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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 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Experimental Investigation of the Impact of Cathode Grade on Sludge Formation at the Cathode Block-Aluminum Interface of Hall–Héroult Cells

The presence of resistive sludge on the cathode surface in Hall–Héroult cells can increase the aluminum production costs and reduces cell lifetime. Modern cells with graphitized cathode blocks generally operate satisfactorily but some are exhibiting excessive deposit formation, thus lower performances. Little attention has ever been given to the role of the cathode grade and its properties on sludge formation. In this investigation, five graphitized industrial cathode grades with varying properties are tested on a bench scale aluminum electrolysis setup with cathodic current density of 0.9 A/cm{sup 2}, under a nitrogen atmosphere at 1233 K (960 °C) for 8 hours with initial bath composition of 10 pct alumina, cryolite ratio of 2.2, 5 pct CaF{sub 2} and no point feeding. Postmortem characterization includes Rietveld refinement of deposits, optical microscopy and SEM-EDS observations of the carbon-aluminum interface. Sludge located near the center of the cathode surface was generated during the experiments despite the absence of point feeding. The sludge profile was variable among grades and could be related to the horizontal and vertical thermal conductivities of the blocks. This study has pushed further the understanding of the mechanisms of sludge formation and dissolution concerning the cathode grade properties.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Pump laser-induced space-charge effects in HHG-driven time- and angle-resolved photoelectron spectroscopy

With the advent of ultrashort-pulsed extreme ultraviolet sources, such as free-electron lasers or high-harmonic-generation (HHG) sources, a new research field for photoelectron spectroscopy has opened up in terms of femtosecond time-resolved pump-probe experiments. The impact of the high peak brilliance of these novel sources on photoemission spectra, so-called vacuum space-charge effects caused by the Coulomb interaction among the photoemitted probe electrons, has been studied extensively. However, possible distortions of the energy and momentum distributions of the probe photoelectrons caused by the low photon energy pump pulse due to the nonlinear emission of electrons have not been studied in detail yet. Here, we systematically investigate these pump laser-induced space-charge effects in a HHG-based experiment for the test case of highly oriented pyrolytic graphite. Specifically, we determine how the key parameters of the pump pulse—the excitation density, wavelength, spot size, and emitted electron energy distribution—affect the measured time-dependent energy and momentum distributions of the probe photoelectrons. The results are well reproduced by a simple mean-field model, which could open a path for the correction of pump laser-induced space-charge effects and thus toward probing ultrafast electron dynamics in strongly excited materials.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Effect of Anode Porosity and Temperature on the Performance and Lithium Plating During Fast-Charging of Lithium-Ion Cells

Twenty-four single-layer approximate to 32 mAh pouch cells are tested to determine the effect of electrode porosity on lithium plating. Twelve cells contain a graphite electrode that is 26% porous, and 47% for the other twelve. The cells are cycled using a 6-C charge and a C/2 discharge protocol at temperatures in the range of 20-50 degrees C. A macro-homogeneous electrochemical model and microstructure analysis tool set are used to help interpret experimental observations for the effect of anode porosity and ambient temperature on fast-charging performance. Additionally, comparison between the two also highlights gaps in current theoretical understanding that need to be addressed. In post-test examination, lithium plating is seen in all cells, regardless of porosity. Elevated temperature is shown to reduce the amount of lithium plating and improve initial fast-charge capacity, but also changes the rate of other, less well-understood degradation mechanisms. Apparent kinetic rate laws, At + Bt 1/2 , where A and B are constants, can be fit to most of the capacity loss and resistance increase data. The relative magnitudes of A and B change with temperature and porosity. The capacity loss data at 50 degrees C from the high-porosity cells are fit by a logistics rate law.

25 ENERGY STORAGE↗
NASA NTRS1984

Repair techniques for celion/LARC-160 graphite/polyimide composite structures

The large stiffness-to-weight and strength-to-weight ratios of graphite composite in combination with the 600 F structural capability of the polyimide matrix can reduce the total structure/TPS weight of reusable space vehicles by 20-30 percent. It is inevitable that with planned usage of GR/PI structural components, damage will occur either in the form of intrinsic flaw growth or mechanical damage. Research and development programs were initiated to develop repair processes and techniques specific to Celion/LARC-160 GR/PI structure with emphasis on highly loaded and lightly loaded compression critical structures for factory type repair. Repair processes include cocure and secondary bonding techniques applied under vacuum plus positive autoclave pressure. Viable repair designs and processes are discussed for flat laminates, honeycomb sandwich panels, and hat-stiffened skin-stringer panels. The repair methodology was verified through structural element compression tests at room temperature and 315 C (600 F).

