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DOE OSTI2025

Microstructurally Strained Pyrochlore–Perovskite Biphasic Electrocatalysts for the Oxygen Evolution Reaction

Efficiency of water splitting for hydrogen production is often limited by the sluggish kinetics of multiple electronic transfers required in the heterogeneous oxygen evolution reaction (OER). Catalyst design for reducing the high OER overpotential remains a major scientific challenge. Lattice-strain engineering, a method for tuning the electronic structure and surface geometric configuration of active sites, may greatly affect the interaction between adsorbates and catalytic surfaces for high activity and stability. Here, in this study, we present the synthesis of biphasic oxides of YPrSrRuMnO x , which consists of distinct phases of Y 2 Ru 2 O 7 pyrochlore and (Pr 0.7 Sr 0.3 )MnO 3 perovskite, and the development of a suitable analytical approach to study the strain–catalytic property relationship. Linear sweep voltammetry results reveal that the biphasic oxide exhibits approximately 3.1 times greater mass activity and 2.4 times larger turnover frequency (TOF) than single-phase Y 2 Ru 2 O 7 in the 0.1 M HClO 4 electrolyte. The biphasic catalyst is also about 3 times more stable than the single-phase oxide under acidic conditions. X-ray photoelectron spectroscopy, nitrogen isotherm, and electrochemical surface area analyses indicate that the oxidation state, specific surface area, and electrochemical surface area do not cause enough difference in the observed enhancement of OER performance. We examined the effects of microstrain on electrocatalysis, originating from lattice mismatch between different phases, using three different structural models. Specifically, we compared the Williamson–Hall method, standard stress–strain analysis, and Rietveld refinement in analyzing the structure–property relationship. Strain mapping using geometric phase analysis (GPA) further revealed significant microstrain and lattice dislocations localized near phase boundaries in the biphasic oxide, in contrast to the uniform strain in single-phase materials. The results reveal that the increased microstrain correlates well with the improved OER performance, as the biphasic oxide catalyst exhibits 2–3 times greater microstrain than Y 2 Ru 2 O 7 pyrochlore.

electrocatalysts↗

DOE OSTI2026

Harnessing Heterologous Bacterial Two-Component Systems as Biosensors to Address Challenges in Fermentation Scale-Up

Scaling up bacterial fermentation from bench to industrial scale often results in unpredictable performance losses, possibly in part due to changes in microenvironmental conditions such as pH. To investigate this, we developed a suite of pH-sensitive biosensors from bacterial two-component systems (TCSs) that provide a dynamic, fluorescent readout in response to extracellular pH changes. TCSs consist of a periplasmic sensor histidine kinase (HK) that, in response to an extracellular stimulus, autophosphorylates intracellularly and subsequently transfers the phosphate to a cognate response regulator (RR) that modulates transcription of target genes. We utilized three pH-responsive TCSs (referred to here as CVJ1, CVJ30, and CVJ79) and linked their output to GFP. This was achieved by placing the RR promoter upstream of GFP or by constructing a chimeric RR composed of the native receiver domain and the DNA-binding domain of another well-characterized RR with a defined promoter. All components - HK, RR (native or chimeric), and GFP under its corresponding promoter - were cloned into a broad-host-range plasmid. Sensors were validated in Escherichia coli and Pseudomonas putida, including the muconic acid-producing strain P. putida TL207. All three biosensors successfully reported pH, with fluorescence (normalized to optical density) correlating strongly with media pH. Among the native sensors, CVJ79 showed the most robust performance while CVJ1 also performed best in its native form; CVJ30 exhibited improved functionality as a chimera, suggesting that modular RR design can enhance compatibility in some heterologous hosts. Further, CVJ79 was activated by alkaline conditions, while CVJ30 responded to acidic environments. Notably, CVJ1 was induced by high pH in wild-type E. coli and P. putida, but low pH in TL207. The observed differences in sensor activation between strains - particularly the divergent response of CVJ1 - suggest that host-specific regulatory pathways may influence how cells perceive and adapt to pH stress. Moving forward, these biosensors can be used to guide the rational design of more robust strains, optimize process conditions in real time, and inform strategies to minimize physiological heterogeneity during scale-up. Integrating these tools into high-throughput screening and bioreactors will be a key step toward improving predictability and performance in industrial bioprocesses.

