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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
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.↗
DOE OSTI2025

srlife : A software tool for estimating the life of high temperature concentrating solar receivers. Part II – Ceramic receivers

As Concentrating Solar Power (CSP) technologies aim for higher operating temperatures to enhance efficiency and meet industrial process heat demands, high-temperature metallic materials, including nickel-based superalloys, face challenges in maintaining structural integrity. Advanced ceramics offer a promising alternative due to their superior high-temperature strength. However, accurately assessing the performance of ceramic components requires a fundamentally different approach from that used for metallic components. This Part II of a two-part paper describes the integration of ceramic statistical failure models within srlife – an open-source tool for predicting the life of high-temperature CSP receivers. These models account for the inherent variability in ceramic strength, as well as the effects of subcritical crack growth (SCG) under high temperature cyclic loads. Here, the paper includes an example problem that demonstrate the process of evaluating ceramic receivers using srlife. Part I details the life estimation process for metallic receivers (i.e. creep-fatigue life) along with input and output data structure, thermohydraulic analysis, and structural analysis. The complete tool is available as open-source software at https://github.com/srlife-project/srlife and can be installed via the PyPi package manager (https://pypi.org). By supporting both ceramic and metallic receiver analyses, srlife facilitates fair comparisons between competing metallic and ceramic designs, enabling accurate evaluations of plant efficiency and the economic benefits of ceramic solar receivers and other components.

High temperature ceramic receivers↗
DOE OSTI2019

Elastic Precursor Decay and Spallation in Nonporous Tungsten Carbide Ceramics

To identify the possible contribution of relaxation processes to the resistance against high-rate deformation, evolution of shock-compression waves in tungsten carbide (WC) ceramics manufactured by spark-plasma sintering at a maximum compressive stress of 27 GPa is measured. Strong elastic precursor decay upon changing the thickness of the samples from 0.15 to 4 mm is revealed. At maximum shock compressive stresses twice exceeding the Hugoniot elastic limit, a decrease in the spall strength value by about 30% from its value in the elastic region is recorded.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Electric-Loading Enhanced Kinetics in Oxide Ceramics: Pore Migration, Sintering and Grain Growth: Final Report

Solid oxide fuel cells and solid oxide electrolysis cells rely on solid electrolytes in which a large ionic current dominates. This project was initiated to investigate microstructural changes in such devices under electrochemical forces, because nominally insignificant processes may couple to the large ionic current to yield non-equilibrium phenomena that alter the microstructure. Our studies had focused on yttria-stabilized cubic zirconia (YSZ) widely used in these devices. The experiments have revealed enhanced grain growth at higher temperatures, pore and gas bubble migration at all temperatures, and the latter also lead to enhanced sintering of highly porous ceramics into fully dense ceramics at unprecedentedly low temperatures. These results have shed light on kinetic processes that fall completely outside the realm of classical ceramic processing. Other fast-oxygen oxide ceramics closely related to, and often used in conjunction with zirconia ceramics, have also be investigated, as are closely related scientific problems in zirconia ceramics. These include crystal structures, defects, diffusion kinetics, oxygen potentials, low temperature sintering, flash sintering, and coarsening theory, and all have resulted in greater clarity in scientific understanding. The knowledge is leveraged to provide new insight to electrode kinetics and near-electrode mixed conductivity and to new materials. In the following areas, our research has resulted in completely new knowledge that defines the state-of-the-art of the field. (a) Electrical current driven non-equilibrium phenomena, (b) Enhanced grain growth under electrochemically reducing conditions, (c) Development of oxygen potential polarization in electrically loaded electrolyte, (d) Low temperature sintering and grain growth, and (e) Structure, defects and cation kinetics of fluorite-structured oxides. Our research has also contributed to synthesis of new energy-relevant electrochemical materials and new understanding of flash sintering, which is a rapid sintering process initiated by a large electrical loading.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Low-Temperature Short-Time SPS Processes to Produce Fine-Grained High-Coercivity Barium Hexaferrite Ceramics from Polyol Nanoparticles

Barium hexaferrite (BaFe{sub 12}O{sub 19}) ceramics were obtained by combination of polyol-synthesized precursors subsequently consolidated by spark plasma sintering (SPS) at a low temperature (800 {sup ∘}C). X-ray powder diffraction studies showed the influence of the experimental parameters to produce a virtually single- or multiphase material. The room temperature magnetic properties exhibited interesting variety of properties, including exchange coupling (spring magnet) between hexaferrite and other magnetic phases. The saturation magnetization and coercive field, at room temperature, are in the 34–70 emu/g and 4.1–5.0 kOe ranges, respectively. The combination of strong coercive field and magnetization resulted in a maximum energy product [(BH)max] = 10.9 kJ/m{sup 3} for the sample with the highest BaFe{sub 12}O{sub 19} content.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

