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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
NASA NTRS1991

Microstructural changes in Beta-silicon nitride grains upon crystallizing the grain-boundary glass

Crystallizing the grain boundary glass of a liquid phase sintered Si3N4 ceramic for 2 h or less at 1500 C led to formation of gamma Y2Si2O7. After 5 h at 1500 C, the gamma Y2Si2O7 had transformed to beta Y2Si2O7 with a concurrent dramatic increase in dislocation density within beta Si3N4 grains. Reasons for the increased dislocation density is discussed. Annealing for 20 h at 1500 C reduced dislocation densities to the levels found in as-sintered materials.

Lee, William E.↗
DOE OSTI2011

Studying the sintering behavior of BeO{sub x}-SiC{sub 1-x} Composite ceramic Material

The sintering behavior for BeO-SiC compacts composite ceramic at different sintering temperatures in air were conducted, resulting data indicated that the percentage of SiC (Wt% 5) sintered at 800 C deg. lead to higher sintering density of (1.80 gm/cm3). The x-ray diffraction pattern analysis indicated nothing change concerning the crystal structure. Microstructure development has been studied as a function SiC content. Silicon carbide found to be suppressed the sinter ability of the matrix BeO powder.

36 MATERIALS SCIENCE↗
NASA NTRS1990

Investigation of mechanical and thermal properties of microwave-sintered lunar simulant materials using 2.45 GHz radiation

The mechanical and thermal properties of lunar simulant material were investigated. An alternative method of examining thermal shock in microwave-sintered lunar samples was researched. A computer code was developed that models how the fracture toughness of a thermally shocked lunar simulant sample is related to the sample hardness as measured by a micro-hardness indentor apparatus. This technique enables much data to be gathered from a few samples. Several samples were sintered at different temperatures and for different times at the temperatures. The melting and recrystallization characteristics of a well-studied binary system were also investigated to see if the thermodynamic barrier for the nucleation of a crystalline phase may be affected by the presence of a microwave field. The system chosen was the albite (sodium alumino silicate) anorthite system (calcium alumino silicate). The results of these investigations are presented.

Meek, T. T.↗
DOE OSTI2025

Development and Validation of MALAMUTE model for Electric Field Assisted Sintering of Structural Materials

Fusion power plant designs feature extreme material performance requirements for structural material candidates. In addition to conventional alloys, more advanced composites and oxide dispersion strengthened (ODS) alloys are being explored, however, achieving the desired microstructures to maximize performance using traditional manufacturing methods can be challenging. The advanced manufacturing (AM) electric field-assisted sintering (EFAS) technique offers improved control over the final microstructure through higher heating and cooling rates and moderate pressures. Modeling and simulation tools show promise in elucidating the process-structure-property-performance (PSPP) correlation for AM-produced parts, including the EFAS process. An inherently multiscale process, the EFAS technique aligns well with the multiscale modeling capability of the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE)[cite]. We present here an electro-thermo-mechanical approach to modeling the EFAS process using the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) code. Prediction of the field and gradient distributions across the EFAS tooling is required to accurately describe the conditions for the lower-scale microstructural evolution models. In this work we present the MALAMUTE model developed to predict the electrical potential, temperature, and mechanical stress distribution across the EFAS graphite tooling and part at the larger engineering-scale. Validation of the MALAMUTE engineering-scale model is completed using data from experimental densification and pre-densified runs of iron powder via EFAS at 1000oC. These runs were conducted using a Thermal Technology DCS-5 EFAS system. Data collected during the experiment runs include the direct current (DC) supplied to the graphite tooling, the temperature of the graphite tooling as measured with a pyrometer, and the force applied to the top of the graphite tooling stack, and the data were recorded every 10 seconds. Our validation approach used the current and force data from the EFAS run as boundary condition inputs to the MAMALUTE simulation; the temperature data were used to evaluate the MALAMUTE EFAS model prediction. Results of the MALAMUTE simulations are employed to connect the external pyrometer temperature measurement to the temperature profile across the part undergoing consolidation. We investigate the impact of material property variation and mesh deformation on the temperature profile as predicted by MALAMUTE. We conclude by highlighting projects where the MALAMUTE EFAS modeling and simulation capabilities will be used to assist experimental design.

