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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 OSTI2025

Stress-dependent χ phase transformation in a Ni-based superalloy

The ongoing push to elevate operating temperatures in aerospace gas turbine engines – driven by goals of enhanced fuel efficiency and reduced CO 2 emissions – mandates advancements in the creep resistance of Ni- and Co-based superalloys, which are integral for critical engine components. This study elucidates the role of stress assisted localized phase transformations in the creep properties of these alloys. By leveraging chemo-mechanical coupling, self-healing γ′ precipitates are designed to immobilize planar defects, thereby increasing creep resistance. Employing advanced characterization techniques such as high-resolution Scanning Transmission Electron Microscopy (HR-STEM), in conjunction with atomistic simulations and thermodynamic calculations, novel deformation pathways facilitated by χ local phase transformation (LPT) strengthening have been uncovered; notably, the formation of χ nano-laths through microtwinning and superlattice intrinsic stacking fault (SISF) shearing. This study highlights critical insights into the compositional boundaries necessary for optimizing LPT strengthening while avoiding deleterious bulk formation of η/χ phases. These advancements will guide the design of new alloys maximizing high-temperature creep strength for advanced aerospace applications.

Egan, Ashton J. [Friedrich-Alexander University Er↗
DOE OSTI2026

Fiber coupled laser ultrasound system using a single mode hollow core fiber for excitation laser: Theory and demonstration for on-machine thickness gauging

Laser ultrasound (LU) is a technique that uses a pump laser and a probe laser to optically generate and detect elastic waves in a material. Despite its advantages over traditional contact transducer-based ultrasound, industrial adoption has been limited by complex optical setups and the inability of multi-mode fibers to deliver a stable Gaussian profile for the pump laser. Here, we report a fully fiber-coupled thermoelastic LU system that uses an anti-resonant hollow-core single-mode fiber to deliver 1 mJ nanosecond pulses of 1064 nm light, while preserving the fundamental Gaussian mode (pump laser). When combined with a fiber-coupled interferometer (probe laser), a small, flexible, and environmentally robust sensor capable of optically generating and detecting high frequency broadband ultrasound is realized. We demonstrate such an LU system implemented in situ on a four-axis precision lathe. High-resolution thickness gauging is performed, before and after precision cutting, by exciting and measuring a zero-group velocity guided wave mode. The measurements are verified with ex-situ traceable coordinate measuring machine data. Mean absolute deviations of 0.1%, of nominal thickness, before cutting, and 0.2% and 0.3%, after stepped and tapered cuts, respectively, are reported. A theoretical background for thermoelastic ultrasound generation in an elastic waveguide is also presented. Attention is given to the effect of the pump laser profile on wave generation to elucidate the importance of using single-mode laser light. The fiber-coupled system demonstrated is well-suited for use in scientific and engineering sensing applications and facilitates the adoption of LU for industrial non-destructive testing.

Engineering↗
DOE OSTI2021

Infiltration metasomatism of the Allende coarse-grained calcium-aluminum-rich inclusions

