49.2% for Mo 2 N and TiN respectively. Density functional theory (DFT) calculations on model surfaces revealed that the binding energy of O (BE *O ) was significantly reduced on Pt/TMNs, from −4.02 eV on Mo 2 N to −1.31 eV on Pt/Mo 2 N and −4.74 eV on TiN to −1.37 eV on Pt/TiN. As a result, C–O bond scission pathways were suppressed, leading to the preferential C–H bond scission that was observed experimentally. The C–O and C–H bond scission trends observed on thin films were then extended to powder catalysts, which demonstrated similar trends toward methanol decomposition. In conclusion, results from the current study establish that by combining UHV studies and DFT calculations over model surfaces, one can effectively predict the catalytic behavior of realistic TMN powder catalysts.

08 HYDROGEN↗
DOE OSTI2024

Synthesizing Highly Crystalline Graphite Powder from Bulk Polyethylene Waste for Lithium-Ion Battery Anodes

Upcycling plastic waste into graphite can potentially be used, in conjunction with other methods, to manage existing waste materials and diversify graphite supply chains. However, synthesizing large quantities of crystalline graphite powder from plastic waste, particularly polyethylene (PE), remains a challenge because PE decomposes into light gases during thermal processing and simple methods do not exist at any appreciable size scale to address this challenge. In this work, a method is developed for air processing bulk forms of PE waste to create stable carbon char that does not readily decompose during high-temperature processing. This method employs solid additives in the form of salts, which are combined with the PE melt during air processing to increase the effective surface area of the melt and improve the oxygen-driven chemistry that stabilizes PE for high-temperature processing. After removal of the solid salt additives from the PE-derived char, it is converted into a highly crystalline bulk graphite powder using an Fe-based catalytic process. The PE-derived graphite anode in a lithium-ion coin cell showed a specific capacity of 345 mAh/g at 0.05C with an initial Coulombic efficiency of 87% and reversible capacity retention of ~100% at different current rates. It also showed a specific capacity of up to 313 mAh/g at 0.5 discharge/charge cycles per hour (0.5C) and Coulombic efficiency of 99.9% after 250 cycles, indicating excellent electrochemical performance as an anode material for lithium-ion batteries. This method illustrates that there are opportunities for upcycling large quantities of PE waste to produce graphite powders suitable for use in LIBs.

25 ENERGY STORAGE↗
DOE OSTI2020

Nanoscale Spatial Distribution of Supported Nanoparticles Controls Activity and Stability in Powder Catalysts for CO Oxidation and Photocatalytic H 2 Evolution

Here we discuss, supported metal nanoparticles are essential components of high-performing catalysts, and their structures are intensely researched. In comparison, nanoparticle spatial distribution in powder catalysts is conventionally not quantified, and the influence of this collective property on catalyst performance remains poorly investigated. Here, we demonstrate a general colloidal self-assembly method to control uniformity of nanoparticle spatial distribution on common industrial powder supports. We quantify distributions on the nanoscale using image statistics and show that the type of nanospatial distribution determines not only the stability, but also the activity of heterogeneous catalysts. Widely investigated systems (Au–TiO 2 for CO oxidation thermocatalysis and Pd–TiO 2 for H 2 evolution photocatalysis) were used to showcase the universal importance of nanoparticle spatial organization. Spatially and temporally resolved microkinetic modeling revealed that nonuniformly distributed Au nanoparticles suffer from local depletion of surface oxygen, and therefore lower CO oxidation activity, as compared to uniformly distributed nanoparticles. Nanoparticle spatial distribution also determines the stability of Pd–TiO 2 photocatalysts, because nonuniformly distributed nanoparticles sinter while uniformly distributed nanoparticles do not. This work introduces new tools to evaluate and understand catalyst collective (ensemble) properties in powder catalysts, which thereby pave the way to more active and stable heterogeneous catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

White Laue and powder diffraction studies to reveal mechanisms of HCP-to-BCC phase transformation in single crystals of Mg under high pressure

