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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 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Design Curve Generation for 3D SiC Fiber Architecture

The design tool provides design curves that allow a simple and quick way to examine multiple factors that can influence the processing and key properties of the preforms and their final SiC-reinforced ceramic composites without over obligating financial capital for the fabricating of materials. Tool predictions for process and fiber fraction properties have been validated for a HNS 3D preform.The virtualization aspect of the tool will be used to provide a quick generation of solid models with actual fiber paths for finite element evaluation to predict mechanical and thermal properties of proposed composites as well as mechanical displacement behavior due to creep and stress relaxation to study load sharing characteristic between constitutes for better performance.Tool predictions for the fiber controlled properties of the SiCSiC CMC fabricated from the HNS preforms will be valuated and up-graded from the measurements on these CMC

matrix materials↗
NASA NTRS1991

Synthesis of high performance ceramic fibers by chemical vapor deposition for advanced metallics reinforcing

The chemical vapor deposition (CVD) synthesis of fibers capable of effectively reinforcing intermetallic matrices at elevated temperatures which can be used for potential applications in high temperature composite materials is described. This process was used due to its advantage over other fiber synthesis processes. It is extremely important to produce these fibers with good reproducible and controlled growth rates. However, the complex interplay of mass and energy transfer, blended with the fluid dynamics makes this a formidable task. The design and development of CVD reactor assembly and system to synthesize TiB2, CrB, B4C, and TiC fibers was performed. Residual thermal analysis for estimating stresses arising form thermal expansion mismatch were determined. Various techniques to improve the mechanical properties were also performed. Various techniques for improving the fiber properties were elaborated. The crystal structure and its orientation for TiB2 fiber is discussed. An overall view of the CVD process to develop CrB2, TiB2, and other high performance ceramic fibers is presented.

Revankar, Vithal↗
NASA NTRS2015

The Effect of Stochastically Varying Creep Parameters on Residual Stresses in Ceramic Matrix Composites

Constituent properties, along with volume fraction, have a first order effect on the microscale fields within a composite material and influence the macroscopic response. Therefore, there is a need to assess the significance of stochastic variation in the constituent properties of composites at the higher scales. The effect of variability in the parameters controlling the time-dependent behavior, in a unidirectional SCS-6 SiC fiber-reinforced RBSN matrix composite lamina, on the residual stresses induced during processing is investigated numerically. The generalized method of cells micromechanics theory is utilized to model the ceramic matrix composite lamina using a repeating unit cell. The primary creep phases of the constituents are approximated using a Norton-Bailey, steady state, power law creep model. The effect of residual stresses on the proportional limit stress and strain to failure of the composite is demonstrated. Monte Carlo simulations were conducted using a normal distribution for the power law parameters and the resulting residual stress distributions were predicted.

processing↗
DOE OSTI2017

Take a Trip Around a 3D Printing Lab (360)

Additive manufacturing has changed the way the world thinks about manufacture and design. Scientists and researchers at Lawrence Livermore National Lab are using a number of 3D printing processes to experiment with unique combinations of plastic, metal, and ceramics.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Additive Manufacturing of Advanced High Temperature Masking Fixtures for EBPVD TBC Coating

The purpose of this Manufacturing Demonstration Facility (MDF) technical collaboration project between Praxair Surface Technologies, Inc. (PST) and Oak Ridge National Laboratory (ORNL) was to develop an additive manufacturing process to fabricate next generation high temperature masking fixtures for coating of turbine airfoils with ceramic Thermal Barrier Coatings (TBC) by the Electron Beam Physical Vapor Deposition (EBPVD) process. Typical masking fixtures are sophisticated designs and require complex part manipulation in order to achieve the desired coating distribution. Fixtures are typically fabricated from high temperature nickel (Ni) based superalloys. The fixtures are fabricated from conventional processes by welding of thin sheet material into a complex geometry, to decrease the weight load for the manipulator and to reduce the thermal mass of the fixture. Recent attempts have been made in order to fabricate the fixtures through casting, but thin walled sections are difficult to cast and have high scrap rates. This project focused on understanding the potential for fabricating high temperature Ni based superalloy fixtures through additive manufacturing. Two different deposition processes; electron beam melting (EBM) and laser powder bed fusion were evaluated to determine the ideal processing route of these materials. Two different high temperature materials were evaluated. The high temperature materials evaluated were Inconel 718 and another Ni base alloy, designated throughout the remainder of this document as Alloy X, as the alloy composition is sensitive. Inconel 718 is a more widely utilized material for additive manufacturing although it is not currently the material utilized for current fixtures. Alloy X is the alloy currently used for the fixtures, but is not a commercially available alloy for additive manufacturing. Praxair determined it was possible to build the fixture using laser powder bed technology from Inconel 718. ORNL fabricated the fixture geometry using the EBM technology in order to compare deposition features such as surface roughness, geometric accuracy, deposition rate, surface and subsurface porosity, and material quality. It was determined that the laser powder bed technology was ideal for the geometry and requirements of the fixture set by Praxair, and Praxair moved forward with the purchase of a laser powder bed system. The subsequent portion of the project focused on determining the ideal processing parameters for alloy X for the laser powder bed system using ORNL’s Renishaw laser powder bed system. Praxair supplied gas atomized powders of alloy X material with properties specified by ORNL. ORNL printed text cube arrays in order to determine the ideal combination of laser powder and laser travel speed in order to maximize material density, improve surface quality, and maintain geometric accuracy. Additional powder supplied by Praxair was used to fabricate a full-scale fixture component.

