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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 541 records · Page 30

Additive manufacturing process parameter determination for a new Fe-C-Cu alloy

As a potential replacement for stainless steel alloys commonly used to print parts with laser powder bed fusion, a new Cu precipitation strengthened ferrous alloy, with composition Fe-0.2C-6Cu (wt%), was recently developed. This material is Co- and Ni-free, printable, has mechanical properties comparable to that of high strength stainless steels (approximately 1300 MPa UTS), and is cost-advantaged relative to existing low-alloy steels for additive manufacturing of parts with complex shapes. To gain traction for broader application, optimal laser powder bed fusion (LPBF) processing conditions to produce nearly defect-free parts without compromising mechanical strength are needed. Here, an optimal processing window based upon laser speeds that achieve minimal porosity was quantified via comparisons of measured melt pool penetration, scan speeds, printed material density and laser beam energy density on a commercial LPBF unit operating at 350 W, 80 μm hatch spacing, and 50 μm layer thickness based upon optimal parameters for 17-4PH. Furthermore, the window is 300 to 500 mm/s to achieve >99.8 % dense Fe-0.2C-6Cu (wt%) specimens. Other defects such as burning, spatter, and lack of fusion were also avoided in this window. The window was validated with in-situ synchrotron X-ray imaging that enabled visualization of the vapor cavity, melting, and solidification during a single laser track scan on a miniature powder bed sample. In addition, in-situ infrared imaging provided temperature fields, cooling rate and solidification range, and confirmed minimal printing defects and spatter within the processing window.

36 MATERIALS SCIENCE↗

Characterizing the plasma-induced thermal loads on a 200 kW light-ion helicon plasma source via infra-red thermography

The light-ion helicon plasma source of the Proto-MPEX linear plasma device has been recently upgraded to enable pulsed (0.5–1 s) operation up to 200 kW. The main objective of this work is to report on the plasma-induced surface heat fluxes incident on the helicon window during high power operation (60–150 kW net power) for the purpose of the design of the upcoming material plasma exposure eXperiment (MPEX). The IR imaging system and associated physics models for the extraction of surface heat fluxes are presented. Furthermore, experimental results demonstrate that the control of the plasma strike point via magnetic flux mapping and the use of dedicated limiters is effective at reducing the heat loads on the dielectric window. Moreover, it is found that the flux mapping must create a gap between the plasma and the dielectric window of at least the plasma radial decay length. Extrapolated to 200 kW net RF power, this mode of operation can reduce the power lost to the dielectric window by 33%. The results presented have direct application to the design of high-powered helicon plasma sources that operate in a steady state. Examples include linear divertor simulators such as MPEX, electric thrusters, negative ion sources for NBI and linear plasma–material interaction test stands.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Stable Cycling of Sodium All‐Solid‐State Batteries with High‐Capacity Cathode Presodiation

Sodium all-solid-state batteries (NaSSBs) with an alloy-type anode (e.g., Sn and Sb) offer superior capacity and energy density compared to hard carbon anode. However, the irreversible loss of Na + at the alloy anode during the initial cycle results in diminished capacity and stability, impairing full-cell performance. Here, this study presents an easy-to-implement cathode presodiation strategy by employing a Na-rich material to address these challenges. Leveraging the high theoretical capacity and suitable voltage window, Na 2 S is chosen as the Na donor, which is activated by creating a mixed electron-ion conducting network, delivering a high capacity of 511.7 mAh g −1 . By adding a small amount (i.e., 3 wt.%) of Na 2 S to the cathode composite, a NaCrO 2 || Sn full cell demonstrated capacity improvement from 90.8 to 118.2 mAh g −1 (based on cathode mass). The capacity-balanced full cell can thus cycle to more than 300 times with >90% capacity retention. This work provides a practical solution to enhance the full-cell performance and advance the transformation from half-cell to full-cell applications of NaSSBs.

25 - ENERGY STORAGE↗

Radical Compatibility with Nonaqueous Electrolytes and Its Impact on an All‐Organic Redox Flow Battery

Abstract Nonaqueous redox flow batteries hold the promise of achieving higher energy density because of the broader voltage window than aqueous systems, but their current performance is limited by low redox material concentration, cell efficiency, cycling stability, and current density. We report a new nonaqueous all‐organic flow battery based on high concentrations of redox materials, which shows significant, comprehensive improvement in flow battery performance. A mechanistic electron spin resonance study reveals that the choice of supporting electrolytes greatly affects the chemical stability of the charged radical species especially the negative side radical anion, which dominates the cycling stability of these flow cells. This finding not only increases our fundamental understanding of performance degradation in flow batteries using radical‐based redox species, but also offers insights toward rational electrolyte optimization for improving the cycling stability of these flow batteries.

