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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 NTRS2006

MSFC Analysis of Thermal Control Materials on MISSE

Many different passive thermal control materials were flown as part of the Materials on International Space Station Experiment, including coatings, anodizes, and multi-layer insulation materials. Engineers and scientists at the Marshall Space Flight Center have analyzed a number of these materials, including: Zinc oxide/potassium silicate coating, Zinc orthotitanate/potassium silicate coating, Sulfuric acid anodized aluminum, Various coatings for part marking, automated rendezvous and capture, and astronaut visual aids, FEP Teflon with silver/Inconel backing, and Beta cloth with and without aluminization. These and other material samples were exposed to the low Earth orbital environment of atomic oxygen, ultraviolet radiation, thermal cycling, and hard vacuum, though atomic oxygen exposure was very limited for some samples. Solar absorptance, infrared emittance, and mass measurements indicate the durability of these materials to withstand the space environment. The effect of contamination from an active space station on the performance of white thermal control coatings is discussed.

Finckenor, Miria↗
NASA NTRS2012

Heated-Atmosphere Airship for the Titan Environment: Thermal Analysis

Future exploration of Saturn's moon Titan can be carried out by airships. Several lighter-than-atmosphere gas airships and passive drifting heated-atmosphere balloon designs have been studied, but a heated-atmosphere airship could combine the best characteristics of both. This work analyses the thermal design of such a heated-atmosphere vehicle, and compares the result with a lighter-than-atmosphere (hydrogen) airship design. A design tool was created to enable iteration through different design parameters of a heated-atmosphere airship (diameter, number of layers, and insulating gas pocket thicknesses) and evaluate the feasibility of the resulting airship. A baseline heated-atmosphere airship was designed to have a diameter of 6 m (outer diameter of 6.2 m), three-layers of material, and an insulating gas pocket thickness of 0.05 m between each layer. The heated-atmosphere airship has a mass of 161.9 kg. A similar mission making use of a hydrogen-filled airship would require a diameter of 4.3 m and a mass of about 200 kg. For a long-duration mission, the heated-atmosphere airship appears better suited. However, for a mission lifetime under 180 days, the less complex hydrogen airship would likely be a better option.

Heller, R. S.↗
DOE OSTI2024

Lattice and Local Electronic Structure Modulation Enables Ultra-Long-Life Li-Rich Cathode Materials

Effectively alleviating severe performance deterioration including rapid capacity decay and continuous voltage fading of Li-rich layered oxide (LLO) cathodes by suppressing the irreversible oxygen release and transition metal (TM) migration is a critical challenge during prolonged cycling. Herein, we report a Sb-doped LLO (SLLO) cathode with shortened TM oct –TM oct distance and modulated local electronic structure, which can significantly enhance the oxygen vacancy formation energy and TM migration energy barriers. Therefore, the SLLO cathode showcases an impressive energy density of 1052 Wh kg –1 at 0.2 C and an outstanding rate capability of 214 mAh g –1 at 5 C with a remarkable capacity retention of 79.2% even after 1000 cycles. It should be pointed out that it exhibits greatly enhanced voltage stability with an outstanding voltage retention of 86.2% after cycling 1600 times at 10 C. In conclusion, this work provides a prototype for significantly enhancing the reversibility in electrochemical reactions of high-capacity layered cathode materials.

25 ENERGY STORAGE↗
DOE OSTI2022

Graphene Nanopattern for Single-Crystal Film Growth, Defect Reduction and Layer Transfer

Thin film heterostructures are key building blocks for advanced electronic and optoelectronic devices. For this, direct heteroepitaxy has been pursued for decades, although it has been challenging to reduce crystal defects stemming from lattice mismatches and thermal mismatches between materials. The layer transfer method has been proposed as an alternative approach, wherein dissimilar materials are separately grown and then hetero-integrated. However, the applicability of layer transfer techniques is limited by several technical challenges, such as controllability, throughput, and damage to the substrate. Remote epitaxy, which is a recently developed method to produce single-crystalline membranes, is a promising approach but cannot be applied to elemental materials such as Si and Ge. In this work, we report graphene nanopattern as a universal template for the growth of single-crystal thin films that can be exfoliated as a freestanding form. This is realized by the chemical inertness of graphene, which allows selective nucleation at the exposed region, followed by lateral overgrowth onto graphene to form a planarized thin film. By employing graphene nanopattern, both group IV and III-V materials are utilized as the substrate as well as the epilayer. The epilayer can be exfoliated at the graphene interface because partially covered graphene effectively weakens the interface, which is corroborated by theoretical analyses of spalling theory. We reveal that graphene nanopattern not only works as a weakened interface for exfoliation, but also allows for dislocation reduction in heteroepitaxial films. This is because of the flexibility and the dangling-bond-free nature of graphene, which provides an additional path for strain relaxation. Therefore, these results represent a meaningful step toward production of high-quality single-crystal membranes that can be hetero-integrated.

