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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 505 records · Page 28

Integrated Thermal Protection Systems and Heat Resistant Structures

In the early stages of NASA's Exploration Initiative, Snecma Propulsion Solide was funded under the Exploration Systems Research & Technology program to develop a CMC heatshield, a deployable decelerator, and an ablative heat shield for reentry vehicles. Due to changes within NASA's Exploration Initiative, this task was cancelled in early FY06. This paper will give an overview of the work that was accomplished prior to cancellation. The Snecma team consisted of MT Aerospace, Germany, and Materials Research & Design (MR&D), NASA Langley, NASA Dryden, and NASA Ames in the United States. An Apollo-type capsule was chosen as the reference vehicle for the work. NASA Langley generated the trajectory and aerothermal loads. Snecma and MT Aerospace began the design of a ceramic aft heatshield (CAS) utilizing C/SiC panels as the capsule heatshield. MR&D led the design of a C/SiC deployable decelerator, NASA Ames led the characterization of several ablators, NASA Dryden led the development of a heath management system and the high temperature structures testing, and NASA Langley led the insulation characterization. Though the task was pre-maturely cancelled, a significant quantity of work was accomplished.

Pichon, Thierry↗

Particulate Titanium Matrix Composites Tested-Show Promise for Space Propulsion Applications

New manufacturing technologies can now produce uniformly distributed particle strengthened titanium matrix composites (TMCs) at lower cost than many types of continuous-fiber composites. The innovative process results in near-final-shape components having a material stiffness up to 26-percent greater than that of components made with conventional titanium materials. This benefit is achieved with no significant increase in the weight of the component. The improved mechanical performance and low-cost manufacturing capability motivated a review of particulate-reinforced metal composite technology as a way to lower the cost and weight of space-access propulsion systems. Focusing on the elevated-temperature properties of titanium alloy Ti-6Al-4V as the matrix material, researchers at the NASA Glenn Research Center conducted experiments to verify the improved performance of the alloy containing 10 wt% of ceramic titanium carbide (TiC) particles. The appropriate blend of metal and ceramic powder underwent a series of cold and hot isostatic pressing procedures to yield bar stock. A set of round dogbone specimens was manufactured from a small sample of the bars. The TMC material proved to have good machinability at this particle concentration as there was no difficulty in producing high-quality specimens.

Thesken, John C.↗

Unconventional Pathways to Carbide Phase Synthesis via Thermal Decomposition of UI 4 (1,4-dioxane) 2

UI4(1,4-dioxane) 2 was subjected to laser-based heating-a method that enables localized, fast heating (T > 2000 °C) and rapid cooling under controlled conditions (scan rate, power, atmosphere, etc.)-to understand its thermal decomposition. A predictive computational thermodynamic technique estimated the decomposition temperature of UI 4 (1,4-dioxane) 2 to uranium (U) metal to be 2236 °C, a temperature achievable under laser irradiation. Dictated by the presence of reactive, gaseous byproducts, the thermal decomposition of UI 4 (1,4-dioxane) 2 under furnace conditions up to 600 °C revealed the formation of UO 2 , UI x , and U(C 1–x O x ) y , while under laser irradiation, UI 4 (1,4-dioxane) 2 decomposed to UO 2 , U(C 1–x O x ) y , UC 2–z O z , and UC. Despite the fast dynamics associated with laser irradiation, the central uranium atom reacted with the thermal decomposition products of the ligand (1,4-dioxane = C 4 H 8 O 2 ) instead of producing pure U metal. In conclusion, the results highlight the potential to co-develop uranium precursors with specific irradiation procedures to advance nuclear materials research by finding new pathways to produce uranium carbide.

36 MATERIALS SCIENCE↗

Magneto-transport evidence for strong topological insulator phase in ZrTe5

Abstract The identification of a non-trivial band topology usually relies on directly probing the protected surface/edge states. But, it is difficult to achieve electronically in narrow-gap topological materials due to the small (meV) energy scales. Here, we demonstrate that band inversion, a crucial ingredient of the non-trivial band topology, can serve as an alternative, experimentally accessible indicator. We show that an inverted band can lead to a four-fold splitting of the non-zero Landau levels, contrasting the two-fold splitting (spin splitting only) in the normal band. We confirm our predictions in magneto-transport experiments on a narrow-gap strong topological insulator, zirconium pentatelluride (ZrTe 5 ), with the observation of additional splittings in the quantum oscillations and also an anomalous peak in the extreme quantum limit. Our work establishes an effective strategy for identifying the band inversion as well as the associated topological phases for future topological materials research.