Wei, Xiaoliang↗

Nanocellulose toward Advanced Energy Storage Devices: Structure and Electrochemistry

We report that cellulose is the most abundant biopolymer on Earth and has long been used as a sustainable building block of conventional paper. Note that nanocellulose accounts for nearly 40% of wood’s weight and can be extracted using well-developed methods. Due to its appealing mechanical and electrochemical properties, including high specific modulus (~100 GPa/(g/cm 3 )), excellent stability in most solvents, and stability over a wide electrochemical window, nanocellulose has been widely used as a separator, electrolyte, binder, and substrate material for energy storage. Additionally, nanocellulose-derived carbon materials have also drawn increasing scientific interest in sustainable energy storage due to their low-cost and raw-material abundance, high conductivity, and rational electrochemical performance. The inexpensive and environmentally friendly nature of nanocellulose and its derivatives as well as simple fabrication techniques make nanocellulose-based energy storage devices promising candidates for the future of “green” and renewable electronics. For nanocellulose-based energy storage, structure engineering and design play a vital role in achieving desired electrochemical properties and performances. Thus, it is important to identify suitable structure and design engineering strategies and to better understand their relationship. In this Account, we review recent developments in nanocellulose-based energy storage. Due to the limited space, we will mainly focus on structure design and engineering strategies in macrofiber, paper, and three-dimensional (3D) structured electrochemical energy storage (EES) devices and highlight progress made in our group. We first present the structure and properties of nanocellulose, with a particular discussion of nanocellulose from wood materials. We then go on to discuss studies on nanocellulose-based macrofiber, paper, and 3D wood- and other aerogel-based EES devices. Within this discussion, we highlight the use of natural nanocellulose as a flexible substrate for a macrofiber supercapacitor and an excellent electrolyte reservoir for a breathable textile lithium–oxygen battery. Paper batteries and supercapacitors using nanocellulose as a green dispersant, nanocellulose-based paper as a flexible substrate, and nanocellulose as separator and electrolyte are also examined. We highlight recent progress on wood-based batteries and supercapacitors, focusing on the advantages of wood materials for energy storage, the structure design and engineering strategies, and their microstructure and electrochemical properties. We discuss the influence of structure (particularly pores) on the electrochemical performance of the energy storage devices. By taking advantage of the straight, nature-made channels in wood materials, ultrathick, highly loaded, and low-tortuosity energy storage devices are demonstrated. Lastly, we offer concluding remarks on the challenges and directions of future research in the field of nanocellulose-based energy storage devices.

25 ENERGY STORAGE↗

Scanning Quantum Cryogenic Atom Microscope

Microscopic imaging of local magnetic fields provides a window into the organizing principles of complex and technologically relevant condensed-matter materials. However, a wide variety of intriguing strongly correlated and topologically nontrivial materials exhibit poorly understood phenomena outside the detection capability of state-of-the-art high-sensitivity high-resolution scanning probe magnetometers. We introduce a quantum-noise-limited scanning probe magnetometer that can operate from room-to-cryogenic temperatures with unprecedented dc-field sensitivity and micron-scale resolution. The Scanning Quantum Cryogenic Atom Microscope (SQCRAMscope) employs a magnetically levitated atomic Bose-Einstein condensate (BEC), thereby providing immunity to conductive and blackbody radiative heating. The SQCRAMscope has a field sensitivity of 1.4 nT per resolution-limited point (approximately 2 μm) or 6 nT/√Hz per point at its duty cycle. Furthermore, compared to point-by-point sensors, the long length of the BEC provides a naturally parallel measurement, allowing one to measure nearly 100 points with an effective field sensitivity of 600 pT/√Hz for each point during the same time as a point-by-point scanner measures these points sequentially. Moreover, it has a noise floor of 300 pT and provides nearly 2 orders of magnitude improvement in magnetic flux sensitivity (down to 10 -6 Φ 0 /√Hz) over previous atomic probe magnetometers capable of scanning near samples. These capabilities are carefully benchmarked by imaging magnetic fields arising from microfabricated wire patterns in a system where samples may be scanned, cryogenically cooled, and easily exchanged. We anticipate the SQCRAMscope will provide charge-transport images at temperatures from room temperature to 4 K in unconventional superconductors and topologically nontrivial materials.

