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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Experimental Research on Selective Laser Melting AlSi10Mg Alloys: Process, Densification and Performance

In this work, a set of experiments was designed to investigate the effect of process parameters on the relative density of the AlSi10Mg parts manufactured by SLM. The influence of laser scan speed v, laser power P and hatch space H, which were considered as the dominant parameters, on the powder melting and densification behavior was also studied experimentally. In addition, the laser energy density was introduced to evaluate the combined effect of the above dominant parameters, so as to control the SLM process integrally. As a result, a high relative density (> 97%) was obtained by SLM at an optimized laser energy density of 3.5-5.5 J/mm{sup 2}. Moreover, a parameter–densification map was established to visually select the optimum process parameters for the SLM-processed AlSi10Mg parts with elevated density and required mechanical properties. The results provide an important experimental guidance for obtaining AlSi10Mg components with full density and gradient functional porosity by SLM.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Powder spreading, densification, and part deformation in binder jetting additive manufacturing

Binder jetting additive manufacturing (AM) can print complex structures in economical and scalable manner. Binder jetting AM comprises of deposition and weak binding of particles, known as green part, at room temperature and subsequent binder removal and sintering densification at high temperatures. However, during the densification (i.e., sintering), the part significantly deforms due to volume shrinkage. The deformation during sintering is difficult to predict, which prevents the widespread application of this technology. In this research, powder spreading simulation using discrete element method (DEM) was performed first to capture local variations in powder bed configuration. Second, finite element method (FEM) with a phenomenological continuum constitutive model was used to predict part shrinkage during the sintering process. DEM simulation showed variations in packing density, particle segregation, formation of uneven powder bed surface, and shift in particle size distribution (PSD). The sintering simulation modeled part deformation with a reasonable accuracy of 3% for solid-state sintering and intermediate liquid phase sintering. A demonstration case with non-uniform initial packing density showed that inhomogeneous green part density and PSD should be accounted for prediction of part deformation in binder jetting AM.

36 MATERIALS SCIENCE↗
DOE OSTI2018

C–S–H gel densification: The impact of the nanoscale on self-desiccation and sorption isotherms

The relationship between humidity and water content in a hydrating cement paste is largely controlled by the nanostructure of the C–S–H gel. Current hydration models do not describe this nanostructure, thus sorption isotherms and self-desiccation are given as constitutive inputs instead of being predicted from microstructural evolution. To address this limitation, this work combines a C–S–H gel description from nanoscale simulations with evolving capillary pore size distributions from a simple hydration model. Results show that a progressive densification of the C–S–H gel must be considered in order to explain the self-desiccation of low-alkali pastes. The impact of C–S–H densification on the evolution of microstructure and sorption isotherms is then discussed, including the effect of water-to-cement ratio, cement powder fineness, and curing temperature. Overall, this work identifies an area where nanoscale simulations can integrate larger-scale models of cement hydration and poromechanics.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Densification of the entropy stabilized oxide (Mg 0.2 Co 0.2 Ni 0.2 Cu 0.2 Zn 0.2 )O

The first entropy-stabilized oxide, (Mg 0.2 Co 0.2 Ni 0.2 Cu 0.2 Zn 0.2 )O, was reported in 2015. Initial studies synthesized this material using solid state processing and were limited to densities < 80%. Here, we report a straightforward solid state route to sinter samples to densities up to 98% of the theoretical by identifying the role of oxygen and promoting the resulting mechanisms in densification. Previous works have studied effects of cation stoichiometry on the entropy-driven reaction to form a single phase, but few have explored the associated effects of anion stoichiometry and/or redox chemistry on both phase stability and densification. We demonstrate here that tuning heating rate and pO 2 during heating of initially-homogeneous calcined powders can enhance densifying diffusion processes and enable reliable sintering of dense (Mg 0.2 Co 0.2 Ni 0.2 Cu 0.2 Zn 0.2 )O samples.