09 BIOMASS FUELS↗

DOE OSTI2021

High stability of flexible perovskite transparent conductive oxide film via van der Waals heteroepitaxy

Transparent conducting oxides (TCOs), such as indium-tin oxide (ITO) and indium gallium zinc oxide (IGZO), are essential components in the design of flexible optoelectronic devices. However, it is still a challenge to prepare low-cost flexible transparent conductive film for achieving the flexible functionality together with high optical transparency and electrical conductivity. Herein, fluorphlogopite (mica) is selected as the bendable and transparent substrate for the fabrication of low-cost perovskite CaVO 3 TCO epitaxial film. Benefitting from thin mica substrate with high Young’s modulus of 200 GPa, flexible CaVO 3 TCO epitaxial film exhibits high mechanical stability in terms of electrical conductivity and optical transparency after bending up to 10 5 cycles. The change of resistance can reflect the bending curvature and strain state. Finally, our results provide a new pathway to design superior mechanical flexibility and stability CaVO 3 TCO films for application in flexible, light-weight, and portable smart optoelectronic devices.

36 MATERIALS SCIENCE↗

NASA NTRS2003

Novel Engineering and Fabrication Techniques Tested in Low-Noise- Research Fan Blades

A major source of fan noise in commercial turbofan engines is the interaction of the wake from the fan blades with the stationary vanes (stators) directly behind them. The Trailing Edge Blowing (TEB) project team at the NASA Glenn Research Center designed and fabricated new fan blades to study the effects of fan trailing edge blowing as a potential noise-reduction concept. The intent is to fill the rotor wake by supplying air to the rotor blade trailing edge at the proper conditions to minimize the wake deficit, and thus generate less noise. The TEB hardware is designed for the Active Noise Control Fan (ANCF) test rig in Glenn's Aeroacoustic Propulsion Laboratory. For this test, the air is fed from an external supply through the shaft of the rig. It is distributed to the base of each blade through an impeller, where it is forced into a plenum at the core of each blade. In actual engine configuration, air would most likely be bled from the compressor, but only at times when noise is an issue, such as takeoffs and landings. Glenn researchers designed and manufactured the blades in-house, using new techniques and concepts. The skins, which were designed for maximum strength in the directions of highest stress, were molded from multiple layers of carbon fiber. Considerable use was made of rapid prototyping techniques, such as laser sintering. The core was sintered from a lightweight polymer, and the retainer was CNC-machined (computer numerical control machined) from aluminum. All the components were joined with a cold-cure aerospace adhesive. These techniques and processes reduced the overall cost and allowed the new concept to be studied much sooner than would be possible using traditional fabrication methods. Since this test rig did not support the use of blade-monitoring techniques such as strain gauges, extensive bench testing was required to qualify the design. The blades were examined using a variety of methods including holography, pull tests (cyclic and failure), shake tests, rap tests, and nondestructive inspection. Acoustic testing of the ANCF fan using TEB has been ongoing since January of 2001. The fan has completed about 100 hr of testing with no structural, vibrational, or fatigue problems. Far-field acoustic measurements, in-duct mode measurements, precise hot wire surveys, and detailed performance measurements are providing data for evaluating the concept. The far-field noise data show that tone noise was reduced significantly with the initial ANCF TEB fan design. In addition, a significant reduction in unsteady stator loading has been measured, indicating the potential for stator broadband noise reduction. The acoustic benefits will be assessed and important design parameters identified to improve the ability to fully exploit any benefit provided by this technique. On the basis of the success of trailing edge blowing, Glenn plans to continue this research with a higher speed, higher pressure ratio fan operating in an acoustic wind tunnel to simulate flight conditions.

