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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
DOE OSTI2022

High-Throughput Nanoindentation Mapping of Additively Manufactured T91 Steel

Here, this work aims to adapt nanoindentation mapping combined with a k-means algorithm as a high-throughput technique to study the nano-scale spatial changes in mechanical properties for a heterogeneous material. This technique can also classify the individual data points based on their properties. Hundreds to thousands of indents were performed on additively manufactured T91 at room temperature, 300°C, 400°C, and 500°C across a square area with a side length of 120 μm to 400 μm. From this data, the hardness and reduced modulus at each point could be calculated and mapped. Using k-means clustering, we were able to arrange the data into three or four clusters corresponding roughly to the ferritic and martensitic phases as well as one or two intermediate clusters sampling both the phases. The hardness of these two phases appears to be quite stable as a function of temperature. Nanoindentation mapping and the k-means algorithm can therefore be used to rapidly assess the feasibility of heterogeneous materials under extreme conditions, such as nuclear reactor steels.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Pitting Corrosion in 316L Stainless Steel Fabricated by Laser Powder Bed Fusion Additive Manufacturing: A Review and Perspective

Abstract 316L stainless steel (316L SS) is a flagship material for structural applications in corrosive environments, having been extensively studied for decades for its favorable balance between mechanical and corrosion properties. More recently, 316L SS has also proven to have excellent printability when parts are produced with additive manufacturing techniques, notably laser powder bed fusion (LPBF). Because of the harsh thermo-mechanical cycles experienced during rapid solidification and cooling, LPBF processing tends to generate unique microstructures. Strong heterogeneities can be found inside grains, including trapped elements, nano-inclusions, and a high density of dislocations that form the so-called cellular structure. Interestingly, LPBF 316L SS not only exhibits better mechanical properties than its conventionally processed counterpart, but it also usually offers much higher resistance to pitting in chloride solutions. Unfortunately, the complexity of the LPBF microstructures, in addition to process-induced defects, such as porosity and surface roughness, have slowed progress toward linking specific microstructural features to corrosion susceptibility and complicated the development of calibrated simulations of pitting phenomena. The first part of this article is dedicated to an in-depth review of the microstructures found in LPBF 316L SS and their potential effects on the corrosion properties, with an emphasis on pitting resistance. The second part offers a perspective of some relevant modeling techniques available to simulate the corrosion of LPBF 316L SS, including current challenges that should be overcome.

Voisin, T. (ORCID:0000000287462659)↗
DOE OSTI2023

Techno-economic evaluation of industrial heat pump applications in US pulp and paper, textile, and automotive industries

Industrial process heat decarbonization through electrification could contribute significantly to climate change mitigation efforts. In the US industry, thermal processes accounted for more than two-thirds of the total final energy demand in 2021. Cross-cutting electrification technologies like industrial heat pumps are suitable for the process heat supply to several industrial unit operations in a sustainable way while also improving overall energy efficiency. This study employs a bottom-up approach to investigate the techno-enviro-economic potentials of deploying high-temperature and steam-generating heat pumps in US textile, pulp and paper, and automotive sectors in different timeframes. The results show that the annual technical potential energy and CO 2 savings by electrifying heat supply are 310 PJ (or 36% of the projected energy demand) and 28 MtCO 2 (or 71% of the projected CO 2 emissions) in 2050 respectively, however, these incur additional costs in each sector (ranging between 5 and 18 $\$$/GJ). The required heating capacity of industrial heat pumps is estimated at 15 GW, which translates roughly into a market of over 6000 heat pump units and an investment volume of $\$$7 billion in the studied processes. Although there may be individual cost-effective opportunities for electrifying heat supply in specific industrial sites, the overall costs are estimated to be high in the three industrial sectors due to the large disparity between electricity and natural gas prices and low heat source temperatures. To overcome the identified techno-economic barriers, comprehensive action plans for different stakeholders are also given. This study provides novel insights that should inform policymakers’ and executives’ decisions about the electrification of the current and future US industrial heat supply in relevant industrial sectors.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Cross-cutting strategies to lower electricity use of miscellaneous electric loads in the domestic sector