MATERIALS SCIENCE↗
DOE OSTI2023

Concurrent reaction-bonded joining and densification of additively manufactured silicon carbide by liquid silicon infiltration

Here, in this study, additive-manufactured silicon carbide preforms were joined and densified by reaction bonding via liquid silicon infiltration. The silicon carbide preforms were first printed by binder jetting additive manufacturing. To demonstrate concurrent joining and densification, two preforms with carbon or parchment papers at the interface were concurrently joined and infiltrated by liquid silicon. Results showed a robust interface with thicknesses ranging from 150 to 500 µm, depending on the paper type and the number of paper layers. High-energy synchrotron X-ray revealed that β-phase silicon carbide was formed inside the interface. Finally, two additively manufactured samples with complicated channel geometry were successfully joined. Energy dispersive spectroscopy of the interface of the channeled samples showed a consistent and robust joining. This concurrent approach of joining and densification enables efficiency improvement of fabricating silicon carbide parts with complicated geometries and widens geometry freedom for additive manufacturing of silicon carbide.

36 MATERIALS SCIENCE↗
DOE OSTI2010

Simulation of the densification of real open-celled foam microstructures

Ubiquitous in nature and finding applications in engineering systems, cellular solids are an increasingly important class of materials. Foams are an important subclass of cellular solids with applications as packing materials and energy absorbers due to their unique properties. A better understanding of foam mechanical properties and their dependence on microstructural details would facilitate manufacture of tailored materials and development of constitutive models for their bulk response. Numerical simulation of these materials, while offering great promise toward furthering understanding, has also served to convincingly demonstrate the inherent complexity and associated modeling challenges. The large range of deformations which foams are subjected to in routine engineering applications is a fundamental source of complication in modeling the details of foam deformation on the scale of foam struts. It requires accurate handling of large material deformations and complex contact mechanics, both well established numerical challenges. A further complication is the replication of complex foam microstructure geometry in numerical simulations. Here various advantages of certain particle methods, in particular their compatibility with the determination of three-dimensional geometry via X-ray microtomography, are exploited to simulate the compression of 'real' foam microstructures into densification. With attention paid to representative volume element size, predictions are made regarding bulk response, dynamic effects, and deformed microstructural character, for real polymeric, open-cell foams. These predictions include a negative Poisson's ratio in the stress plateau, and increased difficulty in removing residual porosity during densification.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Densification and Immobilization of AgI-Containing Iodine Waste Forms Using Spark Plasma Sintering

Here in this study, porous Ag-xerogel (Ag-Xero), Ag-faujasite (Ag-FAU) zeolite, and Ag-mordenite (Ag-MOR) zeolite sorbents were loaded with iodine gas [I 2 (g)] under saturated conditions at 150 °C for 24 h, followed by densification and consolidation into monolithic waste forms using spark plasma sintering (SPS). For Ag-Xero materials, SPS pellets were made with as-loaded samples, while others were made with preheated (PH; 500 °C for 2 h) samples to help with densification. SPS processing was conducted at 50 MPa under different temperatures (T = 200–800 °C) for different times (t = 0.5–30 min), where eleven AgI-Xero samples, five AgI-FAU, and two AgI-MOR separate samples were produced. The primary goal was to look for the optimum processing parameters for each material to yield pellets with high iodine retentions, high densities, and low porosities while preventing AgI decomposition. The Ag-Xero showed the highest iodine loadings (qe = 470 mg g –1 ) compared to Ag-FAU (qe = 368 mg g –1 ) and Ag-MOR (qe = 108 mg g –1 ). Measured iodine concentrations were the highest in AgI-Xero pellets without PH, followed by AgI-Xero with PH, AgI-FAU, and then AgI-MOR. Silver utilization (I/Ag on a mol % basis) values were in the order of AgI-MOR ≈ AgI-Xero (no PH) > AgI-Xero (PH) > AgI-FAU. Chemical durabilities of SPS-densified AgI-Xero (PH) pellets were very favorable, with lower releases than SPS pellets made from AgI-Xero samples without PH. These results show promise for iodine waste form production.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Composite Carbon Molecular Sieve Hollow Fiber Membranes: Resisting Support Densification via Silica Particle Stabilization

