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At least 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Mechanical and Tribological Behavior of ZrB{sub 2}-TiB{sub 2} System Prepared by Mechanical Activation Spark Plasma Sintering Technique

ZrB{sub 2}-TiB{sub 2} system among varying amount of TiB{sub 2} loading (5, 10, 15, 20 and 30 wt.%) was prepared by mechanical activation spark plasma sintering at 2100 °C for 15-min dwell time under 50 MPa uniaxial pressure in argon atmosphere. The effect of the TiB{sub 2} loading on properties like physical, mechanical and tribological of the prepared samples was studied and evaluated with monolithic ZrB{sub 2} ceramic. Finally, almost fully dense samples (> 96% of theoretical density) were fabricated. Microstructural observation and XRD phase analysis of sintered compact revealed that TiB{sub 2} completely went into the ZrB{sub 2} structure by formation of solid solution with ZrB{sub 2} phase. ZrB{sub 2}-TiB{sub 2} (30 wt.%) showed the highest Vickers micro-hardness (H{sub V}) of 20.64 GPa at 10 N load. On addition of TiB{sub 2}, the fracture toughness of the ZrB{sub 2}-TiB{sub 2} improved up to 4.69 ± 0.43 MPa m{sup 1/2} over monolithic ZrB{sub 2} at 10 N load. At 10 N load, the scratch resistance coefficient, wear rate and wear resistance coefficient of ZrB{sub 2}-TiB{sub 2} (30 wt.%) reached a lowest value of 0.32, 0.35 mm{sup 3}/N m and 0.008, respectively, at 10 N load than other ZrB{sub 2} compositions.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of MWCNT Content on the Structure and Properties of Spark Plasma-Sintered Iron-MWCNT Composites Synthesized by High-Energy Ball Milling

The effect of multiwall carbon nanotube (MWCNT) content on the physical and mechanical properties of Fe-MWCNT composites has been studied. High-energy ball milling (HEBM) is employed to produce the composite powder; following this, spark plasma sintering (SPS) process has been adopted for powder consolidation. The composite powder and the sintered products were subjected to structural characterization by XRD. Microstructural studies were carried out by optical, field-emission scanning and high-resolution transmission electron microscopy. While Fourier transform infrared spectroscopic study of composites was done to understand the bonding characteristics, Raman spectroscopy was employed to assess the structural damage of MWCNT after HEBM. The effects of processing on the behavior of C-C, C-O and Fe-O bonds are studied by x-ray photoelectron spectroscopy. Microhardness and compressive strength of composites are also determined. Finally, magnetic and electrical properties of the composites were characterized. It was observed that optimized ball milling conditions help to preserve the structural identity of MWCNT. Consolidation by SPS insured good interfacial bonding. The microhardness and compression strength are significantly improved in MWCNT-reinforced iron matrix composite. MWCNT has appreciably improved the electrical conductivity of the composites. Tethering of MWCNT by iron oxide has led to appreciable improvement in saturation magnetization till 3 wt.% MWCNT.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Compression Molding and Novel Sintering Treatments for Alnico Type-8 Permanent Magnets in Near-Final Shape with Preferred Orientation

We present economic uncertainty in the rare earth (RE) permanent magnet marketplace, as well as in an expanding electric drive vehicle market that favors permanent magnet alternating current synchronous drive motors, motivated renewed research in RE-free permanent magnets like “alnico,” an Al-Ni-Co-Fe alloy. Thus, high-pressure, gas-atomized isotropic type-8H pre-alloyed alnico powder was compression molded with a clean burn-out binder to near-final shape and sintered to density >99% of cast alnico 8 (full density of 7.3 g/cm 3 ). To produce aligned sintered alnico magnets for improved energy product and magnetic remanence, uniaxial stress was attempted to promote controlled grain growth, avoiding directional solidification that provides alignment in alnico 9. Lastly, successful development of solid-state powder processing may enable anisotropically aligned alnico magnets with enhanced energy density to be mass-produced.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Evaluation of sintered bauxite proppant for binary enhanced geothermal systems

Abstract Solid granular proppant particles are widely used in oil and gas development to sustain permeability through fractures after hydraulic stimulation. Similar proppants are of interest for geothermal applications where the goal of sustaining permeability is the same, but the harsh geothermal environment risks rapid proppant degradation that will reduce fracture permeability. Here, we present proppant conductivity experiments using saw cut granite, tensile fractured granite, and aluminum control specimens packed with sintered bauxite ceramic proppants at concentrations of 0.0, 0.1, and 1.0 kg/m 2 . Simulated geothermal conditions included temperatures up to 130 °C and normal closure stresses up to 60 MPa. Compared to unpropped specimens, peak fracture conductivity enhancement was up to 6 orders of magnitude. At simulated geothermal conditions, proppants were able to sustain fracture conductivity over 60 h, but chemical dissolution and decreasing permeability over time were evident. Irreversible conductivity reductions with crushing and embedment of proppants during loading stages were also observed. Overall, sintered bauxite proppant remains a promising option for low-temperature binary-cycle enhanced geothermal systems.

