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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

A Multiphysics Multiscale Simulation Platform for Damage, Environmental Degradation, and Life Prediction of CMCs in Extreme Environments

This project successfully developed a multiphysics, multiscale computational framework to enhance the design and development of CMCs, with a focus on modeling highly nonlinear, time-dependent damage mechanisms and material degradation under extreme conditions, such as those experienced in turbine service environments. The project made significant advances in improving our understanding of progressive damage, oxidative degradation, and time-dependent inelastic deformation in CMCs, with particular attention to the role of uncertainties in predictions. Key outcomes include the integration of advanced material characterization, uncertainty quantification, and multiphysics constitutive models to predict the behavior of CMCs over their service life. A novel multiscale methodology was employed, which integrated microscale constituent behaviors with structural-scale responses, enabling the manufacturing defects in the microstructure that are prone to damage nucleation. Through the development of DL algorithms, the project advanced the prediction of damage initiation and crack propagation, taking into account the defect morphology and statistical variations across multiple scales. The framework was rigorously validated using thermomechanical experiments, which tested CMCs under various mechanical loadings at elevated temperatures, further enhancing the model's predictive capability. Overall, the research outcomes have provided a more accurate, reliable method for predicting CMC component life, significantly advancing material design, and improving component reliability in extreme environments. This work has strong implications for the optimization of turbine components and other high-performance applications where CMCs are used.

03 NATURAL GAS↗
DOE OSTI2023

Assessment of Process Modeling Tools for Determining Variability in Additively Manufactured Parts

The Advanced Materials and Manufacturing Technologies (AMMT) program aims to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy However, the unique aspects of additive manufacturing (AM) materials in terms of their processing history, microstructure, and properties, are a major barrier for qualification and certification of nuclear components. Much of this challenge may be attributed to component scale variations in microstructure and properties that are driven by local influences of process conditions and geometry on thermal history, melt pool dynamics, and corresponding microstructure evolution. Computational modeling tools may be helpful in this regard to aid in predicting and controlling this level of variability. The purpose of this report is to review the current state-of-the-art for process modeling with regards to metal AM. For this purpose, we consider specifically the case study of laser powder bed fusion (LPBF) processing of SS316, a family of alloys that are both commonly used in nuclear energy applications and suitable for AM processing. The report first introduces the necessary components of a process modeling workflow, followed by a review of the current status of each. At the end, application of these modeling tools to understanding variability in AM process given their current state are considered, and recommendations for future development are proposed

36 MATERIALS SCIENCE↗
DOE OSTI2023

3-D Printed Electro-Magnetic Objects for THz Communications

Advanced materials and manufacturing techniques will pave the path towards high quality electro-magnetic circuits that operate up through THz and into optics regime. Digital additive manufacturing (AM) techniques offer game-changing potential for large scale manufacturing of Radio-frequency (RF) circuits and system in custom 2D/3D geometries. The technical collaboration will explore the design flexibility and product customization capabilities of additive manufacturing techniques to process magnetic materials in custom 3D geometries with tailored dielectric properties and frequency response characteristics. Transformation of an RF circuit design idea into a 3D printed system using additive manufacturing techniques will bring together the elements of advanced materials, additive integration, and low-cost manufacturing for future advanced wireless communication systems.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The Scientific Case for Concurrent Neutron and X-ray Scattering and Spectroscopy