We report on the mineralogy, petrography, and O and Al-Mg isotopic systematics of secondary mineralization in the metasomatically altered igneous Ca,Al-rich inclusions (CAIs) [compact type A (CTA), B1, B2, forsterite-bearing B (FoB), and C] from the CV3 carbonaceous chondrite Allende. This alteration affected mainly melilite, and to a lesser degree anorthite, and resulted in the formation of a variety of secondary minerals, including adrianite, Al-diopside, andradite, anorthite, calcite, celsian, clintonite, corundum, dmisteinbergite, ferroan olivine, ferroan monticellite, ferroan Al-diopside, forsterite, grossular, heazlewoodite, hedenbergite, hutcheonite, kushiroite, margarite, monticellite, Na-melilite, nepheline, pentlandite, pyrrhotite, sodalite, spinel, tilleyite, wadalite, and wollastonite. The secondary mineral assemblages are mainly defined by chemical compositions of the primary melilite replaced and elements introduced by an aqueous fluid. Gehlenitic melilite (Åk <35 ) in CTAs and mantles of B1s is mainly replaced by anorthite + grossular; clintonite, corundum, spinel, and Al-diopside are minor. Åkermanitic melilite (Åk 35-90 ) in type B2s, FoBs, and cores of B1s is replaced by the grossular + monticellite + wollastonite, grossular + monticellite, and grossular + Al-diopside assemblages; forsterite, spinel, clintonite, and Na-melilite are minor. In type Cs, lacy melilite (åkermanitic melilite with rounded inclusions of anorthite) is pseudomorphically replaced by the grossular + forsterite + monticellite and grossular + Al-diopside assemblages; Na-melilite is minor. Primary and secondary anorthites in the peripheral portions of CAIs are replaced by nepheline, sodalite, and ferromagnesian olivine. Some CAIs contain voids and cracks filled by andradite, hedenbergite, wollastonite, ±sodalite, ±grossular, ±monticellite, ±tilleyite, and ±calcite. All CAIs studied are surrounded by Wark-Lovering rims, fine-grained matrix-like rims composed of lath-shaped ferroan olivine and abundant nepheline grains, and a layer of salite-hedenbergite pyroxenes + andradite + wollastonite. Grossular associating with monticellite, Al-diopside, and forsterite and replacing åkermanitic melilite ( 27 Al/ 24 Mg ~ 2) has high 27 Al/ 24 Mg ratios (30–100) and shows no resolvable excess of radiogenic 26 Mg (26Mg*). The 27 Al/ 24 Mg ratios (7–10) and 26 Mg* (2–3‰) in the nearly monomineralic grossular veins crosscutting gehlenitic melilite are similar to those of the host melilite and plot along a regression line with 26 Al/ 27 Al ratio of ~5×10 –5 . Oxygen isotopic compositions of secondary minerals in the most Type Bs measured in situ with the UH Cameca ims-1280 and matrix-matched standards plot along mass-dependent fractionation line with Δ 17 O of ~ –3±2‰ with δ 18 O ranging from ~0 to ~10‰. Primary melilite and anorthite in the host CAIs are similarly 16 O-depleted, whereas spinel, forsterite, and most Al,Ti-diopside grains have 16 O-rich compositions (Δ 17 O ~ –25±2‰). Secondary grossular and forsterite in type Cs and type B1 CAI TS-34 show a range of Δ 17 O, from ~ –15 to ~ –1‰; the 16 O-enriched compositions of grossular and forsterite plot along the carbonaceous chondrite anhydrous mineral line. The similar ranges of Δ 17 O and positions on the three-isotope oxygen diagram are observed for primary anorthite; melilite is generally 16 O-depleted compared to anorthite (Δ 17 O ~ –5 to –1±2‰); spinel and fassaite are 16 O-rich (except very Ti-rich fassaite in TS-34 and CTA CAIs). We conclude that Allende CAIs experienced an open-system in situ metasomatic alteration at relatively high temperatures (200-250 °C) in the presence of CO 2 - and H 2 O-bearing fluid with Δ 17 O of ~ –3±2‰ followed by thermal metamorphism at ~ 500 °C on the CV chondrite parent asteroid. During the alteration, most elements were mobile: Si, Na, Cl, K, Fe, S, and Ni were introduced; Al, Ti, Mg, and Ba were locally mobilized; Ca and some Mg and Al were lost from the host inclusions. The alteration occurred after nearly complete decay of 26 Al, >3 Ma after crystallization of CAIs with the canonical ( 26 Al/ 27 Al) 0 of (5.25±0.02)×10 -5 ; 26 Mg* in grossular was inherited from the primary melilite and provide no chronological significance. Oxygen isotopic heterogeneity of primary minerals in the Allende CAIs at least partly is due to isotopic exchange with an aqueous fluid that largely affected melilite, anorthite, perovskite, Zr- and Sc-rich oxides and silicates, and possibly very Ti-rich fassaite.