58 GEOSCIENCES↗
DOE OSTI2017

The Functional Resonance Analysis Method for a systemic risk based environmental auditing in a sinter plant: A semi-quantitative approach

Environmental auditing is a main issue for any production plant and assessing environmental performance is crucial to identify risks factors. The complexity of current plants arises from interactions among technological, human and organizational system components, which are often transient and not easily detectable. The auditing thus requires a systemic perspective, rather than focusing on individual behaviors, as emerged in recent research in the safety domain for socio-technical systems. We explore the significance of modeling the interactions of system components in everyday work, by the application of a recent systemic method, i.e. the Functional Resonance Analysis Method (FRAM), in order to define dynamically the system structure. We present also an innovative evolution of traditional FRAM following a semi-quantitative approach based on Monte Carlo simulation. This paper represents the first contribution related to the application of FRAM in the environmental context, moreover considering a consistent evolution based on Monte Carlo simulation. The case study of an environmental risk auditing in a sinter plant validates the research, showing the benefits in terms of identifying potential critical activities, related mitigating actions and comprehensive environmental monitoring indicators. - Highlights: • We discuss the relevance of a systemic risk based environmental audit. • We present FRAM to represent functional interactions of the system. • We develop a semi-quantitative FRAM framework to assess environmental risks. • We apply the semi-quantitative FRAM framework to build a model for a sinter plant.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2018

Thermophysical properties of sintered aluminum-silicon

The effect of silicon addition to aluminum on the thermophysical properties of Al was experimentally investigated. Thermal diffusivity, heat capacity, density, and thermal expansion of sintered Al-Si samples with Si content ranging 0-8 wt% were measured. For U-Mo/Al dispersion fuel for research reactors, an addition of Si (up to 8 wt% Si) to the Al matrix has been adopted as a method to reduce the formation of interaction layer between the U-Mo and the Al. In this study, the Si-added Al matrix was simulated by using a powder metallurgical method, in which an Al powder and a Si powder were mixed and sintered. All measured properties decreased with the addition of Si. The effect was most pronounced in thermal diffusivity while the decreases in heat capacity and density were relatively insignificant. The measured thermal conductivity from the present study was higher than those measured data for alloy samples available in the literature to the differences in the fabrication method. All measured data including this study, however, were lower than the prediction by the Bruggeman model. It is because the model assumes an ideal heat-transfer conditions such as spherical particles, homogeneous particle distribution, perfect bonding between Al and Si. (C) 2018 Elsevier B.V. All rights reserved.

Cho, Tae Won↗
DOE OSTI2020

Elastic moduli of high-density, sintered monoliths of yttrium dihydride

Yttrium dihydride has been considered as potential nuclear reactor moderator for micro-reactors operating in the thermal energy spectrum due to their ability to retain hydrogen to high temperatures while having a relatively low impact on neutron economy. Despite these advantages, it is difficult to prepare yttrium dihydride in high-density, near net-shape monoliths for moderator applications due to volume expansion upon hydriding and the pyrophoric nature of the material. In this work, high-density monoliths of yttrium dihydride were prepared by direct hydriding and using powder metallurgical methods. Resonant ultrasound spectroscopy was used to measure the elastic moduli of the sintered monoliths, while nanoindentation was used to determine the Young’s modulus and hardness of the directly-hydrided yttrium and the sintered monoliths. Single crystal elastic constants and related properties of yttrium dihydride were also determined using density functional theory (DFT) for comparison. We report mechanical properties of materials produced by both methods were observed to be consistent with the values from literature for yttrium dihydride. Due to the novelty of producing yttrium dihydride by powder metallurgy, this result indicated that the monoliths produced by powder metallurgy were of high quality. To that end, powder metallurgy is believed to be a viable method for large-scale production of yttrium dihydride monoliths for nuclear reactor moderator applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Thermophysical properties of high-density, sintered monoliths of yttrium dihydride in the range 373–773 K

