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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 OSTI2024

Experimental Examination of Additively Manufactured Patterns on Structural Nuclear Materials for Digital Image Correlation Strain Measurements

Abstract Background There are a limited number of commercially available sensors for monitoring the deformation of materials in-situ during harsh environment applications, such as those found in the nuclear and aerospace industries. Such sensing devices, including weldable strain gauges, extensometers, and linear variable differential transformers, can be destructive to material surfaces being investigated and typically require relatively large surface areas to attach (> 10 mm in length). Digital image correlation (DIC) is a viable, non-contact alternative to in-situ strain deformation. However, it often requires implementing artificial patterns using splattering techniques, which are difficult to reproduce. Objective Additive manufacturing capabilities offer consistent patterns using programmable fabrication methods. Methods In this work, a variety of small-scale periodic patterns with different geometries were printed directly on structural nuclear materials (i.e., stainless steel and aluminum tensile specimens) using an aerosol jet printer (AJP). Unlike other additive manufacturing techniques, AJP offers the advantage of materials selection. DIC was used to track and correlate strain to alternative measurement methods during cyclic loading, and tensile tests (up to 1100 µɛ) at room temperature. Results The results confirmed AJP has better control of pattern parameters for small fields of view and facilitate the ability of DIC algorithms to adequately process patterns with periodicity. More specifically, the printed 100 μm spaced dot and 150 μm spaced line patterns provided accurate measurements with a maximum error of less than 2% and 4% on aluminum samples when compared to an extensometer and commercially available strain gauges. Conclusion Our results highlight a new pattern fabrication technique that is form factor friendly for digital image correlation in nuclear applications.

Novich, K. A. (ORCID:0000000204466022)↗
DOE OSTI2021

Penetration of Fission Products Ions into Complex Solids and the Effect of Ionic Wash Methods

During washing of radiologically impacted building surfaces, penetration of radionuclide ions into complex solids associated with these surfaces may occur. This study investigates the penetration of Cs-137, Sr-85, and Eu-152 solutions into numerous common building materials and radionuclide behavior when these materials were exposed to a static bath or low-pressure flow of tap water, 0.1 M potassium chloride (KCl), and 0.5 M KCl. The decontamination efficacy and the depth profile for residual contamination were measured to determine the conditions under which applying a wash solution has benefit compared to physically removing the surface material. On asphalt, 70-80% of the radionuclides were found to be within 0.02 mm of the surface. Concrete is more porous than asphalt, and 80% of the radionuclides were within 0.2 mm of the surface for Cs-137 and Eu-152 and 50-80% for Sr-85. Water effectively removed all contaminants from hard nonporous surfaces. Finally, this paper illustrates that a wash penalty factor concept-defined as ratio of the depth at which 50% of the radioactivity is found in the washed sample divided by the depth at which 50% of radioactivity is found in the control-can serve as a way to quantify whether the wash method increases the depth at which contamination penetrates into the material and thus the material becomes more difficult to decontaminate.

building materials↗
DOE OSTI2025

Mercury sequestration in alkaline salt low-level radioactive waste

Liquid low-level radioactive waste at the Savannah River Site contains several species of mercury, including inorganic, elemental and methylmercury. This waste is solidified and stabilized in a cementitious waste form referred to as saltstone. Soluble mercury is stabilized as β-cinnabar, HgS as the result of reaction between the mercury and sulfur present in blast furnace slag, one of the cementitious regents. In this investigation, Mersorb®, a commercial granular activated carbon impregnated with sulfur, was evaluated as a pretreatment to remove mercury from the solution prior to cementation. Mersorb® was found to remove more than 96 mass percent of the methylmercury in simulated tank waste solution when the mass ratio of Mersorb® to mercury was above 2.5. Slag sequestered relatively more inorganic mercury than organic mercury in simulated tank waste after 24 hours of contact. This is likely due to the mercury-carbon bond being more covalent than the mercury-oxygen bond and therefore more difficult to break and slower to form HgS.