Cunningham, Cameron C.↗

DOE OSTI2025

Coherent Strain-Inhibiting Phase Construction of Lithium-Rich Manganese-Based Oxide Toward High Mechanochemical Stability

A layered lithium-rich manganese-based oxide cathode, containing $R\overline{3}m$ (LiTMO 2 , TM = Mn, Ni, Co) and $C2/m$ (Li 2 MnO 3 ) nanodomains, utilizes both transition metals and oxygen redox to yield substantial energy density. However, the inherent heterogeneous nature and distinct nanodomain redox chemistries of layered lithium-rich oxides will inevitably cause pernicious lattice strain and structural displacement, which can hardly be eliminated by conventional doping or coating strategies and result in accelerated performance decay. Herein, we incorporate a strain-inhibiting perovskite phase coherently grown within the layered structure to effectively restrain the displacement and lattice strain during uneven Li-ion extraction. The enhanced mechanochemical stability of the designed cathode benefits the persistent structure and reversible oxygen redox, thereby achieving high initial Coulombic efficiency and stable cycling and voltage profiles. In conclusion, our approach of lattice engineering alleviates the strain and displacement caused by inhomogeneous reactivity between heterogeneous nanodomains and promotes the development of advanced cathode materials with long durability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Preliminary description of a new creep-fatigue design method that reduces over conservatism and simplifies the high temperature design process

The report provides the initial description of a new creep-fatigue design method for structural components in high temperature nuclear service. The new method is based on an integrated elastic-perfectly plastic (EPP) analysis and Simplified Model Test (SMT) approach that reduces over conservatism, improves the treatment of elastic follow up, and simplifies the design procedure, when compared with the current creep-fatigue design methods in ASME Boiler and Pressure Vessel Code. Developing the design charts for the EPP-SMT design method requires extrapolating SMT test data as a function of hold time and follow up factor. The report develops the preliminary design charts for Alloy 617 at temperatures between 800°C and 950°C by combining two extrapolation approaches developed in a previous work. The report also presents a comparative analysis between the EPP-SMT design method and the current ASME creep-fatigue design methods by evaluating design life of two sample geometries under different loading conditions. Results from the comparative analysis verify the EPP-SMT design charts but suggest the requirement of additional test data in the low strain range regime for improving the extrapolation procedure that will further reduce the over conservatism in the creep-fatigue damage evaluation. The report also concludes that the EPP-SMT design procedure can account for effect of primary load on creep-fatigue life by using a fixed, bounding value of follow up in constructing the design charts. The conclusions to this report describe the future work required to complete this new design method so it can be codified through a nuclear Code Case.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1991

Palladium-chromium static strain gage for high temperature propulsion systems

The present electrical strain gage for high temperature static strain measurements is in its fine-wire and thin-film forms designed to be temperature-compensated on any substrate material. The gage element is of Pd-Cr alloy, while the compensator is of Pt. Because the thermally-induced apparent strain of this compensated wire strain gage is sufficiently small, with good reproducibility between thermal cycles to 800 C, output figures can be corrected within a reasonable margin of error.

Lei, Jih-Fen↗

DOE OSTI2025

Empowering Lineworkers: The Case for Active Exoskeletons in Utility Work

Exoskeletons have evolved from early medical prototypes to advanced systems capable of addressing physical demands in various industries. This report explores the potential of active exoskeleton technology within the utility sector, focusing on its application for linemen who face significant risks of work-related musculoskeletal disorders (WMSDs). By analyzing existing literature on exoskeletons across industries such as construction, manufacturing, and military, the study identifies a gap in utility-specific applications. Task-specific design features like gravity compensation, limb support, and advanced safety measures, improve exoskeletons’ potential to alleviate physical strain, reduce workplace injuries, and enhance productivity. This review emphasizes the need for targeted research and development to optimize exoskeleton designs for the utility sector to provide benefits for workers, companies, and the broader community.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2024