Resisting densification of hollow fiber support layers under high-temperature pyrolysis is vital to form carbon molecular sieve hollow fiber membranes with thin separation layer and attractive productivity. In this paper, a new silica particle stabilization approach is introduced to form thin-skinned composite carbon molecular sieve hollow fiber membranes with excellent resistance to support layer densification. By dispersing small-sized silica particles with low bulk density in the support layer of polymer precursor hollow fibers, composite carbon molecular sieve hollow fiber membranes were formed with highly porous supports. The composite carbon molecular sieve hollow fiber membranes exhibited very attractive selectivities and productivities higher than those of monolithic asymmetric carbon molecular sieve hollow fiber membranes formed by the standard sol–gel support stabilization technique.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The Ideal Crystal Structure of Cristobalite X-I: A Bridge in SiO 2 Densification

On compression of α-cristobalite SiO 2 to pressures above approximately 12 GPa, a new polymorph known as cristobalite X-I forms. The existence of cristobalite X-I has been known for several decades; however, consensus regarding its exact atomic arrangement has not yet been reached. The X-I phase constitutes an important step in the silica densification process, separating low-density tetrahedral framework phases from high-density octahedral polymorphs. It is the only nonquenchable high-density SiO 2 phase, which reverts to the low-density form on decompression at ambient temperature. Recently, an experimental study proposed an octahedral model of SiO 2 X-I with intrinsic structural defects involving partial Si site occupancies. In contrast, our new single-crystal synchrotron X-ray diffraction experiments have shown that the ideal structure of this phase should instead be described by a defect-free model, which does not require partial occupancies. Here, the structure of cristobalite X-I consists of octahedral chains with a 4-60°-2 zigzag chain geometry. This geometry has not been previously considered but is closely related to post-quartz, stishovite, and seifertite. In addition to the ideal, defect-free crystal structure, we also present a description of the defects that are most likely to form within the X-I phase. Density functional theory calculations support our observations, confirming the dynamic stability of the X-I geometry and reasonably reproducing the pressure of the phase transformation. The enthalpy of cristobalite X-I is higher than stishovite and seifertite, but X-I is favored as a high-pressure successor of cristobalite due to a unique transformation pathway. Elastic and lattice dynamical properties of the X-I phase show intermediate values between stable tetrahedral and octahedral polymorphs, confirming the bridge-role of this phase in SiO 2 densification.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2012

Densification of functional plasma polymers by momentum transfer during film growth

Functional plasma polymers were deposited from pure ethylene discharges and with the addition of carbon dioxide or ammonia. The incorporation of oxygen and nitrogen-containing functional groups depends on the fragmentation in the gas phase as well as on the densification during film growth. While a minimum energy per deposited carbon atom is required for cross-linking, the densification and accompanying reduction of functional group incorporation was found to scale linearly with momentum transfer through ion bombardment during film growth.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Enhanced densification under shock compression in porous silicon

Under shock compression, most porous materials exhibit lower densities for a given pressure than that of a full-dense sample of the same material. However, some porous materials exhibit an anomalous, or enhanced, densification under shock compression. The mechanism driving this behavior was not completely determined. We present evidence from atomistic simulation that pure silicon belongs to this anomalous class of materials and demonstrate the associated mechanisms responsible for the effect in porous silicon. Atomistic response indicates that local shear strain in the neighborhood of collapsing pores catalyzes a local solid-solid phase transformation even when bulk pressures are below the thermodynamic phase transformation pressure. This metastable, local, and partial, solid-solid phase transformation, which accounts for the enhanced densification in silicon, is driven by the local stress state near the void, not equilibrium thermodynamics. This mechanism may also explain the phenomenon in other covalently bonded materials.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2013