42 ENGINEERING↗
DOE OSTI2018

A complex approach to assessing porous structure of structured ceramics obtained by SPS technique

Highlights: • A complex approach to microstructural analysis of nanostructured SPS ceramics was presented. • A bunch of gas, intrusion and microscopic methods were applied for open/closed porosity determination in nanoceramics. • Kinetic TPR analysis for structural changes in nanoceramic was carried out. • 3D pore visualization for nanoceramics was provided via SEM/FIB tomography • Porosity calculations were performed via BET, BJH, t-plot, Washburn equation, FEI Avizo 9.1 software results. - Abstract: Spark plasma sintering (SPS) is a highly prospective technology providing rapid consolidation of nano-disperse compositions into structured ceramics with complex structural organization. Characterizing pore structure of such systems remains a challenge due to different types, size and shape of the pores as well as structural defects occurring in the material, thus requiring special methods to quantify certain porosity type. The paper presents a complex approach to studying structure of SPS hematite-based structured ceramics. The method involves a number of gas, intrusion and electron microscopy probing techniques to characterize open and closed pores in the ceramics bulk. Low temperature nitrogen sorption has been implemented to estimate open micro- and mesoporosity in the size range 0.7–50 nm using BET, BJH and t-plot methods to process experimental data. Additionally, structural peculiarities of consolidated structured ceramics have been studied using temperature-programmed reduction (TPR) with the kinetic analysis of the results being carried out. Volume of macropores sized above 50 nm has been measured with mercury intrusion. Closed pores and structural defects have been quantified with SEM and FIB/SEM tomography. By comparing experimental and estimated results we have shown that addressing all porosity types provides a highly precise structural characterization of the material.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2026

Ultrafast Laser Welding and Terahertz Time-domain Spectroscopy of Soda Lime Silicate Glass

Joining and welding techniques of similar and dissimilar materials have reached their limits due to the inflexibility of adapting dielectric materials, e.g., glasses and ceramics, reproducibility for transparent materials, and cycle process time. The ability to join pieces of glasses using laser irradiation allows rapid processing of vacuum insulating glass (VIG) for a widening range of commercial energy-efficient applications. We have used a 1064-nm laser wavelength with 15 picoseconds pulse width and a 155-kHz repetition rate to weld commercial plate glass pieces. The welded samples were characterized via x-ray fluorescence (XRF), time-of-flight secondary ion mass spectrometry (TOF–SIMS), polarimetry, and terahertz time-domain spectroscopy (THz-TDS) to determine the integrity of the weld and chemical changes in the welded areas. Our data shows no significant changes in glass chemistry and structure on average over nano- to micro-scales occurred from the welding process within the limits of the characterization tools. Our results demonstrate successful welding of glass plates without significant changes in the glass chemistry, structure, or properties in the laser-modified region or strains in the bulk glass.

Matthies, Kathleen [ORNL] (ORCID:0009000213135441)↗
DOE OSTI2019

Rational anode design for protonic ceramic fuel cells by a one-step phase inversion method

A one-step phase inversion method was applied to fabricate an optimized anode structure for protonic ceramic fuel cells (PCFCs). The phase inversion process utilized raw starting chemicals, instead of crystalline BaCe 0.7 Z r0.1 Y 0.1 Yb 0.1 O 3-δ (BCZYYb) powder in an energy and time saving process. The resulting large and fingerlike pores exhibited enhanced performance as compared to the disordered pores produced by conventional preparation of anode structures using dry pressing methods. The electrochemical performance of the rational designed anode supported cell were 491, 402, 302 and 200 mW cm -2 at 700, 650, 600 and 550 °C, respectively, which was nearly twice than the cell with dry pressing anode. An equivalent circuit modeling method was used to separate the anode polarization resistance from the single cell, confirming that the overall cell performance improvements were attributed to microstructural modifications of the anode by the phase inversion process. The one-step phase inversion method demonstrated great promise for improved processing of fuel cells and separation membranes.

