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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 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
NASA NTRS1976

Oxidation of metals and alloys in controlled atmospheres using in situ transmission electron microscopy and Auger spectrography

Single-crystalline thin films of copper were oxidized at an isothermal temperature of 425 C and at an oxygen partial pressure of .005 Torr in situ in a high-resolution electron microscope. The specimens were prepared by epitaxial vapor deposition onto polished 100 and 110 faces of rocksalt and mounted in a hot stage inside an ultra-high-vacuum specimen chamber of the microscope. Large amounts of sulfur, carbon, and oxygen were detected by Auger electron spectroscopy on the surface of the as-received films and were removed in situ by ion-sputter etching immediately prior to the oxidation. The nucleation and growth characteristics of Cu2O on Cu were studied. Results show that neither stacking faults nor dislocations are associated with the Cu2O nucleation sites. The growth of Cu2O nuclei is linear with time. The experimental findings, including results from oxygen dissolution experiments and from repetitive oxidation-reduction-oxidation sequences, fit well into the framework of an oxidation process involving (a) the formation of a surface-charge layer, (b) oxygen saturation in the metal and (c) nucleation, followed by surface diffusion of oxygen and bulk diffusion of copper for lateral and vertical oxide growth, respectively.

Rao, D. B.↗
DOE OSTI2024

In situ Synchrotron X‐ray Metrology Boosted by Automated Data Analysis for Real‐time Monitoring of Cathode Calcination

Abstract Synchrotron X‐ray‐based in situ metrology is advantageous for monitoring the synthesis of battery materials, offering high throughput, high spatial and temporal resolution, and chemical sensitivity. However, the rapid generation of massive data poses a challenge to on‐site, on‐the‐fly analysis needed for real‐time process monitoring. Here, a weighted lagged cross‐correlation (WLCC) similarity approach is presented for automated data analysis, which merges with in situ synchrotron X‐ray diffraction metrology to monitor the calcination process of the archetypal nickel‐based cathode, LiNiO 2 . The WLCC approach, incorporating variables that account for peak shifts and width changes associated with structural transformations, enables rapid extraction of phase progression within 10 seconds from tens of diffraction patterns. Details are captured, from initial precursors to intermediates and the final layered LiNiO 2 , providing information for agile on‐site adjustments during experiments and complementing post hoc diffraction analysis by offering insights into early‐stage phase nucleation and growth. Expanding this data‐powered platform paves the way for real time calcination process monitoring and control, which is pivotal to quality control in battery cathode manufacturing.

36 MATERIALS SCIENCE↗
NASA NTRS2000

Soot Reaction Properties (Ground-Based Study)

Three major soot reaction processes are needed to predict soot properties in flame environments: soot growth, or the formation of soot on soot nuclei and soot particles; soot oxidation, or the reaction of soot with oxidizing species to yield the combustion products of soot oxidation; and soot nucleation, or the formation of soot nuclei from soot precursors having large molecular weights (generally thought to be large and particularly stable PAH molecules in flame environments, called stabilomers). These processes are addressed in the following, considering soot growth, oxidation and nucleation, in turn, by exploiting the soot and flame structure results for premixed and diffusion flames already discussed in Section 2.

Dai, Z.↗
DOE OSTI2020

Two-step route to size and shape controlled gibbsite nanoplates and the crystal growth mechanism

Mastery of gibbsite (α-Al(OH) 3 ) nucleation and crystal growth is significant in fundamental aluminum chemistry and also beneficial for industrial applications and the remediation of nuclear waste. Herein, we developed an additive-free two-step route to size and morphology controlled synthesis of gibbsite nanoplates. Independent temperature manipulation of nucleation and crystal growth regimes was used to control the efficacy and yield of the process, producing gibbsite nanoplates with tunable morphologies and sizes. We achieve morphologies ranging from hexagon, pseudo hexagon, truncated triangle to rhombic, and average basal plane diameters from 120 to 850 nm, with thicknesses between 8 and 45 nm. Analysis of gibbsite structure, size and morphology with techniques including powder X-ray diffraction (p-XRD), 27 Al magic angle spinning nuclear magnetic resonance spectroscopy (MAS NMR), scanning electron microscopy (SEM), and atomic force microscopy (AFM) provided key details on the nucleation and crystal growth mechanisms. The results indicate the temperature of the nucleation aging step is the most important factor controlling the final particle size. Particularly small nanoplates were obtained with a low nucleation aging temperature followed by high crystal growth temperature, suggesting that gibbsite growth can be approximated via a LaMer-type burst nucleation and crystal growth mechanism. Scalability was demonstrated by triplicate of 2 L experiments which prepared gibbsite nanoplates of ~200 nm size and with an average yield of ~55% after 84 h. Compared to existing techniques, this improved two-step route is cheaper, more efficient and environmentally friendly.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1975