Advanced ceramic components with embedded sapphire optical fiber sensors for high temperature applications

Here this paper describes an extrusion-based additive manufacturing process that has been developed to enable embedment of sapphire optical fiber sensors in ceramic components during the part fabrication. In this process, an aqueous paste of ceramic particles is extruded through a moving nozzle to build the part layer-by-layer. In the case of sensor embedment, the fabrication process is halted after a certain number of layers have been deposited; the sensors are placed in their predetermined locations, and the remaining layers are deposited until the part fabrication is completed. Because the sensors are embedded during the fabrication process, they are fully integrated with the part and the problems of traditional sensor embedment can be eliminated. Scanning electron microscopy was used to observe the embedded sensors and to detect any possible flaws in the part or embedded sensor. Attenuation of the sensors was measured in near-infrared region (1500–1600 nm wavelength). Standard test methods were employed to examine the effect of embedded fibers on the strength and hardness of the parts. The results indicated that the sapphire fiber sensors with diameters smaller than 250 micrometers were able to endure the freeform extrusion fabrication process and the post-processing without compromising the part properties.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Embedding ceramic components in metal structures with hybrid directed energy deposition

The combined benefit of both additive and subtractive manufacturing within the same gantry system enables hybrid directed energy deposition to create complex geometries with smooth surface finish and superior dimensional accuracy. Moreover, with layer-by-layer access to the structure during both the addition and subtraction of material, the insertion of components is now possible, assuming the components can survive the high temperatures associated with the subsequent metal deposition. Ceramic inserts are of interest for a variety of reasons including (1) to create complex interwoven ductile/brittle composites for ballistics or high-temperature applications or (2) to integrate high-temperature strain or temperature sensors protected within ceramic substrate subsumed into a larger metal structure. Here, in this work, stainless steel substrates were machined to create an internal cavity for the insertion of a ceramic component. During the investigation of several different over-the-ceramic deposition strategies, components were inserted, and different process sequences were allowed to continue to envelop the inserted ceramic with varying success. Unmelted powder was used to serve both as a thermal buffer and to provide a flush surface upon which the laser cladding could continue. Subsequent depositions were attempted with both dry and wet powder (addition of machining coolant to wet). The wet powder has previously been demonstrated to not significantly impact the mechanical properties of a final structure and provided a thermal barrier to protect the ceramic piece from the extreme temperatures of the final metal deposition. The wetting of the powder provided stability and minimized displacement caused by the powder flow from the laser cladding head. Finally, the use of an oblique angle for laser cladding allowed for the redirection of some fraction of the introduced thermal energy away from the ceramic component and, consequently, improved the survival of the ceramic inserts. With this combination of techniques, ceramic inserts survived full embedding within a 3D-printed stainless steel structure.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effects of electrostatic field strength on grain‐boundary core structures in SrTiO 3

Abstract Understanding interactions between externally applied electric fields and the interfacial structures of nanoscale ceramics is important for controlling their functional properties. In ceramic oxides, functional properties are determined by oxygen vacancy concentrations near and within grain‐boundary core structures. In this study it is shown that the application of electrostatic fields ranging from 0 to nominally 170 V/cm during diffusion bonding of bicrystals alters the atomic and electronic core structures of (100) twist grain boundaries in SrTiO 3 . The applied electric field strength affects local oxygen vacancy concentrations and ordering of the oxygen sublattice. Results for this model system indicate that electrostatic fields applied during ceramic manufacturing can be employed as a new processing parameter to tailor defect structure configurations and obtain unprecedented ceramic microstructures. The ability to manipulate interface configurations with electric fields in the absence of any sintering additives may have far reaching implications for tuning polarization and band structures in electroceramics while avoiding effects of often unwanted dopants.

