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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 37 records · Page 2

First Principles Study of Aluminum Doped Polycrystalline Silicon as a Potential Anode Candidate in Li‐ion Batteries

Addressing sustainable energy storage remains crucial for transitioning to renewable sources. While Li‐ion batteries have made significant contributions, enhancing their capacity through alternative materials remains a key challenge. Micro‐sized silicon is a promising anode material due to its tenfold higher theoretical capacity compared to conventional graphite. However, its substantial volumetric expansion during cycling impedes practical application due to mechanical failure and rapid capacity fading. A novel approach is proposed to mitigate this issue by incorporating trace amounts of aluminum into the micro‐sized silicon electrode using ball milling. Density functional theory (DFT) is employed to establish a theoretical framework elucidating how grain boundary sliding, a key mechanism involved in preventing mechanical failure is facilitated by the presence of trace aluminum at grain boundaries. This, in turn, reduces stress accumulation within the material, reducing the likelihood of failure. To validate the theoretical predictions, capacity retention experiments are conducted on undoped and Al‐doped micro‐sized silicon samples. In conclusion, the results demonstrate significantly reduced capacity fading in the doped sample, corroborating the theoretical framework and showcasing the potential of aluminum doping for improved Li‐ion battery performance.

25 ENERGY STORAGE↗

Effect of Processing on Precipitation Kinetics in Nano Polycrystalline 7075 Aluminum Alloy

Fairmount Technologies (FT) seeks to optimize the thermomechanical processing of Aluminum Alloy 7075. The target yield strength is 20% higher than commercially available 7075-T6 temper sheet which will enable structural light weighting by a similar magnitude and reduce the carbon footprint of the transportation sector. To reduce processing cost and make this commercially viable, it is important to understand physical mechanisms driving microstructural changes. A mesoscale phase-field model seeded with experimentally measured microstructures and assessed thermodynamic and kinetic properties will be developed and exercised using HPC at PNNL. It will account for the effect of deformation, temperature, and chemistry on precipitation kinetics in nanocrystalline microstructures. Our objective is to understand this “stress-aging” coupling by performing parametric simulations with mesoscale models for a better understanding of GP zone and η' formation in nanocrystalline 7075 Al. This will help FT optimize processing schedules to achieve desired microstructures that increase both strength and ductility.

36 MATERIALS SCIENCE↗

Influence of degree of ambient medium rarefaction on deformation of copper and aluminum

The influence of high vacuum 1 x 10 to the minus 9th power torr on the plastic deformation of copper and aluminum was studied. When stretching polycrystalline aluminum and copper specimens in vacuum, it was found that the deformation at failure increases and the ultimate strength decreases. Deformation in vacuum is accompanied by the evolution of hydrogen. For copper, gas evolution is observed only at failure, while for aluminum hydrogen evolution takes place in the initial stage and the gas evolution peaks correspond to small steps on the deformation curve.

Lyubarskiy, I. M.↗

Graph-component approach to defect identification in large atomistic simulations

In this work, the graph-theoretical concept of connected components is employed to extract the evolution of defect configurations in a polycrystalline aluminum structure containing ~8.3 million atoms. This graph-component approach is applied to reveal details of defect formation, transport, and transformation in the polycrystalline Al under large shear deformation. Building upon standard nearest neighbor analysis, graph theory and associated tools are used to reduce the multi-million-atom system into discrete component subgraphs that represent distinct structural defects. This method allows the automated identification, characterization, and tracking of defective regions within large volumes of data representing atomic-scale processes. Such analysis elucidates relationships between external stimuli, such as strain, and defect distributions, which have a large influence on material properties. The Graph Analytics for Large Atomistic Simulations (GALAS) codebase that implements this analysis, together with user guidance, is openly available at https://github.com/pnnl/galas.