36 MATERIALS SCIENCE↗

Thermoelectrics: From longitudinal to transverse

Thermoelectric power generation is a promising technology to realize a sustainable society because it directly converts thermal energy into electricity in a solid. Conventional thermoelectric generation is driven by the Seebeck effect, discovered by T.J. Seebeck in 1821, in which a charge current J c is generated in the direction parallel to a temperature gradient ∇T, the longitudinal geometry. Here, the ratio between the generated longitudinal electromotive force and applied ∇T is defined as the Seebeck coefficient. As shown in Figure 1A, a thermoelectric module based on the Seebeck effect typically consists of many pairs (128 for a 12V unit) of p-type and n-type conductors alternately arranged and connected in series. Since the Seebeck coefficient of a p-type (n-type) conductor is positive (negative), the thermopower in each element adds to the total output in the Seebeck module. This configuration is needed to achieve a practical voltage because each element only supplies millivolts but limits the use of thermoelectric generators. The efficiency of thermoelectric generators is characterized by the thermoelectric figure of merit, zT. Despite a 3-fold improvement in zT resulting from materials research over the last two decades, little progress has been made in their practical use; this is ascribed to the technological challenges in contact technology. The contacts on the hot side are subject to thermal degradation. All contacts (512 for a 12V unit) add electrical and thermal contact resistances that reduce the device efficiency to a fraction of that promised by the materials.

30 DIRECT ENERGY CONVERSION↗

Development and Qualification of Advanced Alloys Used in High Helium and Displacement Damage Service for Fusion Energy Applications

This document represents a final report on the Department of Energy (DOE) Office of Science, Office of Fusion Energy Science (OFES) Grant Entitled “Development and Qualification of Advanced Alloys Used in High Helium and Displacement Damage Service for Fusion Energy Applications” (DE-FG02-94ER54275). This grant has been funded since 1994, by a series of five and three-year renewals. We express our deep appreciation for the long-standing support by OFES for our fusion materials research. The latest three-year renewal was awarded in 2019. This renewal subsequently received a 1- year no-cost extension, followed by another funded 1-year phaseout period. Here, we focus on this five-year effort. The final report is composed of 35 Fusion Semiannual Reports covering the period from 2019 to 2024. In addition, Appendix A lists 158 fusion materials papers published since 1994, with the partial, or full, support of the OFES program. We note that, as metrics of their high impact, these papers have received a total of 8582 citations, with an average of 54 per paper.

36 MATERIALS SCIENCE↗

Resilient GaN-based Power Module with Improved Diagnostic for Future Accelerator

Los Alamos Neutron Science Center (LANSCE) and Dual-Axis Radiographic Hydrodynamic Test facility (DARHT) play a pivotal role in advancing scientific research and national security initiatives. As a premier facility for neutron science, LANSCE and DARHT provide invaluable insights into fundamental research, materials science, nuclear physics, high-energy physics, material science, and medical imaging. Existing (DC) power supply and pulse modulation technologies used in LANSCE and DARHT face limitations in terms of reliability, maintainability, and diagnostics which hinder the progress of these cutting-edge facilities. By proposing improvements to LANL accelerator facilities’ performance and addressing component failure, we aim to enhance scientific outcomes and minimize disruptions, allowing for more efficient and productive research activities while ensuring the continuity of valuable contributions to the user community. This proposal aims to revolutionize (DC) power supply and pulse power systems for future particle accelerators via the development of a resilient GaN-based power module with improved diagnostic and redundant submodules.