Densification of Reaction Bonded Silicon Nitride with the Addition of Fine Si Powder Effects on the Sinterability and Mechanical Properties

The densification behavior and strength of sintered reaction bonded silicon nitrides (SRBSN) that contain Lu2O3-SiO2 additives were improved by the addition of fine Si powder. Dense specimens (relative density: 99.5%) were obtained by gas-pressure sintering (GPS) at 1850oC through the addition of fine Si. In contrast, the densification of conventional specimens did not complete at 1950oC. The fine Si decreased the onset temperature of shrinkage and increased the shrinkage rate because the additive helped the compaction of green bodies and induced the formation of fine Si3N4 particles after nitridation and sintering at and above 1600oC. The amount of residual SiO2 within the specimens was not strongly affected by adding fine Si powder because most of the SiO2 layer that had formed on the fine Si particles decomposed during nitridation. The maximum strength and fracture toughness of the specimens were 991 MPa and 8.0 MPa m1/2, respectively.

Lee, Sea-Hoon↗
NASA NTRS1975

Silicon nitride-aluminum oxide solid solution (SiAION) formation and densification by pressure sintering

Stirred-ball-mill-blended Si3N4 and Al2O3 powders were pressure sintered in order to investigate the mechanism of solid solution formation and densification in the Si3N4-Al2O3 system. Powder blends with Si3N4:Al2O3 mole ratios of 4:1, 3:2, and 2:3 were pressure sintered at 27.6-MN/sq m pressure at temperatures to 17000 C (3090 F). The compaction behavior of the powder blends during pressure sintering was determined by observing the density of the powder compact as a function of temperature and time starting from room temperature. This information, combined with the results of X-ray diffraction and metallographic analyses regarding solutioning and phase transformation phenomena in the Si3N4-Al2O3 system, was used to describe the densification behavior.

Yeh, H. C.↗
NASA NTRS1975

Effect of additions of coarse grains and fibers on the densification of a sinterable SiC

This note reports the effects on densification of independent additions of coarse equiaxed SiC grains and fibrous SiC that were mixed with fine beta-SiC to develop a duplex microstructure with improved toughness. The fine-matrix SiC did not contain excess boron and carbon. The equiaxed CVD beta-SiC was introduced in the fine beta-SiC matrix material in amounts of 5 and 10 wt%. Results indicate that the CVD beta-SiC, which is quite coarse, exhibits little indication of sinterability. The effect of these coarse-grained and fibrous additions on the sinterability of fine beta-SiC may result from a geometric type of interaction. This interpretation is reinforced by X-ray diffraction of the powders and sintered pellets via monochromatic CuK-alpha radiation; the diffraction patterns of the sintered composite structures are virtually a combination of those of the components. The addition of nonsinterable SiC to the sinterable material slightly reduces sinterability, the larger particles interacting geometrically with the fine matrix material to prevent complete densification.

Abe, H.↗
NASA NTRS1987

Localized Densification of Tile for Impact Resistance

Densification process increases impact resistance of lightweight, porous silica tile without appreciably raising weight. Colloidal suspension of silica used to increase density of small portion of tile to be strengthened. Process controls penetration of suspension laterally and vertically so densification limited to volume where needed. Insures weight increased only minimally. See also "Attaching Metal Fasteners to Silica Tiles" (MSC-20537).

