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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
NASA NTRS1975

Direct observation of small cluster mobility and ripening

Direct evidence is reported for the simultaneous occurrence of Ostwald ripening and short-distance cluster mobility during annealing of discontinuous metal films on clean amorphous substrates. The annealing characteristics of very thin particulate deposits of silver on amorphized clean surfaces of single crystalline thin graphite substrates were studied by in-situ transmission electron microscopy (TEM) under controlled environmental conditions (residual gas pressure of 10 to the minus 9th power torr) in the temperature range from 25 to 450 C. Sputter cleaning of the substrate surface, metal deposition, and annealing were monitored by TEM observation. Pseudostereographic presentation of micrographs in different annealing stages, the observation of the annealing behavior at cast shadow edges, and measurements with an electronic image analyzing system were employed to aid the visual perception and the analysis of changes in deposit structure recorded during annealing. Slow Ostwald ripening was found to occur in the entire temperature range, but the overriding surface transport mechanism was short-distance cluster mobility.

Heinemann, K.↗
DOE OSTI2021

Eliminating Yield Anisotropy and Enhancing Ductility in Mg Alloys by Shear Assisted Processing and Extrusion

Solid phase processing techniques such as friction stir welding, Shear assisted processing and extrusion (ShAPE)/ friction extrusion and cold spray have been successfully demonstrated as promising thermomechanical methods to produce metallic materials with enhanced performance. In this study, AZ series with and without silicon, ZK60 Mg alloys in as-received forms (as-cast or as-extruded) were processed using Shear Assisted Processing and Extrusion (ShAPE). Microstructural characterization was performed using EBSD and TEM and revealed that as compared to the feedstock materials/ billets, friction extruded Mg alloys had more uniform microstructure, equiaxed grains, finer and homogeneously distributed precipitates and chemical homogeneity. It was also observed that basal planes were not oriented parallel to extrusion axis. As a result, rod products exhibited significantly reduced (in some cases eliminated) yield asymmetry and achieved enhanced ductility, which were uncommon or difficult to attain using conventional processing techniques. In addition, modified texture likely suppressed deformation twinning under compressive deformation.

Shear Assisted Processing and Extrusion, SHAPE, ma↗
DOE OSTI2025

Effects of Surface Treatments on the Outgassing of 3D-Printed 316L Stainless Steel.

Fermi National Accelerator Laboratory (Fermilab) is a world leader in designing and operating particle accelerators for nuclear and particle physics research. These accelerators rely on electric fields to propel particle beams, which are then directed and focused using magnetic fields. To ensure these beams travel without interference, they must move through an ultra-high vacuum environment, typically around 10⁻⁹ torr. Maintaining such a vacuum requires materials with exceptionally low outgassing rates. 316L stainless steel is a common material choice for vacuum systems due to its low outgassing rates, excellent corrosion resistance, non-magnetic properties, and high mechanical strength. When manufactured using traditional methods like machining, extrusion, and casting, the vacuum properties of 316L stainless steel are well understood. However, the behavior of 316L stainless steel produced through additive manufacturing, such as Direct Metal Laser Sintering (DMLS), is not as well documented. This study aims to determine the outgassing rate of 316L stainless steel fabricated using DMLS. The investigation focuses on measuring the outgassing rates of 1.5 2 vacuum reducers and evaluating the effects of surface preparation techniques, such as mechanical polishing and electropolishing, on the outgassing performance. Understanding the outgassing performance of 3D-printed 316L stainless steel could enable Fermilab engineers to adopt this fabrication method for producing complex parts designed for ultra-high vacuum environments. These advancements have the potential to benefit projects, such as the Long-Baseline Neutrino Facility (LBNF) and the Proton Improvement Plan-II (PIP-II), by improving design flexibility and fostering innovation in accelerator development.

Cloud, Jaiden [Central State University]↗
NASA NTRS1978

Advanced solid electrolyte cell for CO2 and H2O electrolysis

A solid electrolyte cell with improved sealing characteristics was examined. A tube cell was designed, developed, fabricated, and tested. Design concepts incorporated in the tube cell to improve its sealing capability included minimizing the number of seals per cell and moving seals to lower temperature regions. The advanced tube cell design consists of one high temperature ceramic cement seal, one high temperature gasket seal, and three low temperature silicone elastomer seals. The two high temperature seals in the tube cell design represent a significant improvement over the ten high temperature precious metal seals required by the electrolyzer drum design. For the tube cell design the solid electrolyte was 8 mole percent yttria stabilized zirconium oxide slip cast into the shape of a tube with electrodes applied on the inside and outside surfaces.