Cementitious Material↗
DOE OSTI2024

Geophysical methods reveal the soil architecture and subsurface stratigraphic heterogeneities across land-lake interfaces along Lake Erie

Abstract Purpose The land-lake interface is a unique zone where terrestrial and aquatic ecosystems meet, forming part of the Earth’s most geochemically and biologically active zones. The unique characteristics of this interface are yet to be properly understood due to the inherently high spatiotemporal variability of subsurface properties, which are difficult to capture with the traditional soil sampling methods. Geophysical methods offer non-invasive techniques to capture variabilities in soil properties at a high resolution across various spatiotemporal scales. Methods We combined electromagnetic induction (EMI), electrical resistivity tomography (ERT), and ground penetrating radar (GPR) with data from soil cores and in situ sensors to investigate hydrostratigraphic heterogeneities across land-lake interfaces along the western basin of Lake Erie. Results EMI revealed high spatial heterogeneities in ECa distribution across the land-lake interfaces, with higher values in the wetland and transition zones compared to the upland zone. Soil ECa maps matched soil maps from a public database with the hydric soil units delineated as high conductivity zones (ECa > 40 mS/m). ERT and GPR showed vertical variation in soil properties with clear stratigraphic boundaries, and correlation of ERT profiles with lithologs from piezometers revealed the stratigraphic units of silt–clay and till sequence down to 3.5 m depth which are consistent with the surficial geology of the study area. Conclusions These results validate the use of multiple geophysical methods for extrapolating soil properties and mapping stratigraphic structures at land-lake interfaces, thereby providing the missing information required to improve the earth system model (ESM) of coastal interfaces.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Digestion processes and elemental analysis of oxide and sulfide solid electrolytes

Detailed elemental analysis is essential for a successful development and optimization of material systems and synthesis methods. This is especially relevant for Li- and Na-containing compounds, found in state-of-the-art and next-generation battery systems. Their materials’ properties and thus the final device performance strongly depend on the crystal structure, the stoichiometry, and defect chemistry, e.g., influencing charge carrier concentration and activation energies for vacancy transport. However, a detailed quantitative analysis of light elements in a heavy matrix, featuring a broad range of solubilities and vapor pressures, is often difficult and associated with large uncertainties and thus neglected in favor of just reporting the stoichiometry as “weighed in.” Here, in this work, we report several approaches to digest and dissolve various oxide and sulfide-based materials, used in next-generation Li batteries, for elemental analysis via optical emission spectroscopy. These include the most common solid electrolytes Li-La-Ti–O, a perovskite material (LLTO), and Li-La-Zr-O which has garnet structure (LLZO). Additionally, a facile thermal digestion process is reported for a surrogate sulfide solid electrolyte (Na 2 S). The digestion procedures reported here are suitable for almost any laboratory environment and, when applied, will improve understanding of the synthesis-structure–property correlations needed to advanced batteries with all solid-state configurations.

Malkowski, Thomas F.↗
DOE OSTI2023

Microstructure Evolution of a Multimodal Gamma-Prime Ni-Based Superalloy Characterized by In Situ Diffraction

The relationship between the evolution of microstructure, deformation micromechanisms and mechanical properties is difficult to establish in multimodal size distribution $_γ$$'$ superalloys, as the microstructure evolves with both temperature and time, and multiple strengthening mechanisms across each size distribution contribute to mechanical performance. In situ X-ray scattering can offer unparalleled insight regarding microstructure evolution at the temperatures and stresses of importance to gas-turbine applications; however, in situ X-ray diffraction has not been applied to the study of multimodal $_γ$$'$ distribution superalloys. Herein, lattice parameter evolution of secondary and tertiary $_γ$$'$ precipitates in a representative superalloy, Nimonic 115, is determined between 750 °C and 950 °C and correlated to room-temperature SEM and microhardness values. A large positive lattice parameter misfit of secondary $_γ$$'$ induces precipitate splitting, and the tertiary $_γ$$'$ goes into dissolution at ~ 800 °C, but with little apparent change in hardness values. The volume fraction of $_γ$$'$ decreases above 900 °C and precipitate-matrix coherency is lost, and there is a corresponding decrease in microhardness values. Importantly, the diffraction analysis demonstrates the capability to determine critical microstructural parameters of both precipitate size distributions in situ, representing an additional tool for determining microstructure-mechanical property relationships of multimodal superalloys.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Uncertainty Quantification in Atomistic Modeling of Metals and Its Effect on Mesoscale and Continuum Modeling: A Review

