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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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

In-situ synchrotron X-ray micro-diffraction investigation of ultra-low-strain deformation microstructure in laminated Ti-Al composites

An ultra-low-strain deformation microstructure was revealed for the first time non-destructively in the bulk interior of an annealed laminated Ti-Al composite-in the "fully recrystallized" Al layer-by a synchrotron-based micro-diffraction technique, namely differential aperture X-ray microscopy (DAXM), through real space mapping with a very high angular resolution (0.01 degrees). This ultra-low-strain deformation microstructure was found to result from the thermal stress, induced during cooling after annealing, due to the different coefficients of thermal expansion for the Ti and Al layers. The annealed sample was further tensile deformed to a strain of 1.66% and followed by in situ DAXM and analyzed by various misorientation mapping methods. The results pointed to the important effects of the initial microstructure and the interface constraint, as well as the grain size and crystal orientation, on the plastic deformation. A gradient in dislocation density from the layer interface to the center was found in the Al layer of the annealed sample, and this gradient increased slightly during tensile deformation. The variation of the dislocation density was further discussed based on the activation and interaction of dislocations in grains of different sizes and orientations during plastic deformation. The findings of this study provided valuable insights in understanding the constraint effect of the laminated metal composite and the design of novel composite materials. (c) 2020 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Crystallographic orientation↗
DOE OSTI2021

Quantifying the temperature of heated microdevices using scanning thermal probes

Quantifying the temperature of microdevices is critical for probing nanoscale energy transport. Such quantification is often accomplished by integrating resistance thermometers into microdevices. However, such thermometers frequently become structurally unstable and fail due to thermal stresses at elevated temperatures. Here, we show that custom-fabricated scanning thermal probes (STPs) with a sharp tip and an integrated heater/thermometer can accurately measure the temperature of microdevices held at elevated temperatures. This measurement is accomplished by introducing a modulated heat input to the STP after contacting the microdevice with the STP's tip and characterizing the DC and AC components of the STP's temperature. From these measured temperature components, the tip-to-sample thermal resistance and the microdevice surface temperature are deduced simultaneously via a simple lumped-capacitance model. The advances presented here can greatly facilitate temperature measurements of a variety of heated microdevices.

42 ENGINEERING↗
DOE OSTI2025

Diffusion of acceptor dopants in monoclinic 𝛽−Ga 2⁢ O 3

𝛽−Ga 2 ⁢O 3 is a promising material for next-generation power electronics because of its ultrawide band gap and high critical breakdown voltage. However, realizing its full potential requires precise control over dopant incorporation and stability. In this work, we use first-principles calculations to systematically assess the diffusion behavior of eight potential deep-level substitutional acceptors (Au, Ca, Co, Cu, Fe, Mg, Mn, and Ni) in 𝛽−Ga 2 ⁢O 3 . We consider two key diffusion mechanisms: (i) interstitial diffusion under nonequilibrium conditions relevant to ion implantation, and (ii) trap-limited diffusion (TLD) under near-equilibrium thermal annealing conditions. Our results reveal a strong diffusion anisotropy along the 𝑏 and 𝑐 axes, with dopant behavior governed by competition between diffusion and incorporation (or dissociation) activation energies. Under interstitial diffusion, Ca$^{2+}_{i}$ and Mg$^{2+}_{i}$ show the most favorable combination of low migration and incorporation barriers, making them promising candidates for efficient doping along the 𝑏 and 𝑐 axes, respectively. In contrast, Au$^{+}_{i}$ diffuses readily, but exhibits an incorporation barrier that exceeds 5 eV, rendering it ineffective as a dopant. From a thermal stability perspective, Co$^{2+}_{i}$ shows poor activation but high diffusion barriers, which may suppress undesirable migration at elevated temperatures. Under trap-limited diffusion, the dissociation of dopant-host complexes controls mobility. Mg$^{2+}_{i}$ again emerges as a leading candidate, exhibiting the lowest dissociation barriers along both axes, whereas Co$^{2+}_{i}$ and Fe$^{2+}_{i}$ display the highest barriers, suggesting improved dopant retention under thermal stress. In conclusion, our findings guide dopant selection by balancing activation and thermal stability, essential for robust semi-insulating substrates.

Defects↗
NASA NTRS1991

Compatible thermal and structural elements for the analysis of beam and plate structures

Energy methods are used to formulate steady-state thermal elements which are compatible with structural beam and plate elements. Comparisons of energy method results with finite element results indicate that the energy methods achieve similar accuracy with fewer degrees of freedom. Limitations of energy methods with regard to discontinuous functions and computational overflow are noted. Thermal stress calculations are simplified by the use of similar formulations for the thermal and structural elements. The advantages that these energy-based elements offer to high-temperature structural optimization are discussed.