Shumar, J. W.↗
NASA NTRS2006

Phosphate Reactions as Mechanisms of High-Temperature Lubrication

One of the major problems preventing the operation of advanced gas turbine engines at higher temperatures is the inability of currently used liquid lubricants to survive at these higher temperatures under friction and wear conditions. Current state-of-the-art organic liquid lubricants rapidly degrade at temperatures above 300 C; hence some other form of lubrication is necessary. Vapor-phase lubrication is a promising new technology for high-temperature lubrication. This lubrication method employs a liquid phosphate ester that is vaporized and delivered to bearings or gears; the vapor reacts with the metal surfaces, generating a solid lubricious film that has proven very stable at high temperatures. In this study, solid lubricious films were grown on cast-iron foils in order to obtain reaction and diffusion rate data to help characterize the growth mechanism. A phenomenological mathematical model of the film deposition process was derived incorporating transport and kinetic parameters that were coupled to the experimental data. This phenomenological model can now be reliably used as a predictive and scale-up tool for future vapor-phase lubrication studies.

Nagarajan, Anitha↗
DOE OSTI2020

Laser-Induced Plasma as a Method for the Metallic Materials Hardness Estimation: An Alternative Approach

The application of an alternative laser-induced breakdown spectroscopy (LIBS) method based on transversely excited atmospheric (TEA) CO2 laser was investigated for the first time for estimating the hardness of metallic materials. The human eye-safe (TEA) CO2 laser, operating at 10.6 µm, was used for plasma generation. The LIBS spectra were recorded by employing a cost-effective CCD camera for the time-integrated and spatial resolved measurements. The cast iron and aluminum alloys samples with different hardness have been tested. The ratio between the magnesium ionic and neutral lines in LIBS spectra was applied for estimating the material hardness. In addition, the hardness of all samples included in this study was determined using the conventional method for material hardness determination, i.e. Vickers hardness test. The linear dependence of magnesium lines intensity ratio on the sample’s hardness was obtained for both kinds of materials. Profilometric measurements were used to verify that the newly-introduced method is almost nondestructive for the investigated metals. The results obtained in the present work confirmed the potential of using this original LIBS system not only for the fast elemental analysis but also for the direct estimation of the hardness of metals and alloys. © 2020, Springer Science+Business Media, LLC, part of Springer Nature.

36 MATERIALS SCIENCE↗
NASA NTRS1978

Influence of high pressure hydrogen on cyclic load crack growth in metals

The effect of high pressure hydrogen on the crack growth rate of various nickel-base alloys was studied at ambient temperature. Considerable enhancement of the cyclic flaw growth rate was observed for Inconel 718, wrought and cast, and Waspaloy, a nickel-base alloy similar to Inconel 718. Only slight enhancement of the flaw growth rate for Alloy 903 was observed.

Jewett, R. P.↗
DOE OSTI2025

An engineering perspective on evaluating mechanisms governing ductility in pure molybdenum

The United States lacks a stable domestic supply of 99 mTc, a critical medical imaging isotope generated from 99 Mo. Accelerator-based production using 100 Mo targets (aMo) introduces mechanical concerns due to the ductile-to-brittle transition temperature inherent to refractory metals like Mo. This study evaluates the tensile behavior of aMo targets from 25 to 1000 °C, compared to powder-metallurgy-processed natural Mo (PMo) and cast-and-rolled Mo (RMo), both as-received and after 5 ppm O 2 exposure in flowing He. RMo showed superior ductility (7.3% at 25 °C, 48% at 1000 °C) and strength, attributed to its fine, elongated grains and high geometrically necessary dislocation density. PMo exhibited variable ductility (up to 33%), while aMo remained brittle, with a maximum elongation of 10.4% at 600 °C. EBSD analysis revealed weak texture in PMo and aMo, but high defect density in aMo limited dislocation mobility. This work links processing, microstructure, and deformation mechanisms to guide fabrication of ductile refractory targets.