Protocols and methodologies for acquiring and analyzing critical-current versus longitudinal-strain data in Bi 2 Sr 2 CaCu 2 O 8+x wires

Abstract In the literature on Bi 2 Sr 2 CaCu 2 O 8+ x (Bi-2212) superconducting wires, it is evident that measurement protocols for transport critical-current I c versus longitudinal strain ϵ and definitions of the so-called ‘strain limit’ are generally dissimilar. Yet, values obtained for the ‘strain limit’ are frequently assimilated to being those of the irreversible strain limit ϵ irr , regardless of the I c degradation-criterion used to define it. In effect, ϵ irr should correspond specifically to the I c ( ϵ ) irreversibility onset , where crack formation in Bi-2212 filaments presumably starts. Because I c ( ϵ ) degradation remains progressive over a fairly wide strain range beyond ϵ irr , the different I c degradation-criteria in use do not yield to the same result and, thus, are not equivalent from metrology perspective. Indeed, in studying densified samples of a modern Bi-2212 round wire, we found ϵ irr ≈ 0.4% and ϵ 5% ≈ 0.6% ( ϵ 5% being the strain where I c degrades by 5%). In this paper, we outline and suggest I c ( ϵ )-measurement protocols and data-analysis methodologies in the hope to converge the various approaches taken for studying Bi-2212 strain properties and, thus, remove related result discrepancies. A unified approach would enable more objective data comparisons among laboratories and among different Bi-2212 conductors. It would pave the way for more rigorous studies of effects potentially associated with wire design, powder, heat treatments, and other such parameters on the conductor’s strain properties.

protocols↗

NASA NTRSDate not supplied

Mass Mitigation in Structural Designs Via Dynamic Properties

The efforts reported here are focused on mitigating unnecessary mass in aerospace hardware. The approach to remove this undesired mass from the design is to leverage both the dynamic strength of materials and the frequency dependency of strain. Analytically predicted dynamic responses of structures are often applied as static loads in stress analyses that ultimately dictate the weight of a structural design. Assuming a dynamic response is a static load and then comparing resulting stress predictions to a static strength property is a long-standing engineering practice. Doing so is known to be, or is assumed to be, conservative. However, little indication of the order of magnitude of embedded conservatism has been identified. NASA/MSFC efforts in 2011, 2019, 2020, and now in 2021 have begun to qualitatively show the order of magnitude of that conservatism. A quick turnaround engineering method is pursued to leverage the subject facets of physics for the purpose of decreasing the weight of flight hardware. Tests performed using simple beams and significant observations are described.

conservative design loads↗

DOE OSTI2022

A System-Level Model for Estimating Residual Strain and Life of Nuclear Reactor Coolant System Components Under Connected-System-Thermal–Mechanical Boundary Conditions

Background: Environmental-assisted fatigue (EAF) is a major issue for the long-term survival of nuclear power plant fleets in the U.S. and worldwide. Multi-material welded regions (e.g., nozzles) and other high-stress regions of reactor coolant system (RCS) components are prone to EAF-related damage. Objective: The discussed work describes a system-level finite element (FE) model of RCS components of a pressurized water reactor (PWR). This is with the goal of predicting the stress hotspots, strain residuals, strain amplitudes and the resulting fatigue lives. Methods: Herein, the FE model was developed considering system-level loading conditions (under connected system thermal-mechanical boundary conditions). Thermal-mechanical stress analysis was performed considering thermal stratification and a design-basis reactor loading cycle. Based on the FE model results, the strain residuals, strain amplitudes and resulting fatigue lives of RCS components were predicted. Results: The results show that some of the RCS components can have significantly different strain amplitudes, residual strain, and fatigue lives, despite having similar geometry and material. Higher residual strain can lead to accelerated cyclic hardening of material and the associated effect of EAF. The simulated component-level strain profile (under realistic multi-axial-multi-physics loading cycle) can guide the selection of appropriate test inputs for conducting laboratory-scale EAF tests, which is a focus of future works. Conclusions: Despite similar geometry and material the RCS component can have significantly different strain profiles and resulting fatigue lives. The discussed approach can help to identify and prioritize the RCS components for conducting expensive nondestructive evaluation (NDE) inspections.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1997