Miscellaneous Electric Loads (MELs) account for roughly one quarter of building electricity use in most developed countries. A product-specific approach to lowering MELs electricity use in this category takes too long and costs too much because there are so many MELs, each providing unique services. An alternative approach focusing on key functionalities was therefore explored. These functionalities include: (1) power management, (2) power scaling, and (3) power conversion. Cross-cutting efficiency improvements to these functionalities can be incorporated into broad categories of MELs, thus saving electricity and lowering costs. Even though the population of MELs is diverse and rapidly evolving, major technical opportunities exist to improve their efficiency in these functionalities. Research into energy-saving solutions within the cross-cutting technologies will probably have larger savings than focusing on single products.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Sputter-Deposited Mo Thin Films: Multimodal Characterization of Structure, Surface Morphology, Density, Residual Stress, Electrical Resistivity, and Mechanical Response

Multimodal datasets of materials are rich sources of information which can be leveraged for expedited discovery of process–structure–property relationships and for designing materials with targeted structures and/or properties. For this data descriptor article, we provide a multimodal dataset of magnetron sputter-deposited molybdenum (Mo) thin films, which are used in a variety of industries including high temperature coatings, photovoltaics, and microelectronics. In this dataset we explored a process space consisting of 27 unique combinations of sputter power and Ar deposition pressure. Here, the phase, structure, surface morphology, and composition of the Mo thin films were characterized by x-ray diffraction, scanning electron microscopy, atomic force microscopy, and Rutherford backscattering spectrometry. Physical properties—namely, thickness, film stress and sheet resistance—were also measured to provide additional film characteristics and behaviors. Additionally, nanoindentation was utilized to obtain mechanical load-displacement data. The entire dataset consists of 2072 measurements including scalar values (e.g., film stress values), 2D linescans (e.g., x-ray diffractograms), and 3D imagery (e.g., atomic force microscopy images). An additional 1889 quantities, including film hardness, modulus, electrical resistivity, density, and surface roughness, were derived from the experimental datasets using traditional methods. Minimal analysis and discussion of the results are provided in this data descriptor article to limit the authors’ preconceived interpretations of the data. Overall, the data modalities are consistent with previous reports of refractory metal thin films, ensuring that a high-quality dataset was generated. The entirety of this data is committed to a public repository in the Materials Data Facility.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Laser spot welding of additive manufactured 304L stainless steel

Here, the goal of this work is to understand if an additively manufactured 304L stainless steel exhibits similar spot-welding behavior as wrought 304L stainless steel. Due to the many differences between an additively manufactured component and wrought product, it is important to determine how the material interacts with the laser and how it affects the weld bead morphology. In this paper, the laser coupling efficiency, weld size, and solidification of spot welds produced in wrought and additively manufactured 304L stainless steel were investigated. The coupling efficiency of wrought and additively manufactured 304L stainless steel of similar surface condition were approximately the same over a range of applied laser energies. Laser welding of the untreated (rougher) surface of additively manufactured 304L, however, showed improved coupling efficiency ranging between 3.3 and 100%. The rougher surface traps the incoming light and increases the coupling efficiency at lower laser energies, while at higher energy, the absorption efficiency is dominated by intrinsic absorption from the keyhole formation rather than surface roughness. The resulting spot weld microstructures differed from welds made in wrought 304L and additively manufactured 304L. Welds made in wrought 304L were fully austenitic containing what is suspected to be massive austenite, which suggests that these welds solidified as primary ferrite. Welds made in additively manufactured 304L were also fully austenitic and contained both cellular austenite and what is suspected to be massive austenite. These observations mean that welds made in additively manufactured 304L solidified as primary ferrite and primary austenite. The differences in weld microstructures made in wrought and AM 304L can be attributed to differences in the composition and solidification rate.

304L stainless steel↗
DOE OSTI2021

Understanding the Value of Energy Storage for Power System Reliability and Resilience Applications

Abstract Purpose of Review The need for energy storage in the electrical grid has grown in recent years in response to a reduced reliance on fossil fuel baseload power, added intermittent renewable investment, and expanded adoption of distributed energy resources. While the methods and models for valuing storage use cases have advanced significantly in recent years, the value of enhanced resilience remains an open research question. Recent Findings The findings of the recent research indicate that energy storage provides significant value to the grid, with median benefit values for specific use cases ranging from under $10/kW-year for voltage support to roughly $100/kW-year for capacity and frequency regulation services. While the value of lost load is used widely to estimate the benefits of mitigating short-duration outages, reaching as high as $719/kilowatt-year, there is no consensus when it comes to monetizing the value of improving grid resilience. Summary This paper presents a use case taxonomy for energy storage and uses the taxonomy to conduct a meta-analysis of an extensive set of energy storage valuation studies. It reviews several approaches for monetizing reliability and resiliency services and presents a proposed approach for valuing resiliency for energy storage investments.