Kim, Hyunseok↗
DOE OSTI2022

Graphene Nanopattern for Single-Crystal Film Growth, Defect Reduction and Layer Transfer

Thin film heterostructures are key building blocks for advanced electronic and optoelectronic devices. For this, direct heteroepitaxy has been pursued for decades, although it has been challenging to reduce crystal defects stemming from lattice mismatches and thermal mismatches between materials. The layer transfer method has been proposed as an alternative approach, wherein dissimilar materials are separately grown and then hetero-integrated. However, the applicability of layer transfer techniques is limited by several technical challenges, such as controllability, throughput, and damage to the substrate. Remote epitaxy, which is a recently developed method to produce single-crystalline membranes, is a promising approach but cannot be applied to elemental materials such as Si and Ge. In this work, we report graphene nanopattern as a universal template for the growth of single-crystal thin films that can be exfoliated as a freestanding form. This is realized by the chemical inertness of graphene, which allows selective nucleation at the exposed region, followed by lateral overgrowth onto graphene to form a planarized thin film. By employing graphene nanopattern, both group IV and III-V materials are utilized as the substrate as well as the epilayer. The epilayer can be exfoliated at the graphene interface because partially covered graphene effectively weakens the interface, which is corroborated by theoretical analyses of spalling theory. We reveal that graphene nanopattern not only works as a weakened interface for exfoliation, but also allows for dislocation reduction in heteroepitaxial films. This is because of the flexibility and the dangling-bond-free nature of graphene, which provides an additional path for strain relaxation. Therefore, these results represent a meaningful step toward production of high-quality single-crystal membranes that can be hetero-integrated.

Kim, Hyunseok↗
NASA NTRS2013

Three-Dimensional (3D) Additive Construction: Printing with Regolith

Three dimensional (3D) printing is a new and booming topic in many realms of research and engineering technology. When it comes to space science and aerospace engineering, it can be useful in numerous ways. As humans travel deeper into space and farther from Earth, sending large quantities of needed supplies from Earth for a mission becomes astronomically expensive and less plausible. In order to reach further to new places, In Situ Resource Utilization (ISRU), a project that pushes for technologies to use materials already present in the destination's environment, is necessary. By using materials already available in space such as regolith from the Moon, Mars, or an asteroid's surface, fewer materials need to be brought into space on a launched vehicle. This allows a vehicle to be filled with more necessary supplies for a deep space mission that may not be found in space, like food and fuel. This project's main objective was to develop a 3D printer that uses regolith to "print" large structures, such as a dome, to be used as a heat shield upon a vehicle's reentry into the atmosphere or even a habitat. 3D printing is a growing technology that uses many different methods to mix, heat, and mold a material into a specific shape. In order to heat the regolith enough to stick together into a solid shape, it must be sintered at each layer of material that is laid. Sintering is a process that heats and compresses a powdered material until it fuses into a solid, which requires a lot of energy input. As an alternative, a polymer can be mixed with the regolith before or as it is sent to the 3D printer head to be placed in the specific shape. The addition of the polymer, which melts and binds at much lower temperatures than sintering temperatures, greatly decreases the required heating temperature and energy input. The main task of the project was to identify a functional material for the printer. The first step was to find a miscible. polymer/solvent solution. This solution was added to the regolith and the solvent was evaporated essentially leaving polymer-coated regolith particles. This material would be sent through the printer head and heated layer by layer to melt the polymer and bind the regolith. This method was one of many in a large goal to utilize materials in space with a custom-made 3D printer that builds dome-shaped habitats and other essential equipment for future deep space missions.

