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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Synergistic Coating-Alloy Development for Harsh Environments

The primary objective of the work was to demonstrate model alloy-coating combinations with: A. Improved oxidation resistance with a barrier coating by at least 2x vs. uncoated alloy; B. Uniform coating on a greater than 100:1 aspect ratio structure; and C. Expected reduction of lifecycle cost of a component of >25% based on customer inputs. All three objectives have been achieved.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Novel Harsh Environment Materials and Fabrication Techniques for Wireless Sensor Applications (Final Report)

The overarching goal of this project is to establish a center of excellence program at the University of Maine that is focused on Harsh Environmental Materials and Fabrication Techniques for Wireless Sensor Applications. UMaine is well-positioned to build on previous successes in the areas of materials science research and sensor engineering. Since 1980, the Laboratory for Surface Science & Technology (LASST) has been a very successful interdisciplinary UMaine research center with a well-established infrastructure to investigate surfaces, interfaces, thin films, and micro/nano-fabrication. This infrastructure established through NSF, DOE, DOD, NASA, the State of Maine, and industry includes (i) a 3,500 ft2 clean room with nano/microfabrication and photolithography instrumentation, (ii) thin film synthesis, processing and characterization, (iii) surface and thin film analytical chemistry tools, and (iv) device packaging, electronic testing, wireless devices, system fabrication, and sensor test facilities. This strong foundation is the basis for a planned significant growth in R&D capacity currently underway. To that end, since the start of this project in the Fall of 2019, LASST has undergone a transition to become a new interdisciplinary center at UMaine, named the Frontier Institute for Research in Sensor Technologies (FIRST). This new focus represents a commitment and investment by UMaine that aligns with the proposed DOE-EPSCoR theme, capitalizing on the state-of-the-art instrumentation to form an energized group of faculty and students pursuing advances in sensor materials, devices, and applications.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Rapid and Efficient Deposition of Metal Oxide Coatings for Bearings and Gears in Harsh Environments

The objective of this project is to develop Tribocoating; an innovative, rapid, low-cost, energy-efficient, and environmentally friendly coating technology designed to enhance the performance and durability of bearings and gears operating under harsh conditions. Tribocoating creates protective metal-oxide tribofilms through in-situ tribosintering of nanocrystals (NCs). Components are simply run in a nano-enabled Tribocoating fluid prior to deployment; no surface pretreatment, coating equipment, or external energy input is required.

17 WIND ENERGY↗
DOE OSTI2021

Application of Cable Condition Monitoring Technologies to Assess Age-Related Degradation of Industrial Cables Installed in Harsh Environments

The aging of electrical cables has been the subject of substantial research and development (R&D) projects performed by national and international laboratories, universities, and private organizations for many years. This R&D was conducted to develop guidance, equipment, and techniques to support aging management of in-service cables in industrial facilities such as nuclear power plants, research reactors, waste facilities, and fuel fabrication plants. Through these research efforts, condition monitoring technologies have been developed that can determine the severity of age-related degradation that occurs in industrial cables and insulation polymers during service. This paper summarizes the results of aging assessments that were performed for cables installed in two U.S. nuclear power plants, one a pressurized water reactor and one a boiling water reactor. These cables had been in service for over 40 years and during plant operation were exposed to harsh environmental conditions including elevated temperatures and radiation. For these assessments, a comprehensive series of measurements was performed to assess the aged condition of the cables. These cables came from different manufacturers, were manufactured in different years, and were constructed with a variety of jacket and insulation polymers including chloro-sulfonated polyethylene (CSPE), cross-linked polyethylene (XLPE)/cross-linked polyolefin (XLPO), neoprene, and ethylene propylene rubber (EPR). The goal of these assessments was to determine the current aged condition of the cable polymers and provide an estimate of how long the cable insulation materials could remain exposed to their in-service environmental conditions before reaching their end-of-life condition. Both nuclear power plants have received license renewals to extend their operation from 40 to 60 years, and the utilities need objective evidence to show that critical components such as cables will be able to function safely and reliably during the extended operating period. Furthermore, the results of these assessments showed that the cables exhibited different aged conditions depending on the type of polymers they were constructed with and the environment they were exposed to during service. Some of the cables and insulation polymers showed signs of significant age-related degradation and were estimated to have approximately 5 years of remaining service life. Other cables exhibited no signs of significant age-related degradation and were estimated to have 50 years or more of remaining service life. Using the results of these cable aging assessments, plant personnel were able to (1) determine the overall aged condition of cables and insulation polymers using objective test results, (2) identify aged or degraded cables before they caused operability issues, and (3) avoid unnecessary and costly replacement of cables that can continue to operate safely and reliably.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Integrating fiber optic sensors into metallic components for sensing in harsh environments

