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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Dielectric strength of noble and quenched gases for high pressure time projection chambers

Abstract Dielectric breakdown strength is one of the critical performance metrics for pure gases and gas mixtures used in large, high pressure gas time projection chambers. In this paper we experimentally study dielectric breakdown strengths of several important time projection chamber working gases and gas-phase insulators over the pressure range 100 mbar to 10 bar, and gap sizes ranging from 0.1 to 10 mm. Gases characterized include argon, xenon, CO $$_2$$ 2 , CF $$_4$$ 4 , and mixtures 90-10 argon-CH $$_4$$ 4 , 90-10 argon-CO $$_2$$ 2 and 99-1 argon-CF $$_4$$ 4 . We develop a theoretical model for high voltage breakdown based on microphysical simulations that use electron swarm Monte Carlo results as input to Townsend- and Meek-like discharge criteria. This model is shown to be highly predictive at high pressure, out-performing traditional Paschen–Townsend and Meek–Raether models significantly. At lower pressure-times-distance, the Townsend-like model is an excellent description for noble gases whereas the Meek-like model provides a highly accurate prediction for insulating gases.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2023

Strength distributions of laminated FeNi-based metal amorphous nanocomposite ribbons

Metal Amorphous Nanocomposite (MANC) materials offer low losses at high magnetic switching frequency, enabling high power density motors with increased rotational speed. While MANCs have high strength, they are brittle. The use of motor components such as a rotor consisting of brittle material presents a reliability concern. Here, a promising MANC alloy is subjected to tensile tests and failure is observed with high-speed photography. A method is developed to prepare tensile specimens of laminated MANC and epoxy layers, simulating the stacking of an epoxy-impregnated tape-wound core. Tensile tests are conducted for single layer ribbon and for five- and ten-layer stacks of laminated material with thin layers of thermosetting epoxy. Failure distributions are shown to have increasing Weibull modulus with increasing layer count. The composite MANC material system is modeled using chain-of-bundles models. Using a k-failure model, we show that single ribbon strength distribution data can be used to predict well the failure distribution of laminated stacks. The agreement occurs when the assumed ineffective length, over which load is recovered in a failed layer, is comparable to the observed interlaminar separation length.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Nanoscale inhomogeneity and the evolution of correlation strength in FeSe$$_{1-x}$$S$$_x$$

Abstract We report a comprehensive study of the nanoscale inhomogeneity and disorder on the thermoelectric properties of FeSe $$_{1-x}$$ 1 - x S $$_x$$ x ( $$0 \le x \le 1$$ 0 ≤ x ≤ 1 ) single crystals and the evolution of correlation strength with S substitution. A hump-like feature in temperature-dependent thermpower is enhanced for x = 0.12 and 0.14 in the nematic region with increasing in orbital-selective electronic correlations, which is strongly suppressed across the nematic critical point and for higher S content. Nanoscale Se/S atom disorder in the tetrahedral surroundings of Fe atoms is confirmed by scanning transmission electron microscopy measurements, providing an insight into the nanostructural details and the evolution of correlation strength in FeSe $$_{1-x}$$ 1 - x S $$_x$$ x .

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Using double pulse laser ablation in air to enhance the strength of laser-driven shocks

In the process of multi-pulse laser ablation, inter-pulse delay time, Δ t , is known to be an important parameter for maximizing ablation efficiency as well as impulse imparted to the target. In this work, using photon Doppler velocimetry, we show that for single pairs of colinear pulses (1064 nm, 8 ns, ∼ 60 J cm -2 per pulse) in air, the peak free surface velocity of the back surface of an aluminum target (125 µm thick) is increased, by a factor of nearly 3, when Δ t = 10 microseconds, compared with both pulses arriving simultaneously (Δ t = 0). Fast imaging of the ablation process suggests this enhancement is due to rarefaction of the contiguous air in the passage of the leading shock produced by ablation, which then in turn allows a larger fraction of the energy of the second pulse to reach the target surface. This interpretation is strengthened by additional experiments in which the two pulses do not overlap on the target surface, but the shock strength is nevertheless enhanced. Given a fixed energy budget this work suggests a prescription for maximizing laser-driven shock strength by judicious choice of inter-pulse delay.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Additive manufacturing of high-strength multiphase nanostructures in the binary Ni–Nb system for the discovery of new types of superalloys