Smiser, Laurence W.↗
NASA NTRS1991

Lunar regolith densification

Core tube samples of the lunar regolith obtained during the Apollo missions showed a rapid increase in the density of the regolith with depth. Various hypotheses have been proposed for the possible cause of this phenomenon, including the densification of the loose regolith material by repeated shaking from the seismic tremors which have been found to occur at regular monthly intervals when the moon and earth are closest to one another. A test bed was designed to study regolith densification. This test bed uses Minnesota Lunar Simulant (MLS) to conduct shaking experiments in the geotechnical centrifuge with an inflight shake table system. By reproducing realistic in-situ regolith properties, the experiment also serves to test penetrator concepts. The shake table system was designed and used for simulation experiments to study effects of earthquakes on terrestrial soil structures. It is mounted on a 15 g-ton geotechnical centrifuge in which the self-weight induced stresses are replicated by testing an n-th scale model in a gravity field which is n times larger than Earth's gravity. A similar concept applies when dealing with lunar prototypes, where the gravity ratio required for proper simulation of lunar gravity effects is that between the centrifugal acceleration and the lunar gravity. Records of lunar seismic tremors, or moonquakes, were obtained. While these records are being prepared for use as the input data to drive the shake table system, records from the El Centro earthquake of 1940 are being used to perform preliminary tests, using a soil container which was previously used for earthquake studies. This container has a laminar construction, with the layers free to slide on each other, so that the soil motion during the simulated earthquake will not be constrained by the otherwise rigid boundaries. The soil model is prepared by pluviating the MLS from a hopper into the laminar container to a depth of 6 in. The container is mounted on the shake table and the centrifuge is operated to generate an acceleration of 10 times Earth's gravity or 60 times the lunar gravity, thus simulating a lunar regolith thickness of 30 ft. The shake table is then operated using the scaled 'moonquake' as the input motion. One or more model moonquakes are used in each experiment, after which the soil is analyzed for its density profile with depth. This is accomplished by removing from the soil bed a column of soil contained within a thin rubber sleeve which has been previously embedded vertically in the soil during pluviation. This column of soil is transferred to a gamma ray device, in which the gamma ray transmission transversely through the soil is measured and compared with standard calibration samples. In this manner, the density profile can be determined. Preliminary results to date are encouraging, and the Center plans to study the effects of duration of shaking, intensity of the shaking motion, and the frequency of the motion.

Ko, Hon-Yim↗
NASA NTRS2000

Recent Advances and Applications in Cryogenic Propellant Densification Technology

This purpose of this paper is to review several historical cryogenic test programs that were conducted at the NASA Glenn Research Center (GRC), Cleveland, Ohio over the past fifty years. More recently these technology programs were intended to study new and improved denser forms of liquid hydrogen (LH2) and liquid oxygen (LO2) cryogenic rocket fuels. Of particular interest are subcooled cryogenic propellants. This is due to the fact that they have a significantly higher density (eg. triple-point hydrogen, slush etc.), a lower vapor pressure and improved cooling capacity over the normal boiling point cryogen. This paper, which is intended to be a historical technology overview, will trace the past and recent development and testing of small and large-scale propellant densification production systems. Densifier units in the current GRC fuels program, were designed and are capable of processing subcooled LH2 and L02 propellant at the X33 Reusable Launch Vehicle (RLV) scale. One final objective of this technical briefing is to discuss some of the potential benefits and application which propellant densification technology may offer the industrial cryogenics production and end-user community. Density enhancements to cryogenic propellants (LH2, LO2, CH4) in rocket propulsion and aerospace application have provided the opportunity to either increase performance of existing launch vehicles or to reduce the overall size, mass and cost of a new vehicle system.

Tomsik, Thomas M.↗
NASA NTRS2002

Liquid Oxygen Propellant Densification Unit Ground Tested With a Large-Scale Flight-Weight Tank for the X-33 Reusable Launch Vehicle

Propellant densification has been identified as a critical technology in the development of single-stage-to-orbit reusable launch vehicles. Technology to create supercooled high-density liquid oxygen (LO2) and liquid hydrogen (LH2) is a key means to lowering launch vehicle costs. The densification of cryogenic propellants through subcooling allows 8 to 10 percent more propellant mass to be stored in a given unit volume, thereby improving the launch vehicle's overall performance. This allows for higher propellant mass fractions than would be possible with conventional normal boiling point cryogenic propellants, considering the normal boiling point of LO2 and LH2.

Tomsik, Thomas M.↗