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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Mechanistic Insights Into Fatigue Life Enhancement of High‐Strength Steel via Ultrasonic Impact Treatment

In this work we explore the impact of Ultrasonic Impact Treatment (UIT) on the fatigue performance of high‐strength microalloyed steel commonly used in crankshaft applications. Building on prior observations of fatigue life improvement with UIT, this work focuses on unraveling the process–structure–performance relationships underpinning these enhancements. Microstructural analysis revealed significant grain refinement in the near‐surface layers, with deformation depth increasing at higher impact energies. This led to increased surface hardness and the development of deeper compressive residual stresses, particularly in samples treated with higher impact energy. Rotating bending fatigue testing showed a substantial improvement in fatigue life for UIT‐treated samples, with the endurance limit nearly doubling compared with untreated specimens. Fractographic analysis revealed a transition in crack initiation from surface defects in untreated samples to interior regions in UIT‐treated samples, characterized by the formation of noninclusion‐induced granular bright facets (GBFs). The observed fatigue enhancement is attributed to the synergistic effects of strain hardening and compressive residual stresses, which increase the surface crack threshold and promote interior crack initiation. This study provides new mechanistic insight into UIT‐induced fatigue resistance and interior failure behavior in high‐strength steels.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Data-Driven Tailoring Optimization of Thermoset Polymers Using Ultrasonics and Machine Learning

Thermoset polymers are highly demanded for their structural robustness, thermal stability, and chemical resistance. Tailoring the properties of these polymers for high-performance applications is often preferred to designing brand-new polymers. However, the traditional destructive techniques used to characterize their properties as a function of manufacturing parameters are expensive and time-consuming. A novel non-destructive, data-driven method leveraging ultrasonics and machine learning techniques to tailor the properties of thermosets as a function of the manufacturing parameters is demonstrated. Thermoset epoxy samples with varying curing temperatures (15–40 °C) and curing agent amounts (±40%) were manufactured and tested. Their curing kinetics were monitored by determining the sound speed in the material in real time, while the longitudinal modulus of the samples was determined post-cure. Machine learning models were developed using a k-nearest neighbors algorithm. These models were implemented to predict the curing and final elastic properties using the manufacturing parameters, i.e., stoichiometry and curing temperature, and vice versa. Understanding and modeling how these parameters affect the cure kinetics and final properties will allow for efficient and reliable optimization of thermoset tailoring and manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Ultrasonic Deterrents To Reduce Bat Mortality at Wind Turbines - Short Science Summary

In North America, several bat species commonly collide with operating turbines. Though the ultimate driver of collisions is unknown, studies suggest that bats may be attracted to turbines because they often approach and spend extended periods of time (seconds to minutes) interacting with turbine structures. To reduce bat mortality at wind farm operators, seek to reduce mortality rates by reducing the amount of time that bats interact with spinning turbine blades (or exposure). Current approaches to reduce exposure include curtailment, whereby turbine operators stop turbine rotors from spinning during periods when bats are expected to be at the highest risk of collision, and deterrent technologies that seek to discourage bats from entering/ limit the amount of time spent within the rotor swept area. We briefly describe the state of the science on ultrasonic deterrent technology, highlight potential drivers of variable efficacy for bat mortality reduction, and suggest next steps focus on identifying the driver(s) of such variability.

bats↗
DOE OSTI2024

High plasticity in refractory composite fabrication by ultrasonic additive manufacturing