58 GEOSCIENCES↗
DOE OSTI2021

Displacement driven balancing of a diamond turning machine flycutter

The spindle balancing operation is critical to the performance of precision lathes and should be conducted anytime the configuration of the spindle or its tooling is modified such that an unbalanced condition may occur. Within the machine tool community, accelerometers are typically used as the feedback device during the balancing operation. At Lawrence Livermore National Laboratory (LLNL), we have nearly 40 years of history using displacement sensors, such as capacitance gauges, in place of accelerometers when balancing precision spindles. The process of balancing a precision machine spindle using displacement sensors is presented in the context of two work examples. In this case, the details of the one-dimensional balancing operation performed after replacing a flycutter on the spindles of two unique large optic diamond turning machines is discussed. The pros and cons of accelerometer driven balancing and displacement driven balancing are also presented. In the accelerometer context, the level of balance achieved for our work example is less than 100 micro-g or a total indicator reading (TIR) of 1.6 µm. The process of balancing has been enhanced over the years as advances have been made in software, data acquisition systems, and instrumentation. The balancing system is described including details about instrumentation, set-up, how phase and spindle structure stiffness is calculated, and how the LLNL developed software that guides the user through the process by suggesting corrective action.

42 ENGINEERING↗
DOE OSTI2023

Evaluation of LPBF Steels for Nuclear Applications

This report provides an update on the prioritization of existing reactor materials for advanced manufacturing. This report is a Milestone 3 deliverable in FY2023, under work package CT-23AN130401 to support research and qualification activities supported by the Advanced Materials and Manufacturing Technologies (AMMT) program here at Argonne National Laboratory (ANL). The focus of FY23 for ANL included the determination of a decision criteria matrix for the prioritization of existing materials, the literature review of a select few Fe-based alloys, and working with vendors to obtain customized powders. The work package also includes fabricating test samples in a Renishaw AM400 Laser Powder Bed Fusion (LPBF) system and optimizing the process parameters. The major outcomes of this work package are: With collaborations from PNNL, ORNL, and INL, we were able to establish a decision criteria matrix containing a total of 6 categories and 31 different criteria. These will be used to downselect alloys for further evaluation; As part of that, 6 different Fe-based alloys were selected, 3 austenitic stainless steels (A709, D9, AFA) and 3 ferritic/martensitic steels (HT9, Grade 91, Grade 92). Customized powders were obtained from vendors in small quantities to fabricate initial prints to check printability of these specific alloys; A total of 72 single track experiments were performed on two alloy systems, 1 austenitic stainless steel (A709) and 1 ferritic/martensitic steel (Grade 91) in order to optimize the process parameters for the full 3d prints. The optimization led to the selection of 20 different processing conditions, 10 for each class of alloys; D9 and AFA alloys showed extensive cracking and porosity in the samples. This was due to less-than-ideal conditions present in the chamber during the deposition. A709 printed using the same process parameters showed almost fully dense samples with no noticeable porosity or any other defects. SEM and EBSD analysis revealed single phase FCC microstructure with cellular structure within the grains; HT9, Grade 91, Grade 92 alloys also showed no noticeable signs of cracking and ImageJ analysis showed porosity <0.5% in all conditions. While Grade 91 and Grade 92 showed single phase BCC microstructures, the presence of martensite laths was noted in HT9 alloy; Future work will include further characterization of these alloys to better understand the microstructural evolution during the 3d printing process.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Microscopic Measurement: Need for Nuclear Material Sample Specimen Characterization Capability

The Surveillance, Fabrication, and Off-Site Operations team at Lawrence Livermore National Laboratory is beginning an update to the nuclear material machining lab in Superblock. Plutonium and other nuclear materials tend to accelerate the aging process for equipment and machines that would otherwise be maintainable for long lives. They have their lifespans shortened from deteriorated seals, embrittled polymer components, accelerated corrosion, and damage to electronics from exposure to radioactive materials. The cost of installation of equipment into a glove box (GB) tends to outstrip the cost of the equipment itself. Due to the magnification of cost, the historical approach to equipment installs has been to purchase and install the highest-quality and most robust equipment available to maximize time between failures and updates. To make room for the installation of a new lathe, the inspection GB is being moved to a different location within the machining lab. As part of the overall effort, the equipment within the inspection GB is being revisited. Current measurement capabilities are antiquated and starting to become problematic due to age. Advances in metrology are sought for more comprehensive characterization of scientific samples. This document aims to identify several options for the replacement of current measurement equipment and identify a system for purchase and eventual installation. The intention is not to select the cheapest system, but rather to identify a system that best meets the needs of both the operators and principal investigators (PI). Following the convention of the SYSM-5620 Design Thinking and System Engineering, it was determined that a laser confocal measurement system from Keyence is the most suitable option for our programmatic need. Form factor, capability, and maintainability were considered. Along with stakeholder input, to ensure the best decision for the Nuclear Material Technology Program.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Benchmarking a 9Cr-2WVTa Reduced Activation Ferritic Martensitic Steel Fabricated via Additive Manufacturing