25 ENERGY STORAGE↗
DOE OSTI2019

Reactive flash sintering of powders of four constituents into a single phase of a complex oxide in a few seconds below 700°C

Abstract Recent work on reactive flash sintering of powders of two oxides, bismuth and of iron oxide, into pure single phase bismuth ferrite, which was accomplished in a few seconds at low furnace temperatures, is expanded to four constituents, alumina, lithia, zirconia, and lanthana, to produce reasonably dense polycrystals of a predominantly single phase, cubic LLZO(Al). Transformation and sintering occur concurrently at a furnace temperature near 700°C, in ambient atmosphere, in just a few seconds. The process may simplify the preparation of complex ceramics with new chemistries and dopants, which are predicted from ab intio calculations to have special attributes, not only because the powders sinter quickly at low temperatures, but also because the need for stoichiometric powders as starting materials is obviated.

Avila, Viviana↗
DOE OSTI2013

Report on Evolutionary Enhancements to UO 2 Pellets

Sintered uranium oxide fuel pellets are the primary fuel used in civilian nuclear reactors. Due to extensive experience and established infrastructure, these ceramic fuels are likely to remain important for nuclear energy well into the future. Fuel pellets are produced mainly through cold-pressing ceramic powder and high temperature sintering. The processing technique presented here is designed to fit into the current fuel pellet production infrastructure with minimal changes to fuel manufacturers and reactor operators. This study makes changes in the UO 2 powder before the pellets are pressed, possibly requiring only minor changes in the manufacturing process.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

In situ transmission electron microscopy study of the microstructural origins for the electric field-induced phenomena in ferroelectric perovskites

Ferroelectrics are important materials due to their extensive technological applications, such as non-volatile memories, field-effect transistors, ferroelectric tunneling junctions, dielectric capacitors, piezoelectric transducers, sensors and actuators. As is well known, the outstanding dielectric, piezoelectric, and ferroelectric properties of these functional oxides originate from their ferroelectric domain arrangements and the corresponding evolution under external stimuli (e.g. electric field, stress, and temperature). Electric field has been known as the most efficient stimulus to manipulate the ferroelectric domains through polarization switching and alignment. Therefore, direct observation of the dynamic process of electric field-induced domain evolution and crystal structure transformation is of significant importance to understand the microstructural mechanisms for the functional properties of ferroelectrics. In this dissertation, electric field in situ transmission electron microscopy (TEM) technique was employed to monitor the real-time evolution of the domain morphology and crystal structure during various electrical processes: (1) the initial poling process, (2) the electric field reversal process, and (3) the electrical cycling process. Two types of perovskite-structured ceramics, normal ferroelectrics and relaxor ferroelectrics, were used for this investigation. In addition to providing the microscopic insight for some wellaccepted phase transformation rules, discoveries of some new or even unexpected physical phenomena were also demonstrated.

36 MATERIALS SCIENCE↗
DOE OSTI2017

ALON® Components With Tunable Dielectric Properties for High Power Accelerator Applications

There are challenges in linear particle accelerators associated with the need to suppress “higher order modes” (HOMs). HOMs are detrimental to accelerator operation as they are a source of beam instability. The absorption/suppression of HOMs and dissipation of the energy of higher order modes is vital to the function of these accelerators. Surmet has identified ALON® Optical Ceramic (Aluminum Oxynitride), a hard, durable ceramic that is fabricated through conventional powder processing techniques, as a potential material for HOM absorber. In this Phase I program, Surmet has produced new ALON-composite HOM absorber materials that function at both ambient and cryogenic temperatures. The composite materials were developed and evaluated in collaboration with Thomas Jefferson National Labs. Success in this Phase I and the potential Phase II will demonstrate the utility of ALON composite components for RF absorbing applications and lay the groundwork for commercialization of such products, with applications in basic science, medical and digital electronics industries.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Thermomechanical Processing of Uranium Alloys with 10 and 50 Weight Percent Zirconium

