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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 OSTI2021

Corrosion Research Survey: Corrosion-Surface Roughness Correlation on Carbon and Stainless Steels

Concerning the SAVY 4000 container LANL inspection acceptance of Ra (surface roughness) and its correlation to subsequent surface corrosion, a problem statement has been identified. The problem statement is as follows: When the 316L container has been subjected to accommodating materials producing high wattage, along with materials that eventually produce HCL (hydrochloric acid) will a higher or lower Ra on the inner surface of the SAVY 4000 container influence the rate or the amount of corrosion? In an effort to address this concern, a literature review covering more fundamental studies that examine the influence of roughness on corrosion in metals are surveyed. The scope is kept relevant to the less dynamic storage conditions that a SAVY container may be exposed to.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Surface Roughness Calculations of Additively Manufactured Cylinders via X-Ray Computed Tomography

X-ray Computed Tomography (X-ray CT) is an analytical technique used in materials science to non–destructively characterize features in variety of materials like polymers, metals, composites, and explosives. It also has the capability of imaging additively manufactured, machined and assembled parts and processes. The non-destructive imaging allows for the analysis of features (voids and cracks), which give a fundamental understanding of material characteristics. Additionally, X-ray CT can obtain accurate measurements of dimensional and topographic variations as a result of different stimuli, and assess accuracy of material production. This study will focus on parts manufactured via metal additive manufacturing (AM). Although, AM produces parts faster and easier, the printing process can produce defects (pores and surface roughness) that undermine the part’s mechanical properties. The analysis of 3D printed objects has a strength in analysis in that the material has an STL file from which the item was printed, which is not available in many manufactured materials (i.e. foams) due to stochastic structures. For this study, the print accuracy of several 3D printed cylinders will be assessed via X-ray CT to determine optimal printing parameters for parts with less defects and stronger mechanical properties. This will be accomplished by having the original STL file serve as the baseline surface to compute difference in the CT rendering to calculate surface roughness for each cylinders.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Predictive numerical modeling of plasma-induced surface roughness and wettability evolution in LM-PAEK/CF tape

Plasma surface modification effectively enhances adhesion in thermoplastic composites, yet its impacts on high-performance polymers like low-melting polyaryletherketone (LM-PAEK) remain inadequately quantified. Here, this study integrates experimental analysis and numerical modeling to characterize surface roughness and wettability changes in LM-PAEK/carbon fiber composites treated with atmospheric plasma. Atomic Force Microscopy quantified surface topography (n = 10 per condition for contact angles), while static contact-angle assessments measured wettability. Roughness rapidly increased from ∼0.2 nm to 1.6 nm, and contact angle reduced from ∼90° to 24°, both stabilizing after 25–30 s of exposure. A semi-empirical, physics-informed framework was calibrated to these data, coupling surface chemistry via the Owens–Wendt decomposition with topography via the Wenzel roughness factor, and evaluated using out-of-sample (cross-validated) tests, while static contact angle assessments measured wettability. Numerical predictions matched experimental results closely (RMSE <5%, R 2 > 0.95). Incorporating material-specific parameters, the calibrated model supports plasma-treatment optimization and provides quantitative guidance for improving interfacial adhesion in thermoplastic composite manufacturing.

Atomic Force Microscopy↗
DOE OSTI2020

Effects of Surface Roughness on the Electrochemical Reduction of CO 2 over Cu

We have investigated the role of surface roughening on the CO 2 reduction reaction (CO 2 RR) over Cu. The activity and product selectivity of Cu surfaces roughened by plasma pretreatment in Ar, O 2 , or N 2 were compared with that of electrochemically polished Cu samples. Differences in total and product current densities, the ratio of current densities for HER (the hydrogen evolution reaction) to CO 2 RR, and the ratio of current densities for C 2+ to C 1 products depend on the electrochemically active surface and are nearly independent of plasma composition. Theoretical analysis of an electropolished and roughened Cu surface reveals a higher fraction of undercoordinated Cu sites on the roughened surface, sites that bind CO preferentially. Roughened surfaces also contain square sites similar to those on a Cu(100) surface but with neighboring step sites, which adsorb OC-COH, a precursor to C 2+ products. Here, these findings explain the increases in the formation of oxygenates and hydrocarbons relative to CO and the ratio of oxygenates to hydrocarbons observed with increasing surface roughness.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