43 PARTICLE ACCELERATORS↗

The NASA MSFC Electrostatic Levitation (ESL) Laboratory: Summary of Capabilities, Recent Upgrades, and Future Work

The NASA Marshall Space Flight Center (MSFC) electrostatic levitation (ESL) laboratory has a long history of providing materials research and thermophysical property data. A summary of the labs capabilities, recent upgrades, and ongoing and future work will be provided. The laboratory has recently added two new capabilities to its main levitation chamber: a rapid quench system and an oxygen control system. The rapid quench system allows samples to be dropped into a quench vessel that can be filled with a low melting point material, such as a gallium or indium alloy. Thereby allowing rapid quenching of undercooled liquid metals. The oxygen control system consists of an oxygen sensor, oxygen pump, and a control unit. The sensor is a potentiometric device that determines the difference in oxygen activity between two gas compartments separated by an electrolyte, which is yttria-stabilized zirconia. The pump utilizes coulometric titration to either add or remove oxygen. The system is controlled by a desktop control unit, which can also be accessed via a computer. This system allows the oxygen partial pressure within the vacuum chamber to be measured and controlled, theoretically in the range from 10-36 to 100 bar. The ESL laboratory also has an emissometer, called the High-Temperature Emissivity Measurement System (HiTEMS). This system measures the spectral emissivity of materials from 600degC to 3,000degC. The system consists of a vacuum chamber, a black body source, and a Fourier Transform Infrared Spectrometer (FTIR). The system utilizes optics to swap the signal between the sample and the black body. The system was originally designed to measure the hemispherical spectral emissivity of levitated samples, which are typically 2.5mm spheres. Levitation allows emissivity measurements of molten samples, but more work is required to develop this capability. The system is currently setup measure the near-normal spectral emissivity of stationary samples, which has been used to take measurements of ablative materials, rocket nozzle coating materials, and materials for spacecraft instruments.

SanSoucie, Michael P.↗

Mechanical properties, strain hardening, and fracture behavior of ultrasonic additively manufactured Zircaloy-4 after low-temperature neutron irradiation

Ultrasonic additive manufacturing (UAM) is a solid-state, layer-by-layer advanced manufacturing process that has the potential to create custom spatially controlled composites with embedded wires and sensors for nuclear component manufacture. For this work, to assess the feasibility of using UAM for nuclear-relevant materials research, the technique was used to produce a 3.5-mm-thick Zircaloy-4 plate for irradiation testing. The UAM Zircaloy-4 specimens were irradiated in the High Flux Isotope Reactor at a target irradiation temperature of 117 °C to 2.9 displacements per atom (dpa) to assess differences in irradiation-hardening behavior as a function of alloy processing path. The UAM and reference baseplate (BP) materials increased in yield strength by 372±27 MPa and 346±21 MPa, respectively, and both suffered significant reductions in uniform and total elongation attributed to irradiation hardening at low-temperature. Although the materials had similar nanoscale defect structures, including nanoscale black dot/loop features and strain-induced dislocation channels, the UAM material’s processing-related defects resulted in accelerated strain localization and failure as demonstrated by lower post-irradiation uniform elongation of UAM specimens (0.5 %) compared to BP (1.5 %) material. The UAM material also showed considerable anisotropy in mechanical response due to crack propagation along weld boundaries, resulting in differences in strength & ductility when tested parallel and perpendicular to the prior UAM build orientation. Therefore, although the fundamental irradiation response of UAM-processed Zircaloy-4 was phenomenologically comparable to that of BP reference material, additional optimization of the UAM processing is needed to produce irradiation-resistant and nuclear-relevant materials.

Digital image correlation↗

Characterization of Long-Term Service Coal Combustion Power Plant Extreme Environment Materials

The objective of this DOE-sponsored project was to develop a comprehensive database of mechanical properties, alloy microstructures, and to a lesser extent, the oxidation/corrosion behaviors of coal-fired power plant components, such as boiler tubing, steam headers, and steam piping, which had been in service for at least 100,000 operating hours (preferably more than 200,000 operating hours) under the operating conditions of high temperatures and high mechanical stresses where creep, fatigue, steam-side oxidation, and fireside corrosion were life-limiting factors. The components included in this database consisted of ferritic steels, creep strength enhanced ferritic (CSEF) steels, and 300-series H-grade stainless steels, as well as dissimilar metal welds (DMWs) among these types of materials. As a result of extensive metallurgical characterization and mechanical testing performed in this project, a comprehensive database on mechanical properties and detailed quantitative microstructural information was successfully developed for several long-term serviced EEM components. Such a database can be used by material research communities to develop, calibrate, refine, and validate mechanical behaviors, models, and other assessment tools for accurate prediction of remaining life of major components under similar EEM operating conditions.