Refractory metal composites are desirable for use in extreme environments that require materials with high specific strengths and resilience to external environments such as that found in nuclear and aerospace. However, due to the high melting temperature of refractories, liquid state joining processes such as welding remains difficult. Ultrasonic additive manufacturing (UAM) provides a potential route for processing refractory composites because it is a solid-state (i.e., no-melting) process and allows for intermittent machining operations to be performed between welds. Further, to demonstrate refractory composite fabrication, this study utilized UAM to machine a cavity to locate and sequester a Mo foil in a Zircaloy-4 (Zry-4) baseplate and additively build over the top with Zry-4 foils, thereby embedding the Mo in Zry-4 matrix. Significant deformation of the Zry-4 microstructure was observed: this deformation caused adiabatic heating and subsequent dynamic recrystallization through the transformation from α→β and then back to α as the material cooled. Flexural testing of the Zr–Mo composite revealed no delamination or failure, but the strength was not as expected, falling lower than a cold-worked Zry-4 sample. Finite element analysis supported that some bonding must have existed between the Zry-4 and Mo. There was indeed an interdiffusion zone at the Zry-4 foil–Mo foil interface, observing a metastable body-centered cubic β-Zr lathe. It was determined that sufficient strain energy was present to encourage the nucleation of the β-Zr grain along α-Zr grains. Future work is warranted to investigate UAM for refractory composite fabrication.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Development of a Flow-through Cell for Ultrasonic Extraction (UE)─Single Particle (SP)─ICP-MS─an Approach for Nano/Microparticle Elemental and Isotopic Analysis

Nanotechnology is a salient part of the scientific landscape, and analytical approaches are rapidly evolving to enable small-scale characterization of nano- and microparticle compositions and impurities. Here, a flow-through sonicating cell was developed for direct particle extraction from a silicon wafer and integrated with an inductively coupled plasma–mass spectrometer (ICP-MS) for subsequent elemental and isotopic characterization of the released particles. Ultrasonic extraction (UE)─single particle (SP)─ICP-MS offers controlled particle mobilization from solid substrates and allows for increased sample throughput by eliminating the need for pre-extraction of particles and decreasing sample preparation steps. Coupling this device to an ICP-MS with a time-of-flight (TOF) mass analyzer, it is possible to distinguish unique isotopic compositions of the particles. Both tungsten and nickel isotopically tagged particles, which were deposited on Si wafers, are presented here with analysis via UE─SP─ICP-MS. This approach could support efforts in the fields of particle synthesis, nuclear safeguards and forensics, environmental monitoring, and semiconductor industries in which the detection of particles from substrates and wafers is critical.

Paul, Molly [ORNL] (ORCID:0009000009672055)↗
DOE OSTI2024

Picosecond Ultrasonics in Magnetic Topological Insulator MnBi 2 Te 4

MnBi 2 Te 4 is a magnetic topological insulator with layered A-type antiferromagnetic order. It exhibits a rich layer- and magnetic-state dependent topological phase diagram; however, much about the coupling between spin, charge, and lattice remains to be explored. Here, in this work, we report that MnBi 2 Te 4 is an excellent acoustic phonon cavity by realizing phonon frequency combs using picosecond ultrasonics. With the generated acoustic phonon wavepackets, we demonstrate that the timing and phase of acoustic echoes can be used to detect the presence of stacking faults between van der Waals layers buried deep within the crystal. Furthermore, by implementing this nondestructive ultrafast optical measurement in conjunction with time-resolved magneto-optical Kerr effect experiments, we uncover that out-of-plane vibrations in MnBi 2 Te 4 do not couple to the magnetic order, i.e. there is no appreciable magnetostriction. Our work points out how a well-developed technique can probe the structural defects and phonon pulse engineering in layered topological insulators.

36 MATERIALS SCIENCE↗
DOE OSTI2025

ASSESSING THE EFFECTIVENESS OF ULTRASONIC IMPACT TREATMENT ON RESIDUAL STRESS PROFILES IN DISSIMILAR WELDED JOINTS

Residual stresses (RS) induced during welding processes are a critical concern in materials engineering, as they can significantly impair the mechanical performance of components by reducing fatigue strength and tensile load capacity. This challenge is especially pronounced in dissimilar metal welds (DMWs), where variations in thermal expansion properties between the joined alloys exacerbate the formation of tensile RS. Conventional post-weld heat treatments, though effective for homogeneous materials, often require substantial energy, specialized equipment, and extensive processing time, making them less practical for DMW applications. Thus, there is a clear need for innovative, energy-efficient techniques to mitigate these detrimental stresses. This study investigates ultrasonic impact treatment (UIT) as a possible alternative for mitigating tensile RS in both similar and dissimilar metal welds. To evaluate UIT’s effectiveness, neutron diffraction (ND) was employed as a nondestructive technique to quantify RS in three orthogonal directions—longitudinal, transverse, and normal. The results showed that UIT significantly reduced peak tensile RS, particularly in the longitudinal direction, by up to 180 MPa in similar welds and up to 150 MPa in dissimilar welds. Given the limited literature on UIT application in DMWs, this work contributes valuable data on stress redistribution mechanisms and highlights UIT’s potential as a practical stress-relief method. The findings lay the groundwork for further investigations aimed at optimizing process parameters and understanding long-term performance in welded joints.