25 ENERGY STORAGE↗
DOE OSTI2022

A Novel Rotating Flexure-Test Technique for Brittle Materials with Circular Geometries

The four-point bend test is one of the simplest and often the preferred flexural strength evaluation method for brittle materials. In this loading mode, fracture often initiates from a critical surface (or subsurface) flaw when subjected to a tensile stress state. However, if the critical flaw exists on the compression side of the test specimen, it may not activate to grow a crack and hence the resulting flexural strength will be higher than the true value. The goal of this study is to measure the true flexural strength of a solid or hollow cylindrical brittle specimen by ensuring that failure occurs at its weakest point by rotating along its longitudinal axis, thereby exposing and activating its critical surface flaw during a four-point bend test. A novel test fixture has been designed and fabricated, and the true flexural strengths of cylindrical brittle and quasi-brittle tubular specimens have been measured and compared to existing experimental data obtained through traditional four-point bend tests. In this work, experimental results showcase the orientation dependance on flexural strength for various materials. Additionally, similarities between experimental findings and those available in literature, including observations of fracture surfaces and relationships between surface roughness and material strength, are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Velocity Extraction Using Complete Time-Domain Waveform Data and Audio Machine Learning

We developed a new machine learning-based tool for extracting information from interferometry measurements: MIDWAZE (Modular Interferometry Direct Waveform AnalyZEr). This paper showcases MIDWAZE’s ability to extract an object’s velocity information from Photonic Doppler Velocimetry (PDV) data at near-human accuracy with little to no human intervention. MIDWAZE can extract velocities roughly 350 times as fast as a human analyst "rushing" to complete their extractions, with similar extraction accuracy. MIDWAZE’s most outstanding feature is that it operates directly in waveform/temporal space, freeing analysis from certain limitations imposed by traditional spectrogram-based approaches and opening the way to "phase aware" PDV analysis. MIDWAZE also has limited ability to discriminate between different solid objects, which we develop as a first step towards automated discrimination of different kinds of objects such as ejecta clouds.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Recent developments in mathematical aspects of relativistic fluids

Abstract We review some recent developments in mathematical aspects of relativistic fluids. The goal is to provide a quick entry point to some research topics of current interest that is accessible to graduate students and researchers from adjacent fields, as well as to researches working on broader aspects of relativistic fluid dynamics interested in its mathematical formalism. Instead of complete proofs, which can be found in the published literature, here we focus on the proofs’ main ideas and key concepts. After an introduction to the relativistic Euler equations, we cover the following topics: a new wave-transport formulation of the relativistic Euler equations tailored to applications; the problem of shock formation for relativistic Euler; rough (i.e., low-regularity) solutions to the relativistic Euler equations; the relativistic Euler equations with a physical vacuum boundary; relativistic fluids with viscosity. We finish with a discussion of open problems and future directions of research.

Disconzi, Marcelo (ORCID:0000000234497778)↗
DOE OSTI2024

Macroscopic Traffic Modeling Using Probe Vehicle Data: A Machine Learning Approach

Abstract The macroscopic fundamental diagram (MFD) captures an orderly relationship among traffic flow, density, and speed at the network level. It is a simple yet powerful tool for modeling traffic dynamics in large urban networks with broad application in traffic control and management. However, empirically derived MFDs in urban regions require high-resolution traffic data from the network. Having the network flow and vehicular density estimated at the (granular) census tract level using vehicle probe data, we apply machine learning methods to predict the MFDs across U.S. urban areas and capture the impacts of location-specific input features on the network flow–density relationships at a large scale. The results show that, among the four tested machine learning approaches (Random Forest, XGBoost, Support Vector Machine, and Neural Network), XGBoost delivers the best performance in predicting network traffic flow based on vehicular density and location attributes. Using interaction Shapley Additive explanation (SHAP) values and partial correlation analysis, we examine the factors influencing MFD shapes across different locations. Our empirical findings reveal that across U.S. urban areas, network topology, transportation infrastructure, and land use are primary factors shaping MFD curves, while demand and trip-related factors play a lesser role. Specifically, higher ranking roads, centrality, and development levels correlate positively with network capacity and critical density, whereas negative associations are observed for network connectivity, mixed-use development, and road roughness levels.