Yttrium dihydride is a promising nuclear reactor moderator for high-temperature, thermal micro-reactors due to its ability to retain hydrogen to high temperatures while having a relatively low impact on neutron economy. However, it is difficult to fabricate yttrium dihydride in high-density, near net-shape monoliths for moderator applications due to challenges associated with the hydrogen absorption process. Here, high-density monoliths of yttrium dihydride were prepared by powder metallurgical methods. The lattice strain and thermal expansion coefficient were measured using neutron diffraction of powders of directly-hydrided yttrium, while the molar heat capacity and thermal diffusivity of sintered yttrium dihydride were measured using differential scanning calorimetry (DSC) and laser flash analysis (LFA), respectively. The molar heat capacity of yttrium dihydride was also calculated using density functional theory (DFT) for comparison. These parameters were used to then calculate the thermal conductivity and resistivity of yttrium dihydride as a function of temperature. The thermophysical properties of materials produced by both methods were observed to be consistent with the values from literature for yttrium dihydride. Due to the novelty of producing yttrium dihydride by powder metallurgical methods, this result indicated that the sintered monoliths were of high quality and that powder metallurgy is a viable method for large-scale production of yttrium dihydride monoliths for nuclear reactor moderator applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Synthesis and flash sintering of (Hf 1-x Zr x )B 2 solid solution powders

(Hf 1-x Zr x )B 2 solid solution powders were synthesized by two methods. First, solution-based processing of HfCl 4 , ZrCl 4 , sucrose, and H 3 BO 3 was conducted followed by heat treatment in Argon to carry out the carbothermal reduction (CTR) reaction to form the diboride powders. Alternatively, in the so-called borohydride reduction (BHR) method, HfCl 4 , ZrCl 4 and NaBH 4 were mixed in an Argon glove box followed by heat treatment in Argon at 700-1500°C. The synthesized powders were characterized by XRD, SEM, TEM, EDS, and TGA, and the influence of different parameters such as starting composition, heat treatment temperature and time on products characteristics were revealed. Both CTR and BHR solid solution powders were then consolidated within ~5 min in a homemade flash sintering (FS) setup. Here, the composition, microstructure, hardness, and thermal-oxidation properties of flash sintered ceramics were characterized, and the implication of this study and directions for future research were discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effects of the addition of boron nitride nanoplate on the fracture toughness, flexural strength, and Weibull Distribution of hydroxyapatite composites prepared by spark plasma sintering

Hydroxyapatite (HA) has inherently low fracture toughness and low flexural strength, thus limiting it from wide scale application as an implant material in the biomedical field. To increase the fracture toughness and flexural strength, HA composites were fabricated by adding boron nitride nanoplatelets (BNNP) as reinforcement. Spark plasma sintering was utilized to achieve fine grain structure. The addition of BNNP facilitated grain size refinement. The BNNP reinforced HA composites exhibited increased fracture toughness (2.3 MPa m 1/2 ) and flexural strength (79.79 MPa) of HA over previous published values (1.0 MPa m 1/2 ). Despite that the Weibull Distribution indicated a sacrifice in mechanical reliability, all the composites fabricated in this study showed a low probability of failure and a factor of safety (~ 5.6) that is consistent with that of human bones (~ 6). In addition, the current study provides an approach to statistically design sintering parameters and mechanical loading for fabrication of ceramics.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Enhancing thermal conductivity of UO 2 with the addition of UB 2 via conventional sintering techniques

We report that uranium dioxide has been the primary fuel type used in light water reactors for more than 40 years and proven to be reliable and robust. However, the Fukushima-Daiichi nuclear accident has motivated new work evaluating fuels with characteristics promoting accident tolerance, including enhanced thermal conductivity. Recently, additives have been investigated to increase thermal conductivity, but research has been largely focused on non-fissile additions. This study investigated the use of fissile additives to not only increase the thermal conductivity but also increase the uranium loading. Uranium diboride was chosen as the additive for this study due to its promising corrosion behavior as well as its significantly higher thermal conductivity at 573 K (25 Wm -1 K -1 ) when compared to UO 2 (7 Wm -1 K -1 ). Uranium diboride powder was fabricated via the arc melting technique and a ball milling process prior to mixing with UO 2 in a 90/10 wt% UO 2 /UB 2 ratio. Green bodies were made using a uniaxial die and subjected to a traditional pressureless sintering technique at 2073 K in argon. Sintered samples were analyzed via laser flash analysis for thermal diffusivity and differential scanning calorimetry for specific heat capacity in order to calculate thermal conductivity. The samples displayed an increase of 36-55% in thermal conductivity between 323 K and 1273 K when compared to the benchmark samples (pure UO 2 ) as reported in open literature.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Testing of spark plasma sintered porous tungsten under neon glow discharge cleaning conditions in LTX-β

