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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 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Photoactive devices including porphyrinoids with coordinating additives

Coordinating additives are included in porphyrinoid-based materials to promote intermolecular organization and improve one or more photoelectric characteristics of the materials. The coordinating additives are selected from fullerene compounds and organic compounds having free electron pairs. Combinations of different coordinating additives can be used to tailor the characteristic properties of such porphyrinoid-based materials, including porphyrin oligomers. Bidentate ligands are one type of coordinating additive that can form coordination bonds with a central metal ion of two different porphyrinoid compounds to promote porphyrinoid alignment and/or pi-stacking. The coordinating additives can shift the absorption spectrum of a photoactive material toward higher wavelengths, increase the external quantum efficiency of the material, or both.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Investigations of non-linear polymers as high performance lubricant additives

Off-the-shelf available engine oils contain an assortment of additives that increase the performance of base oils and maximize the overall efficiency of the machine. With ever increasing requirements for fuel efficiency, the demand for novel materials that outperform older generations is also on the rise. One approach towards increasing overall efficiency is to reduce internal friction and wear in an engine. From an additive approach, this is typically achieved by altering the bulk oil’s viscosity at high temperatures via polymers. In general, the hydrodynamic volume of polymers increase (expand) at elevated temperatures and decrease (contract/deflate) with declining temperatures and this effect is enhanced be carefully designing specific structures and architectures. The natural thinning tendency of base oil with increasing temperatures is in part mitigated by the expansion of the macromolecules added, and the overall effect is decreasing the viscosity losses at high temperatures. Traditional polymer architectures vary from linear to dendritic, where linear polymers of the same chemical composition and molecular weight to its dendritic counterpart will undergo a more significant free volume change in solution with regards to temperature changes. This advantage has been exploited in the literature towards the production of viscosity modifiers. However, one major disadvantage of linear polymers is degradation due to mechanical shear forces and high temperatures causing a shorter additive lifetime. Dendrimers on the other hand are known to demonstrate superior robustness to shear degradation when compared to their respective linear counterparts. An additional advantage of the dendritic architecture is the ability to tailor the peripheral end-groups towards influencing polymer-solvent and/or polymer-surface interactions. Comb-burst hyperbranched polymers are a hybrid of the aforementioned architectures and provide several compromises between the traditional structures including the tailoring of peripheral functional groups, conformational flexibility via lipophilic long chain linkers, and a readily available synthesis amenable to scale-up. In the following communication, the synthesis of an aryl comb-burst hyperbranched polymer will be described. Some of the challenges we had to overcome are being highlighted, such as efforts towards increasing lipophilicity of the molecule via changes in saturated carbon content, controlling polymerization conditions to control average molecular weight and degree of branching. In addition, trends in viscosity modification of the bulk oil and wear/friction studies will be discussed.

Robinson, Joshua W.↗
DOE OSTI2021

Heat treatment to anneal residual stresses during additive manufacturing

The present disclosure relates to a method of producing a product through additive manufacturing with heat treatment. The method involves using a fusing beam to melt powder particles disposed on a substrate, where the fusing beam is impressed with a two dimensional pattern containing image information from a first layer to be printed. The fused powder particles are then heat treated with a beam impressed with an additional two dimensional pattern. The additional two dimensional pattern has image information from the first layer to achieve heat treatment of the product. The heat treatment is completed prior to laying down additional new layers of material. The heat treatment is an annealing operation. The method may further involve providing a new layer of powdered material on top of the layer of fused powder particles subsequent to the heat treatment, and repeating the melting and heat treating operations in a layer-by-layer fashion using the two dimensional pattern and the additional two dimensional pattern, until the part is completed.