Reduced activation ferritic (RAF) martensitic steels are promising candidates for the first wall of fusion reactors. However, current manufacturing capabilities call for these components to be made by welding wrought plates. This limits design freedom and necessitates the use of post-weld heat treatments (PWHT) in accordance with the boiler and pressure vessel code. Additive manufacturing (AM) can offer a unique solution to solve this challenge by leveraging the layer-wise deposition strategy to come up with temper bead deposition techniques to eliminate post-processing heat treatments (PPHT). However, it is necessary to benchmark the properties of RAF steels fabricated by AM with their wrought counterparts to identify the process-structure-property correlation, which is the goal of this study. The study demonstrates that while tensile properties at room temperature and high temperatures are satisfactory, the as fabricated and samples after PPHT have significant heterogeneity in tensile elongation. This has been attributed to the presence of discontinuities in the build. The as-fabricated samples have an average tensile strength of 1190 + 12 MPa and an average elongation of 15 + 5% at room temperature and 658 ± 20 MPa ultimate tensile strength (UTS) and 14 ± 7% at 600 °C. After the post-weld heat treatment, mechanical properties decrease to around 600–650 MPa and an elongation between 20–25% at room temperature to 300 MPa UTS and 25–28% elongation at 600 °C. The characterization of microstructures at various length scales demonstrates that the as-fabricated structure has a significant fraction of delta ferrite in a lath martensitic matrix. No precipitates could be identified in the as-fabricated structure. PPHT led to a decrease in the area fraction of delta ferrite and precipitation of M 23 C 6 and MX. Detailed characterization clearly demonstrates that the lack of precipitates in the as-fabricated structure could be due to the slow tempering response of the alloy. Finally, the needs to develop new alloys to achieve the objectives stated above are articulated.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Influence of Mo Content on the Precipitation Behavior of 13Ni Maraging Ultra-High Strength Steels

This study offers valuable insights into the precipitation behavior of 13Ni maraging steels, emphasizing the role of molybdenum content in their microstructure, strengthening, and precipitate evolution. Precipitate morphology and crystallography were examined using a combination of high-resolution transmission electron microscopy and selected area electron diffraction. Strengthening mechanisms were assessed through Vickers hardness measurements. All the examined samples exhibited a lath martensite microstructure and displayed an increasing hardness over the aging time. The molybdenum content not only influenced the presence of retained austenite in the initial microstructure but also affected the type of precipitates formed during the early aging stages. Initially, Ni 3 Mo precipitates were formed, succeeded by the formation of more stable Fe 2 (Mo,Ti) Laves precipitates. The ultra-high strength of 13Ni maraging steels arises from the combination of the precipitate type and size distribution. The base composition of 13Ni maraging steels achieved a peak hardness of 798 HV1 through the precipitation of Laves Fe 2 (Mo,Ti) phases ranging from 3 to 14 nm in diameter.

13Ni maraging steels↗
DOE OSTI2024

High-Density Polyethylene Custom Focusing Lenses for High-Resolution Transient Terahertz Biomedical Imaging Sensors

Transient terahertz time-domain spectroscopy (THz-TDS) imaging has emerged as a novel non-ionizing and noninvasive biomedical imaging modality, designed for the detection and characterization of a variety of tissue malignancies due to their high signal-to-noise ratio and submillimeter resolution. We report our design of a pair of aspheric focusing lenses using a commercially available lens-design software that resulted in about 200 × 200-μm2 focal spot size corresponding to the 1-THz frequency. The lenses are made of high-density polyethylene (HDPE) obtained using a lathe fabrication and are integrated into a THz-TDS system that includes low-temperature GaAs photoconductive antennae as both a THz emitter and detector. The system is used to generate high-resolution, two-dimensional (2D) images of formalin-fixed, paraffin-embedded murine pancreas tissue blocks. The performance of these focusing lenses is compared to the older system based on a pair of short-focal-length, hemispherical polytetrafluoroethylene (TeflonTM) lenses and is characterized using THz-domain measurements, resulting in 2D maps of the tissue refractive index and absorption coefficient as imaging markers. For a quantitative evaluation of the lens effect on the image resolution, we formulated a lateral resolution parameter, R2080, defined as the distance required for a 20–80% transition of the imaging marker from the bare paraffin region to the tissue region in the same image frame. The R2080 parameter clearly demonstrates the advantage of the HDPE lenses over TeflonTM lenses. The lens-design approach presented here can be successfully implemented in other THz-TDS setups with known THz emitter and detector specifications.