Jones, J. S.↗
NASA NTRS2017

Fully Coupled Aero-Thermochemical-Elastic Simulations of an Eroding Graphite Nozzle

A multiphysics simulation capability has been developed that incorporates mutual interactions between aerodynamics, structural response from aero/thermal loading, ablation/pyrolysis, heating, and surface-to-surface radiation to perform high-fidelity, fully coupled aerothermoelastic ablation simulations, which to date had been unattainable. The multiphysics framework couples CHAR (a 3-D implicit charring ablator solver), Loci/CHEM (a computational fluid dynamics solver for high-speed chemically reacting flows), and Abaqus (a nonlinear structural dynamics solver) to create a fully coupled aerothermoelastic charring ablative solver. The solvers are tightly coupled in a fully integrated fashion to resolve the effects of the ablation pyrolysis and charring process and chemistry products upon the flow field, the changes in surface geometry due to recession upon the flow field, and thermal-structural analysis of the body from the induced aerodynamic heating from the flow field. The multiphysics framework was successfully demonstrated on a solid rocket motor graphite nozzle erosion application. Comparisons were made with available experimental data that measured the throat erosion during the motor firing. The erosion data is well characterized, as the test rig was equipped with a windowed nozzle section for real-time X-ray radiography diagnostics of the instantaneous throat variations for deducing the instantaneous erosion rates. The nozzle initially undergoes a nozzle contraction due to thermal expansion before ablation effects are able to widen the throat. A series of parameters studies were conducted using the coupled simulation capability to determine the sensitivity of the nozzle erosion to different parameters. The parameter studies included the shape of the nozzle throat (flat versus rounded), the material properties, the effect of the choice of turbulence model, and the inclusion or exclusion of the mechanical thermal expansion. Overall, the predicted results match the experiment very well, and the predictions were able to bound the data within acceptable limits.

Blades, E. L.↗
NASA NTRS1989

Impact evaluation of composite floor sections

Graphite-epoxy floor sections representative of aircraft fuselage construction were statically and dynamically tested to evaluate their response to crash loadings. These floor sections were fabricated using a frame-stringer design typical of present aluminum aircraft without features to enhance crashworthiness. The floor sections were tested as part of a systematic research program developed to study the impact response of composite components of increasing complexity. The ultimate goal of the research program is to develop crashworthy design features for future composite aircraft. Initially, individual frames of six-foot diameter were tested both statically and dynamically. The frames were then used to construct built-up floor sections for dynamic tests at impact velocities of approximately 20 feet/sec to simulate survivable crash velocities. In addition, static tests were conducted to gain a better understanding of the failure mechanisms seen in the dynamic tests.

Boitnott, Richard L.↗
DOE OSTI2018

Wear-Resistant Al/SiC-Gr Hybrid Metal Matrix Composite Fabricated by Multiple Annealing and Roll Bonding

The wear-resistant Al/SiC-Gr hybrid composite with a good combination of strength and ductility is fabricated by multiple annealing and roll bonding. The challenge is that graphite acts as a soft lubricating material and prevents the bonding between the layers. In order to evaluate the bond strength, the peeling test is used after cold roll bonding of Al strips with and without the addition of particles under different conditions. Results show that the bond strength increases with increasing the reduction in thickness, decreasing Gr content and performing the post-rolling annealing. During the multiple annealing and roll bonding process, the tensile strength increases with the cost of a small decrease in elongation. A relatively uniform distribution of particles is achieved at the last stages of the process. The Al/SiC-Gr hybrid composite exhibits an improved wear resistance compared with the monolithic Al and Al/SiC composite produced under the same conditions. The conclusion is drawn that a good combination of wear and mechanical properties can be achieved in the hybrid composite that has less amount of Gr.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Self-supported Zn/Si core-shell arrays as advanced electrodes for lithium ion batteries