In-situ quantification of the surface roughness for facile fabrications of atomically smooth thin films

Here in this work we present an in-situ technique to quantify the layer-by-layer roughness of thin films and heterostructures by measuring the spectral profile of the reflection high-energy electron diffraction (RHEED). The characteristic features of the diffraction spot, including the vertical to lateral size ratio c/b and the asymmetrical ratio c 1 /c 2 along the vertical direction, are found to be quantitatively dependent on the surface roughness. The quantitative relationships between them are established and discussed for different incident angles of high-energy electrons. As an example, the surface roughnesses of LaCoO 3 films grown at different temperatures are obtained using such an in-situ technique, which are confirmed by the ex-situ atomic force microscopy. Moreover, the in-situ measured layer-by-layer roughness oscillations of two LaCoO 3 films are demonstrated, revealing drastically different information from the intensity oscillations. The experiments assisted with the in-situ technique demonstrate an outstanding high resolution down to similar to ~0.1 Å. Therefore, the new quantitative RHEED technique with real-time feedbacks significantly escalates the thin film synthesis efficiency, especially for achieving atomically smooth surfaces and interfaces. It opens up new prospects for future generations of thin film growth, such as the artificial intelligence-assisted thin film growth.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2020

Build orientation, surface roughness, and scan path influence on the microstructure, mechanical properties, and flexural fatigue behavior of Ti–6Al–4V fabricated by electron beam melting

In the present work, microstructure and fatigue behavior of Electron Beam Melted (EBM) Ti–6Al–4V have been systematically studied. Fatigue behavior was investigated using four-point bend tests of rectangular bars with internal features fabricated with different build orientations, scan paths, and surface conditions. Microstructural variations were evaluated by optical microscopy and Vickers micro-hardness indentations, both of which were found to be consistent throughout the build and within ranges reported in the literature. The fatigue performance of the EBM material was comparable to wrought Ti–6Al–4V when the loading direction was parallel to the build direction, but severely limited when loaded perpendicular to the build direction or if surface roughness defects were present. Scanning electron microscopy and interrupted fatigue tests were utilized to characterize fracture surfaces, failure mechanisms, crack initiation, and propagation behavior. Crack initiation sites in the vertically-oriented specimens were identified to be melt-related defects formed by insufficient melting.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Role of humidity and surface roughness on direct wafer bonding

Bodies made from elastically stiff material usually bind very weakly unless the surfaces are flat and extremely smooth. In direct wafer bonding flat surfaces bind by capillary bridges and by the van der Waals interaction, which act between all solid objects. Here we study the dependency of the work of adhesion on the humidity and surface roughness in hydrophilic direct wafer bonding. We show that the long-wavelength roughness (usually denoted waviness) has a negligible influence on the strength of wafer bonding (the work of adhesion) from the menisci that form from capillary condensation of water vapor.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

The effect of stretching on polyamide – 6: assessment of crystallinity, mechanical properties, and surface roughness