Hughes, Lauren A.↗
DOE OSTI2013

Development of ITM Oxygen Technology for Integration in IGCC and Other Advanced Power Generation DECISION POINT 1 UNDER PHASE 3

Air Products and the DOE have partnered over a number of years in the development of ITM Oxygen technology in support of gasification technology. Throughout this process, studies of application of the technology to IGCC and oxy-coal combustion have shown significant reduction in capital and operating costs compared to similar systems using conventional cryogenic air separation. Phase 3, the current phase of the program, focuses on the design, construction and operation of a 30- to 100-TPD pilot facility, the Intermediate Scale Test Unit (ISTU). Execution of this phase to date has resulted in significant advances in a number of areas including ceramic membrane material development, module design and production, ceramic-to-metal seal design, process control strategies, and engineering development of process cycles. Phase 3 will be complete upon successful operation of the ISTU in a series of tests making oxygen from ceramic membrane modules and producing power from a hot gas expander. Phase 3 work has extended beyond the planned schedule due to a delay in delivery of equipment from vendors. Air Products is currently managing the equipment delay by close involvement with the vendor to redesign the problematic equipment and oversee its fabrication. The result of these unforeseen challenges is that the ISTU project completion date has been delayed. Tight cost controls have been implemented both by DOE program management and APCI to meet budget constraints despite increased costs due to budget delays. Total project costs have increased in several areas. Increased costs in the ISTU project include purchased equipment, instruments, construction, and contractor engineering. Increased costs for other tasks include additional work in support of module production by Ceramatec, Inc, and increased Air Products labor for component testing. Air Products plans to complete testing as outlined in the SOPO and successfully complete all project objectives by the end of FY14.

Anderson, Lori↗
NASA NTRS2005

Automated Rapid Prototyping of 3D Ceramic Parts

An automated system of manufacturing equipment produces three-dimensional (3D) ceramic parts specified by computational models of the parts. The system implements an advanced, automated version of a generic rapid-prototyping process in which the fabrication of an object having a possibly complex 3D shape includes stacking of thin sheets, the outlines of which closely approximate the horizontal cross sections of the object at their respective heights. In this process, the thin sheets are made of a ceramic precursor material, and the stack is subsequently heated to transform it into a unitary ceramic object. In addition to the computer used to generate the computational model of the part to be fabricated, the equipment used in this process includes: 1) A commercially available laminated-object-manufacturing machine that was originally designed for building woodlike 3D objects from paper and was modified to accept sheets of ceramic precursor material, and 2) A machine designed specifically to feed single sheets of ceramic precursor material to the laminated-object-manufacturing machine. Like other rapid-prototyping processes that utilize stacking of thin sheets, this process begins with generation of the computational model of the part to be fabricated, followed by computational sectioning of the part into layers of predetermined thickness that collectively define the shape of the part. Information about each layer is transmitted to rapid-prototyping equipment, where the part is built layer by layer. What distinguishes this process from other rapid-prototyping processes that utilize stacking of thin sheets are the details of the machines and the actions that they perform. In this process, flexible sheets of ceramic precursor material (called "green" ceramic sheets) suitable for lamination are produced by tape casting. The binder used in the tape casting is specially formulated to enable lamination of layers with little or no applied heat or pressure. The tape is cut into individual sheets, which are stacked in the sheet-feeding machine until used. The sheet-feeding machine can hold enough sheets for about 8 hours of continuous operation.

McMillin, Scott G.↗
NASA NTRS1992

Beneficiation and extraction of nonterrestrial materials, part 2

A review of options for processing extraterrestrial materials was dominated by industrial materials scientist who tried to identify which processes utilizing space materials could be implemented in the near term. The most practical process seem to us to be the extraction of lunar oxygen and the extraction of metals and ceramics from the residues of the reduction process. The growth of space activity will be accompanied by increased demand for liquid oxygen for each round trip to the Moon. The oxygen and the intermediary product water will be needed for the life support at the base. The reduced metals and ceramics may be considered byproducts or may develop into primary products. Some of the same processes would be directly applicable to recovery of products from asteroids. We also discussed other processes for directly utilizing asteroid metals. Some of the topics covered include beneficiation and oxygen extraction methods, metallurgy, and extraterrestrial cement.

Agosto, William N.↗
DOE OSTI2017

Vitrification of Sellafield Wastes with High Metallic Magnesium Alloy Content - 17495