Graphical abstract: Zn/Si core-shell arrays prepared by combined hydrothermal plus sputtering method show good performance with high specific capacity and excellent cycling stability. - Highlights: • Construct Zn/Si core-shell arrays via sputtering. • The Zn/Si core-shell arrays show high capacity and good cycles. • Core-shell arrays is favorable for fast ion/electron transfer. - Abstract: Silicon is considered as the most promising substitute for the commercial graphite anode of lithium ion batteries (LIBs) due to its high capacity and low working voltage. In this work, we realize the rational combination between Zn nanorods and Si forming self-supported Zn/Si core-shell arrays with the aid of hydrothermal and sputtering methods. Amorphous Si layer is well coated on the backbone of Zn nanorods with diameters of 70–80 nm. As a preliminary test, the Zn/Si core-shell arrays are used as the anode of LIBs and demonstrated with a high initial reversible capacity of 2795 mAh g{sup −1} at 0.1C, good high-rate capability with 1985 mAh g{sup −1} at 1C and stable cycling life. The good performance is due to the highly conductive Zn nanorod network and porous core-shell structure providing good mechanical support and fast transport of ions/electrons.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Unraveling interphase-driven failure pathways in LiMn0.6Fe0.4PO4/graphite pouch cells

LiMnxFe1−xPO4 (LMFP) is a promising high-voltage, thermally stable, and earth-abundant cathode material, yet its practical application is limited by interphase instability and Mn dissolution. In this work, we systematically evaluate LiMn0.6Fe0.4PO4/graphite pouch cells using three electrolyte formulations including control carbonate electrolyte, control + 2 wt% vinylene carbonate (VC), and control + 2 wt% VC + 1 wt% 1,3,2-dioxathiolane 2,2-dioxide (DTD), to establish how electrolyte composition governs interphase chemistry and long-term degradation. Electrochemical testing shows that both additives are preferentially reduced prior to ethylene carbonate (EC) during cell formation, generating robust cathode-electrolyte interphase (CEI) and solid-electrolyte interphase (SEI) layers that suppress gas evolution and raise the first-cycle coulombic efficiency to 89.3%. Additionally, the dual-additive electrolyte delivers the most stable performance, retaining over 85% capacity after 600 cycles while minimizing impedance growth under long-term cycling at C/3 and 40 °C. Soft X-ray absorption spectroscopy confirms that VC + DTD effectively suppresses electrolyte oxidation at the cathode surface, and micro-X-ray fluorescence shows substantially reduced Mn dissolution and deposition on the graphite anode. Density functional theory simulations further provided insights into the structural and energetic influences of alkoxide species on the cathode surface, proposing a Mn2+ extraction mechanism. The combined experimental and computational findings establish a mechanistic link between electrolyte composition and interphase evolution, highlighting the effectiveness of electrolyte engineering for extending the operational lifetime of LMFP-based lithium-ion batteries.

Chak, Chanmonirath Michael↗
DOE OSTI2015

Kinetics of Chronic Oxidation of NBG-17 Nuclear Graphite by Water Vapor

This report presents the results of kinetic measurements during accelerated oxidation tests of NBG-17 nuclear graphite by low concentration of water vapor and hydrogen in ultra-high purity helium. The objective is to determine the parameters in the Langmuir-Hinshelwood (L-H) equation describing the oxidation kinetics of nuclear graphite in the helium coolant of high temperature gas-cooled reactors (HTGR). Although the helium coolant chemistry is strictly controlled during normal operating conditions, trace amounts of moisture (predictably < 0.2 ppm) cannot be avoided. Prolonged exposure of graphite components to water vapor at high temperature will cause very slow (chronic) oxidation over the lifetime of graphite components. This behavior must be understood and predicted for the design and safe operation of gas-cooled nuclear reactors. The results reported here show that, in general, oxidation by water of graphite NBG-17 obeys the L-H mechanism, previously documented for other graphite grades. However, the characteristic kinetic parameters that best describe oxidation rates measured for graphite NBG-17 are different than those reported previously for grades H-451 (General Atomics, 1978) and PCEA (ORNL, 2013). In some specific conditions, certain deviations from the generally accepted L-H model were observed for graphite NBG-17. This graphite is manufactured in Germany by SGL Carbon Group and is a possible candidate for the fuel elements and reflector blocks of HTGR.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

Evaluating electrolyte additives for lithium-ion cells: A new Figure of Merit approach