Polyamide-6 (PA6), or nylon-6, is a widely used low-cost polymer material for various applications. Manufacturing PA6 into fibers involves a spinning process such as melt extrusion, which orients the polymer chains into a semicrystalline structure. When stretching the produced fibers to high strains, the PA6 fibers transition the metastable gamma phase back into the stable gamma phase. The effects of these large stretches on mechanical properties have not been explored after the stretch has been released. In this study, the effects on mechanical properties were studied by stretching the PA6 fibers from 10% to 50% tensile strain and subsequently releasing the fibers. The stretched fibers were characterized by X-ray diffraction and atomic force microscopy to determine the changes to the crystal structure and surface roughness. The stretched fibers were then tensile tested to failure and the tensile properties were examined. The stress-strain curves on the post-stretched PA6 fibers showed clear softening in the fibers with lower initial moduli after 30% stretching. Furthermore, these results may hold a clue to softening of fibers in applications with repeated loading and have implications for mechanical stability and fatigue of this polymeric material.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Surface Roughness Effects on Heat Transfer in Additively Manufactured sCO 2 Cycle Heat Exchangers

An experimental study was performed to consider the impact of surface roughness on heat transfer and pressure drop to supercritical carbon dioxide (sCO 2 ) in additively manufactured channels. All tests were performed in the Heat Exchange and Experimental Testing (HEET) rig at the U.S. Department of Energy’s (DOE) National Energy Technology Laboratory (NETL) in Morgantown, West Virginia. Four test articles were considered. The first was a hydrodynamically smooth, drawn tube. The other three were additively manufactured channels with square and rectangular cross sections, which were characterized by sand-grain roughness to hydraulic diameter ratios spanning 0.0029 to 0.0073. Friction factors were determined by measuring the tube mass flow rate and pressure drop. The tube side heat transfer coefficient was measured using the Wilson plot technique. It was found that the friction factor results were 8% greater than the Colebrook correlation. Greater deviation was observed between the heat transfer results and the correlations. The Gnielinski correlation overpredicted the experimental points by nominally 30% and the Norris correlation overpredicting the experimental points by nominally 25%. A thermal performance factor was formed from the friction factor augmentation and Nusselt number augmentation results. These results indicated a 10% improvement in heat duty for a heat exchanger constructed utilizing a tube with ϵ/D_h =0.0073 relative to a heat exchanger utilizing a smooth, conventional tube.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Upstream surface roughness and terrain are strong drivers of contrast in tornado potential between North and South America

Central North America is the global hotspot for tornadoes, fueled by elevated terrain of the Rockies to the west and a source of warm, moist air from equatorward oceans. This conventional wisdom argues that central South America, with the Andes to the west and Amazon basin to the north, should have a “tornado alley” at least as active as central North America. Central South America has frequent severe thunderstorms yet relatively few tornadoes. Here, we show that conventional wisdom is missing an important ingredient specific to tornadoes: a smooth, flat ocean-like upstream surface. Using global climate model experiments, we show that central South American tornado potential substantially increases if its equatorward land surface is smoothed and flattened to be ocean-like. Similarly, we show that central North American tornado potential substantially decreases if its equatorward ocean surface is roughened to values comparable to forested land. A rough upstream surface suppresses the formation of tornadic environments principally by weakening the poleward low-level winds, characterized by a weakened low-level jet east of the mountain range. Results are shown to be robust for any midlatitude landmass using idealized experiments with a simplified continent and mountain range. Our findings indicate that large-scale upstream surface roughness is likely a first-order driver of the strong contrast in tornado potential between North and South America.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

The emergence of small-scale self-affine surface roughness from deformation

Most natural and man-made surfaces appear to be rough on many length scales. There is presently no unifying theory of the origin of roughness or the self-affine nature of surface topography. One likely contributor to the formation of roughness is deformation, which underlies many processes that shape surfaces such as machining, fracture, and wear. Using molecular dynamics, we simulate the biaxial compression of single-crystal Au, the high-entropy alloy Ni 36.67 Co 30 Fe 16.67 Ti 16.67 , and amorphous Cu 50 Zr 50 and show that even surfaces of homogeneous materials develop a self-affine structure. By characterizing subsurface deformation, we connect the self-affinity of the surface to the spatial correlation of deformation events occurring within the bulk and present scaling relations for the evolution of roughness with strain. These results open routes toward interpreting and engineering roughness profiles.