47 OTHER INSTRUMENTATION↗
NASA NTRS1965

Metal bellows custom-fabricated from tubing

Mandrel assembly mounted in a lathe chuck is used with a forming wheel to roll-form bellows from standard sheet metal tubing. Spacers and mandrels of various sizes custom-fabricate bellows of any desired dimensions.

Source record↗
NASA NTRS1974

Light-weight spherical submergence vessel

Design vessel with very low thickness-to-radius ratio to obtain low weight, and fabricate it with aid of precision tracer-lathe to limit and control imperfections in spherical shape. Vessel is thin-walled, spherical, monocoque shell constructed from hemispheres joined with sealed and bolted meridional flange.

Baker, I.↗
NASA NTRS1971

Rock sampling

A method for sampling rock and other brittle materials and for controlling resultant particle sizes is described. The method involves cutting grooves in the rock surface to provide a grouping of parallel ridges and subsequently machining the ridges to provide a powder specimen. The machining step may comprise milling, drilling, lathe cutting or the like; but a planing step is advantageous. Control of the particle size distribution is effected primarily by changing the height and width of these ridges. This control exceeds that obtainable by conventional grinding.

Blum, P.↗
NASA NTRS1973

Analysis of the ultrafine fraction of the Apollo 14 regolith

Analyses were obtained on more than 2400 randomly selected particles from the sub-37 micron (ultrafine) fraction of ten Apollo 14 regolith samples. The analyses were conducted with an energy dispersive electron microprobe system. The semiquantitative data were used to group the particles into ten categories. The pyroxene/plagioclase and olivine/plagioclase ratios are inconsistent with those ratios in the Apollo 14 breccias and rocks. The data suggest that fragmented basalts similar to Apollo 12 olivine basalts may have made significant contributions to the ultrafine fraction of the Fra Mauro regolith. Among a number of unusual particles encountered are brown, birefringent lath-shaped grains with 60 wt % SiO2 and 34 wt % FeO(FeSi2O5) and a glass with 20 to 25 wt % CaO, 0 to 8 wt % MgO, 40 to 45 wt % Al2O3 and approximately 30 wt % SiO2.

Finkelman, R. B.↗
NASA NTRS1975

Interactive cutting path analysis programs

The operation of numerically controlled machine tools is interactively simulated. Four programs were developed to graphically display the cutting paths for a Monarch lathe, Cintimatic mill, Strippit sheet metal punch, and the wiring path for a Standard wire wrap machine. These programs are run on a IMLAC PDS-ID graphic display system under the DOS-3 disk operating system. The cutting path analysis programs accept input via both paper tape and disk file.

Weiner, J. M.↗
NASA NTRS1975

Petrographic analysis of Apollo 16 samples 66083,1 and 67943,1

Sample 66083,1 was a 0.5 g sample of 2-4 mm fines from a clod of white impact ejecta. Petrography of 12 fragments of it reveals the following types of fragments: a breccia with a glassy matrix containing about 20-30% of crystal fragments, a fragment of partly devitrified glass, a fine-grained feldspar-rich rock containing plagioclase laths with about 10% of interstitial pyroxene and olivine, a breccia consisting of clasts of plagioclase and plagioclase-rich rock in a fine-grained microcrystalline feldspathic groundmass, a fragment of plagioclase clasts in a fine-grained groundmass of plagioclase and ferromagnesians with some opaques, and a crystalline rock made of subequal amounts of plagioclase and ferromagnesians with some opaque material. For sample 67943,1, all but two fragments could be classed as brecciated anorthosites.

Mason, B.↗