Tsoras, Alexandra↗
NASA NTRS1997

SYNTHESIS OF NOVEL ALL-DIELECTRIC GRATING FILTERS USING GENETIC ALGORITHMS

We are concerned with the design of inhomogeneous, all dielectric (lossless) periodic structures which act as filters. Dielectric filters made as stacks of inhomogeneous gratings and layers of materials are being used in optical technology, but are not common at microwave frequencies. The problem is then finding the periodic cell's geometric configuration and permittivity values which correspond to a specified reflectivity/transmittivity response as a function of frequency/illumination angle. This type of design can be thought of as an inverse-source problem, since it entails finding a distribution of sources which produce fields (or quantities derived from them) of given characteristics. Electromagnetic sources (electric and magnetic current densities) in a volume are related to the outside fields by a well known linear integral equation. Additionally, the sources are related to the fields inside the volume by a constitutive equation, involving the material properties. Then, the relationship linking the fields outside the source region to those inside is non-linear, in terms of material properties such as permittivity, permeability and conductivity. The solution of the non-linear inverse problem is cast here as a combination of two linear steps, by explicitly introducing the electromagnetic sources in the computational volume as a set of unknowns in addition to the material unknowns. This allows to solve for material parameters and related electric fields in the source volume which are consistent with Maxwell's equations. Solutions are obtained iteratively by decoupling the two steps. First, we invert for the permittivity only in the minimization of a cost function and second, given the materials, we find the corresponding electric fields through direct solution of the integral equation in the source volume. The sources thus computed are used to generate the far fields and the synthesized triter response. The cost function is obtained by calculating the deviation between the synthesized value of reflectivity/transmittivity and the desired one. Solution geometries for the periodic cell are sought as gratings (ensembles of columns of different heights and widths), or combinations of homogeneous layers of different dielectric materials and gratings. Hence the explicit unknowns of the inversion step are the material permittivities and the relative boundaries separating homogeneous parcels of the periodic cell.

Zuffada, Cinzia↗
NASA NTRS2002

Micro-Mechanical Modeling of Ductile Fracture in Welded Aluminum-Lithium Alloys

This study describes a 3-D computational framework to model stable extension of a macroscopic crack under mode I conditions in ductile metals. Material separation occurs through a local fracture mechanism based on the growth and coalescence of micro voids dispersed in the material. The Gurson-Tvergaard plasticity model for void materials describes the eventual loss of material stress capacity under sustained loading. Fixed-sized computational cell elements defined on a thin layer adjacent to the crack plane provide an implicit length scale for continuum damage model. Outside this layer, the material remains undamaged by void growth, consistent with metallurgical observations. The key micro-mechanics parameters are D, the thickness of cell layer, and f 0 , the initial cell porosity.

Ahmed Ibrahim↗
DOE OSTI2025

UV-Enabled Defect Engineering in Multilayer GaSe and InSe and UV Writing of the Grating Pattern

III–VI post-transition-metal chalcogenides are layered semiconductor materials that exhibit direct band gaps in multilayers. Defect engineering is essential in 2D layered semiconductors for functional devices. Here, in this work, we report defect engineering in multilayer gallium selenide (GaSe) and indium selenide (InSe), where defects generated by ultraviolet (UV, 325 nm) laser irradiation result in an additional photoluminescence (PL) line. The additional PL line is due to defect-bound excitons. Characteristics of the defect emission are similar in GaSe and InSe samples subjected to UV irradiation, air annealing, and hydrostatic pressure. Two-beam UV interference was applied to create grating patterns with a periodic array of low and high densities of defects in GaSe. Density functional theory has identified the defect type in GaSe. The results provide valuable insights into defect generation and UV scribing of photonic circuits in 2D Se-based multilayers for optical integration in a 2D platform.