DeMuth, James A.↗
DOE OSTI2021

Additive manufacturing of power poles using bamboo-polymer composites: A quick solution for power grid restoration

Polymer additive manufacturing (AM) technology is rapidly growing and its transition to become an advanced manufacturing technique now offers possibilities for unconventional applications. One of these potential applications is on site additive manufacturing of power poles. During natural incidents such as storms and hurricanes, power lines can be severely damaged and there may not be sufficient spare power poles to replace. In such situations, additive manufacturing of power poles on site can offer a fast, temporary solution during emergencies. The ability of freeform manufacturing of parts with complex geometries makes large scale AM attractive for various applications; however, due to residual stress build up and need for different mechanical requirements for different applications, reinforcement of the AM feedstock is necessary. In addition to carbon and glass fibers, bio-derived fibers can also be used as a reinforcing phase, both to utilize the natural resources at the emergency area and in terms of long-term sustainability. In this project, design and additive manufacturing of a 13.1 m power pole was demonstrated. Three different feedstock material options (polystyrene, cellulose ester and polycarbonate reinforced with glass and bamboo fibers) and two different pole designs were investigated. As-printed part tensile properties both in printing and interlayer directions were measured and a power pole was printed as six pieces and put together successfully. Finally, a conceptual design of a portable power pole manufacturing approach was proposed.

Tekinalp, Halil↗
DOE OSTI2024

Additive manufacturing system with at least one electronic nose

An additive manufacturing system comprising at least one electronic nose (e-nose) is provided. The e-nose may comprise a housing and gas sensors. The housing may have an air channel. The active sensor portion of the sensors are positioned in the air channel. The housing may be mounted to an extruder head of an additive manufacturing device. The system may also comprise a processor. The processor may determine whether there is an abnormality in an additive manufacturing process based on one or more combinations of outputs from the gas sensors received during the additive manufacturing process input into a deployed machine learning model; and generate a report for the additive manufacturing process containing the determination.

Ivanov, Ilia N.↗
DOE OSTI2024

Wire arc additive manufactured A36 steel performance for marine renewable energy systems

Additive manufacturing has established itself to be advantageous beyond small-scale prototyping, now supporting full-scale production of components for a variety of applications. Despite its integration across industries, marine renewable energy technology is one largely untapped application with potential to bolster clean energy production on the global scale. Wave energy converters (WEC) are one specific facet within this realm that could benefit from AM. As such, wire arc additive manufacturing (WAAM) has been identified as a practical method to produce larger scale marine energy components by leveraging cost-effective and readily available A36 steel feedstock material. The flexibility associated with WAAM can benefit production of WEC by producing more complex structural geometries that are challenging to produce traditionally. Additionally, for large components where fine details are less critical, the high deposition rate of WAAM in comparison to traditional wrought techniques could reduce build times by an order of magnitude. In this context of building and supporting WEC, which experience harsh marine environments, an understanding of performance under large loads and corrosive environments must be understood. Hence, WAAM and wrought A36 steel tensile samples were manufactured, and mechanical properties compared under both dry and corroded conditions. Here, the unique microstructure created via the WAAM process was found to directly correlate to the increased ultimate tensile and yield strength compared to the wrought condition. Static corrosion testing in a simulated saltwater environment in parallel with electrochemical testing highlighted an outperformance of corroded WAAM A36 steel than wrought, despite having a slighter higher corrosion rate. Ultimately, this study shows how marine energy systems may benefit from additive manufacturing components and provides a foundation for future applications of WAAM A36 steel.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A Reaction Between High Mn–High Al Steel and CaO-SiO{sub 2}-Type Molten Mold Flux: Reduction of Additive Oxide Components in Mold Flux by Al in Steel

The interfacial reaction between high-Mn–high-Al steel and CaO-SiO{sub 2}-type mold flux was investigated, with particular emphasis on the reduction of additive oxide components by Al. Typical additive oxide components (B{sub 2}O{sub 3}, Na{sub 2}O) could be reduced by Al, thereby losing their initial role in the flux. It is proposed to consider the chemical stability of the additive components in the flux in addition to the physico-chemical properties of the flux when developing the mold flux chemistry.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Catalytic Electrolyte Additive for High-Loading and Lean Electrolyte Li–S Batteries