The design of next-generation alloys through the integrated computational materials engineering (ICME) approach relies on multiscale computer simulations to provide thermodynamic properties when experiments are difficult to conduct. Atomistic methods such as density functional theory (DFT) and molecular dynamics (MD) have been successful in predicting properties of never before studied compounds or phases. However, uncertainty quantification (UQ) of DFT and MD results is rarely reported due to computational and UQ methodology challenges. Over the past decade, studies that mitigate this gap have emerged. These advances are reviewed in the context of thermodynamic modeling and information exchange with mesoscale methods such as the phase-field method (PFM) and calculation of phase diagrams (CALPHAD). The importance of UQ is illustrated using properties of metals, with aluminum as an example, and highlighting deterministic, frequentist, and Bayesian methodologies. Finally, challenges facing routine uncertainty quantification and an outlook on addressing them are also presented.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Insights into Defect-Mediated Nucleation of the Equilibrium B2 Phase in Face-Centered Cubic High-Entropy Alloys

A fine scale second phase distribution is important for strengthening metallic materials. High precipitate density is often difficult to achieve due to sluggish precipitation kinetics and limited nucleation sites. Based on the CALPHAD predictions, transition element-based complex concentrated alloys (CCAs)/ High Entropy Alloys (HEAs), have a highly stable face-centered cubic (FCC) phase and intermetallic B2 phase. The precipitation of the strengthening B2 phase is often limited to low fractions in these alloys due to a high nucleation barrier in the FCC matrix. Here, by illustrating in three different alloys, we present a defect mediated nucleation of a high fraction equilibrium B2 phase. The degree of cold work is used to manipulate the phase fraction, morphology, and distribution of B2 precipitates. Our approach synergistically improves the strength and ductility of these alloys and is widely applicable to many other complex alloys.

Sharma, Abhishek↗
DOE OSTI2021

Defect Characterization Using Positron Annihilation Spectroscopy on Laser-Ablated Surfaces

In recent years, short, pulsed laser ablation has been gaining popularity for machining small-scale test geometries from bulk samples and for efficient serial sectioning. These laser-based techniques are being added to the toolbox in material science, which makes it necessary to understand the changes in the material that occur from the laser–material interaction. Positron annihilation spectroscopy is a unique, nondestructive technique to investigate small defects in materials difficult to investigate by other tools. In this work, Doppler broadening and positron lifetime annihilation spectroscopy are utilized to help quantify the damage in materials treated with short, pulsed lasers. Using a femtosecond laser on single crystal silicon, this manuscript shows that clusters of vacancy-like defects and small voids increase systematically with laser power. Lastly, the damage induced by the laser can also reach to micrometer depths.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Advances in Processing, Manufacturing, and Applications of Magnetic Materials

Magnetic materials are increasingly important for many green energy technologies. Probably, the best known of these are permanent magnets. They are used to supply a magnetic field and are widely used in actuators, motors, generators, data storage, and sensors. These are “hard magnets,” meaning that they retain a large permanent magnetization (difficult to be demagnetized), which is what makes them so useful in motors where an opposing magnetic field can be used to push against them. A coercivity (resistance to demagnetization) of ~400 Oe (32,000 A/m) or more is typically the threshold value for a hard magnet and is typical of isotropic sintered ferrite (SrFe 12 O 19 ) such as found in many “refrigerator magnets.” Comparably important soft magnets are useful for directing magnetic fields and can be very easily (de)magnetized. As such, they typically have a coercivity < 12.5 Oe (1000 A/m), and specialized very soft magnets can have coercivities < 0.00125 Oe (1 A/m). Some common applications include coil cores, transformer cores, and magnetic shielding. Additionally, they are important for many AC electrical applications such as inductors, filters, and resonators, particularly at high frequencies up to and including microwaves.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Preliminary Study on Machining of Additively Manufactured Ti-6Al-4V