The interrogation of materials with X-rays or neutrons to determine the structure, energetics, and dynamics of materials is fundamental to advancing materials' physical and chemical science and developing innovative material technologies. A transcending challenge in developing novel materials is that progress hinges on understanding the structure and dynamics across multiple time and length scales in complex materials that feature multiple components, interfaces, and compositions. Despite the ever-growing demands on materials’ characterization, existing approaches are almost exclusively based on isolated X-ray or neutron scattering, i.e., an approach commensurate with the more narrowly defined needs of fifty years ago. A three-day workshop sponsored by the U.S. National Science Foundation (NSF) analyzed the demand for concurrent neutron and X-ray (NeX) experiments. It was held at the Spring Hill Suites, San Jose, California, from June 2 to 4, 2022. In this workshop, 70 national and international experts ascertained the crucial need to establish NeX capabilities to advance the science of complex materials and systems in the US. Here, we illustrate the need for NeX scattering and spectroscopy experiments by showcasing examples that span areas as diverse as biomaterials, energy science, soft matter, and nanomaterials. To provide NeX capability will require new instrumentation that enables concurrent experiments. Affected areas include chemistry, soft matter, quantum materials, pure and applied chemistry, bioscience, geoscience, and applied materials. NeX benefits research outcomes due to the complementarity of the two techniques, which is essential for better model refinement. While joint refinement of data from separate neutron and X-ray experiments is critical to avoid ambiguities, especially in multiphase-multicomponent materials, concurrent experiments overcome scientific and technical barriers associated with single measurements, separated by location and, thus, time. Among all the examples, these factors introduce uncertainties in the results that complicate data analysis. [1,2] [3] While models are strongly sample-dependent, the principles of joint refinement are generally applicable to these disciplines, including the development of advanced parameterization, modeling, and analysis techniques that also consider the temporal and spatial resolutions of the two methods, leading to unambiguous data interpretation. Solutions for technical barriers must be found to realize NeX experiments, including developing robust sample environments that meet the optical requirements of neutrons and X-rays.

36 MATERIALS SCIENCE↗
NASA NTRS2005

Subscale Test Methods for Combustion Devices

Stated goals for long-life LRE s have been between 100 and 500 cycles: 1) Inherent technical difficulty of accurately defining the transient and steady state thermochemical environments and structural response (strain); 2) Limited statistical basis on failure mechanisms and effects of design and operational variability; and 3) Very high test costs and budget-driven need to protect test hardware (aversion to test-to-failure). Ambitious goals will require development of new databases: a) Advanced materials, e.g., tailored composites with virtually unlimited property variations; b) Innovative functional designs to exploit full capabilities of advanced materials; and c) Different cycles/operations. Subscale testing is one way to address technical and budget challenges: 1) Prototype subscale combustors exposed to controlled simulated conditions; 2) Complementary to conventional laboratory specimen database development; 3) Instrumented with sensors to measure thermostructural response; and 4) Coupled with analysis

Anderson, W. E.↗
NASA NTRS1987

Time-temperature-stress capabilities of composite materials for advanced supersonic technology application

Advanced composites will play a key role in the development of the technology for the design and fabrication of future supersonic vehicles. However, incorporating the material into vehicle usage is contingent on accelerating the demonstration of service capacity and design technology. Because of the added material complexity and lack of extensive data, laboratory replication of the flight service will provide the most rapid method to document the airworthiness of advanced composite systems. Consequently, a laboratory program was conducted to determine the time-temperature-stress capabilities of several high temperature composites. Tests included were thermal aging, environmental aging, fatigue, creep, fracture, tensile, and real-time flight simulation exposure. The program had two phases. The first included all the material property determinations and aging and simulation exposures up through 10,000 hours. The second continued these tests up to 50,000 cumulative hours. This report presents the results of the Phase 1 baseline and 10,000-hr aging and flight simulation studies, the Phase 2 50,000-hr aging studies, and the Phase 2 flight simulation tests, some of which extended to almost 40,000 hours.

Kerr, James R.↗
DOE OSTI2020

A review of composite solid-state electrolytes for lithium batteries: fundamentals, key materials and advanced structures

All-solid-state lithium ion batteries (ASSLBs) are considered next-generation devices for energy storage due to their advantages in safety and potentially high energy density. As the key component in ASSLBs, solid-state electrolytes (SSEs) with non-flammability and good adaptability to lithium metal anodes have attracted extensive attention in recent years. Among the current SSEs, composite solid-state electrolytes (CSSEs) with multiple phases have greater flexibility to customize and combine the advantages of single-phase electrolytes, which have been widely investigated recently and regarded as promising candidates for commercial ASSLBs. Based on existing investigations, herein, we present a comprehensive overview of the recent developments in CSSEs. Initially, we introduce the historical development from solid-state ionic conductors to CSSEs, and then summarize the fundamentals including mechanisms of lithium ion transport, key evaluation parameters, design principles, and key materials. Finally, four main types of advanced structures for CSSEs are classified and highlighted according to the recent progress. Moreover, advanced characterization and computational simulation techniques including machine learning are reviewed for the first time, and the main challenges and perspectives of CSSEs are also provided for their future development.