The cycle life of high-energy Li–S cells is largely constrained by the quick electrolyte depletion. LiNO 3 has been a well-established additive known for protecting the Li metal anode and stabilizing the battery from polysulfide “shuttling”. However, it can be depleted prematurely and can pose safety risks when exposed to carbon, sulfur, or Li metal under harsh conditions. Here, in this study, LiPO 2 F 2 was explored as a safe and durable alternative additive in ether-based electrolytes. LiPO 2 F 2 demonstrates superior performance in Li/S batteries, especially under high sulfur loading (∼4 mg/cm 2 ) and lean electrolyte conditions (E/S = 4), achieving a long-term cycling stability of 40%, compared to 14.7% with LiNO 3 . This additive facilitates the disproportionation of polysulfides, reducing their dissolution and mitigating the shuttle effect. Additionally, LiPO 2 F 2 promotes the formation of a stable solid-electrolyte interphase (SEI) composed of inorganic anion-derived species, improving the battery’s overall stability and functionality. These findings blaze a trail in the design of safer and more durable electrolytes for Li–S batteries.

Li-S batteries↗
DOE OSTI2026

Integrative Additive Design for Robust SEI Formation in NMC811||Silicon Batteries

Silicon (Si) is considered a promising replacement for graphite anodes in lithium-ion batteries (LIBs) due to its high abundance and exceptional specific capacity, but its widespread commercialization has been hindered by poor electrochemical performance. Among various strategies, the use of functional additives has emerged as one of the most effective and cost-efficient methods to enhance the electrochemical properties of LIBs. In this study, several additives—vinylene carbonate (VC), vinyl ethylene carbonate (VEC), lithium difluorophosphate (LiDFP), lithium difluoro(oxalato)borate (LiDFOB), lithium tetrafluorooxalatophosphate (LiTFOP), and lithium difluorobis(oxalato)phosphate (LiDFBOP)—were systematically investigated in LiNi₀.₈Mn₀.₁Co₀.₁O₂ (NMC811)||Si full cells. Notably, LiDFBOP, a lithium salt containing two oxalate groups, outperformed all other additives, delivering the best capacity retention after 300 cycles. Comprehensive characterizations, including FTIR, SEM, and XPS, revealed that LiDFBOP's superior performance stems from its ability to form a more stable solid electrolyte interphase (SEI) on the Si anode, owing to its favorable molecular structure that integrates the beneficial features of the other additives.

25 ENERGY STORAGE↗
DOE OSTI2016

Effect of additional elements on compositional modulated atomic layered structure of hexagonal Co{sub 80}Pt{sub 20} alloy films with superlattice diffraction

The effect of additional element on compositionally modulated atomic layered structure of hexagonal Co{sub 80}Pt{sub 20} alloy films with superlattice diffraction was investigated. In this study it is found that the addition of Cr or W element to Co{sub 80}Pt{sub 20} alloy film shows less deterioration of hcp stacking structure and compositionally modulated atomic layer stacking structure as compared to Si or Zr or Ti with K{sub u} of around 1.4 or 1.0 × 10{sup 7} erg/cm{sup 3} at 5 at.% addition. Furthermore, for O{sub 2} addition of O{sub 2} ≥ 5.0 × 10{sup −3} Pa to CoPt alloy, compositionally modulated atomic layer stacking structure will be deteriorated with enhancement of formation of hcp stacking structure which leads higher K{sub u} of 1.0 × 10{sup 7} erg/cm{sup 3}.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Detection of Part Porosity in Additive Manufacturing Using Machining

Monitoring of part porosity in additive manufacturing is critical for part qualification and process parameter development. This article describes the monitoring of porosity in additive manufacturing using machining. Grade 91 steel samples with different levels of porosity were additively manufactured using a laser blown-powder process. The samples were machined, and the tool position and cutting power were monitored using the machine controller and an external power transducer, respectively. Results show that the power transducer is sensitive to machining porosities. A novel approach using the standard deviation of cutting power was developed to determine the location of porosities along the length of the machining pass. Test cuts were completed at different machining process parameters. Results showed that the probability of detection was one for pore volume greater than 0.3 mm 3 at different machining parameters. In conclusion, although the detection of porosity using machining is a destructive method for evaluation, it offers a low-cost and fast approach for monitoring porosity in additive manufacturing.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.