Advances in Thin Film Sensor Technologies for Engine Applications

Advanced thin film sensor techniques that can provide accurate surface strain and temperature measurements are being developed at NASA Lewis Research Center. These sensors are needed to provide minimally intrusive characterization of advanced materials (such as ceramics and composites) and structures (such as components for Space Shuttle Main Engine, High Speed Civil Transport, Advanced Subsonic Transports and General Aviation Aircraft) in hostile, high-temperature environments and for validation of design codes. This paper presents two advanced thin film sensor technologies: strain gauges and thermocouples. These sensors are sputter deposited directly onto the test articles and are only a few micrometers thick; the surface of the test article is not structurally altered and there is minimal disturbance of the gas flow over the surface. The strain gauges are palladium-13% chromium based and the thermocouples are platinum-13% rhodium vs. platinum. The fabrication techniques of these thin film sensors in a class 1000 cleanroom at the NASA Lewis Research Center are described. Their demonstration on a variety of engine materials, including superalloys, ceramics and advanced ceramic matrix composites, in several hostile, high-temperature test environments are discussed.

Lei, Jih-Fen↗

NASA NTRS1985

An evaluation of foldable elastic tubes for application in space structures

An experimental investigation and design study has been performed on one type of foldable elastic tube in order to assess its suitability as a member of deployable space structures. It is demonstrated that one or more slots inserted longitudinally in the center of the tube to alleviate strain serves to prevent collapse of the tube. The nonlinear spring characteristics of the tube that are required for computer-based deployment dynamic analysis of space structures are determined, and it is shown that strain energy levels over a certain range are realizable for tubes representing space structure members in the 15-20 ft length range. Approximate strain energy/geometric parameter relationships are developed which may be useful for preliminary design or concept studies.

Jones, I. W.↗

DOE OSTI2024

Fatigue and Creep-Fatigue Evaluation of Alloy 709 at 760 and 816°C

A significant research and development effort is underway to support the qualification of Alloy 709 as a Class A construction material in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors. This initiative includes a comprehensive Alloy 709 code qualification plan aimed at generating extensive material testing data crucial for compiling the code case data package. The data package is essential in establishing material-specific design parameters for Alloy 709 to be used as Section III, Division 5 Class A construction material for fast reactors, molten salt reactors and gas-cooled reactors. An ASME Section III, Division 5 material code case requires the evaluation of mechanical properties from a minimum of three commercial heats, covering anticipated compositional ranges. A key part of the data package involves fatigue and creep-fatigue testing at elevated temperatures, needed for developing the fatigue design curves and the damage envelope of the creep-fatigue interaction diagram (D-diagram). This paper summarizes the strain-controlled fatigue testing on three commercial heats of Alloy 709 at 760 and 816°C with strain ranges between 0.25% and 3%. The fatigue failure data are used to generate a preliminary fatigue design curve. Additionally, the creep-fatigue testing results at 816°C with tensile hold times of 10, 30, and 60 minutes are presented in support of developing the D-diagram for Alloy 709.

Wang, Yanli↗

NASA NTRS1990

TRANSTRAIN: A program to compute strain transformations in composite materials

Over the years, the solid rocket motor community has made increasing use of composite materials for thermal and structural applications. This is particularly true of solid rocket nozzles, which have used carbon phenolic and, increasingly, carbon-carbon materials to provide structural integrity and thermal protection at the high temperatures encountered during motor burn. To evaluate the degree of structural performance of nozzles and their materials and to verify analysis models, many subscale and full-scale tests are run. These provide engineers with valuable data needed to optimize design and to analyze nozzle hardware. Included among these data are strains, pressures, thrust, temperatures, and displacements. Recent nozzle test hardware has made increasing use of strain gauges embedded in the carbon composite material to measure internal strains. In order to evaluate strength, these data must be transformed into strains along the fiber directions. The fiber-direction stresses can then be calculated. A computer program written to help engineers correctly manipulate the strain data into a form that can be used to evaluate structural integrity of the nozzle is examined.