Mechanisms of hexagonal close-packed (HCP) to body-centered cubic (BCC) phase transformation in Mg single crystals are observed using a combination of polychromatic beam Laue diffraction and monochromatic beam powder diffraction techniques under quasi-hydrostatic pressures of up to 58 ± 2 GPa at ambient temperature. Although experiments were performed with both He and Ne pressure media, crystals inevitably undergo plastic deformation upon loading to 40–44 GPa. The plasticity is accommodated by dislocation glide causing local misorientations of up to 1°–2°. The selected crystals are tracked by mapping Laue diffraction spots up to the onset of the HCP to BCC transformation, which is determined to be at a pressure of 56.6 ± 2 GPa. Intensity of the Laue reflections from HCP crystals rapidly decrease but no reflections from crystalline BCC phase are observed with a further increase of pressure. Nevertheless, the powder diffraction shows the formation of 110 BCC peak at 56.6 GPa. The peak intensity increases at 59.7 GPa. Upon the full transformation, a powder-like BCC aggregate is formed revealing the destructive nature of the HCP to BCC transformation in single crystals of Mg.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Enhancement of edge turbulence concomitant with ELM suppression during boron powder injection in EAST

A reproducible, quasi-stationary edge localized mode (ELM)-suppressed scenario was obtained over a wide range of plasma parameters by continuous injection of boron (B) powder into an upper-single null discharge in the experimental advanced superconducting tokamak [Sun et al., Nucl. Fusion 61, 014002 (2021)]. This powder-induced ELM-absent regime is associated with an edge harmonic mode (EHM) that provides continuous particle exhaust to maintain constant density without confinement degradation and impurity accumulation, the latter of which is often observed in ELM-free regimes. A flow rate threshold of B powder injection, leading to a threshold intensity of the EHM, is necessary for full ELM suppression. The fundamental harmonic of the EHM exhibits a toroidal mode number n = 1. The mode is observable in the entire poloidal cross section with a peak near the upper X-point in an upper-single null configuration. Here, the EHM spans radially across the pedestal and scrape-off layer, peaking inside the separatrix. The EHM appears to be insensitive to q 95 , heating power, plasma toroidal rotation, and pedestal collisionality.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Deuterium recycling and wall retention characteristics during boron powder injection in EAST

Boron (B), as a low-Z material, is widely employed for wall conditioning to enhance plasma performance in fusion devices. In the Experimental Advanced Superconducting Tokamak, a series of experiments involving real-time B powder injection has been conducted to investigate fuel particle behavior. It was observed that fuel particle recycling decreased with an increase in the amount of B powder injected, resulting in an increase in short-term fuel retention. The fuel recycling decreased by up to 80%, as indicated by divertor neutral pressure and D α line emission. Furthermore, each B atom exhibited a trapping capacity of 0.3 D particles during B powder injection at a typical flow rate. The real-time B injection had no wall hysteresis effect on D retention, implying that cumulative B injection and deposited film did not affect long-term D retention. The possible mechanism for D retention is the formation of B-C-O-D compounds and co-deposition between B and D particles during discharges. This investigation would be valuable for evaluating T retention when B is used as wall conditioning material in future fusion reactor devices.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Considerations for quantitative in situ X-ray powder diffraction studies of solid-state reactions

The importance of sample preparation in collecting high-fidelity powder diffraction data suitable for quantitative structure and phase analysis is well established. Such powder diffraction experiments are increasingly being appliedin situ, during reactions, to explore solid-state reactivity. When appliedin situ, X-ray diffraction is widely used to gain insight into the mechanism and kinetics, and to identify dynamic intermediate states. Here, using a model ion-exchange reaction (NaFeO 2 + LiCl → LiFeO 2 + NaCl), we show that sample preparation not only influences the fidelity of powder diffraction analysis but also impacts the observed reaction progress. Specifically, we found that the observed reaction progress can differ by ∼50% depending on the capillary sample preparation. Thus, forin situdiffraction studies of solid-state reactions, packing fraction is an important and previously unrecognized consideration that impacts reproducibility and fidelity of the reaction study.