36 - MATERIALS SCIENCE↗
NASA NTRS1977

Friction and wear of sintered fiber-metal abradable seal materials

Three abradable gas path seal material systems based on a sintered NiCrAlY fibermetal structure were evaluated under a range of wear conditions representative of those likely to be encountered in various knife-edge seal (labyrinth or shrouded turbine) applications. Conditions leading to undesirable wear of the rotating knife were identified and a model was proposed based on thermal effects arising under different rub conditions. It was found, and predicted by the model, that low incursion (plunge) rates tended to promote smearing of the low density sintered material with consequent wear to the knife-edge. Tradeoffs benefits between baseline 19 percent dense material, a similar material of increased density, and a self lubricating coating applied to the 19 percent material were identified based on relative rub tolerance and erosion resistance.

Bill, R. C.↗
DOE OSTI2023

Microstructure characterization of electric field assisted sintering (EFAS) sintered metallic and ceramic materials using local thermal diffusivity measurement

Electric Field Assisted Sintering (EFAS, also referred to as spark plasma sintering) is a powerful technology for the consolidation of powder materials. The high heating rate during the sintering process is critical for minimizing energy consumption, but it can also cause microstructure heterogeneities in sintered parts, such as spatially varied porosity. The examination of localized porosity usually requires the use of a scanning electron microscope with a carefully prepared surface. In this paper, photothermal radiometry is used to measure local thermal diffusivity and extract localized porosity of EFAS-sintered parts by using a percolation-threshold model. Applying this approach, we identified the radial position-dependent porosity variation in EFAS parts, which is likely formed due to the large temperature gradient during the sintering process. This approach has a unique advantage because it can measure samples with minimal or no surface preparation, enabling the possibility of in situ characterization in EFAS with proper system modification. Necessary modifications on the measurement approach for EFAS deployment and in situ characterization are also discussed.

36 MATERIALS SCIENCE↗
NASA NTRS1978

Rub tolerance evaluation of two sintered NiCrAl gas path seal materials

Two strength level variations of sintered NiCrAl (about 40 percent dense), candidate high pressure turbine seal materials, were subject to rub tolerance testing against AM 355 steel blade tips. The high strength material (17 N/sq mm tensile strength) showed frictional and radial loads that were 20 to 50 percent higher than those measured for the low strength material (15.5 N/ sq mm tensile strength). Measured wear to the AM 355 blade tips was not significantly different for the two sintered NiCrAl seal materials. Wear of the sintered NiCrAl was characterized by material removal to a depth greater than the depth to which blade tips were driven into the seal, indicating self-erosion effects.

Bill, R. C.↗
DOE OSTI2012

Development of mixed conducting dense nickel/Ca-doped lanthanum zirconate cermet for gas separation application

Highlights: Black-Right-Pointing-Pointer Phase pure La{sub 1.95}Ca{sub 0.05}Zr{sub 2}O{sub 7-{delta}} (LCZ) material is prepared by combustion synthesis. Black-Right-Pointing-Pointer LCZ and Ni-LCZ bulk samples are prepared with theoretical density close to 100%. Black-Right-Pointing-Pointer Bulk electrical conductivity {approx}400 S/cm is obtained for Ni-LCZ cermet at 750 Degree-Sign C. -- Abstract: La{sub 1.95}Ca{sub 0.05}Zr{sub 2}O{sub 7-{delta}} (LCZ) and Ni-LCZ cermet have been prepared by combustion synthesis and conventional solid state mixing methods respectively. Both the materials are sintered in air and controlled atmosphere (5% H{sub 2} in Ar). The density obtained for the material sintered at 1400 Degree-Sign C in controlled atmosphere is found to be more than 99.5%. This sintering temperature (1400 Degree-Sign C) is considered to be much lower compared to the conventional sintering temperature. The corresponding total conductivity for such Ni-LCZ cermet materials is {approx}400 S/cm measured at 750 Degree-Sign C having 40 vol% of Ni and 60 vol% LCZ.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Sintering of Iron Ores in a Millipot in Comparison with Tablet Testing and Industrial Process