20 FOSSIL-FUELED POWER PLANTS↗

Mechanical Impact Testing: A Statistical Measurement

In the decades since the 1950s, when NASA first developed mechanical impact testing of materials, researchers have continued efforts to gain a better understanding of the chemical, mechanical, and thermodynamic nature of the phenomenon. The impact mechanism is a real combustion ignition mechanism that needs understanding in the design of an oxygen system. The use of test data from this test method has been questioned due to lack of a clear method of application of the data and variability found between tests, material batches, and facilities. This effort explores a large database that has accumulated over a number of years and explores its overall nature. Moreover, testing was performed to determine the statistical nature of the test procedure to help establish sample size guidelines for material characterization. The current method of determining a pass/fail criterion based on either light emission or sound report or material charring is questioned.

Engel, Carl D.↗

Shielded and Low-Damping SPM Probes For Quantitative Electrical and Electrochemical Characterization (Phase IIB)

The purpose of this DOE SBIR award was to develop new scanning probe microscopy tools for the elucidation of electrical and electrochemical properties at the nanoscale. High performance probes are important for energy materials research. In both solar cells and batteries, the essential physics and chemistry occur at the nanoscale and nanoscale characterization tools are required for their elucidation. The introduced new models are a shielded probe and an electrically insulated probe where only less than one micron of a conductive tip is exposed. In Phases I and IIa, we explored the development of cost-effective methods to insulate cantilevers from aqueous solutions and patented a technology that provides an insulated electrical contact to the tip. Also, our technology was adapted to be compatible with all popular commercial AFM systems. In Phase IIb, we improved reproducibility and batch size to drive down costs while maintaining quality control with testing. We transformed our product into a convenient turnkey solution to make electrochemical characterization approachable to a wide range of researchers. In January 2021, the technology was well received by the AFM community and Nanosurf Inc. (Woburn, MA) acquired Scuba Probe Technologies. The technology and expertise of Scuba Probe Technologies complements Nanosurf’s development of the full range of nano-electrical characterization tools.

36 MATERIALS SCIENCE↗

Design tool for estimating metal hydride storage system characteristics for light-duty hydrogen fuel cell vehicles

The U.S. Department of Energy (DOE) has developed the Framework model to simulate fuel cell-based light-duty vehicle operation for various hydrogen storage systems. This transient model simulates the performance of the storage system, fuel cell, and vehicle for comparison to DOE's Technical Targets using four drive cycles. Metal hydride hydrogen storage models have been developed for the Framework model. Despite the utility of this model, it requires that material researchers input system design specifications that cannot be easily estimated. To confront this challenge, a design tool has been developed that allows researchers to directly enter physical and thermodynamic metal hydride properties into a simple sizing module that then estimates the systems parameters required to run the storage system model. This design tool can also be used as a standalone MS Excel model to estimate the storage system mass and volume outside of Framework and compare it to the DOE Technical Targets. This model will be explained and exercised with existing hydrogen storage materials.

33 ADVANCED PROPULSION SYSTEMS↗

Automation of Laser Plasma Focused Ion Beam Microscopy for Next-Gen Energy Materials

Automation can revolutionize the use of ultrafast laser ablation and plasma-focused ion beam (PFIB) techniques for high-throughput, reproducible cross-sectioning and various sample preparation in materials characterization. As these methods become essential for analyzing complex energy materials and next-generation devices, efficient, standardized workflows are needed to minimize variability and enhance precision. This work highlights our advancements in developing automated processes for sample preparation that integrates machine learning, workflow optimization, and large-scale data acquisition to improve efficiency and scalability in applications such as electrolyzers, photovoltaic cells, and microelectronics. To streamline cross-sectioning and lamella fabrication, we have implemented fully automated workflows that standardize laser ablation and PFIB milling sequences. These workflows incorporate pre-programmed protocols for material removal, alignment, and thinning, reducing user intervention and ensuring consistency across different sample types. Machine learning algorithms further enhance automation by predicting optimal milling strategies and adapting parameters based on material properties and sectioning requirements. This approach significantly improves throughput while maintaining the structural integrity of prepared samples for high-resolution imaging and analysis, including transmission electron microscopy. Beyond sample preparation, our automation platform enables the acquisition of large, high-resolution datasets through serial sectioning, image alignment, and 3D reconstruction. These automated routines facilitate multi-scale characterization, capturing structural and compositional details from the nanoscale to the device level. By reducing variability and increasing efficiency, our automated approach enhances defect analysis, failure diagnostics, and process optimization, accelerating advancements in materials research and device engineering.