Abstract Ni-based superalloys have been studied extensively due to their impressive mechanical properties, including strength and creep resistance at high temperatures. Growing interest surrounding additive manufacturing (AM) methods has led to recent investigations of alloys that are traditionally difficult to process, including Ni-based superalloys. Recent work has shown that AM methods enable high-throughput materials discovery and optimization of difficult- or impractical-to-process alloys, including those with high or even majority refractory element compositions. This work focuses on AM-enabled investigations of composition-dependent mechanical and microstructural properties for Ni–Nb binary alloys. Specifically, we report on the mechanical behavior of compositionally-graded Ni x Nb 1− x and uniform composition Ni 59.5 Nb 40.5 specimens made with AM. The AM fabrication process resulted in extraordinarily high strength, attributed to the formation of a dual-phase microstructure consisting of δ-Ni 3 Nb and µ-Ni 6 Nb 7 intermetallic compounds with nanostructured and multimodal grain size and eutectic lamellar spacing. Graphic Abstract

Jones, M. R.↗
DOE OSTI2021

Developing a New Polyolefin Precursor for Low-Cost, High-Strength Carbon Fiber

Current high-strength carbon fibers (CFs) are mostly derived from PAN polymer precursor, which are very expensive with limited usage in the high-end products. On the other hand, it has also stimulated research interest to develop new low-cost precursors and manufacturing process. Despite numerous studies, researchers have yet to develop a new polymeric precursor that is less expensive, melt-spinnable, and offers a high C-yield. In this three-year R&D project, we proposed three consecutive research phases, including (i) the development of new polyolefin-based precursors that can be thermally transformed to C material in one heating step under inert atmosphere and achieved a C-yield >80%, which is more than 60% higher than that of current PAN precursor, (ii) With the suitable new polyolefin-based precursor, we can focus on CF manufacturing process, including fiber spinning, stabilization, and carbonization, to form high quality carbon fibers with the desirable polymorphous morphology, and (iii) the investigation of thermal conversion process under tension for converting polyolefin-based precursor fibers to high tensile strength carbon fibers with specific graphite crystallite size, orientation of basal line, order-disorder ratio, fiber diameter, and reduced structural defect (voids). composites.

08 HYDROGEN↗
DOE OSTI2021

Advanced High-Strength Steel - Basics and Applications in the Automotive Industry

Challenged to improve safety and fuel economy, automakers continually search for new materials to meet high standards. Several factors drive the material R&D and selection for automotive applications, including safety, fuel efficiency, environmentalism, manufacturability, durability, and quality. In the highly competitive automotive industry, cost is an extremely important factor in material selection. As the motivation to reduce the mass of vehicles continues to grow, automakers seek to maximize the efficiency of their materials selection. Materials in automotive applications are selected to minimize weight while meeting key criteria, including crash performance, stiffness, and forming requirements. Since the 1920s, steel has been the material of choice for automakers worldwide. The weight percentage of steel used in vehicles relative to other materials has grown from around 50% in the early 1980s to about 60% in 2010 for North American light vehicles. Today, steel makes up around 65% of an average automobile’s weight and is the backbone of the entire vehicle. On average, that is 900 kg of steel used per vehicle. To further enhance passenger safety, vehicle performance, and fuel efficiency, reducing the weight of vehicles has become one of the top priorities for the automotive industry. Advanced high-strength steels (AHSSs) are a new generation of steel grades that provide much higher strength and other advantageous properties than other materials while maintaining the high formability required for manufacturing. AHSSs help engineers meet requirements for safety, efficiency, emissions, manufacturability, durability, and quality at a low cost. The relevance of AHSSs is quickly increasing in the automotive industry, and AHSSs are the key material for vehicle mass reduction. Different types of AHSS help parts meet the varied performance demands in different areas of the vehicle, including both the crumple zone and passenger compartment.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Laser-based Adhesion Strength Measurements for Advanced Manufactured Sensor Adhesion Characterization