This paper demonstrates that tungsten (W) based powder reconstituted Plasma Facing Components (PFCs) can be treated in situ in a fusion reactor to remove W oxide and carbon (C) contamination. Doing so should ease the challenge of using these materials in a Capillary Porous System (CPS) with lithium (Li) by enabling better wetting and less contamination of the Li by the underlying CPS. Most powder reconstituted materials including 3D printed and sintered PFCs suffer from a high surface contamination from oxides and surface C, which complicates their use with liquid Li, a primary PFC candidate. Spark plasma sintered porous W samples were fabricated to be used as a CPS with liquid Li. The samples were characterized in terms of morphology and surface chemistry. Analysis confirms a high C and oxygen (O) contamination. We present the results of exposing this type of CPS to Glow Discharge Cleaning (GDC) cycles in the Lithium Tokamak Experiment-β (LTX-β). The sample was exposed to neon (Ne) GDC in the midplane of the low-field side of LTX-β and analyzed in vacuo with Temperature Programmed Desorption (TPD) and Secondary Ion Mass Spectrometry (SIMS) to investigate the effects the Ne GDC had on the chemical composition of the sample. The combination of Ne GDC with rapid heating as done in TPD was successful in reducing the W oxides and removing the C contamination.

Capillary porous system↗
DOE OSTI2021

Processing and microstructure of ZrB 2 –SiC composite prepared by reactive spark plasma sintering

In-situ formation of ZrB 2 –SiC composites was investigated by reactive spark plasma sintering of precursor powders according to the reaction B4C + 2ZrC + 3Si → 3SiC + 2ZrB 2 . The reaction and process presented here involves a diffusion reaction between B4C and ZrC which facilitates the formation of ZrB 2 , while liquid phase sintering of silicon facilitates atomic diffusion and combines with free C from the B4C and ZrC reaction to form SiC within minutes of heating and there were some residual unreacted precursor materials. An interpenetrating matrix of ZrB 2 –SiC was formed that shows increased fracture toughness (6.03 ± 0.45 MPa m 1/2 ) despite relatively low density (95 %).

36 MATERIALS SCIENCE↗
DOE OSTI2016

Modeling the interface of platinum and α-quartz(001): Implications for sintering

We present a first-principles study which aims to understand the metal–support interaction of platinum nanoparticles on α-quartz(001) and, more generally, silica. The thermodynamic stability of the α-quartz(001) surface and its interface with Pt(111) are investigated as a function of temperature and partial pressure of H 2 O and O 2 . Potential defects in the α-quartz(001) surface as well as the adsorption energies of the Pt atom are also studied. This allows us to draw conclusions concerning nanoparticle shape and the resistance toward particle migration based on the interface free energies. We find that, as for the clean α-quartz(001) surface, a dry, reconstructed interface is expected at temperatures that are high but within experimentally relevant ranges. On an ideal, dry, reconstructed surface, particle migration is predicted to be a fast sintering mechanism. On real surfaces, defects may locally prevent reconstruction and act as anchoring points. Finally, the energetics of the adsorption of platinum atoms on α-quartz(001) do not support surface-mediated single-atom migration as a viable path for sintering on the investigated surfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Pressure-Induced Multidimensional Assembly and Sintering of CuInS 2 Nanoparticles into Lamellar Nanosheets with Band Gap Narrowing

Two-dimensional (2D) nanomaterials have fascinating structural, electrical, and optical properties, especially strong excitonic effects due to decreased dielectric screening. However, constructing 2D ultrathin nanomaterials, with the exception of layered materials, remains a challenge. In this work, we successfully realize oriented attachment on guiding one-dimensional chalcopyrite CuInS 2 nanocrystal (NC) formation and 2D assembly into lamellar nanosheets by applying pressure-driven sintering of zero-dimensional CuInS2 nanoparticles (NPs). We discuss the atomic-level mechanism of such phenomena and illustrate a pressure-driven processing diagram that reveals the sintering process of NPs coordinated by pressure and structural transformation. Optical measurements exhibit that the band gap has a narrowing by 0.21 eV compared with the initial 2.03 eV upon decompression to ambient conditions. Our findings represent a significant step forward in gaining an in-depth understanding of the pressure-driven morphology engineering of nanomaterials and provide a promising strategy to prepare 2D NCs, thereby greatly increasing the choice of materials for various applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Ceria Incorporation in Sinter-Resistant Platinum-Based Catalysts