Ahmed, Rafiq↗

NASA NTRS1993

Structural tailoring of aircraft engine blade subject to ice impact constraints

Results are presented for the minimum weight design of SR2 unswept blade made of (titanium/graphite-epoxy/titanium) sub s fiber composite. The blade which is rotating at high RPM is subject to ice impact. The root chord length, blade thicknesses at five stations, and graphite-epoxy ply orientation are chosen as design variables. Design constraints are placed on the behavior variables: local leading edge strain and root damage parameter (combined stress failure criteria) as a function due to ice impact, maximum spanwise centrifugal stress at the root of the deformed blade due to local damage, first three natural frequencies, and resonance margin after impact. The method of feasible directions is employed to solve the inequality constrained minimization problem. The effect of ice speed and the ice impact location on the final design are discussed.

Reddy, E. S.↗

DOE OSTI2020

Support of the Development of EPP Plus SMT Design Method (FY2020 Test Results)

Experiments in support of the development of the integrated Elastic–Perfectly Plastic (EPP) analysis and Simplified Model Test (SMT) design methodology continued in FY 2020. The previously developed single-bar SMT (SBSMT) technique was successfully extended to tubular shaped Alloy 617 specimens for evaluation of the effect of primary pressure load on SMT creep-fatigue (CF) properties at 950°C. A series of pressurized SMT tests were performed with various elastic follow-up factors and strain ranges. The results show that the primary pressure load reduces the SMT CF cycles. The reduction of SMT CF life due to primary load was found to be dependent on strain ranges, elastic follow up and test temperatures. These results are crucial for verification of the EPP strain range analysis in the EPP+SMT evaluation procedure. Additionally, hold time effect on the SMT CF life cycles is a determining factor for generating the EPP+SMT CF design curves. Lack of test data in the high cycle and low strain range region results in major uncertainty in developing the design curves. In FY2020, experiments were designed, and testing started on Alloy 617 at 950°C to fill the gap in experimental data. The on-going CF and additional SMT CF with elastic follow-up at low strain ranges will generate the information needed to verify the methods for extrapolation to long hold time and finalize the EPP+SMT design method.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Tuning Point Defects by Elastic Strain Modulates Nanoparticle Exsolution on Perovskite Oxides

Exsolution generates stable and catalytically active metal nanoparticles via phase precipitation out of a host oxide. An ability to control the size and dispersion of the exsolution particles is desirable for design of nanostructured (electro)catalysts. In this work, we demonstrate that tuning point defects by lattice strain affects both the thermodynamics and the kinetics of iron (Fe 0 ) exsolution on La 0.6 Sr 0.4 FeO 3 (LSF) thin film model. By combining in situ surface characterization and ab initio defect modeling, we show oxygen vacancy and Schottky defects to be the primary point defects formed upon Fe0 exsolution. Lattice strain tunes the formation energy, and thus the abundance of these defects, and alters the amount and size of the resulting exsolution particles. In addition, we find that the density of exsolved nanoparticles matches the concentration of oxygen vacancy pairs, thus pointing to the surface oxygen vacancy pairs as preferential nucleation sites for exsolution. The tensile-strained LSF with a facile formation of these critical point defects results in a higher Fe 0 metal concentration, a larger density of nanoparticles, and a reduced particle size at its surfaces. These results provide important mechanistic insights and highlight the role of point-defect engineering in designing nanostructured catalysts in energy and fuel conversion technologies.

36 MATERIALS SCIENCE↗