Vause, R. F.↗
DOE OSTI2022

Hotspot testing of glass/backsheet and glass/glass PV modules pre-stressed in extended thermal cycling

This paper investigates the effect of hotspot (HS) stress endurance of two of the latest designs of monocrystalline modules: a half-cell glass/backsheet (G/B) module and a full-cell glass/glass (G/G) module. These modules have already been pre-stressed in extended thermal cycling with 600 cycles per the IEC 61215 standard to represent field-stressed modules. This study differs from the other conventional studies wherein only fresh modules are subjected to hotspot endurance stress. The G/G module reached a maximum temperature of approximately 200 °C at a cell shading of 25 %, 55 °C higher than the maximum hotspot temperature of 145 °C in the G/B module. A significant burn mark, without glass shattering, was observed in the hotspot-stressed cell of the G/G module due to the current mismatch induced by partial shading. Most of the cells in the G/G module appear to be severely damaged (severe dark areas), as observed in the electroluminescence (EL) image, while the dark regions were rarely present in the G/B module. The EL image also illustrates multiple cell cracks that resist current flow and eventually contribute to the full-cell module degradation. About 8.3 % degradation in maximum power was observed for the G/G module and 1.3 % for the G/B module after the sequential stress tests. The lower degradation in the G/B module can potentially be attributed to its design, which comprises of two parallel strings, each having 72-half-cells and benefits from lower heat dissipation. Furthermore, this indicates that the half-cell design could potentially minimize the hotspot degradation and failures in crystalline-silicon modules.

14 SOLAR ENERGY↗
DOE OSTI2026

Status and performance of the GlueX DIRC

In support of the future physics program at Ce+BAF, we propose a prototype positron target. The prototype target consists of a tungsten disk mounted on a water-cooled copper support structure to enhance heat removal. The primary goals of this work are to benchmark CFD simulations, ensure vacuum integrity at the 10^-6 Pa level, achieve stable target rotation up to 10 Hz, and implement efficient water-based cooling for sustained high-power operation. To manage the thermal load, the target is designed to rotate, allowing the deposited heat to spread over a larger region, and thereby reducing localized thermal stress while maintaining the maximum temperature below 1000 K. To experimentally evaluate the thermal performance and structural stability of the target, we plan to conduct high-power laser heating tests at Laser Lab 5, LERF Building, JLab. These tests will serve as a stepping-stone for the positron production target at CEBAF.

Stevens, J.R. [College of William and Mary, Willia↗
NASA NTRS1977

Preliminary study of cyclic thermal shock resistance of plasma-sprayed zirconium oxide turbine outer air seal shrouds

Several experimental concepts representing potential high pressure turbine seal material systems were subjected to cyclic thermal shock exposures similar to those that might be encountered under severe engine start-up and shut-down sequences. All of the experimental concepts consisted of plasma-sprayed yttria stabilized ZrO2 on the high temperature side of the blade tip seal shroud. Between the ZrO2 and a cooled, dense metal backing, various intermediate layer concepts intended to mitigate thermal stresses were incorporated. Performance was judged on the basis of the number of thermal shock cycles required to cause loss of seal material through spallation. The most effective approach was to include a low modulus, sintered metal pad between the ZrO2 and the metallic backing. It was also found that reducing the density of the ZrO2 layer significantly improved the performance of specimens with plasma-sprayed metal/ceramic composite intermediate layers.

Bill, R. C.↗
NASA NTRS1980

Finite element stress analysis of a notched coupon specimen for in-plane shear behaviour of composites

The results of a linear elastic, plane stress finite element investigation of the stress distribution in a double V-notched coupon specimen are presented for an isotropic material (steel) and five graphite/polyimide laminates: (0), (90), (0/90)s, (plus or minus 45)s and (0/90/plus or minus 45)s. Stress contours, stress profiles, and stress concentration factors are presented for specimens loaded through rigid fixtures. It is shown that the finite element analysis predicts a region of essentially uniform pure shear in the central portion of the specimen for all laminates considered. Stress concentrations vary considerably with laminate configuration. The influences of elastic fixtures and thermal stresses on the stress distribution in (0) laminates are also investigated. The (0) laminate is predicted to exhibit maximum pure shear in the center of the test section for both rigid and elastic fixtures. It is concluded that the specimen is a practicable candidate for use as a composite shear specimen.