EisaZadeh, Hamid [Western Carolina University, Cul↗
DOE OSTI2025

Sound Speeds of Solids from Ultrasonic Pulse Receiver Measurements

A common method of determining elastic material properties is utilizing an ultrasonic pulse receiver. This is a non-destructive test (NDT) causing no plastic deformation of the material. It requires a pulse generator, oscilloscope, and two transducers to measure the sound velocity of a material. Both longitudinal and shear sound velocities may be obtained by utilizing the appropriate transducer. Acoustic nondestructive testing methods are often used in manufacturing certification processes and for material defect detection in industry. These methods can also be utilized to directly measure the elastic moduli of a material without damaging the material. Overall, it is a low-cost experiment with minimal preparation, and is easy to use.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Enhancing physicochemical, bioactive, and nutritional properties of sweet potatoes: Ultrasonic contact drying with slot jet nozzles compared to hot-air drying and freeze drying

Sweet potatoes are a rich source of nutrients and bioactive compounds, but their quality can be impacted by the drying process. This study investigates the impact of slot jet reattachment (SJR) nozzle and ultrasound (US) combined drying (SJR + US) on sweet potato quality, compared to freeze-drying (FD), SJR drying, and hot air drying (HAD). SJR + US drying at 50 °C closely resembled FD in enhancing quality attributes and outperformed HAD and SJR in key areas such as rehydration, shrinkage ratios, and nutritional composition. Notably, SJR + US at 50 °C produced the highest total starch (36.84 g/100 g), total dietary fiber (8.48 g/100 g), total phenolic content (158.19 mg GAE/100 g), total flavonoid content (119.08 mg QE/g), DPPH antioxidant activity (6.44 μmol TE/g), β-carotene (31.98 mg/100 g), and vitamin C (5.27 mg/100 g). It also exhibited higher glass transition temperatures (Tg: 14.49 °C), indicating better stability at room temperature. The hardness values for SJR + US samples were similar to FD, while HAD samples had the highest hardness. SJR + US at 50 °C resulted in the lowest total color changes (ΔE), indicating minimal impact on appearance. Additionally, FTIR analysis revealed that peaks in specific spectral regions indicated superior preservation of bioactive compounds in SJR + US samples compared to other methods, which was also confirmed by principal component analysis (PCA) and heatmap visualization. Overall, these findings suggest that SJR + US is an effective alternative to conventional drying techniques, significantly improving the quality of dried sweet potatoes.

Color↗
DOE OSTI2025

Large‐Scale 2D Perovskite Nanocrystals Photodetector Array via Ultrasonic Spray Synthesis

Abstract 2D perovskite (PVSK) single crystals have received significant attention due to their unique optical and optoelectronic properties. However, current synthesis methods face limitations, particularly in large‐area fabrication, which remain critical barriers to practical applications. In this study, the synthesis of red/green/purple‐blue‐colored 2D PVSK nanocrystals over a large area (4‐inch wafer) and the fabrication of high‐performance photodetector arrays are presented via a facile yet efficient spray‐coating approach with a liquid‐bridge transport effect. The photodetector array achieves 100% working yield, high photo‐responsivity (1.5 × 10 6 A W −1 ) and specific‐detectivity (1.1 × 10 16 Jones) with competitive photomapping characteristics. An intelligent vision system for automatic shape recognition is further demonstrated with a recognition rate exceeding 90%. This study provides significant advances in the scalable synthesis of nanoscale 2D PVSK crystals, their integration into large‐area optoelectronic devices, and their potential use in artificial‐intelligence systems.

Lee, Yoon Ho [Davidson School of Chemical Engineer↗