2D multilayered materials↗
DOE OSTI2025

Final Design for Thermal/Epithermal eXperiments (TEX) with Lithium Absorbers to Provide Validation Benchmarks for Y-12 Electrorefining Facility

One of the main goals of the Thermal/Epithermal eXperiments (TEX) project is to use existing Nuclear Criticality Safety Program (NCSP) assets to create critical experiment plutonium and uranium test beds for materials important to criticality safety that have insufficient benchmark evaluations. The plutonium test bed experiments were completed in 2018 and are published in the 2020 edition of the International Criticality Safety Benchmark Evaluation Project (ICSBEP) Handbook. The uranium test bed assemblies were completed in 2023 and accepted in the 2024 edition of the ICSBEP Handbook. The Nuclear Criticality Safety (NCS) group at Y-12 National Security Complex has identified programmatic need for validation cases for uranium electrorefining operations at Y-12. The electrorefining operation credits lithium enriched in 6 Li in addition to 35 Cl as absorbers in the design criticality safety evaluation for precluding criticality under upset conditions in the large and geometrically unfavorable electro-refiner. There is, however, inadequate experimental validation for the 6 Li absorbers. As an extension of the TEX uranium test bed, TEX-Cl critical experiments were performed with sodium chloride salt to address the 35 Cl thermal absorption as well as other validation needs at Los Alamos National Laboratory (LANL). These experiments were completed in 2024 and accepted into the 2025 ICSBEP Handbook. To continue the methodology used in TEX-Cl, TEX-Li aims to accomplish the same. The overall design of both experiments was to use commercially available, high purity, salts with polyethylene moderator and HEU plates to configure a critical assembly. Three experiments are planned for TEX-Li using encapsulated lithium carbonate (Li 2 CO 3 ), with natural 6 Li abundance. For all experiments, the highly enriched uranium (HEU) Jemima plates will be used as fissile material. Multiple layers will be stacked together with encapsulated Li 2 CO 3 alternated with polyethylene in standard configurations. Standard stacking was found to be optimal in matching the different sensitivity profiles provided by the Y-12 models. Three configurations are proposed with varying polyethylene moderation and a constant 1/4” absorber thickness. The first uses 11 layers of 5/4” polyethylene, the second uses 9 layers of 3/4” polyethylene, and the third uses 10 layers of 1/2” polyethylene. Calculations showed that some alternative forms of lithium-based materials provided slightly less-optimal sensitivity profiles when compared to lithium carbonate but come with other drawbacks. These alternatives included lithium aluminate (LiAlO 2 ), Aluminum-2050 alloy, Aluminum-8090, Aluminum-2095, lithium hydride (LiH), and lithium fluoride (LiF). Lithium aluminate and aluminum-2050 provided comparable sensitivity profiles when compared to lithium carbonate and can be used instead if lithium carbonate cannot be readily procured. After a broad material study, lithium carbonate outperformed any alternative material with a balance in affordability and workability. The assessment of experimental uncertainties of the non-absorber and absorber components was predicted to be 0.00089 and 0.00093 Δk eff , respectively. The largest uncertainties may be reduced with precision dimensional inspection of the components. Many of the parts and equipment for IER 575 have already been fabricated or procured for previous projects and therefore do not contribute significantly to the overall cost of this experiment. This includes the Jemima plates and Comet critical assembly machine, which are existing NCSP assets, as well as the aluminum platen and polyethylene reflector rings, which were fabricated and authorized for the TEX experiment involving HEU with polyethylene. Lithium carbonate containers will be procured by LANL and will be filled by LLNL. The total material costs for TEX-Li experiments are estimated to be on the order of $\$$47,400. Precision inspection, including dimensional, mass, density, and impurity, is recommended for all components for an estimated cost of $\$$12,000.

35Cl↗
NASA NTRS2007

Method of Fabricating a Composite Apparatus

A method for fabricating a piezoelectric macro-fiber composite actuator comprises making a piezoelectric fiber sheet by providing a plurality of wafers of piezoelectric material, bonding the wafers together with an adhesive material to from a stack of alternating layers of piezoelectric material and adhesive material, and cutting through the stack in a direction substantially parallel to the thickness of the stack and across the alternating layers of piezoelectric material and adhesive material to provide at least one piezoelectric fiber sheet having two sides comprising a plurality of piezoelectric fibers in juxtaposition to the adhesive material. The method further comprises bonding two electrically conductive films to the two sides of the piezoelectric fiber sheet. At least one conductive film has first and second conductive patterns formed thereon which are electrically isolated from one another and in electrical contact with the piezoelectric fiber sheet.