Jin, Ling↗
DOE OSTI2026

Modeling the influence of the solid electrolyte interphase on the sand’s time and dendrite formation on lithium metal electrodes

Lithium metal is a sought after battery material for its high energy density due to the low electrochemical potential and density. However, lithium metal is also highly reactive, which results in a strong propensity for dendrite formation. The Sand’s time has previously been used to predict the time of dendrite initiation on metals that do not form a solid-electrolyte interphase (SEI), but it has been shown that the Sand’s time is not accurate for lithium electrodes when using transport parameters associated with the electrolyte. Thus, we built a numerical model to simulate lithium ion transport through a growing SEI to predict the Sand’s time. The numerical model is shown to be more accurate than previous analytical solutions, especially for low current densities. We then analyze the sensitivity of the Sand’s time to different SEI properties and the chemical potential gradients present in the SEI, driving lithium transport. The results showed that high lithium concentration has a greater impact at high current density, while fast diffusivity is more important at low current density. Lastly, we modeled the influence of surface roughness on the plating evolution and chemical potential gradients when an SEI is present in comparison to the electrolyte. As a result, we demonstrate that the SEI plays a critical role in lithium electrode stability, and that improved characterization techniques are needed to better understand transport through the SEI and increase lithium metal utilization in energy storage devices.

Chemistry↗
DOE OSTI2020

Effects of cryogenic temperature and grain size on fatigue-crack propagation in the medium-entropy CrCoNi alloy

CrCoNi-based high-entropy alloys have demonstrated outstanding mechanical properties, particularly at cryogenic temperatures. Here we investigate the fatigue-crack propagation properties of the equiatomic, single-phase, face-centered cubic, medium-entropy alloy (MEA), CrCoNi, that displays exceptional strength, ductility and toughness, all of which are enhanced at cryogenic temperatures. Fatigue-crack growth is examined, at a load ratio of 0.1 over a wide range of growth rates, from ~10 –11 to >10 –7 m/cycle, at room (293 K) and cryogenic (198 K, 77 K) temperatures for two grain sizes (~7 and 68 µm), with emphasis on near-threshold behavior. We find that the ΔK th fatigue thresholds are increased with decreasing temperature and increasing grain size: from 5.7 MPa√m at 293 K to 8 MPa√m at 77 K in the fine-grained alloy, and from 9.4 MPa√m at 293 K to 13.7 MPa√m at 77 K in the coarse-grained alloy. Mechanistically, transgranular cracking at 293 K transitions to a mixture of intergranular and transgranular at cryogenic temperatures, where the increased propensity of nano-twins appears to inhibit growth rates by deflecting the crack path. However, the main factor affecting near-threshold behavior is roughness-induced crack closure from interference between the crack flanks, which is enhanced by the rougher fracture surfaces at low temperatures, particularly in the coarser-grained microstructure. Here, fatigue-crack propagation behavior in CrCoNi is comparable to nickel-based superalloys but is superior to that of the high-entropy CrMnFeCoNi (Cantor) alloy and many high-strength steels, making the CrCoNi alloy an excellent candidate material for safety-critical applications, particularly involving low temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Multimodal 3D characterization of voids in shock-loaded tantalum: Implications for ductile spallation mechanisms

Predicting the failure of crystalline materials at high strain rates requires knowledge of the underlying failure mechanisms and their dependence on microstructure. However, little experimental consensus exists on the underlying micromechanics of spallation. In this study, a 3D-EBSD characterization experiment is performed on tantalum prior to and after partial spallation by plate impact, which allowed for the statistical assessment of the microstructural neighborhoods surrounding incipient voids. In analyzing the resulting dataset containing 5884 grains and 467 voids, it is observed that the voids were roughly spherical and consistent in size throughout the spalled material. The voids mostly resided at quadruple points, at triple junctions, at grain boundaries, and within grains, in decreasing order of prevalence. Moreover, voids tended to form at grain boundaries with high degrees of plastic incompatibility, growing into the plastically soft grain but orienting primarily with or perpendicular to the loading direction. Here, the statistics from these analyses of 3D microstructural data support dynamic cavitation models for ductile spallation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

The hierarchical energy landscape of screw dislocation motion in refractory high-entropy alloys