The Sellafield nuclear complex, located in northwest England, is the largest such site in the United Kingdom. Sellafield Limited, which is the operating contractor for the Nuclear Decommissioning Authority, is evaluating thermal treatment technologies for a potential future facility to process a variety of Intermediate Level Waste sludges and slurries accumulated from historical site operations. In support of that effort, Atkins and the Vitreous State Laboratory (VSL) of The Catholic University of America conducted studies to evaluate the feasibility and implications of installing a joule-heated ceramic melter (JHCM) vitrification system to process a variety of sludge and slurry radioactive wastes at the Sellafield site. These sludges have the potential to contain a significant proportion of reactive metals in localized regions. The metallic fraction derives from unreacted Magnox spent fuel cladding. Thus, an important objective of this work was to investigate the performance of JHCM technology for the treatment of streams with localized regions of high reactive metal contents. The present work was focused on Site Ion Exchange Effluent Plant (SIXEP) Magnox sludges, investigated previously. Suitable waste simulants were developed for the SIXEP Magnox sludge waste stream, which included surrogates for all important radionuclides. High waste-loading, fully compliant glass formulations were designed using a combination of previous experience, extensive waste glass data bases, and small-scale crucible melts. Glasses from the test melts were characterized for properties that are important for processability and product quality. The most viable compositions were then selected for small-scale melter trials to collect information on processing rates and behavior, off-gas and secondary waste compositions, and overall system mass balance. These data were used to support the technology evaluation, which considered such factors as minimization of inactive additions, waste volume reduction, retention of radionuclides, minimization of secondary wastes, and overall process efficiency and effectiveness. The data were also used to develop sizing estimates for the full-scale facility and to estimate treatment durations under various treatment scenarios. A series of tests was then performed with partial replacement of the magnesium hydroxide with a metallic magnesium alloy that is close in composition to Magnox alloy. A commercially available magnesium alloy, Elecktron AZ31B, which has a nominal magnesium content of 95.7%, was used for this purpose. The testing was performed on a DuraMelter 10 (DM10) JHCM system to characterize the melter off-gas, glass product, and the effects of magnesium alloy particle size on feed processing. Data on processing rate and any processing issues, product glass composition, off-gas composition including hydrogen, and system operating parameters, including flows, temperatures, pressures, etc., were collected and analyzed to evaluate the effects of magnesium alloy on the vitrification process. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Identifying Bounds of Inorganic Content in Solventless Processing of Hybrid Solid Electrolytes

Solid-state lithium batteries require safe, robust electrolytes to enable higher energy densities and improved safety over conventional cells. Hybrid polymer–ceramic electrolytes are a promising solution, combining the processability of polymers with the high ionic conductivity and mechanical strength of inorganic fillers. In this work, we demonstrate a solventless, UV-curing method to produce hybrid solid electrolytes using a poly(ethylene glycol) dimethyl ether (PEGDME)-based photocurable matrix incorporating Li 1.5 Al 0.5 Ge 1.5 (PO 4 ) 3 (LAGP) or Li 7 La 3 Zr 2 O 12 (LLZO) ceramic electrolyte. Inorganic filler loadings up to ∼55 wt.% could be successfully incorporated via this process which was the highest inorganic content at which the slurry remains processable and cured into a uniform film. The resulting UV-cured composite electrolytes remain flexible and exhibit room-temperature ionic conductivities on the order of 10 −4 S·cm −1 , along with notably improved lithium-ion transference numbers compared to conventional polymer electrolytes. Similar performance and processing limits were observed for both LAGP and LLZO, indicating that ceramic filler chemistry does not significantly affect the UV-curing process or the electrolyte's ion transport properties in this regime. Eliminating solvents from fabrication not only simplifies processing and mitigates environmental concerns but also enables higher solid contents that enhance mechanical strength and help suppress lithium dendrite formation. In conclusion, this scalable approach thus paves the way for manufacturing robust composite solid electrolytes for next-generation solid-state batteries (SSBs).

Batteries↗
DOE OSTI2018

NSRD-12, Novel Mini-Tubular HEPA Media for Nuclear Facility Ventilation Systems

The overall goal is to improve safety of DOE nuclear facilities during fire scenarios by developing improved filtration technology, increasing performance while reducing pressure drop. Ceramic filtration technology can provide robust, passive mitigation against radiological releases.The primary objective of this report is to demonstrate that mini-tubular ceramic (MTC) media can reduce pressure drop across a filter compared to flow through a membrane. A secondary objective is to obtain a baseline filtration efficiency measurement. Reducing pressure drop across a filter through MTC design can be combined with nanofiber technology to improve filter performance. Developing MTC media can also solve processing challenges associated with manufacturing ceramic nanofiber membranes and coatings by electrospinning. This work will support developing specifications for industry codes and standards such as ASME AG-1, Subsection FO, Ceramic Filters.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Corrosion Performance of Composite MAO/TiO{sub 2} Sol–Gel Coatings on Magnesium Alloy AZ91D