We report additively manufactured metals differ from their conventionally produced counterparts due to the inherent material inhomogeneity, porosity, and thermal stress induced by the process. These differences make the machining of additively manufactured metals more difficult and cause premature tool failure or unexpected surface finish at certain conditions. This study takes the first step to investigate and identify the causes of these issues, particularly for Ti-6Al-4V. Printed and wrought samples, as well as heat treatment effect, are compared in a dry cutting condition at a cutting speed of 90 m/min in terms of cutting power, vibration, temperature, and produced surface finish. The results show a lower cutting power and more vibration for as-printed Ti samples, indicating a less ductile microstructure and inclusion of pores. Heat treatment can eliminate these phenomena. There is no significant difference found in the produced surface finish at the current cutting condition.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Characterization of Fe-6Si Soft Magnetic Alloy Produced by Laser-Directed Energy Deposition Additive Manufacturing

Abstract Commercial electrical steels, Fe-Si alloys with < 4 wt.% Si, are inexpensive and efficient materials for electrical power conversion. Further efficiency improvements require increasing the silicon concentration to 6 wt.%, at which point the material becomes brittle and difficult to form by conventional rolling and sheet fabrication methods. Additive manufacturing stands to overcome challenges with commercial manufacturing techniques by leveraging near-net-shape fabrication. The wide array of process conditions provides additive manufacturing with increased flexibility, enabling control over the microstructure and mechanical properties. This work explores the microstructures and magnetic properties of ring-shaped Fe-Si alloys produced using concentric and cross-hatch tool paths on a laser-directed energy deposition additive manufacturing system. Concentric-built samples exhibit elongated grain structures while cross-hatch-built samples comprise lower aspect ratio grain structures. Thermal finite element analysis simulations model the stress conditions produced by the different scan path geometries. Microhardness measurements probe the mechanical properties as a function of anneal temperature, providing a qualitative understanding of the intergranular defect density. Soft magnetic properties measured under quasistatic and AC conditions show frequency- and microstructure-dependent coercivity and permeability. Finally, analysis of the core loss quantifies how the build strategies and thermal treatments influence efficiency in electrical power conversion applications. Understanding the influences of scan path geometry and thermal treatment provides a pathway towards application of additively manufactured soft magnetic materials.

Adamczyk, Jesse M.↗
DOE OSTI2024

Standardization Gaps in Powder Feedstock Characterization and Establishing Acceptability for Reuse in Additive Manufacturing

Characterization techniques for powder feedstocks used in additive manufacturing (AM) have long been relied upon to describe the inputs to an AM workflow. However, functional gaps remain between tests to measure intrinsic and extrinsic properties with the direct performance within AM equipment. Furthermore, the common practice of reusing powder through multiple build cycles introduces effects and changes to feedstock performance that are otherwise difficult to measure quantitatively. Here, standardization and the development of new test methods have not kept pace with the rapid evolution of the AM industry and its reliance on highly coupled process-structure–property-performance relationships.

Characterization and Analytical Technique↗
DOE OSTI2025

Chloride Molten Salt Electrolysis Enables Integrated and Energy-Efficient Process for NdFeB Magnet Fabrication

Rare-earth elements (REEs) have been identified by NATO, the USDOE, and USGS as critical materials, i.e., materials which have significant demand yet pose supply-chain risks. Many of the existing processes for separations, metallization, and final parts production used across the REE supply chain involve energy intensive steps. For example, neodymium (Nd or NdPr) is produced using oxyfluoride electrolysis of Nd 2 O 3 , which requires hydrofluoric acid to produce a key electrolyte component (NdF 3 ) and generates undesired perfluorocarbon (PFC) gases. Such challenges make securing a resilient supply chain for NdFeB permanent magnets in countries like the United States prohibitively difficult. Here, we propose a chloride-based MSE process that circumvents these challenges, delivering high-purity NdPr from a (NdPr)Cl 3 feed from upstream REE separations. This eliminates environmentally-damaging steps of oxalate or carbonate precipitation and calcination, and enables superior production rates due to greater solubility of (NdPr)Cl 3 in chloride melts compared to Nd 2 O 3 . We show that CMSE generates high-purity NdPr (99.4 wt.%) while being energy-efficient (~ 6 kWh/kg-Nd). NdPr from CMSE was used to fabricate a NdFeB magnet with an excellent maximum energy product (> 40 MGOe), comparable to commercially available NdFeB magnets. This establishes CMSE as a leading approach for integrated, energy-efficient NdFeB magnet production.