25 ENERGY STORAGE↗
NASA NTRS1982

"SiAION" Materials for Advanced Structural Applications

New ceramics for gas turbines and other applications are strong, oxidation resistant, and chemically stable. Recently prepared state-of-the-art report on SiAION materials includes work on phase relations, crystal structure, synthesis, fabrication, micro-structure, and properties of various SiAION's.

Dutta, S.↗
DOE OSTI2024

New Directions for Thermoelectrics: A Roadmap from High‐Throughput Materials Discovery to Advanced Device Manufacturing

Thermoelectric materials, which can convert waste heat into electricity or act as solid‐state Peltier coolers, are emerging as key technologies to address global energy shortages and environmental sustainability. However, discovering materials with high thermoelectric conversion efficiency is a complex and slow process. The emerging field of high‐throughput material discovery demonstrates its potential to accelerate the development of new thermoelectric materials combining high efficiency and low cost. The synergistic integration of high‐throughput material processing and characterization techniques with machine learning algorithms can form an efficient closed‐loop process to generate and analyze broad datasets to discover new thermoelectric materials with unprecedented performances. Meanwhile, the recent development of advanced manufacturing methods provides exciting opportunities to realize scalable, low‐cost, and energy‐efficient fabrication of thermoelectric devices. This review provides an overview of recent advances in discovering thermoelectric materials using high‐throughput methods, including processing, characterization, and screening. Advanced manufacturing methods of thermoelectric devices are also introduced to realize the broad impacts of thermoelectric materials in power generation and solid‐state cooling. In the end, this article also discusses the future research prospects and directions.

Song, Kaidong↗
NASA NTRS1999

NASA GRC's High Pressure Burner Rig Facility and Materials Test Capabilities

The High Pressure Burner Rig (HPBR) at NASA Glenn Research Center is a high-velocity. pressurized combustion test rig used for high-temperature environmental durability studies of advanced materials and components. The facility burns jet fuel and air in controlled ratios, simulating combustion gas chemistries and temperatures that are realistic to those in gas turbine engines. In addition, the test section is capable of simulating the pressures and gas velocities representative of today's aircraft. The HPBR provides a relatively inexpensive. yet sophisticated means for researchers to study the high-temperature oxidation of advanced materials. The facility has the unique capability of operating under both fuel-lean and fuel-rich gas mixtures. using a fume incinerator to eliminate any harmful byproduct emissions (CO, H2S) of rich-burn operation. Test samples are easily accessible for ongoing inspection and documentation of weight change, thickness, cracking, and other metrics. Temperature measurement is available in the form of both thermocouples and optical pyrometery. and the facility is equipped with quartz windows for observation and video taping. Operating conditions include: (1) 1.0 kg/sec (2.0 lbm/sec) combustion and secondary cooling airflow capability: (2) Equivalence ratios of 0.5- 1.0 (lean) to 1.5-2.0 (rich), with typically 10% H2O vapor pressure: (3) Gas temperatures ranging 700-1650 C (1300-3000 F): (4) Test pressures ranging 4-12 atmospheres: (5) Gas flow velocities ranging 10-30 m/s (50-100) ft/sec.: and (6) Cyclic and steady-state exposure capabilities. The facility has historically been used to test coupon-size materials. including metals and ceramics. However complex-shaped components have also been tested including cylinders, airfoils, and film-cooled end walls. The facility has also been used to develop thin-film temperature measurement sensors.