Process development for producing fine-grain casting in space

Assessment of grain growth kinetics at temperatures near the melting point and investigation into the use of potential nucleating agents in combination with the naturally occurring BeO led to the definition of critical low-g experiments which would help to determine whether one or both of these possibilities are valid and whether space processing would be able to yield fine grain ingot beryllium.

Gelles, S. H.↗
NASA NTRS1975

Oxide nucleation on thin films of copper during in situ oxidation in an electron microscope

Single-crystal copper thin films were oxidized at an isothermal temperature of 425 C and at an oxygen partial pressure of 0.005 torr. Specimens were prepared by epitaxial vapor deposition onto polished faces of rocksalt and were mounted in a hot stage inside the ultrahigh-vacuum chamber of a high-resolution electron microscope. An induction period of roughly 30 min was established which was independent of the film thickness but depended strongly on the oxygen partial pressure and to exposure to oxygen prior to oxidation. Neither stacking faults nor dislocations were found to be associated with the Cu2O nucleation sites. The experimental data, including results from oxygen dissolution experiments and from repetitive oxidation-reduction-oxidation sequences, fit well into the framework of an oxidation process involving the formation of a surface charge layer, oxygen saturation of the metal with formation of a supersaturated zone near the surface, and nucleation followed by surface diffusion of oxygen and bulk diffusion of copper for lateral and vertical oxide growth, respectively.

Heinemann, K.↗
NASA NTRS2026

Hybrid Modeling Study on Grain Evolution in the Metal Welding Process and Its Potential Lunar Application

Metal is most commonly used structural material in a wide range of spacecraft, and welding is the principal method for joining metal components into functional systems. However, conducting welding experiments under extreme environments—such as microgravity or vacuum conditions in space—is prohibitively expensive and experimentally challenging. To overcome these limitations, multi-physics computational welding models provide a cost-effective and versatile alternative. In this work, the authors have developed a coupled thermal (fluid) microstructure simulation framework to model metal welding under varying gravity conditions. The framework integrates a mixed-mode heat transfer formulation (conduction, convection, and radiation) with molten pool fluid dynamics, enabling accurate prediction of temperature fields and weld-pool geometry. A grain growth model is further incorporated to capture the spatial and temporal evolution of microstructure, including grain size distribution and morphological transitions during solidification. This approach provides detailed insight into molten pool evolution and grain-level microstructure development throughout the welding process. By explicitly parameterizing environmental conditions, the model supports extrapolation to off-Earth manufacturing scenarios such as welding on the lunar surface. Tantalum—chosen in this study due to its high melting point, oxidation resistance, and mechanical stability at elevated temperatures—serves as the material system for model demonstration. Beyond Tantalum, the integrated multi-physics framework offers broad applicability for predictive welding simulations of various structural and refractory metals or alloys used in extreme terrestrial or extraterrestrial environments.

kinetic Monte Carlo (SPPARKS)↗
NASA NTRS2003

Flight Planning for the International Space Station - Levitation Observation of Dendrite Evolution in Steel Ternary Alloy Rapid Solidification (LODESTARS)