Wilkie, W. Keats↗
NASA NTRS2017

An Overview of Materials Structures for Extreme Environments Efforts for 2015 SBIR Phases I and II

Technological innovation is the overall focus of NASA's Small Business Innovation Research (SBIR) program. The program invests in the development of innovative concepts and technologies to help NASA's mission directorates address critical research and development needs for Agency projects. This report highlights innovative SBIR 2015 Phase I and II projects that specifically address areas in Materials and Structures for Extreme Environments, one of six core competencies at NASA Glenn Research Center. Each article describes an innovation, defines its technical objective, and highlights NASA applications as well as commercial and industrial applications. Ten technologies are featured: metamaterials-inspired aerospace structures, metallic joining to advanced ceramic composites, multifunctional polyolefin matrix composite structures, integrated reacting fluid dynamics and predictive materials degradation models for propulsion system conditions, lightweight inflatable structural airlock (LISA), copolymer materials for fused deposition modeling 3-D printing of nonstandard plastics, Type II strained layer superlattice materials development for space-based focal plane array applications, hydrogenous polymer-regolith composites for radiation-shielding materials, a ceramic matrix composite environmental barrier coating durability model, and advanced composite truss printing for large solar array structures. This report serves as an opportunity for NASA engineers, researchers, program managers, and other personnel to learn about innovations in this technology area as well as possibilities for collaboration with innovative small businesses that could benefit NASA programs and projects.

integrated reacting fluid dynamics and predictive ↗
DOE OSTI2020

Roll-To-Roll Atomic Layer Deposition of Titania Nanocoating on Thermally Stabilizing Lithium Nickel Cobalt Manganese Oxide Cathodes for Lithium Ion Batteries

Conformal coating of ceramic layers (nm-thick) on Ni-rich layered cathode materials is an effective strategy for improving high-temperature longevity of Li-ion batteries (LIBs). In this work, we develop a roll-to-roll atomic layer deposition (R2R ALD) apparatus for growing uniform nanolayers of TiO 2 . We explore the effect of ALD parameters (temperature: 120–180 °C and line speed: 2–40 mm s –1 ) on the TiO 2 surface coating and subsequently investigate the electrochemical performance of the as-prepared cathodes. The capacity retention of TiO 2 -coated porous electrodes is substantially improved compared to that of the pristine cathode material for high-temperature cycling. Electrochemical impedance spectroscopy confirms that the ALD-TiO 2 coating suppresses the undesired side reactions initiated at the electrode/electrolyte interface, reduces charge transfer resistance, and ultimately facilitates the Li + transport through the composite cathode nanostructure. The robust design of the ALD-TiO 2 cathode material enables high-temperature operation (>55 °C) with enhanced specific capacity, superior rate capability, excellent cyclability, and ultra-high coulombic efficiency within a wide potential window (3.0–4.35 V). Furthermore, the R2R ALD technique developed in this work paves the way for large-scale fabrication of ceramic-coated cathode sheets with a production rate reaching 2.4 m min –1 for a continuous coating operation.

25 ENERGY STORAGE↗
NASA NTRS2015

Methods of Fabricating a Layer of Metallic Glass-Based Material Using Immersion and Pouring Techniques

Systems and methods in accordance with embodiments of the invention implement layers of metallic glass-based materials. In one embodiment, a method of fabricating a layer of metallic glass includes: applying a coating layer of liquid phase metallic glass to an object, the coating layer being applied in a sufficient quantity such that the surface tension of the liquid phase metallic glass causes the coating layer to have a smooth surface; where the metallic glass has a critical cooling rate less than 1000 K/s; and cooling the coating layer of liquid phase metallic glass to form a layer of solid phase metallic glass.