42 ENGINEERING↗
DOE OSTI2023

Bias-pulsed atomic layer etching of 4H-silicon carbide producing subangstrom surface roughness

A new approach to atomic layer etching (ALE) has been demonstrated, and its application to 4H-SiC is reported here. By pulsing only the DC bias for an Ar/Cl2 inductively coupled plasma-reactive ion etching system, the etch cycle duration is reduced by more than an order of magnitude relative to conventional ALE processes. Gas flows are not changed throughout the ALE process. With this process protocol, we achieved an etch rate of 2.48±0.09 Å/cycle with 6 s cycles, an RMS surface roughness (Rq) of 0.83±0.08 Å, and an ALE synergy value of S = 99%. The parameters explored within this ALE process demonstrate effective subangstrom smoothening of 4H-SiC surfaces and is well-suited for a variety of classical and quantum device nanofabrication.

42 ENGINEERING↗
DOE OSTI2025

Mediation of Colloidal Encounter Dynamics by Surface Roughness

Rigorous understanding on the self-assembly of colloidal nanocrystals is crucial to develop tailored nanostructured materials for energy storage, sensing, and optical fields. Despite extensive studies on the self-assembly, a mechanistic understanding of self-assembly under an external field still remains an ongoing challenge. Here, in this work, we used optical tweezers that impose an external attractive force field, resulting in the self-assembly of alpha-phase sodium yttrium fluoride nanocrystals. The dynamic force that is strongly dependent on the surface roughness of the nanocrystals is shown to be a decisive factor for a direct contact between the nanocrystals, manifested by the roughness-dependent hydrodynamic resistivity and Langevin dynamic simulations. Our study provides direct evidence that the role of dynamics is equally important in understanding the self-assembly, which has been rarely observed in the self-assembly in contrast with many studies on the equilibrium forces. These results may have further impact in other fields, such as having explanatory power for the probability of nonclassical crystal growth or the structure of viral spike proteins that affect the probability of viruses binding with cells.

Felsted, Robert G. [Univ. of Washington, Seattle, ↗
DOE OSTI2023

Effects of additively manufactured surface roughness on small diameter plenums with multiple side discharges for high temperature gas turbine blade cooling applications

Combined heat and power (CHP) applications have significant environmental and economic benefits that are consistent with the goals of the U.S. Department of Energy (DOE). One area that is currently being studied includes the potential benefits of CHP turbine operation at higher turbine inlet temperatures. Internal cooling concepts enabled by additive manufacturing (AM) are of primary interest. Here, the effectiveness of internal cooling is hindered by many factors such as velocity distribution of the cooling air to the hot surface considering impingement cooling. To simulate cooling air exiting from a series of orifices for internal cooling in an airfoil, a straight smooth wall tubing with multiple side discharging orifices is used and compared to additively manufactured tubing (Ti6Al4V Grade 23) with orifice size and spacing as well as inner and outer diameters identical to the smooth wall tubing. Similar to flow discharging form perforated pipes, the flow discharged from individual orifices along the tubes in this study is found to be nonuniformly distributed, and the horizontal (axial direction) momentum can be observed from the experimental data. Discharge velocities have been measured with two-dimensional (2D) particle imaging velocimetry (PIV) and single element hot wire anemometry. Numerical analysis has also been conducted to predict the velocity distributions along the orifices in the smooth wall and additive manufacturing (AM) tubing, which are inherited with surface roughness. Numerical and measured results in this study are compared, presented, and discussed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

The Role of Phytoplankton Biomacromolecules in Controlling Ocean Surface Roughness