Herakovich, C. T.↗
NASA NTRS1981

Large-area silicon-on-ceramic substrates for low-cost solar cells

The SCIM (Silicon-Coating-By-Inverted Meniscus) process to produce SOC (silicon-on-ceramic) substrates has been investigated for various growth conditions and substrate velocities (4-30 cm/min). Slotted mullite-based substrates (10-cm-wide by 100-cm-long) have been coated with smooth, continuous silicon layers, with thicknesses in the range from 100 to 300 microns. Thermal stress (which can be a problem at low velocities) is prevented by proper thermal design. The highest SCIM-coated SOC cell efficiencies to date are 7.5% (AM1, AR) as compared to 10.5% (AM1, AR) for dip-coated SOC cells. Substantial improvements in cell efficiency are expected when high purity parts are installed in the SCIM-coater.

Schuldt, S. B.↗
NASA NTRS1985

Experimental and analytical study of ceramic-coated turbine-tip shroud seals for small turbine engines

The results of an experimental and analytical evaluation of ceramic turbine tip shrouds within a small turbine engine operating environment are presented. The ceramic shrouds were subjected to 1001 cycles between idle and high power and steady-state conditions for a total of 57.8 engine hr. Posttest engine inspection revealed mud-flat surface cracking, which was attributed to microcracking under tension with crack penetration to the ceramic and bond coat interface. Sections and micrographs tend to corroborate the thesis. The engine test data provided input to a thermomechanical analysis to predict temperature and stress profiles throughout the ceramic gas-path seal. The analysis predicts cyclic thermal stresses large enough to cause the seal to fail. These stresses are, however, mitigated by inelastic behavior of the shroud materials and by the microfracturing that tensile stresses produce. Microfracturing enhances shroud longevity during early life but provides the failure mechanism during life but provides the failure mechanism during extended life when coupled with the time dependent inelastic materials effects.

Biesiadny, T. J.↗
NASA NTRS1988

Structural tailoring of high-speed turbine blades (SSME/STAEBL)

Space shuttle main engine (SSME) blades are subject to severe thermal, pressure, and forced vibration environments. Structural optimization provides an automated alternative to time consuming iterations. Any number of analyses, design variables, and constraints can be incorporated in a structural optimization computer code. This idea was applied to develop the code SSME/STAEBL, which is a stand alone code suitable for automated design of SSME turbopump blades. Additions and modifications of STAEBL included in SSME/STAEBL include the following: (1) thermal stress analysis, (2) gas dynamic (pressure) loads, (3) temperature-dependent material and thermal properties, (4) forced vibrations, (5) tip displacement constraints, (6) single crystal material analysis, (7) blade cross-section stacking offsets, and (8) direct time integration algorithm for transient dynamic response.

Rubinstein, Robert↗
NASA NTRS1988

Elevated temperature crack growth

The problem of crack growth in hot path components such as combustor liners is complicated by several practical and theoretical considerations. The loading environment of such components involves high temperature levels and gradients that lead to considerations such as thermal stresses, crack closure, hold time, inelastic strains (both time dependent and independent), and Thermal Mechanical Fatigue (TMF). In general, a good understanding of the influence of these factors on crack growth was not obtained. At the same time, several nonlinear fracture mechanics parameters were suggested for such applications; however, most of the proposed methods were not tested for broad applications such as required for hot section components. It was the purpose of this program to evaluate proposed nonlinear methods by performing a thorough experimental and analytical study. The results illustrated that much progress was made in developing nonlinear methods.

Kim, K. S.↗
NASA NTRS2004

Advanced Oxide Material Systems for 1650 C Thermal/Environmental Barrier Coating Applications

Advanced thermal and environmental barrier coatings (TEBCs) are being developed for low-emission SiC/SiC ceramic matrix composite (CMC) combustor and vane applications to extend the CMC liner and vane temperature capability to 1650 C (3000 F) in oxidizing and water-vapor-containing combustion environments. The advanced 1650 C TEBC system is required to have a better high-temperature stability, lower thermal conductivity, and more resistance to sintering and thermal stress than current coating systems under engine high-heat-flux and severe thermal cycling conditions. In this report, the thermal conductivity and water vapor stability of selected candidate hafnia-, pyrochlore- and magnetoplumbite-based TEBC materials are evaluated. The effects of dopants on the materials properties are also discussed. The test results have been used to downselect the TEBC materials and help demonstrate the feasibility of advanced 1650 C coatings with long-term thermal cycling durability.