36 MATERIALS SCIENCE↗

Lunar and Planetary Science XXXV: Interplanetary Dust and Aerogel

Contents include the following: Isotopically Primitive Interplanetary Dust Particles of Cometary Origin: Evidence from Nitrogen Isotopic Compositions. The Solar Nebula s First Accretionary Particles (FAPs) Are They Preserved in Collected Interplanetary Dust Samples? On the Origin of GEMS. An Analytical SuperSTEM for Extraterrestrial Materials Research. Sub-Micrometer Scale Minor Element Mapping in Interplanetary Dust Particles: A Test for Stratospheric Contamination. First Report of Taenite in an Asteroidal Interplanetary Dust Particle: Flash-heating Simulates Nebular Dust Evolution. FTIR Analyses of IDPs: Comparison with the InfraRed Spectra of the Interstellar Medium. Mineralogical Study of Hydrated IDPs: X-Ray Diffraction and Transmission Electron Microscopy. Focused Ion Beam Recovery and Analysis of Interplanetary Dust Particles (IDPs) and Stardust Analogues. Technique for Concentration of Carbonaceous Material from Aerogel Collectors Using HF-Vapor Etching. Synchrotron X-Ray Analysis of Captured Particle Residue in Aerogel. In-Situ Analyses of Earth Orbital Grains Trapped in Aerogel, Using Synchrotron X-Ray Microfluorescence Techniques. Igneous Rims on Micrometeorites and the Sizes of Chondrules in Main Belt Asteroids.

Source record↗

Advanced Turbine Technology Applications Project (ATTAP)

ATTAP activities during the past year were highlighted by an extensive materials assessment, execution of a reference powertrain design, test-bed engine design and development, ceramic component design, materials and component characterization, ceramic component process development and fabrication, component rig design and fabrication, test-bed engine fabrication, and hot gasifier rig and engine testing. Materials assessment activities entailed engine environment evaluation of domestically supplied radial gasifier turbine rotors that were available at the conclusion of the Advanced Gas Turbine (AGT) Technology Development Project as well as an extensive survey of both domestic and foreign ceramic suppliers and Government laboratories performing ceramic materials research applicable to advanced heat engines. A reference powertrain design was executed to reflect the selection of the AGT-5 as the ceramic component test-bed engine for the ATTAP. Test-bed engine development activity focused on upgrading the AGT-5 from a 1038 C (1900 F) metal engine to a durable 1371 C (2500 F) structural ceramic component test-bed engine. Ceramic component design activities included the combustor, gasifier turbine static structure, and gasifier turbine rotor. The materials and component characterization efforts have included the testing and evaluation of several candidate ceramic materials and components being developed for use in the ATTAP. Ceramic component process development and fabrication activities were initiated for the gasifier turbine rotor, gasifier turbine vanes, gasifier turbine scroll, extruded regenerator disks, and thermal insulation. Component rig development activities included combustor, hot gasifier, and regenerator rigs. Test-bed engine fabrication activities consisted of the fabrication of an all-new AGT-5 durability test-bed engine and support of all engine test activities through instrumentation/build/repair. Hot gasifier rig and test-bed engine testing activities were performed.

Source record↗

Lewis' enhanced laboratory for research into the fatigue and constitutive behavior of high temperature materials

Lewis Research Center's high temperature fatigue laboratory has undergone significant changes resulting in the addition of several new experimental capabilities. New materials testing systems have been installed enabling research to be conducted in multiaxial fatigue and deformation at high temperature, as well as cumulative creep-fatigue damage wherein the relative failure-life levels are widely separated. A key component of the new high-temperature fatigue and structures laboratory is a local, distributed computer system whose hardware and software architecture emphasizes a high degree of configurability, which in turn, enables the researcher to tailor a solution to the problem at hand.

Mcgaw, Michael A.↗