To explore the feasibility of small-scale sintering pot testing, a ‘millipot’ facility (diameter of 53 mm and height of 400 mm) was established and used to examine the sintering performance of iron ores and other non-traditional ferrous materials. The sintering performance of a millipot was examined across a range of different operational conditions (coke rate and suction pressure) and compared with an industrial sinter strand operation. Tablet tests were also performed to assist in the design of the millipot experiments and identify conditions for achieving mineral composition similar to the industrial sinter. For the millipot experiments, the materials used need to be compacted to increase the bulk density, and a higher coke rate is required to compensate the high heat loss caused by wall effects. A higher suction pressure is also necessary to maintain an oxidizing atmosphere in the sinter bed. As expected, it was not possible to eliminate the wall effect, which resulted in more primary hematite at edges of the sintered column. However, the sintered material from the center of column simulates industrial sinter reasonably well. As such, millipot provides a practical way to evaluate the sintering process and material performance at laboratory scale, helping to bridge the gap between tablet sintering and large scale pot sintering, or full scale plant trial. The results of millipot testing can be used for designing larger scale experiments or commercial sintering trials.

36 MATERIALS SCIENCE↗
DOE OSTI2014

High energy X-ray diffraction study of a dental ceramics–titanium functional gradient material prepared by field assisted sintering technique

A functional gradient material with eleven layers composed of a dental ceramics and titanium was successfully consolidated using field assisted sintering technique in a two-step sintering process. High energy X-ray diffraction studies on the gradient were performed at High Energy Material Science beamline at Desy in Hamburg. Phase composition, crystal unit edges and lattice mismatch along the gradient were determined applying Rietveld refinement procedure. Phase analysis revealed that the main crystalline phase present in the gradient is α-Ti. Crystallinity increases stepwisely along the gradient with a decreasing increment between every next layer, following rather the weight fraction of titanium. The crystal unit edge a of titanium remains approximately constant with a value of 2.9686(1) Å, while c is reduced with increasing amount of titanium. In the layer with pure titanium the crystal unit edge c is constant with a value of 4.7174(2) Å. The lattice mismatch leading to an internal stress was calculated over the whole gradient. It was found that the maximal internal stress in titanium embedded in the studied gradient is significantly smaller than its yield strength, which implies that the structure of titanium along the whole gradient is mechanically stable. - Highlights: • High energy XRD studies of dental ceramics–Ti gradient material consolidated by FAST. • Phase composition, crystallinity and lattice parameters are determined. • Crystallinity increases stepwisely along the gradient following weight fraction of Ti. • Lattice mismatch leading to internal stress is calculated over the whole gradient. • Internal stress in α-Ti embedded in the gradient is smaller than its yield strength.

36 MATERIALS SCIENCE↗
NASA NTRS2017

Fabrication of Lightweight Radiation Shielding Composite Materials by Field Assisted Sintering Technique (FAST)

Advances in radiation shielding technologies are needed to protect humans and electronic components from all threats of space radiation over long durations. In this paper, we report on the use of the innovative and novel fabrication technology known as Field Assisted Sintering Technology (FAST) to fabricate lightweight material with enhanced radiation shielding strength to safeguard humans and electronics suitable for next generation space exploration missions. The base materials we investigated were aluminum (Al), the current standard material for space hardware, and Ultra-High Molecular Weight Polyethylene (UHMWPE), which has high hydrogen content and resistance to nuclear reaction from neutrons, making it a good shielding material for both gamma radiation and particles. UHMWPE also has high resistance to corrosive chemicals, extremely low moisture sensitivity, very low coefficient of friction, and high resistance to abrasion. We reinforced the base materials by adding high density (ie, high atomic weight) metallic material into the composite. These filler materials included: boron carbide (B4C), tungsten (W), tungsten carbide (WC) and gadolinium (Gd).