Hyer, Holden C. [Oak Ridge National Laboratory (OR↗
NASA NTRS2004

Shaping off-axis metallic membrane reflectors using optimal boundary shapes and inelastic strains

This paper will describe a novel concept for constructing off-axis membrane reflector surfaces. Membrane reflectors have been extensively studied, including investigations into inflated lenticular architectures, shaping by spin casting, shaping using electrostatic forces, and shaping by evacuating behind a membrane surface stretched between circular or annular-shaped supports.

membrane↗
DOE OSTI2023

Ultrafine-grained Fe-TiB 2 high-modulus nanocomposite steel with high strength and isotropic mechanical properties by laser powder bed fusion

Fe-TiB 2 metal matrix composite, also called high-modulus steels (HMSs), are of great interest for applications in fuel-efficient transportation infrastructure, aerospace, and wear industries due to their high specific stiffness and yield strength. However, conventional cast Fe-TiB 2 HMSs often contain coarse and sharp-edged TiB 2 particles which easily trigger premature cracking during loading. Here, we synthesized a Fe-TiB 2 nanocomposite HMS via laser powder bed fusion (LPBF) additive manufacturing of mixed micro-sized powders of Fe, Ti, and Fe 2 B. We investigated the microstructure formation and mechanical behavior of the Fe-TiB 2 HMS. We found that in situ chemical reaction of Ti and Fe 2 B enables the formation of TiB 2 particles at nanoscale during rapid solidification of LPBF. These nanoscale TiB 2 particles can serve as heterogeneous nucleation sites and promote the formation of ultrafine and equiaxed α-Fe grains with random crystallographic textures, which differ from many other additively manufactured (AM) metal alloys characteristic of strong crystallographic textures. As such, isotropic mechanical properties were achieved in the AM Fe-TiB 2 nanocomposite HMS with a high elastic modulus of ~ 240 GPa, an exceptional yield strength of ~ 1450 MPa, and a large plasticity of ~ 20% under compression. Quantitative analysis reveals that the high yield strength primarily originates from strengthening contributions of the ultrafine grains with an average grain size of ~450 nm, the nanoscale TiB 2 reinforcing particles of 20–180 nm, and a high density of printing-induced dislocations of the order of 10 15 m –2 . In situ synchrotron high-energy X-ray diffraction unveils the load partitioning from the softer α-Fe matrix to the stiffer and stronger TiB 2 nanoparticles, contributing to the sustained strain hardening during compression. Our work not only provides a general pathway for achieving high-performance metal matrix nanocomposites by in situ chemical reaction and precipitation of ceramic nanoparticles during additive manufacturing, but also offers mechanistic insights into the deformation mechanism of nanoparticle-reinforced HMS composites.

36 MATERIALS SCIENCE↗
NASA NTRS1976

Space Processing Applications Rocket project, SPAR 1

The experiment objectives, design/operational concepts, and final results of each of nine scientific experiments conducted during the first Space Processing Applications Rocket (SPAR) flight are summarized. The nine individual SPAR experiments, covering a wide and varied range of scientific materials processing objectives, were entitled: solidification of Pb-Sb eutectic, feasibility of producing closed-cell metal foams, characterization of rocket vibration environment by measurement of mixing of two liquids, uniform dispersions of crystallization processing, direct observation of solidification as a function of gravity levels, casting thoria dispersion-strengthened interfaces, contained polycrystalline solidification, and preparation of a special alloy for manufacturing of magnetic hard superconductor under zero-g environment.

Reeves, F.↗
NASA NTRS1982

High-temperature ceramic heat exchanger element for a solar thermal receiver

A study has been completed on the development of a high-temperature ceramic heat exchanger element to be integrated into a solar reciver producing heated air. A number of conceptual designs were developed for heat exchanger elements of differing configuration. These were evaluated with respect to thermal performance, pressure drop, structural integrity, and fabricability. The final design selection identified a finned ceramic shell as the most favorable concept. The ceramic shell is surrounded by a larger metallic shell. The flanges of the two shells are sealed to provide a leak-tight pressure vessel. The ceramic shell is fabricated by an innovative combination of slip casting the receiver walls and precision casting the heat transfer finned plates. The fins are bonded to the shell during firing. Fabrication of a one-half scale demonstrator ceramic receiver has been completed.