74 ATOMIC AND MOLECULAR PHYSICS↗

Impacts of the Addition of Sodium Reactor Experiment (SRE) and DR-3 Fuel from H-Canyon to Tank 40 on Acid Stoichiometry and Hydrogen Production

H-Canyon plans to discard Sodium Reactor Experiment (SRE) material that is currently stored in Tanks 16.3 and 16.4. Savannah River Remediation (SRR) determined that a portion of the SRE material can be added to Sludge Batch 9 (SB9) in Tank 40 and the remainder will be added to Sludge Batch 10 (SB10) that is currently being prepared in Tank 51. A processing flowsheet for both the nitric-formic acid flowsheet and the nitric-glycolic acid flowsheet were previously developed for SB9 sludge-only and coupled operation with the Actinide Removal Process – Modular Caustic Side Solvent Extraction Unit (ARP-MCU) and the Salt Waste Processing Facility (SWPF). Due to the compositional change in Tank 40 after the addition of SRE material, it is necessary to determine the influence on the acid stoichiometry operating window and hydrogen production for SB9 processing. An assessment was completed to address the influence of an addition of SRE and DR-3 Fuel from H-Canyon on the chemistry of Tank 40, the defined acid stoichiometry window (with and without SWPF streams) for the nitric-formic and nitric-glycolic acid flowsheets, and the resulting influence of the hydrogen production. Hydrogen production during the SRAT/SME cycles consists of thermolytic, radiolytic, and catalytic hydrogen. For the nitric-formic acid flowsheet, catalytic hydrogen dominates the hydrogen production during DWPF operation mode for the SRAT and SME vessels. This report was written to summarize that assessment. No SRNL testing is needed prior to adding up to 7,100 additional gallons of SRE and DR-3 Fuel from H-Canyon to Tank 40. Also, the addition of SRE will not exceed the Shielded Cells reported values for catalytic hydrogen for either the nitric-formic acid flowsheet (Technical Safety Requirement (TSR) limit of 0.15 lb/h) or the nitric-glycolic acid flowsheet (TSR limit 0.024 lb/h). The addition of the ARP stream from SWPF and the use of the nitric-glycolic acid flowsheet are both expected to decrease hydrogen generation, leading to a larger safety margin in the CPC.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

The simulated space proton environment for radiation effects on Space Telescope Imaging Spectrograph (STIS)

The space telescope imaging spectrograph (STIS) is a second generation instrument planned for the Hubble Space Telescope (HST) which is currently in orbit. Candidate glasses and other transmitting materials are being considered for order sorters, in-flight calibration filters, detector windows, and calibration lamps. The glasses for in-flight calibration filters showed significant drop in UV transmission, but can probably still be used on STIS. The addressed topics include the Hubble radiation environment, simulation of orbital exposure at Harvard Cyclotron Laboratory, measurement of spectral transmission, and comments on individual samples.

Becher, Jacob↗

Transparent conductive coatings in the far ultraviolet

In certain cases a space-borne optical instrument with a dielectric window requires a transparent conductive coating deposited on the window to remove the electrostatic charge collected due to the bombardment of ionized particles. Semiconductor and metal films are studied for use as transparent conductive coatings for the front window of far ultraviolet camera. Cr is found to be the best coating material. The theoretical search for the semiconductor and metal coating materials and experimental results for ITO and Cr films are reported.

Kim, Jongmin↗

Particle Ejection and Levitation Technology (PELT)

Each of the six Apollo landers touched down at unique sites on the lunar surface. Aside from the Apollo 12 landing site located 180 meters from the Surveyor III lander, plume impingement effects on ground hardware during the landings were not a problem. The planned return to the Moon requires numerous landings at the same site. Since the top few centimeters of lunar soil are loosely packed regolith, plume impingement from the lander will eject the granular material at high velocities. A picture shows what the astronauts viewed from the window of the Apollo 14 lander. There was tremendous dust excavation beneath the vehicle. With high-vacuum conditions on the Moon (10 (exp -14) to 10 (exp -12) torr), motion of all particles is completely ballistic. Estimates derived from damage to Surveyor III caused by the Apollo 12 lander show that the speed of the ejected regolith particles varies from 100 m/s to 2,000 m/s. It is imperative to understand the physics of plume impingement to safely design landing sites for future Moon missions. Aerospace scientists and engineers have examined and analyzed images from Apollo video extensively in an effort to determine the theoretical effects of rocket exhaust impingement. KSC has joined the University of Central Florida (UCF) to develop an instrument that will measure the 3-D vector of dust flow caused by plume impingement during descent of landers. The data collected from the instrument will augment the theoretical studies and analysis of the Apollo videos.