Prasad, Narasimha↗
DOE OSTI2010

Method of forming aluminum oxynitride material and bodies formed by such methods

Methods of forming aluminum oxynitride (AlON) materials include sintering green bodies comprising aluminum orthophosphate or another sacrificial material therein. Such green bodies may comprise aluminum, oxygen, and nitrogen in addition to the aluminum orthophosphate. For example, the green bodies may include a mixture of aluminum oxide, aluminum nitride, and aluminum orthophosphate or another sacrificial material. Additional methods of forming aluminum oxynitride (AlON) materials include sintering a green body including a sacrificial material therein, using the sacrificial material to form pores in the green body during sintering, and infiltrating the pores formed in the green body with a liquid infiltrant during sintering. Bodies are formed using such methods.

Bakas, Michael P↗
DOE OSTI2017

All-Materials-Inclusive Flash Spark Plasma Sintering

A new flash (ultra-rapid) spark plasma sintering method applicable to various materials systems, regardless of their electrical resistivity, is developed. A number of powders ranging from metals to electrically insulative ceramics have been successfully densified resulting in homogeneous microstructures within sintering times of 8–35 s. A finite element simulation reveals that the developed method, providing an extraordinary fast and homogeneous heating concentrated in the sample’s volume and punches, is applicable to all the different samples tested. The utilized uniquely controllable flash phenomenon is enabled by the combination of the electric current concentration around the sample and the confinement of the heat generated in this area by the lateral thermal contact resistance. The presented new method allows: extending flash sintering to nearly all materials, controlling sample shape by an added graphite die, and an energy efficient mass production of small and intermediate size objects. This approach represents also a potential venue for future investigations of flash sintering of complex shapes.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The Li{sup +} conducting composite based on LiTi{sub 2}(PO{sub 4}){sub 3} and Li{sub 3}BO{sub 3} glass

Highlights: • Addition of the LBO glass enhance total ion conductivity up to four orders of magnitude. • Transport of Li{sup +} could be attributed to two media: grains and grain boundaries. • Sintering temperature is the most influential factor affecting the σ{sub tot}. • Melting of the LBO above 700 °C supports the sintering process. - Abstract: The LiTi{sub 2}(PO{sub 4}){sub 3} based composites containing amorphous Li{sub 3}BO{sub 3} were formed and investigated by means of X–ray diffractometry, thermogravimetry, scanning electron microscopy, impedance spectroscopy and density methods. The study shows that when a polycrystalline LiTi{sub 2}(PO{sub 4}){sub 3} material is sintered with Li{sub 3}BO{sub 3} glass, the resultant ceramics exhibit very high total ion conductivity. The maximum conductivity of 1.43 × 10{sup −4} S cm{sup −1} at 30 °C was achieved for the LTP–0.3LBO material sintered at 900 °C compared to 5.15 × 10{sup −8} S cm{sup −1} of the ceramic LiTi{sub 2}(PO{sub 4}){sub 3}.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1989

The low magnetic field properties of superconducting bulk yttrium barium copper oxide - Sintered versus partially melted material

A comparison of the low magnetic field properties of sintered (990 C) and partially melted samples (1050 C) has been performed. Changes in the microstructure produced by recrystallization from the melt result in a significant increase in flux pinning at 77 K. Low-frequency (10-100 Hz), low-ac magnetic-field (0.01-9.0 Oe) ac susceptibility data show that gross changes in the loss component accompany the observed changes in microstructure. The effects of applied dc magnetic fields (10-220 Oe) on the ac responses of these microstructures have also been probed.

Hein, R. A.↗