During rapid solidification, a molten sample is cooled below its equilibrium solidification temperature to form a metastable liquid. Once nucleation is initiated, growth of the solid phase proceeds and can be seen as a sudden rise in temperature. The heat of fusion is rejected ahead of the growing dendrites into the undercooled liquid in a process known as recalescence. Fe-Cr-Ni alloys may form several equilibrium phases and the hypoeutectic alloys, with compositions near the commercially important 316 stainless steel alloy, are observed to solidify by way of a two-step process known as double recalescence. During double recalescence, the first temperature rise is associated with formation of the metastable ferritic solid phase with subsequent conversion to the stable austenitic phase during the second temperature rise. Selection of which phase grows into the undercooled melt during primary solidification may be accomplished by choice of the appropriate nucleation trigger material or by control of the processing parameters during rapid solidification. Due to the highly reactive nature of the molten sample material and in order to avoid contamination of the undercooled melt, a containerless electromagnetic levitation (EML) processing technique is used. In ground-based EML, the same forces that support the weight of the sample against gravity also drive convection in the liquid sample. However, in microgravity, the force required to position the sample is greatly reduced, so convection may be controlled over a wide range of internal flows. Space Shuttle experiments have shown that the double recalescence behavior of Fe-Cr-Ni alloys changes between ground and space EML experiments. This program is aimed at understanding how melt convection influences phase selection and the evolution of rapid solidification microstructures.

Flemings, Merton C.↗
DOE OSTI2022

An OpenMP GPU-offload implementation of a non-equilibrium solidification cellular automata model for additive manufacturing

Here, in this paper, performance strategies on GPU-based HPC platforms of a cellular automata (CA) simulation code for non-equilibrium solidification, including nucleation, grain growth, solute partitioning and transport for the metal additive manufacturing (AM) process are investigated using OpenMP 4.5. To accurately report the speed-up for multicore CPUs and GPUs, a rigorous performance analysis employed optimizations appropriate for both CPU-only code (baseline) and GPU offload codes for an isothermal test problem. The performance results on Summit at the Oak Ridge Leadership Computing Facility indicate that using a precomputed list of interface cells significantly decreased the wall-clock time on GPUs. The speedup due to GPU acceleration was evaluated for a full Summit node and measured to be 1.8X when comparing a 6 MPI tasks run with 6 GPUs versus 36 MPI tasks on the CPU only. That speed-up was found to be 7.9X when comparing 6 MPI tasks with 6 GPUs versus the 6 MPI tasks running on the CPU only. Performance measurements showed that system total time is almost constant for runs with more than 96 MPI tasks (or GPUs), indicating that the GPU-accelerated code showed an excellent weak scaling performance. Finally, a rapid directional solidification problem was considered to demonstrate the CA code capability on Summit. It was found that a mesh size of at least 0.05 μm is recommended for the AM-like simulations in order to obtain accurate elongated grain microstructure and elongated subgrain features, which are in qualitative good agreement with experimental data. The results presented in this study indicate that the performance strategies on GPU-based HPC platforms for the CA code are appropriate for novel HPC exascale platforms.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Visualizing Lithium Dendrite Formation within Solid-State Electrolytes

Solid-state electrolyte (SSE) is promising for application in allsolid-state lithium metal batteries because of its reliable safety and longevity. The failure of SSE to suppress dendrite formation of Li metal anodes has been conventionally explained by uneven Li deposition at Li/SSE interfaces and its subsequent dendritic growth. While Li deposition within SSE has been recently proposed as another key cause for SSE failure, little is known regarding the Li growth details inside the SSE itself. In this work, we performed in situ microscopic observation of Li deposition inside the SSE and obtained visualized evidence regarding the dynamic process of Li dendrite formation and growth. Here, Li is seen to directly nucleate and propagate within the SSE, leading to its structural cracking. Such behavior should be caused by the presence of P- and S-based crystalline defects in Li 3 PS 4 SSE, which is consistent with the cryo-transmission electron microscopy observations and theoretical calculations. This observation provides important insights into the growth mechanisms of Li dendrites within a working lithium battery.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Coupled Roles of Surface Chemistry and Hydrogen-Assisted Cycling in Ruthenium Atomic Layer Deposition on Silicon Oxides