Robinson, R. Craig↗
DOE OSTI2025

SiC Receiver/Reactor by Additive Manufacturing for Concentrated Solar Thermocatalysis with Thermal Energy Storage (Final Technical Report - Public)

The direct use of solar thermal energy provides opportunities for low-cost heating sources for a variety of applications. Ultra-high temperatures around 1000°C are high value and highly useful for energy-demanding industries. Many materials cannot withstand these conditions. In the area of Sustainable Chemicals, further limitations on material stability exist. Combining state-of-the-art materials with new designs provides a promising pathway for harvesting solar thermal energy and performing high temperature chemical processes. However, conventional manufacturing limits the potential for design flexibility. In this project, Additive Manufacturing was combined with advanced materials and new chemical reactor designs. In addition, 24/7 energy is necessary for chemical processing, and designs for ultra-high temperature thermal storage were devised. Specifically, preliminary design of a novel solar thermal receiver was developed in this project and designed to work with thermocatalytic reactors for producing sustainable chemicals and fuels. An ultra-high temperature particle storage system and heat exchangers were proposed to transport ultra-hot air as thermal fluid for the system. On a broader scale, this system could be used to tap solar thermal energy for a centralized facility with capability of transferring that heat to various segments at a full range of temperatures to 1000°C. The project pushed the temperature boundaries past those in current use, and Additive Manufacturing was envisaged for fabricating the receiver to meet requirements of extreme environments. An extensive analysis of silicon carbide additive manufacturing was performed to compare the thermal and mechanical properties of complex geometries compared to conventional material and those manufactured via other methods. The Additive Manufacturing via Binder-Jet printing was optimized and characterized to provide high quality and reproducible components capable of withstanding the proposed extreme environments. The designs for the concentrating solar thermal cavity with ultra-hot air thermal fluid showed high performance in simulations, attributable to the complex optimized geometries of the 3D printed systems. The bright future of Additive Manufacturing with advanced materials developments should provide more options and even higher quality as the technology further develops. Current costs for Additive Manufacturing of advanced ceramics is relatively low, however post-processing of the materials for extreme environments is currently high. There is little industrial-scale infrastructure for these, but it is growing as niche applications become more mainstream. The results of the project can be translated into similar extreme environments for concentrating solar thermal energy as well as its integration with ultra-hot air thermal fluids. A number of industries that require ultra-high temperatures need to electrify or otherwise decarbonize for climate goals, and this project showed that theoretically there is a pathway to do so with direct concentrated solar thermal power.

10 SYNTHETIC FUELS↗
DOE OSTI2022

Analysis of Deformation Mechanisms, Strain Localization, and Fracture in Highly Irradiated Austenitic Steels – Light-Water Reactor Core Materials – via Advanced inSEM Techniques

The present report describes the establishing of an advanced experimental approach – high-resolution digital image correlation or µDIC – for testing miniature irradiated specimens in the ORNL’s Low Activation Materials Development and Analysis (LAMDA) facility. As expected, the µDIC approach will allow for studying strain localization inside grains, for instance, during dislocation channel-grain boundary interaction processes. This information is of high importance for understanding degradation processes in irradiated austenitic steels – in-core materials of Light Water Reactors. The Level 4 report provides a brief introduction, lists materials designated for µDIC testing and delivered in LAMDA this FY, discusses methodical concerns and preliminary observations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Qualification Framework Evaluations, Status Quo, and Recommendations

The Advanced Materials and Manufacturing Technology (AMMT) program develops cross-cutting technologies in support of a broad range of nuclear reactor technologies and maintains U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of AMMT is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. The acceleration of qualification processes is one of the key aspects and qualification processes for the nuclear industry is not necessarily equivalent or benchmarked against other industries.

36 MATERIALS SCIENCE↗
NASA NTRS2012

Antimicrobial Materials for Advanced Microbial Control in Spacecraft Water Systems

Microbial detection, identification, and control are essential for the maintenance and preservation of spacecraft water systems. Requirements set by NASA put limitations on the energy, mass, materials, noise, cost, and crew time that can be devoted to microbial control. Efforts are being made to attain real-time detection and identification of microbial contamination in microgravity environments. Research for evaluating technologies for capability enhancement on-orbit is currently focused on the use of adenosine triphosphate (ATP) analysis for detection purposes and polymerase chain reaction (peR) for microbial identification. Additional research is being conducted on how to control for microbial contamination on a continual basis. Existing microbial control methods in spacecraft utilize iodine or ionic silver biocides, physical disinfection, and point-of-use sterilization filters. Although these methods are effective, they require re-dosing due to loss of efficacy, have low human toxicity thresholds, produce poor taste, and consume valuable mass and crew time. Thus, alternative methods for microbial control are needed. This project also explores ultraviolet light-emitting diodes (UV-LEDs), surface passivation methods for maintaining residual biocide levels, and several antimicrobial materials aimed at improving current microbial control techniques, as well as addressing other materials presently under analysis and future directions to be pursued.