36 MATERIALS SCIENCE↗

Broadband, millimeter-wave antireflection coatings for large-format, cryogenic aluminum oxide optics

Here, we present two prescriptions for broadband (~77 -252 GHz), millimeter-wave antireflection coatings for cryogenic, sintered polycrystalline aluminum oxide optics: one for large-format (700 mm diameter) planar and plano–convex elements, the other for densely packed arrays of quasi-optical elements—in our case, 5 mm diameter half-spheres (called “lenslets”). The coatings comprise three layers of commercially available, polytetrafluoroethylene-based, dielectric sheet material. The lenslet coating is molded to fit the 150 mm diameter arrays directly, while the large-diameter lenses are coated using a tiled approach. We review the fabrication processes for both prescriptions, then discuss laboratory measurements of their transmittance and reflectance. In addition, we present the inferred refractive indices and loss tangents for the coating materials and the aluminum oxide substrate. We find that at 150 GHz and 300 K the large-format coating sample achieves (97±2)% transmittance, and the lenslet coating sample achieves (94±3)% transmittance.

36 MATERIALS SCIENCE↗

Multiscale Modeling of Grain-Boundary Fracture: Cohesive Zone Models Parameterized From Atomistic Simulations

A multiscale modeling strategy is developed to study grain boundary fracture in polycrystalline aluminum. Atomistic simulation is used to model fundamental nanoscale deformation and fracture mechanisms and to develop a constitutive relationship for separation along a grain boundary interface. The nanoscale constitutive relationship is then parameterized within a cohesive zone model to represent variations in grain boundary properties. These variations arise from the presence of vacancies, intersticies, and other defects in addition to deviations in grain boundary angle from the baseline configuration considered in the molecular dynamics simulation. The parameterized cohesive zone models are then used to model grain boundaries within finite element analyses of aluminum polycrystals.

Glaessgen, Edward H.↗

Test Structures For Bumpy Integrated Circuits

Cross-bridge resistors added to comb and serpentine patterns. Improved combination of test structures built into integrated circuit used to evaluate design rules, fabrication processes, and quality of interconnections. Consist of meshing serpentines and combs, and cross bridge. Structures used to make electrical measurements revealing defects in design or fabrication. Combination of test structures includes three comb arrays, two serpentine arrays, and cross bridge. Made of aluminum or polycrystalline silicon, depending on material in integrated-circuit layers evaluated. Aluminum combs and serpentine arrays deposited over steps made by polycrystalline silicon and diffusion layers, while polycrystalline silicon versions of these structures used to cross over steps made by thick oxide layer.

Buehler, Martin G.↗

Hydrogen partitioning in pure cast aluminum as determined by dynamic evolution rate measurements

Hydrogen in pure aluminum can be found in two different states. One is related to a presence in gas-filled pores, while the other state involves the formation of a solid solution between hydrogen and aluminum. The considered investigation is concerned with the distribution of the hydrogen between various states. A dynamic technique is employed to measure the evolution of hydrogen from commercially available samples of polycrystalline pure aluminum under ultrahigh vacuum conditions. The obtained data are compared with the results of a statistical analysis concerning the porosity in the cast aluminum. It was found that more than 99 pct of the hydrogen in the aluminum is located in large pores. Less than 1 pct of the hydrogen is partitioned between the solid solution and the small pores.

Outlaw, R. A.↗

Annealing Effects on Creep and Rupture of Polycrystalline Alumina-Based Fibers

Continuous-length polycrystalline aluminum-oxide-based fibers are being considered as reinforcements for advanced high-temperature composite materials. For these fine-grained fibers, basic issues arise concerning grain growth and microstructural instability during composite fabrication and the resulting effects on the fiber's thermo-mechanical properties. To examine these issues, commercially available Nextel 610 (alumina) and Altex (alumina-silica) fibers were annealed at 1100 and 1300 C for up to 100 hr in air. Changes in fiber microstructure, fiber tensile creep, stress rupture, and bend stress relaxation (BSR) that occurred with annealing were then determined. BSR tests were also used to compare as-received and annealed fibers to other polycrystalline oxide fibers. Annealing was shown to have a significant effect, particularly on the Altex fiber, and caused it to have increased creep resistance.