Ruthenium (Ru) is a promising interconnect material for advanced semiconductor technologies due to its favorable scaling characteristics, including a short electron mean free path and strong electromigration resistance. In semiconductor integration, silicon oxide-based dielectrics serve as dominant insulating materials and constitute ubiquitous interfaces for metallization; however, their formation-dependent surface chemistry and its impact on Ru growth remain insufficiently explored. Here, we investigate Ru ALD on native oxide SiO x (N-SiO x ) and thermally grown SiO 2 (T-SiO 2 ) as model substrates using bis(ethylcyclopentadienyl)ruthenium(II) [Ru(EtCp) 2 ] under two distinct reactant-sequence environments: AB-type (Ru(EtCp) 2 /O 2 ) and hydrogenassisted ABC-type (Ru(EtCp) 2 /O 2 /H 2 ). Under the AB-type process, both N-SiO x and T-SiO 2 exhibit pronounced nucleation delay. N-SiO x shows earlier nucleation and higher nucleation density than T-SiO 2 , plausibly attributed to differences in surface hydroxyl populations. Similar temperature-dependent phase evolution is observed on both substrates, with mixed Ru and RuO 2 phases at 250 °C and predominantly metallic Ru at 300 °C accompanied by increased morphological roughening. In contrast, incorporating an H 2 subpulse (ABC-type) mitigates nucleation delay, particularly on hydroxyl-deficient T-SiO 2 , thereby reducing the substratedependent disparity observed under AB cycling. Moreover, RuO 2 formation is suppressed even at 250 °C on both substrates, shifting growth toward more metallic Ru with reduced resistivity (∼20 μΩ·cm at ∼ 20 nm on N-SiO x ). These trends suggest that H 2 influences the surface reaction pathway, contributing to enhanced metallic stabilization and altered early stage growth kinetics. Overall, this work clarifies the coupled roles of substrate chemistry and reactant-sequence design in governing Ru nucleation and early stage film evolution, providing insight relevant to next-generation interconnect integration and future area-selective deposition strategies.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Design Principles for the Synthesis of Self-Pillared ZSM-5 Zeolite Nanosheets

The design of next-generation materials for emerging energy and environmental applications heavily relies on empirical approaches to direct nonclassical nucleation and crystal growth pathways, polymorphism, intercrystalline transformations, and seed-assisted growth processes. A long-standing obstacle to nanoporous materials design is the complexity of their crystallization, which hinders the development of predictive models and/or physical descriptors that can guide their synthesis. In this study, we use a combination of state-of-the-art synthesis, characterization, and computational design to prepare hierarchical MFI-type zeolites, which we couple with benchmark catalytic testing to assess structure-property-performance relationships. These hierarchical materials are intergrowths of two commercially relevant zeolite frameworks, MFI and MEL, prepared as self-pillared pentasil (SPP) zeolites through seed-assisted, organic-free syntheses for which little theoretical guidance existed. Here, by comparing a large library of zeolite seeds with different pore sizes, dimensions, and structural composite building units, we determined the relative impact of seed and silica source selection, among other synthesis variables. Combined experimental and computational studies are used to test several hypotheses in literature to rationalize the choice of seed structure and establish a more robust selection criteria for seed-assisted synthesis of zeolites. Specifically, we show that a data-driven approach to develop structural descriptors correlates to new, facile routes to rationally design SPP zeolites, addressing knowledge gaps in the fundamental understanding of (non)classical crystal growth mechanisms that are characteristic of nanoporous aluminosilicates.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Do Arctic mixed-phase clouds sometimes dissipate due to insufficient aerosol? Evidence from comparisons between observations and idealized simulations