Source record↗

Single Piece Redundant, Bi-Directional, Seal Damage Prevention Pressure Seal

An example seal for use with a laminated window is described. The seal includes a first end formed from a first material and a second end formed from the first material, with the first material being compressible when a pressure force is applied to the first material. The seal also includes a connection portion positioned between the first end and the second end. At least some of the connection portion is formed from a second material having a greater indentation hardness than an indentation hardness of the first material. An example method for installing a seal is also described.

Smallwood, Drew L.↗

Demonstration of Wide Area Radiological Decontamination and Mitigation Technologies for Building Structures and Vehicles - 16508

Researchers at the U.S. Environmental Protection Agency in collaboration with the Department of Homeland Security conducted the 'Wide-Area Urban Radiological Contaminant, Mitigation, and Clean-Up Technology Demonstration' in Columbus, Ohio on June 22-25, 2015. EPA's National Homeland Security Research Center (NHSRC) demonstrated five wide-area radiological decontamination technologies (including strippable coatings, gels, and chemical foam technologies) on an urban building. Decontamination technologies were applied to remove the contaminants from the building's surfaces by physical, chemical, or other methods, which in practice could reduce radiation exposure level. In addition, NHSRC teamed with the Department of Homeland Security (DHS) to demonstrate several radiological contaminant mitigation technologies including building and vehicle wash technologies, as well as several approaches to contain wash water and radioactive particles. 'Radiological contaminant mitigation' technologies are measures taken to reduce adverse impacts of radiological contamination on people and the environment, and facilitate such purposes as restoration of first responder services and critical infrastructure. Radiological contaminant mitigation technologies are designed for containing and removing radiological contamination on the surface in the first hours or days following a radiological event (early phase response). Such technologies include 'radiological particle containment', which is design to prevent the spread of particles which might result from vehicle or foot traffic. Radiological particle containment technologies are applicable for early phase response to contain the radionuclides and to reduce radiation dose to responders and the public. Mitigation also includes 'gross decontamination' technologies, which perform a type of decontamination that is conducted with the goal of reducing contamination levels. This reduction may not meet final cleanup levels, but may be useful to mitigate some public hazard or contain contamination. The purpose of the demonstrations was to educate potential end-users and stakeholders of this technology about a 'Toolbox of Options' for radiological decontamination, as well as radiological contaminant mitigation. Both demonstrations were conducted using a 75-year old brick building and the surrounding area (including parking lots) in Columbus, OH. No radioactive contaminants were applied during either demonstration, as the objective was to duplicate and implement realistic operational conditions for these technologies. Surrogate contaminants such as particle tracers were used in several demonstrations. The decontamination technologies were used in a scaled-up setting with application to the building. Contaminant mitigation technologies were demonstrated on the building as well as on vehicles. Example technology application techniques/accessories included an articulating boom lift, repelling boatswain chair, stand-alone surface material structures, high-volume foam applicators, fire truck foam applicator, a vehicle wash tent for vehicles, particle tracers to simulate radiological contaminants, and high- and low-technology liquid containment approaches. Results and stakeholder observations from the demonstration are now publically in a report entitled 'Technical Report for the Demonstration of Radiological Decontamination and Mitigation Technologies for Building Structures and Vehicles' available at http://www.epa.gov/hsresearch Example information that was obtained included decontamination rate, contaminant mitigation and containment capacity, user friendliness of each technology, the required utilities (electric, water, etc.) for each technology, skill of worker required, and the cost. The condition (color, texture, integrity, etc.) of each building material present on the structure along with all structural components such as gutters, windows, doors, etc. were carefully examined and documented. All demonstrations were open to individuals, organizations, and local, state, federal, tribal, and international governments who may be involved with implementing or planning radiological incident response. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Turning Normal to Abnormal: Reversing CO 2 /C2–Hydrocarbon Selectivity in HKUST–1