Electrolyte additives are known to improve the performance of lithium-ion cells. In this work we examine the performance of Li 1.03 Ni 0.5 Mn 0.3 Co 0.3 O 2 -graphite (NMC532/Gr) cells containing combinations of lithium bis(oxalate)borate (LiBOB), vinylene carbonate (VC), trivinylcyclotriboroxane (tVCBO), prop-1-ene-1,3-sultone (PES), phenyl boronic acid ethylene glycol ester (PBE), tris(trimethylsilyl) phosphite (TMSPi), triethylphosphite (TEPi), and lithium difluoro(oxalate)borate (LiDFOB) added to our baseline (1.2M LiPF 6 in EC:EMC, 3:7 w/w) electrolyte. In order to rank performance of the various electrolytes, we developed two separate figures of merit (FOM), which are based on the energy retention and power retention of the cells. Using these two metrics in conjunction, we show that only one of the fifteen electrolyte formulations tested significantly outperforms the baseline electrolyte: this electrolyte contains the 0.25 wt% tVCBO + 1 wt% TMSPi additive mix. Little correlation was observed between the FOMs for energy retention and power retention, which indicates that the mechanisms that govern these performance parameters are likely independent of each other. In conclusion, our FOM approach has general applicability and can be used to develop electrolyte and electrode formulations that prolong the life of lithium-ion batteries.

25 ENERGY STORAGE↗
NASA NTRS1975

Effects of environment on the fatigue of graphite-epoxy composites

Torsional and flexural fatigue tests were performed on both uniaxial (0 deg) and crossplied (plus or minus 45 deg) graphite-epoxy materials at temperatures of 24 and 74 C in environments of air and water. The results of the torsion testing showed that the number of cycles required to cause an initial decrease in stiffness as well as the rate of stiffness loss was a function of temperature and environment; the most significant losses were noted for tests at the higher temperature in water. The torsional fatigue specimens were subsequently tested in four-point bending to determine the effect of torsional damage on longitudinal properties. This damage caused changes in the flexural stiffness, failure stress, and failure energy, depending on the stress and environmental histories. The flexural fatigue tests also showed a significant effect of water (at 24 C) on the material behavior. These results are compared with the results of previous investigations and are discussed in terms of proposed damage mechanisms.

Sumsion, H. T.↗
NASA NTRS1992

Long-life assessment of graphite epoxy materials for Space Station Freedom pressure vessels

Graphite/epoxy composite overwrapped pressure vessels are being considered for use on Space Station Freedom because of their light weight and high efficiency. These composite pressure vessels weigh roughly one-third of comparable all-metal aluminum pressure vessels, and could result in a 15,000-lb weight saving for the propulsion and fluid management and distribution systems. These vessels must resist failures under sustained pressure loads for crew safety considerations and adequate protection of the space structure during their 30-yr life. Weibull statistical analysis techniques have been applied, and a model developed, for predicting long-term stress-rupture behavior based on published short-term test data on composite strands and pressure vessels. Graphite/epoxy materials are calculated to have a 99.99-percent probability of surviving stress rupture for 30 yr under a sustained load of 50 percent ultimate failure strength. Stress-rupture lifetimes are predicted to increase as the size of the pressure vessels increases in support of the viscoelastic load-transfer mechanism proposed for stress rupture of fiber/epoxy composite materials.

Thomas, Donald A.↗
DOE OSTI2014

A New On-the-Fly Sampling Method for Incoherent Inelastic Thermal Neutron Scattering Data in MCNP6

At thermal energies, the scattering of neutrons in a system is complicated by the comparable velocities of the neutron and target, resulting in competing upscattering and downscattering events. The neutron wavelength is also similar in size to the target's interatomic spacing making the scattering process a quantum mechanical problem. Because of the complicated nature of scattering at low energies, the thermal data files in ACE format used in continuous-energy Monte Carlo codes are quite large { on the order of megabytes for a single temperature and material. In this paper, a new storage and sampling method is introduced that is orders of magnitude less in size and is used to sample scattering parameters at any temperature on-the-fly. In addition to the reduction in storage, the need to pre-generate thermal scattering data tables at fine temperatures has been eliminated. This is advantageous for multiphysics simulations which may involve temperatures not known in advance. A new module was written for MCNP6 that bypasses the current S(α,β) table lookup in favor of the new format. The new on-the-fly sampling method was tested for graphite for two benchmark problems at ten temperatures: 1) an eigenvalue test with a fuel compact of uranium oxycarbide fuel homogenized into a graphite matrix, 2) a surface current test with a \broomstick" problem with a monoenergetic point source. The largest eigenvalue difference was 152pcm for T= 1200K. For the temperatures and incident energies chosen for the broomstick problem, the secondary neutron spectrum showed good agreement with the traditional S(α,β) sampling method. These preliminary results show that sampling thermal scattering data on-the-fly is a viable option to eliminate both the storage burden of keeping thermal data at discrete temperatures and the need to know temperatures before simulation runtime.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1984