Chemistry↗
DOE OSTI2021

Development of Multi-Filament Textured-Powder Bi-2212/Ag Wire With Enhanced Local Area Ratio

The performance and cost of Bi-2212/Ag wire is limited by the large fraction of Ag matrix (~3:1) that is required in the oxide-powder-in-tube fabrication process. An alternative fabrication process is being developed in which fine-powder Bi-2212 is uniaxially compressed to form bars with a thin Ag foil sheath. The fine powder naturally textures (aligns the a-b planes perpendicular to the direction of compaction) with texture >80% using 200 MPa compression. A billet is formed by stacking trapezoidal- cross-section bars in a symmetric 8-12-16 pattern around an Ag rod and enclosed in an Ag-wall extrusion can. Here, the billet is extruded and drawn to fine wire. Results are presented on present status of the development and testing.

17 WIND ENERGY↗
DOE OSTI2020

Understanding Laser Powder Bed Fusion Surface Roughness

Abstract Surface roughness is a well-known consequence of additive manufacturing methods, particularly powder bed fusion processes. To properly design parts for additive manufacturing, a comprehensive understanding of the inherent roughness is necessary. While many researchers have measured different surface roughness resultant from a variety of parameters in the laser powder bed fusion process, few have succeeded in determining causal relationships due to the large number of variables at play. To assist the community in understanding the roughness in laser powder bed fusion processes, this study explored several studies from the literature to identify common trends and discrepancies amongst roughness data. Then, an experimental study was carried out to explore the influence of certain process parameters on surface roughness. Through these comparisons, certain local and global roughness trends have been identified and discussed, as well as a new framework for considering the effect of process parameters on surface roughness.

Engineering↗
DOE OSTI2020

Comprehensive Studies on Hot Compaction and Vibration-Assisted Compaction Tests of Aluminum Powder

Abstract Aluminum powder compaction was studied using both test and simulation. Cold compaction, hot compaction, and vibration-assisted (cold) compaction tests were conducted to achieve different density ratios. First, the hot compaction test (at 300 °C, compression pressure 140 MPa) improved about 6% compared with cold compaction under the same compression pressure. Second, although the relative density ratio does not obviously improve at a vibration-assisted (cold) compaction, the strength of the specimens made under vibration loading is much better than those of cold compaction. Additionally, finite element models with well-calibrated Drucker–Prager Cap (DPC) material constitutive model were built in abaqus/standard to simulate the powder compaction process. The results of the finite element model have very good correlations with test results up to the tested range, and this finite element model further predicts the loading conditions needed to achieve the higher density ratios. Two exponential equations of the predicted density ratio were obtained by combining the test data and the simulation results. A new analytical solution was developed to predict the axial pressure versus the density ratio for the powder compaction according to DPC material model. The results between the analytical solution and the simulation model have a very good match.

Engineering↗
DOE OSTI2024

A Microchannel Heat Exchanger Produced From a Metal Matrix Composite by Hybrid Laser Powder Bed Fusion and Inkjet Printing

Abstract This paper explores the production of an oxide dispersion strengthened (ODS) 304L stainless steel microchannel heat exchanger (HX) using a hybrid additive manufacturing process of laser powder bed fusion and inkjet printing. The study investigates the capabilities and economics of the hybrid inkjet-laser powder bed fusion (LPBF) process and evaluates the dimensional accuracy, functionality, and mechanical properties of the resulting ODS alloy. The effectiveness and pressure drop of the ODS heat exchangers produced by the hybrid LPBF tool are also determined. Results show that the inkjet-doped samples have a lower mean channel height with higher standard deviation than samples produced by LPBF alone. This is attributed to greater absorption of laser energy for the powder coated with the oxide precursor. The economic analysis shows that the hybrid process has a potential for reducing the unit cost of the heat exchanger based on cost modeling assumptions.