As part of the advanced manufacturing (AM) focus of the Nuclear Energy Enabling Technologies (NEET) Advanced Sensors and Instrumentation (ASI) Program, new in-house capabilities to fabricate and test novel active and passive in-pile sensors are being developed at the Idaho National Laboratory (INL). These advanced-manufactured sensors, such as peak temperature monitors and strain gauges, must be miniaturized and be able to provide real-time feedback, all while withstanding the coupled extremes of temperature and radiation typically observed in the environment of a nuclear test reactor. Fabricating durable and robust in-pile sensors with high fidelity requires a fundamental understanding of the optimal process parameters required in the AM technique, as well as the effect of deviations from optimal process parameters on the sensor-substrate adhesion and the ultimate robustness of the sensor. This report presents the use of a laser-based, non-contact approach for characterizing the adhesion of sensors manufactured using aerosol jet printing (AJP) that comprise of silver nanoparticle inks deposited and sintered on austenitic stainless steel (SS) 316L substrates. The effect of substrate surface roughness, surface energy, ink sintering time and sintering temperature on the printed sensor topography and the sensor-substrate adhesion has been systematically investigated. The sensor-substrate interfacial adhesion strength was determined from the critical laser pulse energy required to ablate/ detach the printed sensor from the substrate. Measurements of the sensor topography using optical profilometry revealed that post-deposition sintering at 400°C for 60 minutes resulted in a reduced sensor thickness, while plasma treating the substrate prior to printing yielded sensors with uniform thickness profiles transverse to the print direction. Sintering temperature and time were found to be the dominant parameters that affected sensor-substrate adhesion, followed by substrate surface roughness. The laser-based and locally-destructive approach for adhesion strength measurements shows promise in overcoming the challenges and limitations of current standardized peel tests and can be developed into a post-fabrication process control protocol for evaluating the durability of AM printed sensors in a high throughput fashion. Future studies will investigate the use of laser-induced spallation techniques as well as non-destructive laser ultrasonic methods for sensor-substrate adhesion characterization on sensors manufactured using AJP and other AM techniques such as plasma jet printing (PJP).

42 ENGINEERING↗
DOE OSTI2021

An initial framework for the rapid qualification of long-term creep rupture strength via microstructural modeling

This report describes the development and testing of a new method for extrapolating short-term creep rupture test data to predict long-term rupture strength. The goal of this work is to reduce the time required to qualify new materials for nuclear service by reducing the lead time required for dedicated, long-term material testing to establish key long-term material properties. The new approach described here uses a physics-based model to predict the long-term creep rupture strength of 316H stainless steel using only short-term test data. The key idea is to use Bayesian inference to find the statistical distribution of the model parameters that best explain the short-term rupture data. Because the model is physics-based these parameters are all microstructural quantities that can be measured through detailed material characterization experiments. The Bayesian prior distributions provide a means for incorporating this characterization data into the final model to improve the accuracy of the long-term model predictions. However, where such data is not available the process still produces an accurate model based on an uniformed prior. Our hypothesis is that this approach more accurately extrapolates the short-term test data when compared to current, empirical methods. The report proves this hypothesis using actual long-term rupture data available for 316H, including tests with rupture times greater than 200,000 hours. The general approach developed here could be applied to other materials and other time-dependent material properties. Applying this new technique to develop long-term qualified material properties, potentially in conjunction with other accelerated qualification approaches like staggered qualification test programs, could greatly reduce the time required to qualify new materials for nuclear service.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

AA 7075 Sheet with 700 MPa Strength for Automotive Structural Components: CRADA 520 [Abstract only]

Fairmount Technologies is developing a new metal forming machine intended to produce ultra-high strength Aluminum Alloy AA 7075 sheets and is seeking to collaborate with PNNL to optimize the production process, as well as the strength and formability of the sheet produced. Results will be used to infer (and optionally demonstrate) whether aluminum components such as side-impact beams can be successfully formed from this sheet.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Development of a Castable High Strength Secondary Aluminum Alloy from Recycled Wrought Aluminum Scrap

A new process for recycling scrap AA7075 aerospace alloys directly into a high strength castable secondary alloy is demonstrated. The process involves enhancing the castability of the utilized primary wrought aluminum scrap feedstock by scrap alloy chemistry optimization and zirconium additions in order to mitigate the inherent hot tearing tendency of 7075 alloys. By utilizing the new process, the hot tearing index of scrap AA7075 was reduced from 26 to 4. Defect-free castings were obtained in pilot-scale castings trials. The developed secondary 7075 alloy also satisfied preset target mechanical properties with strength levels exceeding 250 MPa and elongation levels higher than 3%. The validity of the new approach and its readiness for transition to commercial practice was demonstrated by casting cylinder heads directly from the modified 7075 scrap.