Zhu, Dong-Ming↗
DOE OSTI2021

Crystal plasticity model of residual stress in additive manufacturing using the element elimination and reactivation method

Selective laser melting is receiving increasing interest as an additive manufacturing technique. Residual stresses induced by the large temperature gradients and inhomogeneous cooling process can favour the generation of cracks. In this work, a crystal plasticity finite element model is developed to simulate the formation of residual stresses and to understand the correlation between plastic deformation, grain orientation and residual stresses in the additive manufacturing process. The temperature profile and grain structure from thermal-fluid flow and grain growth simulations are implemented into the crystal plasticity model. An element elimination and reactivation method is proposed to model the melting and solidification and to reinitialize state variables, such as the plastic deformation, in the reactivated elements. The accuracy of this method is judged against previous method based on the stiffness degradation of liquid regions by comparing the plastic deformation as a function of time induced by thermal stresses. The method is used to investigate residual stresses parallel and perpendicular to the laser scan direction, and the correlation with the maximum Schmid factor of the grains along those directions. The magnitude of the residual stress can be predicted as a function of the depth, grain orientation and position with respect to the molten pool. The simulation results are directly comparable to X-ray diffraction experiments and stress–strain curves.

316 stainless steel↗
DOE OSTI2024

Fractal Nanostructured Solar Selective Surfaces for Next Gen Concentrating Solar Power (Final Report)

This project reports a novel coating with enhanced solar absorptance and reduced thermal emittance with high efficiency at elevated temperature for next-generation concentrated solar power (CSP) plants, with targeted operating temperatures around 750°C. Highly textured single and multimetallic oxide coatings were electrodeposited onto Inconel substrate by systematically varying the composition and process parameters. The optimized coating exhibited micro-to-nano structures designed to match the wavelengths in the visible region of the solar spectrum. These structures facilitate resonant absorption of solar radiation, significantly boosting solar absorption and accommodating thermal stress during high temperature exposure. A high solar absorptance exceeding 0.985 and a low thermal emittance below 0.5, yielding a thermal efficiency near 95%, was achieved for the optimized coatings without any anti-reflective overcoat, that remained robust after 750 h of isothermal exposure to 750°C in air. The coatings are also robust to severe mechanical and environmental stressors. The innovative approach presented in this study demonstrates the potential for tailoring air-stable solar absorber coatings to achieve high absorption, low emittance, and excellent high-temperature endurance, meeting the rigorous demands of next-generation CSP systems. A technoeconomic analysis reveals the economic advantage of the coatings for Gen3 CSP installations in different geographical zones globally.

14 SOLAR ENERGY↗
DOE OSTI2026

Understanding Electric Vehicle Range and Charging Needs: Interactions Between Ambient Temperature, Commute Patterns, and State-of-Charge Usage

Electric vehicle (EV) performance can vary substantially under real-world operating conditions, particularly due to ambient temperature effects on energy consumption, battery behavior, and thermal management requirements. This study quantifies how weather conditions, daily driving patterns, and State-of-Charge (SOC) usage strategies jointly influence EV driving range, charging frequency, and overall energy efficiency. A detailed and experimentally validated Autonomie vehicle model is developed, integrating a powertrain, a mono-zonal cabin model, and a battery electro-thermal model. Three battery sizes (200-, 300-, and 400-mile homologated ranges) are assessed across five commute profiles (20–200 miles) and six ambient temperatures (−18 °C to 50 °C), including scenarios with and without preconditioning. Results show that extreme temperatures could significantly decrease the maximum achievable range by up to 55% in cold conditions (−18 °C) and 40% in hot conditions (50 °C), relative to moderate conditions. Larger battery packs retain a greater fraction of their nominal range under thermal stress, while smaller packs experience sharper relative penalties due to the higher contribution of thermal loads to total energy demand. The analysis further demonstrates that limiting operation to partial SOC windows (e.g., 80–20%), a common real-world practice, significantly reduces achievable range and increases charging frequency, particularly in cold weather. Thermal preconditioning while plugged in is shown to mitigate these effects for short trips, reducing energy consumption by up to 31% in hot conditions and 7% in cold conditions. The findings demonstrate how climate, SOC usage behavior, and thermal management jointly shape the practical driving capability of EVs, highlighting the importance of efficient thermal management and realistic user charging strategies for ensuring reliable EV operation across diverse climatic scenarios.

33 ADVANCED PROPULSION SYSTEMS↗