Engineering↗
DOE OSTI2021

Standoff Detection of Oil and Powder Mixtures at 12 Meters Using a Tunable Quantum Cascade Laser-Based System with a Close Focus Telescope and Uncooled Infrared Detector

We have designed and demonstrated a quantum cascade laser (QCL) based standoff system that utilizes an uncooled mercury cadmium telluride (MCT) detector with lock-in signal processing for chemical identification at a distance of 12.5 meters in indoor ambient light conditions. In the system, a tunable quad-QCL operating (1 MHz) in quasi-continuous wave mode between 8.45 and 10.03 μm (~1182 to 1000 cm –1 ) serves as the active mid-infrared source for remotely interrogating mineral, powder, and thin film oil samples including powder mixtures (6, 12.5, 25, and 50%) of crystalline quartz (SiO 2 ) in KBr. Light as reflected from a given sample is collected using a 10-inch (25.4 cm) Dall Kirkham telescope and coupled with ZnSe optics to an uncooled MCT detector. Furthermore, the mixture dependence of the highly transparent KBr and strongly absorbing quartz was found to fit a modified version of the Schatz reflectance model for compacted powder mixtures. All reflectance spectra reported are relative to an Au-coated diffuse reflector. A NIST traceable polystyrene standard reflector was also used to determine the QCL wavelength tuning range and calibration.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Evaluation of “Tight Oil” Well Performance and Completion Practices in the Powder River Basin - “Time Slice” Analysis

The objective of this paper is to assess how well completion practices and well performance have evolved over time (“time slices”) in the tight sands and shales of the Powder River Basin (PRB). This information can provide a foundation for helping operators define more effective well completion practices and thus optimize well performance in an emerging “tight oil” basin. To start, the authors assembled a “database” containing well completion practices, production data, and geologic information for more than 800 horizontal (Hz) wells targeting three “tight oil” formations -- Turner, Frontier, and Mowry--placed on production in the past dozen years. To control for the impact of geologic and reservoir properties on well performance, the authors defined 12 geologically distinct areas (“partitions”) for the Turner, Frontier, and Mowry Shale in the Powder River Basin (4 partitions in each formation). This paper discusses the methodology for establishing “time slices” for each partition within each of the three “tight oil” formations, including (1) taking out, to the extent practical, the effects of geology by partitioning the three “tight oil” formations based on their geologic parameters; (2) using type curves and estimated ultimate recoveries (EURs) to establish a reliable measure of well performance; and (3) rigorously inspecting the production and well completion data to assure a quality dataset. Partition #2, a high thermal maturity area of the Frontier Sandstone in the western Powder River Basin, helps illustrate the results of the study. Using a dataset of 55 Hz wells, the study found that well performance has steadily improved, with oil EURs increasing from 180 MBbl in 2012-13 to 290 MBbl in 2018-19. Much of this improvement was due to the use of longer Hz laterals, increasing notably from 3,765 ft in 2012-13 to 10,260 ft in 2018-19. More intensive completion practices contributed, as well. For example, the number of frac stages more than doubled, from 17 to 35, and proppant concentrations increased from 1,060 lbs/ft to 1,320 lbs/ft. Finally, the data show diminishing returns to longer laterals and more intensive completion practices. For example, the key performance measure of oil EUR per 1,000 ft of lateral is decreasing. For 2012-13, Hz wells recovered 50 MBbl of oil per 1,000 ft of lateral while the more recent 2018-19 Hz wells only provide 30 MBbl of oil per 1,000 ft of lateral. Considerable insight can be gained by using “time slices” and geologic partitioning to better understand the relationship between changes in well drilling and completion practices and changes in well performance in emerging “tight oil” plays. The results from this study can also serve as a foundation for subsequent, more intense efforts involving data analytics for defining more optimum well completion practices targeting specified geologic settings and formations.