Materials science↗
DOE OSTI2019

Cancer Treatment-Associated Pericardial Disease: Epidemiology, Clinical Presentation, Diagnosis, and Management

Purpose of Review: Cancer therapeutics have seen tremendous growth in the last decade and have been effective in the treatment of several cancer types. However, with advanced therapies like kinase inhibitors and immunotherapies, there have been unintended consequences of cardiotoxicities. While traditional chemotherapy and radiation-induced cardiotoxicity have been well studied, further research is needed to understand the adverse effects of newer regimens. Recent Findings: Both immune-mediated and non-immune-medicated cytotoxicity have been noted with targeted therapies such as tyrosine kinase inhibitors and immune checkpoint inhibitors. In this manuscript, we describe the pericardial syndromes associated with cancer therapies and propose management strategies. Pericardial effusion and pericarditis are common presentations in cancer patients and often difficult to diagnose. Concomitant myocarditis may also present with pericardial toxicity, especially with immunotherapies. In addition to proper history and physical, additional testing such as cardiovascular imaging and tissue histology need to be obtained as appropriate. Holding the offending oncology drug, and institution of anti-inflammatory medications, and immunosuppressants such as steroids are indicated. Summary: A high index of suspicion, use of standardized definitions, and comprehensive evaluation are needed for early identification, appropriate treatment, and better outcomes for patients with cancer treatment-associated pericardial disease. Further research is needed to understand the pathophysiology and to evaluate how the management of pericardial conditions in these patients differ from traditional management and also evaluate new therapies.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2019

Small cell carcinoma of the bladder: the characteristics of molecular alterations, treatment, and follow-up

Small cell carcinoma of the bladder (SCCB) is a rare disease associated with high invasiveness and mortality. Histologically, SCCB is difficult to distinguish from small cell lung cancer (SCLC); however, it shares more similar molecular alterations with urothelial carcinoma (UC). As a result, now, the widely accepted theory about the cells of origin is that SCCB and UC probably have a common clone origin. Even the former probably comes from a preexisting UC. At present, given its rarity, early diagnoses, treatments, and follow-ups are not well established, which are vital to patients with SCCB. Inspirationally, in recent years, with the development of molecular diagnostic methods, molecular alterations of SCCB have been understood partially, which are propitious to excavate new potential therapeutic strategies and establish sound follow-ups. Therefore, the future will be light for patients with SCCB.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2020

Generation and representation of synthetic smart meter data

Advanced energy algorithms running at big-data scale will be necessary to identify, realize, and verify energy savings to meet government and utility goals of building energy efficiency. Any algorithm must be well characterized and validated before it is trusted to run at these scales. Smart meter data from real buildings will ultimately be required for the development, testing, and validation of these energy algorithms and processes. However, for initial development and testing, smart meter data are difficult to work with due to privacy restrictions, noise from unknown sources, data accessibility, and other concerns which can complicate algorithm development and validation. This paper describes a new methodology to generate synthetic smart meter data of electricity use in buildings using detailed building energy modeling, which aims to capture the variability and stochastics of real energy use in buildings. The methodology can create datasets tailored to represent specific scenarios with known truth and controllable amounts of synthetic noise. Knowledge of ground truth also allows the development and validation of enhanced processes which leverage building metadata, such as building type or size (floor area), in addition to smart meter data. The methodology described in this paper includes the key influencing factors of real-world building energy use including weather data, occupant-driven loads, building operation and maintenance practices, and special events. Data formats to support workflows leveraging both synthetic meter data and associated metadata are proposed and discussed. Finally, example use cases of the synthetic meter data are described to illustrate potential applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Structure-aware methods for expensive derivative-free nonsmooth composite optimization

We present new methods for solving a broad class of bound-constrained nonsmooth composite minimization problems. These methods are specially designed for objectives that are some known mapping of outputs from a computationally expensive function. We provide accompanying implementations of these methods: in particular, a novel manifold sampling algorithm (MS-P) with subproblems that are in a sense primal versions of the dual problems solved by previous manifold sampling methods and a method (GOOMBAH) that employs more difficult optimization subproblems. For these two methods, we provide rigorous convergence analysis and guarantees. We demonstrate extensive testing of these methods. Open-source implementations of the methods developed in this manuscript can be found at https://github.com/POptUS/ IBCDFO/.

97 MATHEMATICS AND COMPUTING↗