The integration of fiber optic sensors into high-temperature materials is critical for real-time monitoring and autonomous operation of engineering systems. This study demonstrated a spark plasma sintering (SPS)-assisted embedding process for integrating sapphire fiber optic sensors into stainless steel components during part fabrication. Optical fibers were encapsulated in stainless steel 316L powders which were sintered at different fabrication conditions using SPS to investigate the effects of sintering parameters on the embedment. Measurements of optical transmittance, combined with microstructural analysis (X-ray computed tomography and scanning electron microscopy) and mechanical testing (tensile and microhardness), were conducted to examine the fiber functionality, fiber–matrix bonding quality, and properties of the sintered materials. Here, the results show that under suitable fabrication conditions, intact optical fibers can be encapsulated in highly-densified (>98 % relative density) stainless steel components. These conditions also led to a good bond at the fiber–matrix interface with micron-sized material interdiffusion across the interface. The sintering parameters were observed to affect fiber optical attenuation, where high temperature, pressure, and hold time during SPS enhanced fiber–matrix bonding and adversely affected optical transmission. Tensile testing confirmed the superior tensile strength and ductility of the matrix fabricated by SPS. Furthermore, the materials exhibited limited strength reduction (~70 MPa) upon the integration of fibers. This study demonstrates the effectiveness of SPS for fiber-material integration for high-temperature applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Characterization and novel application of power over fiber for electronics in a harsh environment

Power-over-Fiber (PoF) technology has been used extensively in settings where high voltages require isolation from ground. In a novel application of PoF, power is provided to photon detector modules located on a surface at ∼ 300 kV with respect to ground in the planned DUNE experiment. In cryogenic environments, PoF offers a reliable means of power transmission, leveraging optical fibers to transfer optical power. PoF technology excels in maintaining low noise levels when delivering power to sensitive electronic systems operating in extreme temperatures and high voltage environments. This paper presents the R&D effort of PoF in extreme conditions and underscores its capacity to revolutionize power delivery and management in critical applications, offering a dependable solution with low noise, optimal efficiency (∼ 51%), and superior isolation.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Micromachined ceramic-based chipless LC resonator for high-temperature wireless sensing applications in harsh environments

The primary objective of this work was the fabrication and testing of a wireless LC resonator based on micro-patterned electroceramic materials for the monitoring of high-temperature systems. The twodimensional planar LC resonator sensors were designed and simulated using ANSYS Maxwell software, and these sensors were then fabricated from electrically conductive La 2 NiO 4 /Al 2 O 3 particulate inks. Initially, the phases of La 2 NiO 4 /Al 2 O 3 composite were evaluated by XRD. The patterning and deposition of the ink were completed using a novel micro-casting process onto Al 2 O 3 ceramic substrates, and the final pattern was bonded onto the substrate at 1200 °C for 2 h. The features and the reliability were analyzed by SEM microscopy. The frequency shift with respect to temperature was measured, which is directly related to changes in the sensor’s dielectric permittivity and pattern dimensions. The sensors were characterized at 500 °C–1000 °C in an ambient atmosphere with an RF signal ranging from 10–80 MHz at 175 kHz·s –1 sweep rate. The sensors showed a sensitivity of ~350 kHz °C –1 from 500 °C–1000 °C. Here, a new robust and adaptive signal processing approach was introduced to increase the degree of freedom for analyzing wireless sensors.

42 ENGINEERING↗
DOE OSTI2023

Low Cost Glass-Ceramic Matrix Composites for Harsh Environment Heat Exchangers (Final Technical Report)

Nearly all high temperature heat exchangers are currently constructed from metallic alloys that can have good capability but are limited to hot inlet temperatures in the range of 1,200 to 1,400 °F. In general, increasing the hot inlet temperature will improve existing application cycles to operate more efficiently, and it will enable new application cycles to be viable that otherwise would not be. The objective of this project was to mature the technologies associated with the development of a ceramic-class heat exchanger that would significantly increase the operating temperature to 1,600 °F and above. The approach taken was to use Glass-Ceramic Matrix Composite (G-CMC) material and to fabricate coupon-scale tube sheet heat exchangers (HXs) to identify risks, refine details of the process and develop a pathway for this novel approach.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Luminescent Materials for the Detection of Economically Critical Metals in Harsh Environments

Renewable energy technologies used for electric vehicles and wind turbines are heavily reliant upon metals, such as rare earth elements, cobalt, lithium, and nickel. Indeed, there are 50 minerals that are currently considered “economically critical” by the 2022 United States Geological Survey. With anticipated global adoption of renewable energy technologies, producing sufficient metals to meet this demand presents a significant challenge, particularly due to the current monopolistic market for many of these metals. The production of metals from unconventional sources, such as coal utilization byproducts, is one of many promising strategies to boost domestic supply. However, sensitive, rapid, and inexpensive characterization technologies are needed to minimize production costs associated with metals prospecting and processing. Photoluminescence-based sensing techniques are particularly intriguing due to their potential for low cost and portability, coupled with high sensitivity and selectivity. This presentation focuses on the development of high-performance sensing materials for a range of critical metals, including metal-organic frameworks capable of sensitizing detection of parts-per-billion concentrations of six different rare earth elements, nanoparticles that can detect down to 600 parts-per-billion levels of cobalt, and thin films that sense aluminum down to 120 parts-per-billion. These materials are highly selective, capable of withstanding low pH conditions, and provide a response within minutes. Importantly, each sensing material is integrated with a custom-built, fully portable fiber-optic spectrometer for potential field deployment, providing significant cost savings over commercial instruments, along with potential advantages such as material regeneration for use across multiple sensing cycles and solvent removal for enhanced emission signal. These results highlight the exciting potential of luminescence platforms as cost-effective alternatives for metals characterization.

Crawford, Scott↗