Goldsby, J. C.↗

Compositional screening of Ce-doped (Gd,Lu,Y) 3 (Al,Ga) 5 O 12 ceramics prepared by quenching from melt and their luminescence properties

Quenching from the melt using an Optical Floating Zone furnace was investigated as a possible high-throughput preparation method in order to screen novel scintillating materials. To validate this method, polycrystalline rare-earth aluminum garnets and yttrium gallium aluminum garnets were synthesized and characterized by X-ray diffraction, photoluminescence and radioluminescence emission spectra as well as radioluminescence imaging and compared to the previously reported properties of those materials. In order to achieve rapid, but quantitative comparison of the materials, pellets fabricated from the synthesized powders were sintered; two different sintering conditions were investigated and compared. Therefore, a simplistic energy deposition and light absorption model for brightness of opaque samples under X-ray irradiation was developed to estimate the relative scintillation efficiency of the materials. Based on the results, Y 3 Al 5 O 12 , LuY 2 Al 5 O 12 and GdY 2 Al 5 O 12 seem to have the highest scintillation efficiency among the prepared samples.

36 MATERIALS SCIENCE↗

Effect of Nuclear Radiation on Materials at Cryogenic Temperatures

The tensile properties for 33 polycrystalline structural materials including aluminum, titanium, nickel and iron alloys were obtained at -256.5 C (30 deg R) after irradiation exposure at this temperature to 10(exp 17) nvt (E greater than 0.5 Mev), at -256.5 C without previous irradiation, and at approximately 27 C (540 deg R) without previous irradiation. The data were evaluated statistically to permit identification of cryogenic effects and nuclear-cryogenic effects. A number of conclusions were drawn regarding suitability of certain of the materials for use in nuclear-cryogenic applications and regarding the need for further investigation.

NEUTRON BOMBARDMENT↗

Monotectic and syntectic alloys. Experiment MA-044

The flight test furnace run of the monotectic and syntectic alloys experiment was successfully performed during the Apollo-Soyuz Test Project mission in July 1975. Examination of the returned sample cartridges and the formal comparative characterization of the low-g and one-g processed samples of lead-zinc and aluminum antimonide were completed. The results for aluminum antimonide show that polycrystalline and multiphased material can be homogenize in space under low-g conditions. Microstructural study on the lead-zinc flight samples shows that complete interdiffusion of lead and zinc had not been achieved, even though the flight data indicated a soak temperature in the miscible region that was 40 K above the published consolute temperature.

Lacy, L. L.↗

Thermal exposure effects on the mechanical properties of a polycrystalline alumina fiber/aluminum matrix composite

The effects of thermal exposures and elevated test temperature on the mechanical properties of a unidirectional polycrystalline alumina fiber reinforced aluminum matrix composite were investigated. Test temperatures up to 590 K and 2500 hours exposures at 590 K did not significantly affect fiber dominated properties but did severely degrade matrix dominated properties. Fiber strength, degraded by the fabrication process, was restored by post fabrication thermal exposures. Possible degradation mechanisms are discussed.

Olsen, G. C.↗

Fabrication and evaluation of low fiber content alumina fiber/aluminum composites

The mechanical fabrication of low volume percent fiber, polycrystalline alumina fiber reinforced aluminum composites was accomplished. Wire preform material was prepared by liquid-metal infiltration of alumina fiber bundles. The wires were subsequently encapsulated with aluminum foil and fabricated into bulk composite material by hot-drawing. Extensive mechanical, thermal and chemical testing was conducted on preform and bulk material to develop a process and material data base. In addition, a preliminary investigation of mechanical forming of bulk alumina fiber reinforced aluminum composite material was conducted.

Hack, J. E.↗