Additive Manufacturing↗
DOE OSTI2021

Manipulating the Crystallization Kinetics by Additive Engineering toward High-Efficient Photovoltaic Performance

Additive processing is proven to be an effective method to improve the efficiency and stability of perovskite solar cells; however, its intrinsic role in directing the crystallization pathway and thus morphology formation remains unknown. In situ grazing-incidence wide-angle x-ray scattering (GIWAXS) is applied to study the function of a 1,8-diiodooctane (DIO) additive in manipulating the crystallization behavior of perovskite thin films. It is seen that the DIO additive could induce multi-stage intermediate crystallization phases and increases the activation energy for nucleation and growth, which postpones the perovskite phase transformation time and broadens the transition zone. The elongated crystallization process affords improved perovskite thin film crystallinity and reduces defect density, which enables a longer carrier diffusion length. As a result, improved device efficiency, moisture, and thermal stability can be achieved. The following study provides a new prospective in understanding the additive function in perovskite thin film morphology control from fundamental parameters, indicating the importance of minor processing conditions in global property management toward high device performance.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Developing Efficient Benzene Additives for 19.43% Efficiency of Organic Solar Cells by Crossbreeding Effect of Fluorination and Bromination

Employing volatile solid additives have emerged as a promising method to optimize the morphology and improve the performance of organic solar cells (OSCs). However, principles governing the efficient design of solid additives remain elusive. In this work, the programmed fluorination and/or bromination on benzene core to develop efficient additives for OSCs is reported. The programmed fluorination and/or bromination endow the five halogen benzene derivatives, 1,3,5-trifluorobenzene, hexafluorobenzene, 1,3,5-tribromo-2,4,6-trifluorobenzene (TFTB), 1,3,5-tribromobenzene, and hexabromobenzene, with different melting and boiling points, volatility, as well as interactions with the host blend. Studies indicate that the additives with extremely high and low volatility are almost powerless and even detrimental to the morphology evolution. Among them, the combination of fluorine and bromine atoms on TFTB not only enables the more appropriate m.p./b.p. and volatility, but also exerts stronger molecular interactions with the host blend, giving rise to higher ordered molecular packing and more favorable morphology. Importantly, TFTB exhibits good universality to optimize the performances of OSCs with high power conversion efficiencies (PCEs; over 18%) in a group of binary blend systems, and an impressive PCE of 19.43% in the ternary PBTz-F:PM6:L8-BO system.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Boron‐polymer composites engineered for compression molding, foaming, and additive manufacturing

Abstract Boron (specifically 10 B) is the element of choice to shield thermal neutrons due to its large (n, α) cross‐section; however, very few polymer composites containing high boron concentrations are available. This study aimed to determine the maximum possible amount of boron that could be introduced into a polymer matrix. Diverse manufacturing techniques, ranging from additive manufacturing to compression molding, were employed to fabricate inks and filaments for 3D printing, foams, and flexible pads. Composites using siloxanes, poly(lactic acid), and acrylonitrile butadiene styrene containing up to 80 wt% boron were sucessufully fabricated. The addition of known plasticizers (polyethylene glycol) and reinforcing agents (carbon nanofibers and fumed silica) helped to overcome fabrication problems such as clogging of the printing nozzle or crumbling of compression molded parts. In addition, the thermal‐mechanical properties of these novel boron composites were determined and shown to vary according to boron concentration, presence of additives, and fabrication techniques utilized.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Improving Cooperative Interactions Between Halogenated Aromatic Additives and Aromatic Side Chain Acceptors for Realizing 19.22% Efficiency Polymer Solar Cells