Hofmann, Douglas↗
DOE OSTI2024

Scale-Up of Lithium Iron & Aluminum Nickelate Advanced Cathode and Fabrication of A Battery Pack Comprising The Same

Global battery manufacturers are increasingly worried about the serious supply chain constraint caused by rapid fluctuations in cobalt prices over the years. We present a novel cobalt-free, nickel-rich layered cathode material called NFA class (LiNixFeyAlzO2) to tackle this challenge. Spherical NFA(OH)2 precursors were successfully synthesized by incorporating Ni, Fe, and Al elements using a co-precipitation reaction in a continuous stirred tank reactor. The LiNFAO2 cathode, composed of LiNi0.85Fe0.05Al0.1O2, was synthesized and analyzed using X-Ray diffraction, Mössbauer spectroscopy, and scanning electron microscopy (SEM). The material's electrochemical behavior was evaluated through various techniques at different lithiation/delithiation states in two voltage ranges. The cobalt-free material exhibits a high capacity of 190 mAh/g at 0.1C within the voltage range of 3V-4.5V, as demonstrated by electrochemical performance evaluations. Rate and cycling evaluations showed good rate capability and cycling stability, with 88% capacity retention after 100 cycles at C/3 within the voltage range of 3V-4.3V. Our research shows the great potential of cobalt-free NFA cathodes as a feasible option for developing cost-effective lithium-ion batteries.

25 ENERGY STORAGE↗
DOE OSTI2026

Revealing the Hidden Third Dimension of Point Defects in Two-Dimensional MXenes

Point defects govern many important functional properties of two-dimensional (2D) materials. However, resolving the three-dimensional (3D) arrangement of these defects in multi-layer 2D materials remains a fundamental challenge, hindering rational defect engineering. Here, we overcome this limitation using an artificial intelligence-guided electron microscopy workflow to map the 3D topology and clustering of atomic vacancies in Ti3C2TX MXene. Our approach reconstructs the 3D coordinates of vacancies across hundreds of thousands of lattice sites, generating robust statistical insight into their distribution that can be correlated with specific synthesis pathways. This large-scale data enables us to classify a hierarchy of defect structures-from isolated vacancies to nanopores-revealing their preferred formation and interaction mechanisms, as corroborated by molecular dynamics simulations. This work provides a generalizable framework for understanding and ultimately controlling point defects across large volumes, paving the way for the rational design of defect-engineered functional 2D materials.

2D materials↗
NASA NTRS2008

MISSE Thermal Control Materials with Comparison to Previous Flight Experiments

Many different passive thermal control materials were flown as part of the Materials on International Space Station Experiment (MISSE), including inorganic coatings, anodized aluminum, and multi-layer insulation materials. These and other material samples were exposed to the low Earth orbital environment of atomic oxygen, ultraviolet radiation, thermal cycling, and hard vacuum, though atomic oxygen exposure was limited for some samples. Materials flown on MISSE-1 and MISSE-2 were exposed to the space environment for nearly four years. Materials flown on MISSE-3, MISSE-4, and MISSE-5 were exposed to the space environment for one year. Solar absorptance, infrared emittance, and mass measurements indicate the durability of these materials to withstand the space environment. Effects of short duration versus long duration exposure on ISS are explored, as well as comparable data from previous flight experiments, such as the Passive Optical Sample Assembly (POSA), Optical Properties Monitor (OPM), and Long Duration Exposure Facility (LDEF).

Finckenor, Miria↗
DOE OSTI2020

Origins of Irreversibility in Layered NaNi x Fe y Mn z O 2 Cathode Materials for Sodium Ion Batteries

Layered NaNi x Fe y Mn z O 2 cathode (NFM) is of great interest in sodium ion batteries due to its high theoretical capacity and utilization of abundant, low-cost, environmentally-friendly raw materials. Nevertheless, there remains insufficient understanding on the concurrent local environment evolution in each transition metal (TM) that largely influences the reversibility of the cathode materials upon cycling. In this work, we investigate the reversibility of TM ions in layered NFMs with varying Fe contents and potential windows. Utilizing ex situ synchrotron X-ray absorption near edge spectroscopy (XANES) and extended X-ray absorption fine structure (EXAFS) of pre-cycled samples the valence and bonding evolution of the TMs are elucidated. It is found that Mn is electrochemically inactive as indicated by the insignificant change of Mn valence and Mn-O bonding distance. Fe is electrochemically inactive after the first five cycles. The Ni redox couple contributes most of the charge compensation for NFMs. Ni redox is quite reversible in the cathodes with less Fe contents. Furthermore, the Ni redox couple shows significant irreversibility with high Fe content of 0.8. The electrochemical reversibility of the NFM cathode becomes increasingly enhanced with the decrease of either Fe content or with lower upper charge cutoff potential.

25 ENERGY STORAGE↗