Satellite altimetric data routinely map sea surface topography by measuring the ocean return signal. One source of altimeter measurement contamination occurs when the radar ocean backscatter becomes unusually large, a situation termed a Sigma-0 bloom. Past research suggests Sigma-0 blooms are associated with weak wind and natural surface slick conditions where capillary waves at the air–sea interface are suppressed. To date, no explicit connection between these conditions and Sigma-0 bloom presence has been provided. Using a series of simplified equations, our reduced model determines capillary wave heights from estimates of planktonic carbon concentrations and regional wind speed. Our results suggest that the radar signal reflection increases as capillary wave height decreases. This relationship depends on surfactant concentration, surfactant composition, and wind speed. Model sensitivity analysis indicates that the interface reflectivity depends on biological activity and wind speed. Our proposed simplified model provides a method to identify potential Sigma-0 bloom regions. We conclude that because of the demonstrated impact of biological surfactants on ocean roughness, it is necessary to consider the biological activity, i.e., phytoplankton bloom events, when interpreting signals from radar altimetry and when developing ocean hydrology models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

ICP etching of GaN microstructures in a Cl 2 –Ar plasma with subnanometer-scale sidewall surface roughness

In this work, substrate temperature, RF power, and ICP power were investigated for their effects on GaN micropillar sidewall roughness and etch characteristics. Elevated substrate temperature was shown to improve the sidewall etch morphology at low RF powers (reduced physical bombardment) and low ICP powers (lower plasma densities). Increased lateral etching is observed with both increased ICP power and substrate temperature, which both act to increase the chemical component of the etch. Etch conditions with a high chemical driving force resulted in faceting along the a-plane on the sidewalls. This faceting produced extremely smooth surfaces with root-meansquare roughness (R q ) as low as 0.20 nm which is comparable to typical epitaxy-ready surfaces and smaller than the a-plane lattice spacing of 0.3186 nm. The smooth surfaces produced in this study enable possibilities for laser facets or for new device structures that require high quality surfaces for GaN regrowth.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Ion irradiation effects on Cr-coated zircaloy-4 surface wettability and pool boiling critical heat flux.

The concept of coating the currently used nuclear fuel cladding (zirconium-based alloy, typically Zircaloy-4 or Zirc-4) with an oxidation preventive layer is a progressing Accident tolerant Fuel (ATF) candidate alloys. The coated Zirc-4-based alloys could be a solution to suppress undesirable fast reaction kinetics with high-temperature steam. Zirc-4 has been the most preferred cladding material in pressurized water reactors (PWRs). Chromium (Cr) based alloys as a coating material provides excellent corrosion protection and good strength and wear resistance. In this paper, we present the surface wettability measurements and pool boiling Critical Heat Flux (CHF) for Cr-coated Zirc-4 claddings pre- and post-exposure to an ion irradiation environment. The wettability measurements, including static contact angle (contact angle, θ) and average surface roughness (surface roughness, Ra), are introduced for samples of different coating thicknesses (5–30 μm thick). The coatings fabricated by the cold spray of Cr-Al particles to 10 mm × 10 mm × 1.95 mm Zirc-4 substrates. Post fabrication, a Pilgering (cold rolling) process, was applied to finalize the coating thickness and resulted in a significant reduction in surface roughness of initially fabricated rough surfaces. The process produced three distinguished samples 5-μm unpolished (as machined), 5-μm, and 30-μm polished (cold rolled). The measurements are presented for the three surfaces and bare Zirc-4 as a baseline surface. The contact angle analyses were implemented in theoretical models from the literature to predict pool boiling CHF. Pool boiling experiments were conducted to measure the pool boiling CHF values and compare them to the predicted values. Scanning Electron Microscope (SEM) images and Energy Dispersive X-ray Spectroscopy (EDS) analysis was performed to characterize the surfaces for better understanding and interpreting the results. The SEM images showed localized surface damage due to ion irradiation. No recognized change in the measured surface roughness due to ion irradiation. The contact angles of irradiated Cr-coated surfaces are consistently higher (10°) than pre-irradiated surfaces. Decreasing the Cr-coating layer thickness resulted in lower contact angle pre- and post- ion irradiation. The predicted pool boiling CHF using the Kandlikar model is in good agreement with the experimentally measured CHF values within ±12% for all samples.

36 MATERIALS SCIENCE↗