Electron radiation effects on the thermal expansion of graphite/resin composites

The effects of 1 MeV electron radiation on the thermal expansion characteristics of two graphite reinforced resin matrix composite systems were studied. Specimens of both graphite/epoxy (T300/5208) and graphite/polyimide (C6000/PMR15) were irradiated to a total dose of 6 x 10 to the 9th rads at two different rates. Dynamic mechanical analyses (DMA) were performed to study changes in resin chemistry. Thermal expansion results indicate that radiation did produce permanent residual strains of up to -70 x 10 to the -6th for the graphite/epoxy when exposed to temperatures up to +280 F. However, no permaanent changes in the coefficient of thermal expansion (CTE) were observed. No permanent residual strains or changes in the CTE attributable to radiation were observed for the graphite/polyimide specimens. DMA results indicate that electron radiation caused chemical changes in the epoxy matrix. These changes resulted in a lower glass transition temperature and broader 'rubbery region' which extended into the temperature range of the thermal expansion tests.

Bowles, D. E.↗
DOE OSTI2020

Gear Test Assembly - Report on Experimental Testing (FY2020)

The Gear Test Assembly (GTA) has completed Campaign #2 of in-sodium testing at the Mechanisms Engineering Test Loop (METL). Campaign #1 was conducted in 2019 and completed 19,600 cycles, correlating to 9,800 fuel assembly maneuvers. Campaign #1 was terminated following a shaft seizure caused by a failed bearing in the sodium gearbox. Campaign #2 was conducted in the spring of 2020 and completed 2,768 cycles, correlating to 1,384 fuel assembly maneuvers. Campaign #2 was terminated following elevated vibration measurements coming from the sodium gearbox. Following cleaning and disassembly, a bearing was found to have failed in the sodium gearbox. Campaign #1 used tapered roller bearings made of 52100 steel with a heat treatment from the manufacturer that allows for operation to 350°C. Campaign #2 used the same tapered roller bearings, but with no heat treatment. A new dynamic shaft seal design was used in Campaign #2 that led to significant reductions in argon consumption and graphite debris generation. A modified external gearbox system led to no external bearing failures and allowed for higher torque output. Finally, modifications to the Carbonation System led to a more effective carbonation process and all-around reduction in turnaround time.

42 ENGINEERING↗
NASA NTRS1979

Mechanical and thermophysical properties of graphite/polyimide composite materials

An on-going program to characterize advanced composites for up to 50,000 hours of exposure to simulated supersonic cruise environments is summarized. Results are presented for up to 25,000 hours of thermal exposure and 10,000 hours of flight simulation at temperatures up to 560K (550 F) with emphasis on HTS/710 graphite/polyimide composite material. Results to date indicate that the maximum use temperature for HTS/710 may be reduced to 505K (450 F) for long-time (1000 hours) application such as the supersonic transport. Preliminary thermophysical properties data for HTS/PMR15 graphite/polyimide were generated. These data include thermal conductivity, thermal expansion, and specific heat from 115K (-252 F) to 590K (600 F) and emittance at room temperature and 590K (600 F). The purpose in generating these data was to validate use of state-of-the-art property measurement methods for advanced graphite fiber reinforced resin matrix composites. Based on results to this point, thermal expansion measurements for composites are most difficult to perform. A high degree of caution in conducting thermal expansion tests and analyzing results is required to produce reliable data.

Rummler, D. R.↗
NASA NTRS1997

Compression Response of a Sandwich Fuselage Keel Panel With and Without Damage

Results are presented from an experimental and analytical study of a sandwich fuselage keel panel with and without damage. The fuselage keel panel is constructed of graphite-epoxy skins bonded to a honeycomb core, and is representative of a highly loaded fuselage keel structure. The face sheets of the panel contain several terminated or dropped plies along the length of the panel. The results presented provide a better understanding of the load distribution in damaged and undamaged thick-face-sheet composite sandwich structure with dropped plies and of the failure mechanisms of such structure in the presence of low-speed impact damage and discrete-source damage. The impact-damage condition studied corresponds to barely visible impact damage (BVID), and the discrete-source damage condition studied is a notch machined through both face sheets. Results are presented from an impact-damage screening study conducted on another panel of the same design to determine the impact energy necessary to inflict BVID on the panel. Results are presented from compression tests of the panel in three conditions: undamaged; BVID in two locations; and BVID in two locations and a notch through both face sheets. Surface strains in the face sheets of the undamaged panel and the notched panel obtained experimentally are compared with finite element analysis results. The experimental and analytical results suggest that for the damage conditions studied, discrete-source damage influences the structural performance more than BVID.

McGowan, David M.↗