Strumpf, H. J.↗
NASA NTRS1986

Locating Cracks Amid Pitting and Corrosion

Use of two fluorescent penetrants reveals cracks. New inspection technique for locating cracks in metal parts. Dual-dye technique used to inspect metal parts having surface-roughness-height ratings from 125 to 450 microinch (3.2 to 11.4 micrometer). Parts have included shot-peened machined aluminum extrusions; partially machined aluminum castings; aluminum, steel, and titanium tabular weldments; aircraft landing-gear components; chemically milled aluminum sheet and extrusions; and rough-machined aluminum and steel forgings. Also used on nonporous ceraminc parts.

Fahey, P. P.↗
NASA NTRS1999

The Development of Lightweight Electronics Enclosures for Space Applications

This paper outlines the end to end effort to produce lightweight electronics enclosures for NASA GSFC electronics applications with the end goal of presenting an array of lightweight box options for a flight opportunity. Topics including the development of requirements, design of three different boxes, utilization of advanced materials and processes, and analysis and test will be discussed. Three different boxes were developed independently and in parallel. A lightweight machined Aluminum box, a cast Aluminum box and a composite box were designed, fabricated, and tested both mechanically and thermally. There were many challenges encountered in meeting the requirements with a non-metallic enclosure and the development of the composite box employed several innovative techniques.

Fenske, Matthew T.↗
NASA NTRS1999

The Development of Lightweight Electronics Enclosures for Space Applications

This paper outlines the end to end effort to produce lightweight electronics enclosures for NASA GSFC electronics applications with the end goal of presenting an array of lightweight box options for a flight opportunity. Topics including the development of requirements, design of three different boxes, utilization of advanced materials and processes, and analysis and test will be discussed. Three different boxes were developed independently and in parallel. A lightweight machined Aluminum box, a cast Aluminum box and a composite box were designed, fabricated, and tested both mechanically and thermally. There were many challenges encountered in meeting the requirements with a non-metallic enclosure and the development of the composite box employed several innovative techniques.

Fenske, Matthew T.↗
DOE OSTI2024

A portable and reusable sensor system based on graphene for real-time and sensitive detection of lead ions in water

Long-term exposure to Pb 2+ can cause irreversible damage to the nervous, cardiovascular, and reproductive systems. Therefore, developing a fast and sensitive detection system capable of monitoring minuscule concentrations of Pb 2+ is essential. In this study, we demonstrated a fully portable sensor system enabling rapid, sensitive, and real-time monitoring of Pb 2+ . The sensor system adopted the remote-gate field-effect transistor (RGFET) detection scheme and was easy to operate, even for non-experts. The sensor system comprised two printed circuit boards (PCBs): a sensor PCB with a remote-gate electrode and an analyzer PCB with a metal-oxide-semiconductor field-effect transistor (MOSFET) transducer and peripheral electronics to manage sensor signals. To achieve a high sensitivity for Pb 2+ , we utilized graphene ink drop-casted on the sensor PCB as a sensing membrane. The graphene film was easy to deposit and remove, enabling the sensor PCB to be reused multiple times. The sensor system was further linked to a smartphone application that instantly monitors the sensor response, allowing for rapid point-of-use detection. The sensor exhibited a high sensitivity of 21.7% when the limit of detection (LOD) value of 1 nM (∼0.2 ppb) was detected, and the typical detection time for each sample was approximately 60 seconds. This portable sensor system advances sensing technologies and could potentially supplement expensive, laborious conventional sensing equipment.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1981

Ceramic technology for solar thermal receivers

The high-temperature capability, resistance to corrosive environments and non-strategic nature of ceramics have prompted applications in the solar thermal field whose advantages over metallic devices of comparable performance may begin to be assessed. It is shown by a survey of point-focusing receiver designs employing a variety of ceramic compositions and fabrication methods that the state-of-the-art in structural ceramics is not sufficiently advanced to fully realize the promised benefits of higher temperature capabilities at lower cost than metallic alternatives. The ceramics considered include alumina, berylia, magnesia, stabilized zirconia, fused silica, silicon nitride, silicon carbide, mullite and cordierite, processed by such methods as isostatic pressing, dry pressing, slip casting, extrusion, calendaring and injection molding.

Kudirka, A. A.↗