This work focuses on casting and thermomechanical processing for moderate sized (500-1000g) 10% by weight and 50% by weight uranium-zirconium alloys. Three castings of uranium – 10wt% zirconium and a fourth casting of uranium – 50wt% zirconium were completed using different castings processes. The first casting process relied on only induction mixing within the VIM system thereby eliminating the need for an arc-melting feedstock preparation step. The second casting process used the arc-melting process prior for feedstock to the same VIM system. In this study, the induction mixing process alone with a graphite crucible appears insufficient for the fabrication of UZr alloys. Graphite is suitable with the use of master alloy UZr feedstock produced by arc-melting. There was a moderate increase of approximately 100 ppm of carbon within the U10Zr alloys. However, there was a near 1000 ppm increase of carbon in the U50Zr alloy. This carbon content is considered too high for forming processes, and therefore, warrants the use of a ceramic crucible for UZr castings near 50wt% zirconium. Zirconia does not appear suitable for UZr castings near 50wt% zirconium. The use of Beryllia or Thoria may be a more suitable option. However, due to the significantly lower liquidus and lower zirconium content, Zirconia crucibles do appear viable for carbon reduction in the U10Zr system. Two thermomechanical processes are also studied in this work - hot extrusion of the U50Zr system and heat treatment in an argon atmosphere. This work demonstrated that extrusion of the U50Zr alloy near 680°C is a viable choice even with +1000 ppm carbon. Extrusion of the U50Zr system near 630°C was unsuccessful and does not appear viable unless significant force and tooling strength is available. There appears to be a moderate increase in extrudate hardness when compared to as-cast. Heat-treatment reduced the hardness of as-cast alloys in the U10Zr castings as well as resolve some variance in the microstructures. However, for the U50Zr billet that did not successfully extrude at 630°C, heat treatment at 900°C for 96 hours did not have a significant impact on hardness or microstructure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Computational Fluid Dynamics Modeling to Simulate a Combined Reforming Process for Syngas and Hydrogen Production

An Oxygen Transport Membrane (OTM) combined reforming technology for producing syngas and hydrogen integrates the advantages of multiple processes—steam methane reforming (SMR), autothermal reforming (ATR), an air separation unit (ASU)—into a single integrated technology. The OTM consists of a primary reforming tube, in which desulfurized natural gas is partially reformed by steam at high pressure in the presence of a metal catalyst. This process is followed in series by a ceramic OTM with a secondary reformer, in which residual methane reforms and O 2 - ions react with a portion of the CO and H 2 fuel to provide the heat to support both primary and secondary reforming. Although the OTM combined reformer technology for syngas and H 2 production has been substantially developed in the last decade, several challenges that affect the overall production efficiency and reliability are yet to be fully understood, addressed, and resolved. Therefore, developing Computational Fluid Dynamics (CFD) models that incorporate fluid dynamics, mass transport, kinetics, heat transport, and structural mechanics is critical to understanding and minimizing the probability of tube failures during the startup and operation. In this report, an exhaustive literature review was performed to survey the current state of technology for producing syngas and H 2 using either conventional or renewable energy sources. The feedstocks reviewed include natural gas and coal for the conventional technologies, whereas biomass, solar, wind, and nuclear energy for the renewable technologies. The existing industry-grade COMSOL multiphysics models of OTM were upgraded for the latest software release. In addition, they were improved to help achieve grid and solver independence and were successfully ported on the ORNL high-performance computing clusters to speed up their run times. A 42% reduction in the simulation run time was achieved. A new higher-fidelity CFD model of an OTM tube was developed in the StarCCM+ simulation platform. This new model was designed to simulate various physics using first principles, e.g., turbulent flow, heat transfer, and chemical reactions while avoiding unnecessary simplifications. The resulting predictions were qualitatively assessed and provided useful insights into the multiphysics complexity of an OTM tube.

08 HYDROGEN↗
NASA NTRS1972

Strain-biased PLZT input devices /page composers/ for holographic memories and optical data processing.

The features of a new class of transparent ferroelectric ceramic materials, called PLZT, are described. PLZT are shown to have very strong electrooptic properties and memory, and are switched through transparent electrodes when mechanically strained. Because of these properties, they can be used to fabricate two-dimensional page composers for coherent optical systems. Techniques for fabricating such devices are outlined along with preliminary test results. Applications in displays are shown to be also feasible.

Roberts, H. N.↗
NASA NTRS1979

Scaling and the start-up phase of space industrialization

By terrestrial standards very little mass is needed to construct the space portion of a 10,000 megawatt (10 GW) power system. Use of lunar materials makes it reasonable to consider alternatives to silicon solar cells for conversion of sunlight to electricity and thereby avoid present major problems associated with solar cell production. Machinery needed on the moon to excavate lunar materials and deliver them to a transport system, to beneficiate lunar materials, to produce glasses and ceramics from lunar materials and to chemically process lunar materials into their major oxides and elements are minor mass fractions of the total mass of equipment needed in space to produce an SPS. In addition the processing equipment can throughput several hundred times their own mass each year with very little requirement for makeup mass from earth.

Criswell, D. R.↗
NASA NTRS1987

Making a Silicon-Nitride/Silicon-Carbide Composite

Hot pressing and nitriding produce strong fiber/matrix material. Fabrication method developed for processing strong and tough silicon-based ceramic composite material, SiC/RBSN, which consists of reaction-bonded Si3N4 (RBSN) reinforced by continuous-length, high-modulus, high strength silicon carbide (SiC) fibers prepared by chemical-vapor deposition method. Increased toughness and ultimate strength of SiC/RBSN composite makes it potential structural material for advanced heat engines.

Bhatt, R. T.↗