36 MATERIALS SCIENCE↗
DOE OSTI2024

High Strength Aluminum Additive Manufacturing

High-strength aluminum alloys for elevated temperature applications are desirable to replace heavier and more expensive titanium alloys. However, most aluminum alloys lose a large fraction of their strength at temperatures above approximately 200°C. ORNL has designed DuAlumin-3D, an alloy with nominal composition Al-9Ce-4Ni-0.5Mn-1Zr (wt.%), which utilizes the high cooling rates in additive manufacturing (AM) to achieve a refined microstructure, and thermally stable mechanical properties. DuAlumin-3D was fabricated by laser powder bed fusion and tested for its tensile mechanical properties across a range of temperature, and for its room temperature high-cycle fatigue resistance. The alloy was tested in both the as-printed and heat treated conditions, and both parallel and perpendicular to the AM build direction. The alloy was found to have anisotropic mechanical behavior in the as-printed state, but the anisotropy significantly decreased (both for tensile and fatigue properties) following heat treatment. The tensile properties significantly out-performed benchmark wrought 2219-T61 across a wide temperature range. The room temperature fatigue performance was approximately similar to 2219-T61.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Ply Strength Prediction of Unidirectional Continuous Carbon Fiber Composites

As inhomogeneous orthotropic materials, composite mechanical properties can be difficult to predict. Even with tight fabrication process controls, there is always some microstructural variation that will affect these properties. As a highly defect-dependent phenomena, mechanical strength is even more subject to variation, especially considering that composites exhibit multiple potential failure modes. The most direct way to determine composite material strength is via experimental testing, maintaining loading and specimen morphology as close as possible to the in situ states. When multiple materials and designs are being considered, this process is often prohibitively costly and slow. However, some approximations and rules of thumb can consistently guide the design process and consideration of alternatives.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Tailoring Carbide Dispersed Steels: A Path to Increased Strength and Hydrogen Tolerance

The use of transition metal carbides is reported for use as a hydrogen trapping mechanism for ferritic and austenitic steel materials. The program combined computational modeling and simulations to guide experiments towards candidate metal carbide traps, both for interfacial and interior trapping. It was found that interfacial trapping is less effective than interior trapping, with the group IVB transition metal carbides being the most effect internal traps with a loss of carbon. The sub-stoichiometric rocksalt structure accommodate the hydrogen atoms in its octahedral interstices. Using percolation theory, carbon loss of approximately 25% or more was sufficient to ensure an interconnected network of vacancies for such trapping from the surface to the internal sites within the carbide. Using this as a guide, the program developed a means to provide a uniform dispersion of ZrC nanoparticles with either Fe or 304L micron-scale powders which was then consolidated by direct current sintering. Electrolytic hydrogen diffusivity studies confirmed the reduction of hydrogen diffusion in the matrix with increasing ZrC content, which was a linear response over the sample range studied (0.01 to 1.0 wt.%). The consolidated material was micro-tensile tested in either a non-hydrogen or hydrogen charge condition and compared to a control with no carbides. Additions up to 0.05 wt.% ZrC increased the yield strength with no loss in ductility in either the non-hydrogen or hydrogen tested condition. ZrC concentrations above this amount further increased the yield strength at the expense of ductility. While these samples had a lower absolute ductility value prior to failure, the relative change in ductility between the non-hydrogen and hydrogen charge states was less for the carbides than that of the control. Metal-rich ZrC nanoparticles were fabricated through a conformal coating process yielding ZrC0.66 particles that were then incorporated into a metal matrix. Notch fatigue testing in a hydrogen environment was conducted where the number of cycles to failure was found to be less in the control than that of the carbide addition. However, the spread in experimental data and the number of samples tested limits a conclusive outcome based on defects noticed in the gauge section of all the powder processed samples. The collective outcomes of this report provide further insight into the mechanisms by which carbides act as hydrogen traps; a means to process such carbides through powder metallurgy; and their associated mechanical performance in either a non-hydrogen or hydrogen-charged condition.