Birmele, Michele↗
DOE OSTI2026

Mechanical Behavior of Neutron Irradiated Refractory Multi-Principal Element Alloys Processed via Spark Plasma Sintering

The search for advanced materials capable of withstanding the extreme conditions of Generation IV reactors is a critical area in materials science research. These reactors operate under severe environments, including high temperatures, corrosion, stress, and irradiation damage. Consequently, there is a need for innovative alloy systems to ensure the reliability and longevity of proposed Generation IV reactor components. Refractory multi-principal-element alloys (RMPEA) have emerged as a promising candidate due to their exceptional properties. These alloys, characterized by their composition of multiple principal elements in near-equiatomic ratios, exhibit superior resistance to irradiation damage, reduced void swelling, enhanced microstructural stability, and minimal irradiation-induced hardening. While initial studies on RMPEAs have shown promising results, most research has been limited to thin films, nanocrystalline microstructures, and ion irradiation, which do not accurately represent the behavior of bulk materials. To address this gap, our research focused on the neutron irradiation of bulk RMPEAs. We aim to conduct comprehensive post-irradiation examinations (PIE) of RMPEAs irradiated at the Advanced Test Reactor at Idaho National Laboratory. The RMPEAs were synthesized using spark plasma sintering (SPS) with mechanically alloyed metallurgical powder. The RMPEA specimens are a MoNbTi alloy system with additions of -Zr, and -ZrV. Furthermore, PIE consisted of mechanical testing and advanced materials characterization. The mechanical testing consisted of sub-sized tensile testing, micro- and nano- indentation. Microstructural characterization included scanning electron microscopy and transmission electron microscopy. Mechanical testing coupled with advanced microscopy techniques provides insight into phase morphology and its effects on the mechanical properties of the RMPEA specimens. The results indicate that both pristine and irradiated RMPEA specimens exhibited brittle behavior during tensile testing, which can be attributed to their heterogeneous microstructure. The SPS manufacturing process did not include any post treatment, which resulted in a heterogeneous microstructure. Energy-dispersive X-ray spectroscopy revealed the presence of intermetallic such as laves phases within the microstructure. Specifically, Ti-rich precipitates were observed in the MoNbTi specimen, while Mo-rich precipitates were found in the MoNbTiZrV specimen. Nano-hardness testing of pristine samples showed that the laves phases exhibited higher hardness values compared to the matrix phase, suggesting that precipitate hardening is likely the dominant hardening mechanism in these specimens. The results from this work will be used to build a finite element model to predict mechanical behavior of future MPEA compositions. Thus, enabling for a streamlined approach to developing novel MPEAs for the nuclear industry.

36 - MATERIALS SCIENCE↗
NASA NTRS2005

Materials Requirements for Advanced Propulsion Systems

NASA's mission to "reach the Moon and Mars" will be obtained only if research begins now to develop materials with expanded capabilities to reduce mass, cost and risk to the program. Current materials cannot function satisfactorily in the deep space environments and do not meet the requirements of long term space propulsion concepts for manned missions. Directed research is needed to better understand materials behavior for optimizing their processing. This research, generating a deeper understanding of material behavior, can lead to enhanced implementation of materials for future exploration vehicles. materials providing new approaches for manufacture and new options for In response to this need for more robust materials, NASA's Exploration Systems Mission Directorate (ESMD) has established a strategic research initiative dedicated to materials development supporting NASA's space propulsion needs. The Advanced Materials for Exploration (AME) element directs basic and applied research to understand material behavior and develop improved materials allowing propulsion systems to operate beyond their current limitations. This paper will discuss the approach used to direct the path of strategic research for advanced materials to ensure that the research is indeed supportive of NASA's future missions to the moon, Mars, and beyond.

Whitaker, Ann F.↗