Abstract. Mixed-phase clouds are ubiquitous in the Arctic. These clouds can persist for days and dissipate in a matter of hours. It is sometimes unknown what causes this sudden dissipation, but aerosol–cloud interactions may be involved. Arctic aerosol concentrations can be low enough to affect cloud formation and structure, and it has been hypothesized that, in some instances, concentrations can drop below some critical value needed to maintain a cloud. We use observations from a Department of Energy ARM site on the northern slope of Alaska at Oliktok Point (OLI), the Arctic Summer Cloud Ocean Study (ASCOS) field campaign in the high Arctic Ocean, and the Integrated Characterisation of Energy, Clouds, Atmospheric state, and Precipitation at Summit – Aerosol Cloud Experiment (ICECAPS-ACE) project at the NSF (National Science Foundation) Summit Station in Greenland (SMT) to identify one case per site where Arctic boundary layer clouds dissipated coincidentally with a decrease in surface aerosol concentrations. These cases are used to initialize idealized large eddy simulations (LESs) in which aerosol concentrations are held constant until, at a specified time, all aerosols are removed instantaneously – effectively creating an extreme case of aerosol-limited dissipation which represents the fastest a cloud could possibly dissipate via this process. These LESs are compared against the observed data to determine whether cases could, potentially, be dissipating due to insufficient aerosol. The OLI case's observed liquid water path (LWP) dissipated faster than its simulation, indicating that other processes are likely the primary drivers of the dissipation. The ASCOS and SMT observed LWP dissipated at similar rates to their respective simulations, suggesting that aerosol-limited dissipation may be occurring in these instances. We also find that the microphysical response to this extreme aerosol forcing depends greatly on the specific case being simulated. Cases with drizzling liquid layers are simulated to dissipate by accelerating precipitation when aerosol is removed while the case with a non-drizzling liquid layer dissipates quickly, possibly glaciating via the Wegener–Bergeron–Findeisen (WBF) process. The non-drizzling case is also more sensitive to ice-nucleating particle (INP) concentrations than the drizzling cases. Overall, the simulations suggest that aerosol-limited cloud dissipation in the Arctic is plausible and that there are at least two microphysical pathways by which aerosol-limited dissipation can occur.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1981

Holographic microscopy studies of emulsions

A holographic microscopy system that records and observes the dynamic properties of separation of dispersed immiscible fluids is described. The holographic construction system and reconstruction system that were used to obtain particle size and distribution information from the holograms are discussed. The holographic microscopy system is used to observed the phase separating processes in immiscible fluids that were isothermally cooled into the two phase region. Nucleation, growth rates, coalescence, and particle motion are successfully demonstrated with this system. Thus a holographic particle sizing system with a resolution of 2 micrometers and a field of view of 100 cu cm was developed that provides the capability of testing the theories of separating immiscible fluids for particle number densities in the range of 10 to 10 to the 7th power particles.

Witherow, W. K.↗
NASA NTRS1979

Influence of convection on free growth of dendrite crystals from solution

The free growth of dendrites in a uniformly supercooled solution was examined using cine photography with a Schlieren optical system. Crystals were grown in the bulk of the solution from a centrally located capillary tube, nucleated at the interface with a liquid nitrogen cooled wire. Crystals propagated along the tube, the slower growing orientations eliminated, and emerged at the tip, usually growing parallel to the tube direction. For both sodium sulfate decahydrate from its solution and ice from sodium chloride solution, growth rate and fineness of dendrites increased with supercooling. In sodium sulfate, upward convection of the less dense depleted solution occurs; downward convection was observed for the rejected, more concentrated sodium chloride solution. In both cases, there was a spatial and temporal delay in the release of the convective plume from the moving dendrite tip. The role of this convection on the growth characteristics and the production of secondary crystals is examined. A proposed low-g experiment to examine differences in growth rate, crystal texture, and secondary nucleation in a reduced convective regime where molecular diffusion is the dominant transfer process is discussed.

Hallett, J.↗
NASA NTRS1989

An ion microprobe study of the intra-crystalline behavior of REE and selected trace elements in pyroxene from mare basalts with different cooling and crystallization histories

The effects of crystallization interaction on the trace element zoning characteristics of pyroxenes are analyzed using electron and ion microprobe techniques. Four pigeonite basalts with similar isochemical composition, but different cooling rates and crystallization histories are studied. Pyroxene quadrilaterals displaying crystallization trends are presented. The crystal chemical rationalization of REE zoning, pattern shapes, and abundances are examined. The data reveal that the trace element zoning characteristics in pyroxene and the partitioning of trace elements between pyroxene and the melt are related to the interaction between the efficiency of the crystallization process, the kinetics at the crystal-melt interface, the kinetics of plagioclase nucleation and the characteristics of the crystal chemical substitutions in the pyroxene and the associated crystallizing phase.