Processing additive plays an important role in the standard operation procedures for fabricating top performing polymer solar cells (PSCs) through efficient interactions with key photovoltaic materials. However, improving interaction study of acceptor materials to high performance halogenated aromatic additives such as diiodobenzene (DIB) is a widely neglected route for molecular engineering toward more efficient device performances. Here, in this work, two novel Y-type acceptor molecules of BTP-TT and BTP-TTS with different aromatic side chains on the outer positions are designed and synthesized. The resulting aromatic side chains significantly enhanced the interactions between the acceptor molecules and DIB through an arene/halogenated arene interaction, which improved the crystallinity of the acceptor molecules and induced a polymorph with better photovoltaic performances. Thus, high power conversion efficiencies (PCEs) of 18.04% and 19.22% are achieved in binary and ternary blend devices using BTP-TTS as acceptor and DIB as additive. Aromatic side chain engineering for improving additive interactions is proved to be an effective strategy for achieving much higher performance photovoltaic materials and devices.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Experimental Validation of an Additively Manufactured Stiffness-Optimized Short-Fiber Reinforced Composite Clevis Joint

This effort describes experiments for the validation of the response of an additively manufactured stiffness-optimized short-fiber reinforced composite. A Direct Ink Write (DIW) method is used to additively manufacture a clevis joint plate which was designed such that its compliance would be minimized (i.e., stiffness maximized) for far-field axial loading. A unique aspect of the optimization scheme is that it accounts for manufacturing constraints, such as tool turn radius and tool path spacing. Along with the optimized clevis joint plate, additively manufactured 0°–90° and ± 45° composite plates of the same number of layers, as well as a control 0°–90° sample of resin only, were also studied. In addition to far-field load-displacement, near-field strain was monitored using digital image correlation (DIC). The results showed that the optimized plate did indeed exhibit the largest stiffness, based on far-field measurements. DIC-measured strains showed that locally the axial strain component, which is the largest, was also minimized for the optimized specimen, although the other strain components followed different trends. Furthermore, in the experiments it was seen that the optimized design exhibited a nonlinear/hysteretic behavior which is believed to be a consequence of its internal gap/cell structure. This internal structure, which results by optimized placement of material, although explicitly not accounted for in the optimization, may affect global response. Lastly, although not a part of the optimization study itself, the failure load for the optimized joint plate was also seen to be the largest of all the cases studied.

42 ENGINEERING↗
DOE OSTI2018

Ca Addition Effects on the Microstructure, Tensile and Corrosion Properties of Mg Matrix Alloy Containing 8 wt.% Mg{sub 2}Si

The microstructure, tensile properties and corrosion behavior of the Mg-8 wt.% Mg{sub 2}Si-x%Ca alloy have been studied by the use of optical microscopy, scanning electron microscopy equipped with energy-dispersive spectroscopy, x-ray diffraction, standard tensile testing, polarization test and electrochemical impedance spectroscopy (EIS) measurements. Microstructural studies indicated that Ca modifies both primary and eutectic Mg{sub 2}Si phase. It was found that the average size of primary Mg{sub 2}Si particles is about 60 μm, which is dropped by about 82% in the alloy containing 0.05 wt.% Ca. By the addition of different Ca contents, Ca-rich intermetallics (i.e., CaSi{sub 2} and CaMgSi) were formed. The modification mechanism of adding Ca during solidification was found to be due to the strong effect of CaMgSi phase as a heterogonous nucleation site, apart from CaSi{sub 2} which was reported before, for Mg{sub 2}Si intermetallics. Tensile testing results ascertained that Ca addition enhances both ultimate tensile strength (UTS) and elongation values. The optimum amount of Ca was found to be 0.1 wt.%, which improved UTS and elongation values from about 130 MPa and 2% to 165 MPa and 5.5%, whereas more Ca addition (i.e., 3 wt.%) reduced the tensile properties of the alloy to about 105 MPa and 1.8%, which can be due to the formation of CaMgSi intermetallics with deteriorating needle-like morphology. Polarization and EIS tests also showed that the Mg-3%Si-0.5%Ca alloy pronounces as the best anti-corrosion alloy. Nevertheless, further added Ca (up to 3 wt.%) deteriorated the corrosion resistance due to predominance of worse galvanic coupling effect stemmed from the presence of stronger CaMgSi cathode in comparison with Mg{sub 2}Si. With higher Ca additions, an adverse effect was seen on corrosion resistance of the Mg-3%Si alloy, as a result of forming a weak film on the alloy specimen surface.

36 MATERIALS SCIENCE↗