High-entropy alloys (HEAs) with concentrated solid solutions are conceived to possess a rugged atomic and energy landscape in which dislocation motion necessarily proceeds to accommodate mechanical deformation. Fundamental questions remain as to how rough the energy landscape is and to what extent it can be influenced by the local ordering of their constituent elements. Here, we construct and report the potential energy landscape (PEL) governing screw dislocation motion in refractory HEAs that reveals a hierarchical and multilevel structure with a collection of small basins nested in large metabasin. This striking feature pertaining to HEAs exerts a trapping force and back stress on saddle point activations, retarding dislocation movement. Further, by introducing chemical short-range order, the energy landscape is smoothed but skewed to different degrees that shifts the rate-liming process from kink-glide to kink-pair nucleation. The chemical disorder-roughened PEL in HEAs, analogous to structural disorder induced in metallic glasses, signifies the role of various barrier-hopping processes underlying the extraordinary mechanical behaviors of the two distinct groups of materials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Correlating aluminum layer deposition rates, Josephson junction microstructure, and superconducting qubits’ performance

An ultra-thin aluminum oxide layer is a key component for Josephson junctions (JJ) in superconducting quantum bits (qubits). This layer serves as a barrier layer for Cooper pairs tunneling between the superconducting electrodes and significantly influences the overall performance of the junction. In this study, we investigate the impact of aluminum deposition rates on the microstructure and chemical variation of the aluminum oxide layer, as well as the device's yields and qubits’ lifetimes. Surprisingly, although the oxide layer roughness and thickness variation improve noticeably with an increasing Al deposition rate from 0.5 Å/s to 5 Å/s, the qubit's coherence time is almost unchanged. We attribute this to the fact that Cooper pairs tunnel only through the thinnest region of the barrier. Additionally, we revealed a stress-induced grain boundary sliding short-circuit failure mechanism in the JJ. Our discovery provides a vital understanding of oxide microstructure and JJ functionality, which are critical for improving the coherence time of superconducting qubits.

Coherence time↗
DOE OSTI2025

Economics of electric vehicle corridor fast charging in the United States

Corridor direct-current fast charging (DCFC) stations enable long-distance electric vehicle travel, yet their economics remain uncertain due to high capital costs, low initial utilization, and exposure to utility demand charges. This study evaluates the long-term economics of corridor DCFC across the United States, incorporating capital and operating expenses-including charging equipment and real-world utility tariffs-alongside modeled station utilization, financial incentives, and ancillary retail revenue. In the Baseline scenario, modeled breakeven costs for corridor DCFC average $\$$0.42/kWh over 20 years, yet fewer than half of stations reach cost parity with gasoline on a per-mile basis. Utilization is the primary driver of cost variation, with low-utilization stations costing roughly six times more per kilowatt-hour than the national average. Excluding stations that fail to reach cost parity reduces National Highway System coverage within 50 miles from 94% to 67%, underscoring the trade-off between market-driven deployment and comprehensive network coverage. These results provide guidance for charging providers, utilities, planners, and policymakers seeking to develop and sustain a financially viable national corridor charging network.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Parametrically designed surface topography on CAD models of additively manufactured lattice structures for improved design validation

Additively Manufactured (AM) lattice structures of the laser powder bed fusion (LPBF) process generally have different surface geometries depending on the overhang angle and location. This means that the design validation stage is often challenging, considering it is based on an ideal Computer Aided Design (CAD) model that is not truly representative, since the AM part will be different in terms of dimensional accuracy and surface finish. Previous studies have relied on the design of surface textures that are independent of the overhang angle, or techniques based on directly using X-ray Computed Tomography (XCT) data. In this paper, a new technique for designing surface texture on the CAD of lattices has been investigated and correlated with areal surface roughness parameters. After extracting areal surface parameters from the XCT data of the lattice, the method allowed for the design of this surface texture on the part CAD taking in consideration if its up skin or down skin, without using XCT data as the main input. By applying this method, it is possible to obtain a lattice CAD model with a designed surface texture and geometry that is more representative of the actual AM lattice. The mean deviation between the CAD model with the designed surface and the XCT was a third of the one between the XCT and the initial CAD. The proposed method allows for designing and replicating LPBF AM surfaces on the CAD of a lattice, taking into consideration the dimensional deviation caused by AM surfaces, especially on overhangs. Assuming that an LPBF AM process is stable and produces approximately the same AM surface, this method can be used to predict the geometry of a lattice, providing a cost-effective and efficient methodology that minimizes the time needed for design validation.

42 ENGINEERING↗