02 PETROLEUM↗
DOE OSTI2020

Synthesis and Flash Sintering of (Hf1-xZrx)B2 Solid Solution Fine Powders

Fine powders of (Hf1-xZrx)B2 solid solution were synthesized by two methods. In the first one, solution-based processing of HfCl4, ZrCl4, sucrose and H3BO3 was carried out followed by heat treatment (e.g., at 1500 °C for 1 h) in Argon to achieve the carbothermal reduction (CTR) reaction to form the boride solid solution. In the second one, called boron hydride reduction (BHR) method, HfCl4, ZrCl4 and NaBH4 were directly mixed in a glove box followed by heat treatment in Argon at elevated temperatures from 700 to 1500 °C. In addition, the powders synthesized via both methods were flash sintered without sample preheating in a homemade setup. The synthesized powders as well as the flash sintered bulk ceramics were characterized using different techniques including XRD, SEM, EDS, TEM, TGA-DSC, and Vickers hardness test to reveal the inter-relationships between starting materials composition, processing conditions, and the resulting materials microstructure and physical/chemical properties.

Belisario, Jose↗
DOE OSTI2022

Developing New Polymeric Powder Feedstocks for Selective Laser Sintering: Emphasizing Particle Size and Shape

Although selective laser sintering is considered a major player in the additive manufacturing community, significant limitations exist when it comes to processing the polymeric powder feedstocks in the laser sintering machine. While these limitations – such as inadequate and uneven heating and complex thermal phenomena leading to curling and shrinkage – cannot be ignored and are being addressed in the community, it is also vitally important to turn our attention to the expansion of commercially available powder feedstocks. A major drawback of SLS is the lack of available feedstocks. At Los Alamos National Laboratory, a primary desire for advancement in the manufacturing or development of new feedstocks lies in the nuclear weapons applications program. New feedstocks with greater thermal stability and performance would provide the opportunity for insertion of production parts, rather than just prototype parts. Additionally, the ability to print with so-called commodity polymers like polyethylene and polypropylene poses great economic advantages for prototyping and production of large batches of parts. However, a gap exists between the Lab’s needs and what is commercially available – a gap which could be filled by collaboration with the broader industrial sector. Furthermore, connecting with and building relationships with industry partners allows for greater control and input in the developmental process of new powders. This would provide reliable feedstocks, improved quality assurance, and overall higher performance of processes across the additive manufacturing community.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Gas-phase Radiolysis in Plutonium Dioxide Powder

A sample of PuO 2 powder undergoes self radiolysis, causing water present in the solid to generate hydrogen, oxygen, and minor species (e.g. H 2 O 2 ). This is a matter of concern for stored PuO 2 , since the gases could react exothermically and rupture the container. In experiments at LANL, most PuO 2 /salt samples generate mostly H 2 , but a few samples generate a mixture of H 2 and O 2 together. In these special cases, the mixture of H 2 and O 2 in the pore volumes of the powder will then be subject to radiolysis, causing the reverse reaction H 2 + O 2 $\Rightarrow$ H 2 O. In order to understand the steady-state quantities of these gases, it is necessary to estimate the amount of energy from the alpha irradiation that drives this reaction. This report outlines one possible approach for this process, yielding a value for the fractional amount of radiation deposited in the gas phase of 294 ppm. This corresponds to the case of a powder with porosity of 78%. We then use a comprehensive chemical kinetics model based on elementary gas phase reactions to calculate the rate of conversion back to water. We estimate a reduction in the H 2 pressure of about 12 kPa/month, which applies only when O 2 is simultaneously present in the gas phase.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Recycling and Reuse of Tungsten-Rhenium Refractory Alloy Powder for Additive Manufacturing (Quarterly Progress Report - 01 April 2023-30 June 2023)

Savannah River National Laboratory in partnership with 6K Inc is working on demonstrating laser and electron-beam powder bed additive manufacturing processes of W-24Re alloy and developing powder reconditioning (deoxidation) technology via plasma spheroidization and investigating the properties and performance of additively manufactured W-24Re components produced using both virgin and recycled powders.

36 MATERIALS SCIENCE↗