08 HYDROGEN↗
DOE OSTI2024

Deriving Effective Coupling Strength With Born-Oppenheimer Approx.

Tunable couplers have been important in the development of superconducting quantum computers. The ability to maintain zero coupling between qubits during operation, a feature of high-fidelity quantum gates, has been shown to be possible with the use of tunable couplers. As an example, Sete et al., 2021 showed this was possible with a tunable coupler between transmons: the qubit-coupler and qubit-qubit couplings create a net effective coupling strength between the qubits that can be tuned to zero. However, the derivation of the effective coupling strength between the qubits is quite complex. We propose a simpler method of obtaining this effective coupling with the Born-Oppenheimer approximation.

Wichmann, Conrad↗
DOE OSTI2025

Develop a new integrated macro→micro←nano (MMN) multiscale modeling framework to optimize high strength aluminum alloys and processes for vehicle light-weighting​

Bending tests provide a means to study plane strain fracture performance of 6000 series aluminum alloys. Metrics from bending tests have been correlated with self-pierce riveting (SPR) performance of a high strength AA6111 automotive aluminum alloy in previous works. Using the ORNL HPC resources, this project developed an innovative macro→micro←nano (MMN) multiscale microstructure-based finite element (FE) code to further the understanding of microstructural relationship to fracture properties of high strength 6000 series alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2025

High Strength and Fracture Resistance of Reduced-Activity W-Ta-Ti-V-Zr High-Entropy Alloy for Fusion Energy Applications

Refractory high-entropy alloys (HEAs) are promising candidates for next-generation nuclear applications, particularly fusion reactors, due to their excellent high-temperature mechanical properties and irradiation resistance. Here, the microstructure and mechanical behavior were investigated for an equimolar WTaTiVZr HEA, designed from a palette of low-activation elements. The as-cast alloy exhibited a dendritic microstructure composed of W-Ta rich dendrites and Zr-Ti-V rich inter-dendritic regions, both possessing a body-centered cubic (BCC) crystal structure. Room temperature bulk compression tests showed ultra-high strength of around 1.6 GPa and plastic strain ~6%, with fracture surfaces showing cleavage facets. The alloy also demonstrated excellent high-temperature strength of ~650 MPa at 500 °C. Scratch-based fracture toughness was ~38 MPa√m for the as-cast WTaTiVZr HEA compared to ~25 MPa√m for commercially used pure tungsten. This higher value of fracture toughness indicates superior damage tolerance relative to commercially used pure tungsten. These results highlight the alloy’s potential as a low-activation structural material for high-temperature plasma-facing components (PFCs) in fusion reactors.

Physics↗
DOE OSTI2023

A Multicontinuum-Theory-Based Approach to the Analysis of Fiber-Reinforced Polymer Composites with Degraded Stiffness and Strength Properties Due to Moisture Absorption

Marine energy generation technologies such as wave and tidal power have great potential in meeting the need for renewable energy in the years ahead. Yet, many challenges remain associated with marine-based systems because of the corrosive environment. Conventional materials like metals are subject to rapid corrosive breakdown, crippling the lifespan of structures in such environments. Fiber-reinforced polymer composites offer an appealing alternative in their strength and corrosion resistance, but can experience degradation of mechanical properties as a result of moisture absorption. An investigation is conducted to test the application of a technique for micromechanical analysis of composites, known as multicontinuum theory and demonstrated in past works, as a mechanism for predicting the effects of prolonged moisture absorption on the performance of fiber-reinforced composites. Experimental tensile tests are performed on composite coupons with and without prolonged exposure to a salt water solution to obtain stiffness and strength properties. Multicontinuum theory is applied in conjunction with micromechanical modeling to deduce the effects of moisture absorption on the behavior of constituent materials within the composites. The results are consistent with experimental observations when guided by known mechanisms and trends from previous studies, indicating multicontinuum theory as a potentially effective tool in predicting the long-term performance of composites in marine environments.

36 MATERIALS SCIENCE↗