In this paper, the composite coatings on the surface of magnesium alloy were successfully prepared by the combination of micro-arc oxidation (MAO) and sol–gel method. Oxide ceramic layers were formed on AZ91D magnesium alloy using MAO process. The sol–gel layers were coated on MAO ceramic layers. The composition of the composite coatings was analyzed by x-ray diffraction and x-ray photoelectron spectroscopy. The microstructure of the composite coatings was analyzed by scanning electron microscope. The results show that the composite coatings can reduce the gap membrane effectively. The polarization curves and electrochemical impedance spectroscopy were used to evaluate the corrosion resistance. The results of corrosion tests show that the sol–gel layer enhances the corrosion resistance of the magnesium alloys significantly.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Design and fabrication of a 30 T superconducting solenoid using overpressure processed Bi2212 round wire

High field superconducting magnets are used in particle colliders, fusion energy devices, and spectrometers for medical imaging and advanced materials research. Magnets capable of generating fields of 20-30 T are needed by future accelerator facilities. A 20-30 T magnet will require the use of high-temperature superconductors (HTS) and therefore the challenges of high field HTS magnet development need to be addressed. Superconducting Bi 2 Sr 2 CaCu 2 O x (Bi2212) conductors fabricated by the oxide-powder-in-tube (OPIT) technique have demonstrated the capability to carry large critical current density of 10 5 A/cm 2 at 4.2 K and in magnetic fields up to 45 T. Available in round wire multi-filamentary form, Bi2212 may allow fabrication of 20-50 T superconducting magnets. Until recently the performance of Bi2212 has been limited by challenges in realizing high current densities (J c ) in long lengths. This problem now is solved by the National High Magnetic Field Lab using an overpressure (OP) processing technique, which uses external pressure to process the conductor. OP processing also helps remove the ceramic leakage that results when Bi-2212 liquid leaks out from the sheath material and reacts with insulation, coil forms, and flanges. Significant advances have also been achieved in developing novel insulation materials (TiO 2 coating) and Ag-Al sheath materials that have higher mechanical strengths than Ag-0.2wt.% Mg, developing heat treatment approaches to broadening the maximum process temperature window, and developing high-strength, mechanical reinforced Bi-2212 cables. In the Phase I work, we leveraged these new opportunities to prototype overpressure processed solenoids and test them in background fields of up to 14 T. Additionally a design of a fully superconducting 30 T solenoid was produced. This work in conjunction with the future path outlined in the Phase II proposal would provide a major step toward qualifying Bi2212 technology for use in high-field accelerator magnets. Additionally, the performance parameters match key requirements of a final muon beam cooling solenoid. This technology will also be of interest to high-field NMR manufacturers.

43 PARTICLE ACCELERATORS↗
DOE OSTI2015

Development of ITM oxygen technology for integration in IGCC and other advanced power generation

Ion Transport Membrane (ITM) technology is based on the oxygen-ion-conducting properties of certain mixed-metal oxide ceramic materials that can separate oxygen from an oxygen-containing gas, such as air, under a suitable driving force. The “ITM Oxygen” air separation system that results from the use of such ceramic membranes produces a hot, pure oxygen stream and a hot, pressurized, oxygen-depleted stream from which significant amounts of energy can be extracted. Accordingly, the technology integrates well with other high-temperature processes, including power generation. Air Products and Chemicals, Inc., the Recipient, in conjunction with a dozen subcontractors, developed ITM Oxygen technology under this five-phase Cooperative Agreement from the laboratory bench scale to implementation in a pilot plant capable of producing power and 100 tons per day (TPD) of purified oxygen. A commercial-scale membrane module manufacturing facility (the “CerFab”), sized to support a conceptual 2000 TPD ITM Oxygen Development Facility (ODF), was also established and operated under this Agreement. In the course of this work, the team developed prototype ceramic production processes and a robust planar ceramic membrane architecture based on a novel ceramic compound capable of high oxygen fluxes. The concept and feasibility of the technology was thoroughly established through laboratory pilot-scale operations testing commercial-scale membrane modules run under industrial operating conditions with compelling lifetime and reliability performance that supported further scale-up. Auxiliary systems, including contaminant mitigation, process controls, heat exchange, turbo-machinery, combustion, and membrane pressure vessels were extensively investigated and developed. The Recipient and subcontractors developed efficient process cycles that co-produce oxygen and power based on compact, low-cost ITMs. Process economics assessments show significant benefits relative to state-of-the-art cryogenic air separation technology in energy-intensive applications such as IGCC with and without carbon capture.

Armstrong, Phillip A.↗