Shearer, C. K.↗
NASA NTRS1994

Observation of hydration of single, modified carbon aerosols

We have compared the hydration behavior of single carbon particles that have been treated by exposure to gaseous H2SO4 with that of untreated particles. Untreated carbon particles did not hydrate as the relative humidity varied from 0 to 80% at 23 C. In contrast, treated particles hydrated under subsaturation conditions; mass increases of up to 30% were observed. The mass increase is consistent with sulfuric acid equilibration with the ambient relative humidity in the presence of inert carbon. For the samples studied, the average amount of absorbed acid was 14% +/- 6% by weight, which corresponds to a surface coverage of approximately 0.1 monolayer. The mass fraction of surface-absorbed acid is comparable to the soluble mass fraction observed by Whitefield et al. (1993) in jet aircraft engine aerosols. Estimates indicate this mass fraction corresponds to 0.1% of the available SO2 exiting an aircraft engine ending up as H2SO4 on the carbon aerosol. If this heterogeneous process occurs early enough in the exhaust plume, it may compete with homogeneous nucleation as a mechanism for producing sulfuric acid rich aerosols.

Wyslouzil, B. E.↗
NASA NTRS2004

Geochemical and Mineralogical Indicators for Aqueous Processes in Gusev Crater and on Meridiani Planum

The Athena Science Instrument Payload is providing geochemical and mineralogical information for determining the properties of rocks, soils, and outcrops at the Mars Exploration Rovers landing sites. These measurements indicate that a variety of aqueous processes as well as various degrees of alteration occurred at the two landing sites. Light-toned rocks around the Spirit landing site appear to have coatings or alteration rinds that may have resulted from limited aqueous alteration on the surfaces of basaltic rocks. Hematite and high Fe(III)lFe(total) occur at the surfaces of these rocks. High concentrations of elements highly mobile in water (i.e., S, Cl, and Br) occur in rock veins, vugs, and coatings and at the bottom of soil trenches in the "intercrater plains." One scenario for the formation of rock coatings or rinds and translocation of mobile elements is that water might have occurred briefly at the Martian surface during periods of high obliquity and thin films of water may have mobilized elements and altered the surfaces of rocks. Outcrops on the slopes of the Columbia Hills appear to be extensively altered as suggested by their relative "softness" (measured as resistance to abrasion) as compared to basalts on the adjacent plains, high Fe(III)lFe(total), iron mineralogy dominated by nanophase Fe(III) oxides and hematite, and high Br and CI concentrations beneath outcrop surfaces. These outcrops may have formed by the alteration of basaltic rocks and/or volcaniclastic materials by solutions that were rich in volatile elements (e.g., Br, CI, S). However, it is not clear whether aqueous alteration occurred at depth (e.g., metasomatism), by hydrothermal solutions (e.g., associated with volcanic or impact processes), by vapors rich in volcanic gases, or by low-temperature solutions. The occurrence of jarosite, hematite, and other sulfates (e.g., Mg sulfates) in Eagle and Endurance crater outcrops are strong indicators of aqueous processes at Meridiani Planum. These phases occur with siliciclastic materials in outcrops. Jarosite can only form by aqueous processes under very acidic conditions; e.g., acid sulfate weathering conditions resulting from the oxidation of Fe sulfides or by sulfuric acid alteration of basalts by solutions associated with S02-rich volcanic gases. It is plausible that acidic solutions rich in sulfur (and Fe(II)) reacted with basaltic sediments (which provided a host of soluble cations) under oxidizing conditions and then, through evaporation, formed sediments rich in jarosite and other sulfates along with siliciclastic materials. Hematite-rich spherules in outcrops may have formed by aqueous processes within the sedimentary layers, which promoted transport of Fe (II) solutions to nucleation sites where oxidation and precipitation occurred to form hematite-rich spherules.

Ming, Douglas W.↗