Metal–organic frameworks (MOFs) can efficiently purify hydrocarbons from CO 2 , but their rapid saturation, driven by preferential hydrocarbon adsorption, requires energy-intensive adsorption–desorption processes. To address these challenges, an innovative approach is developed, enabling control over MOF flexibility through densification and defect engineering, resulting in an intriguing inverse CO 2 /C2 hydrocarbon selectivity. Here, in this study, the densification process induces the shearing of the crystal lattice and contraction of pores in a defective CuBTC MOF. These changes have led to a remarkable transformation in selectivity, where the originally hydrocarbon-selective CuBTC MOF becomes CO 2 -selective. The selectivity values for densified CuBTC are significantly reversed when compared to its powder form, with notable improvements observed in CO 2 /C 2 H 6 (4416 vs 0.61), CO 2 /C 2 H 4 (15 vs 0.28), and CO 2 /C 2 H 2 (4 vs 0.2). The densified material shows impressive separation, regeneration, and recyclability during dynamic breakthrough experiments with complex quinary gas mixtures. Simulation studies indicate faster CO 2 passage through the tetragonal structure of densified CuBTC compared to C 2 H 2 . Experimental kinetic diffusion studies confirm accelerated CO 2 diffusion over hydrocarbons in the densified MOF, attributed to its small pore window and minimal interparticle voids. This research introduces a promising strategy for refining existing and future MOF materials, enhancing their separation performance.

36 MATERIALS SCIENCE↗

Final Results of Shuttle MMOD Impact Database

The Shuttle Hypervelocity Impact Database documents damage features on each Orbiter thought to be from micrometeoroids (MM) or orbital debris (OD). Data is divided into tables for crew module windows, payload bay door radiators and thermal protection systems along with other miscellaneous regions. The combined number of records in the database is nearly 3000. Each database record provides impact feature dimensions, location on the vehicle and relevant mission information. Additional detail on the type and size of particle that produced the damage site is provided when sampling data and definitive spectroscopic analysis results are available. Guidelines are described which were used in determining whether impact damage is from micrometeoroid or orbital debris impact based on the findings from scanning electron microscopy chemical analysis. Relationships assumed when converting from observed feature sizes in different shuttle materials to particle sizes will be presented. A small number of significant impacts on the windows, radiators and wing leading edge will be highlighted and discussed in detail, including the hypervelocity impact testing performed to estimate particle sizes that produced the damage.

Hyde, J. L.↗

Direct-write orientation of charge-transfer liquid crystals enables polarization-based coding and encryption

Abstract Optical polarizers encompass a class of anisotropic materials that pass-through discrete orientations of light and are found in wide-ranging technologies, from windows and glasses to cameras, digital displays and photonic devices. The wire-grids, ordered surfaces, and aligned nanomaterials used to make polarized films cannot be easily reconfigured once aligned, limiting their use to stationary cross-polarizers in, for example, liquid crystal displays. Here we describe a supramolecular material set and patterning approach where the polarization angle in stand-alone films can be precisely defined at the single pixel level and reconfigured following initial alignment. This capability enables new routes for non-binary information storage, retrieval, and intrinsic encryption, and it suggests future technologies such as photonic chips that can be reconfigured using non-contact patterning.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Epitaxial growth of Bi 2 Se 3 in the (0015) orientation on GaAs (001)

Here we present that materials with van der Waals bonding show exotic physics and may have applications in a variety of areas including new optoelectronic devices, spintronic devices, and as quantum materials. To date, control over the morphology and surface orientation of thin films of these materials without substrate pretreatment has been difficult. In this paper, the authors report the growth of Bi 2 Se 3 on GaAs (001) substrates. By controlling the growth conditions and adatom mobility, the authors are able to obtain epitaxial growth in the (0015) orientation without substrate prepatterning. Although the growth window is small, this demonstration opens the door for future control of the orientation of van der Waals materials through control of parameters during growth and via interaction with the substrate.

36 MATERIALS SCIENCE↗

Novel Materials for Next-Generation Accelerator Target Facilities

As beam power continues to increase in next-generation accelerator facilities, high-power target systems face crucial challenges. Components like beam windows and particle-production targets must endure significantly higher levels of particle fluence. The primary beam’s energy deposition causes rapid heating (thermal shock) and induces microstructural changes (radiation damage) within the target material. These effects ultimately deteriorate the components’ properties and lifespan. With conventional materials already stretched to their limits, we are exploring novel materials including High-Entropy Alloys and Electro spun Nanofibers that offer a fresh approach to enhancing tolerance against thermal shock and radiation damage. Following an introduction to the challenges facing high-power target systems, we will give an overview of the promising advancements we have made so far in customizing the compositions and microstructures of these pioneering materials. Our focus is on optimizing their in-beam thermomechanical and physics performance. Additionally, we will outline our ongoing plans for in-beam irradiation experiments and advanced material characterizations. The primary goal of this research is to push the frontiers of target materials, thereby enabling future multi-MW facilities that will benefit various programs in high-energy physics and beyond.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