Platinum group metals (PGM) are widely used for exhaust emission abatement. Sintering during the high-temperature emission control conditions decreases noble metal utilization efficiency. Efficient use of scarce noble metals requires sinter-resistant catalysts. Here we extend an approach to synthesize catalysts consisting of platinum nanoparticles encapsulated in a mixture of cerium and aluminum oxides (Pt@Al 2 O 3 -CeO 2 ). We tested the activity of this catalyst toward carbon monoxide, propene, and propane oxidation chosen as model oxidation reactions for emission control catalysts. Pt@Al 2 O 3 -CeO 2 catalysts demonstrated similar activity and stability upon aging as the comparison system without ceria, Pt@Al 2 O 3 , while maintaining small Pt nanoparticles and ceria crystallites. Additionally, we studied the influence of various thermal treatments on CO oxidation activity and determined that a steam treatment can activate low temperature CO oxidation activity of Pt@Al 2 O 3 -CeO 2 . STEM-EDS analysis revealed that thermal treatments led to the co-location of Pt and CeO 2 and temperature programmed-reduction analysis revealed that the steam treatment specifically enhanced CO oxidation activity through surface reduction of the CeO 2 . As a result, we demonstrate the versatility of this encapsulation approach to generate mixed metal-oxide supports with improved metal-support interactions without hindering nanoparticle stability.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2021

Machine learning-based microstructure prediction during laser sintering of alumina

Abstract Predicting material’s microstructure under new processing conditions is essential in advanced manufacturing and materials science. This is because the material’s microstructure hugely influences the material’s properties. We demonstrate an elegant machine learning algorithm that faithfully predicts the microstructure under new conditions, without the need of knowing the governing laws. We name this algorithm, RCWGAN-GP, which is regression-based conditional generative adversarial networks with Wasserstein loss function and gradient penalty. This algorithm was trained with experimental SEM micrographs from laser-sintered alumina under various laser powers. The RCWGAN-GP realistically regenerates the SEM micrographs under the trained laser powers. Impressively, it also faithfully predicts the alumina’s microstructure under unexplored laser powers. The predicted microstructure features, including the morphology of the sintered particles and the pores, match the experimental SEM micrographs very well. We further quantitatively examined the prediction accuracy of the RCWGAN-GP. We trained the algorithm with computer-created micrograph datasets of secondary-phase growth governed by the well-known Johnson–Mehl–Avrami (JMA) equation. The RCWGAN-GP accurately regenerates the micrographs at the trained time series, in terms of the grains’ shapes, sizes, and spatial distributions. More importantly, the predicted secondary phase fraction accurately follows the JMA curve.

08 HYDROGEN↗
DOE OSTI2021

All solid thick oxide cathodes based on low temperature sintering for high energy solid batteries

Solid-state batteries (SSBs) could significantly improve the safety and energy density over conventional liquid cells. One key enabling technology is the use of solid electrolytes. NASICON-type Li 1.3 Al 0.3 Ti 1.7 (PO 4 ) 3 (LATP) is a very attractive solid-state electrolyte for the cathode side due to its high oxidation potential and high ionic conductivity. The usage, however, is limited by its large interfacial resistance against most of the cathode materials as well as the thermodynamic instability during high temperature sintering needed to achieve high mass density. Here we construct thin, percolative, and mixed conductive interphases through in situ low-melting-point liquid sintering. These mixed conductive interphases drastically improve the kinetics, leading to high-loading solid LATP/LiCoO 2 cathodes achieving capacity loading of up to ~6 mA h cm –2 . The technique is also applicable to Ni-rich cathode materials, achieving up to ~10 mAh cm –2 , which can lead to more than 400 W h kg –1 cells in SSBs. Furthermore, our composite cathodes show a ten-times and three-times area capacity improvement over the state-of-the-art cathodes using oxide and sulfide SSEs, respectively.

25 ENERGY STORAGE↗