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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 721 records · Page 40
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Investigation of sol-gel feedstock additions and process variables on the density and microstructure of UN microspheres

The kernel of fully ceramic microencapsulated (FCM) fuel requires a material with high fissile density. For that reason, among others, UN is the appropriate chemical state for low enriched U fuel. The UN kernels are spheres ~800 μm in diameter made using a sol-gel process. The effect of additives on the chemistry and density of the UN microspheres are investigated in this work. Gadolinium nitrate hexahydrate, Gd 2 O 3 , B, SiO 2 and SiC were incorporated into the sol-gel broth in varying concentrations. It was found that Gd can serve as both a sintering aid and burnable poison when added to the sol-gel broth as a Gd(NO 3 ) 3 6H 2 O. However, even with the increased theoretical density of the UN microspheres, the U density was still too low for the FCM design that replaces UO 2 pellets in a commercial light water reactor. Silicon carbide and B were also successfully added but produced a lower density final product. Other sol-gel processing variables were investigated. In conclusion, the pour density of the sol-gel feedstock was found to influence the final converted UN kernel density.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Synergistically-enhanced ion track formation in pre-damaged strontium titanate by energetic heavy ions

Latent ion tracks created by energetic heavy ions (12 MeV Ti to 946 MeV Au) in single crystal SrTiO 3 are investigated in this paper using Rutherford backscattering spectrometry and scanning transmission electron microscopy. The results demonstrate that pre-existing irradiation damage, introduced via elastic collision processes, interacts synergistically with the electronic energy deposition from energetic heavy ions to enhance formation of latent ion tracks. The average amorphous cross-section increases with the level of pre-damage and is linearly proportional to the electronic energy loss of the ions, with a slope dependent on the pre-damage level. For the highest energy ions (629 MeV Xe and 946 MeV Au), the tracks are continuous over the pre-damaged depth, but become discontinuous beyond the pre-damaged region. Finally, this work provides new understanding and insights on ion-solid interactions that significantly impact the interpretation of latent track formation processes, models of amorphization, and the fabrication of electro-ceramic devices.

36 MATERIALS SCIENCE↗
DOE OSTI2017

In-situ 3D visualization of composite microstructure during polymer-to-ceramic conversion

One route for producing fiber-reinforced ceramic-matrix composites entails repeated impregnation and pyrolysis of a preceramic polymer in a fiber preform. The process relies crucially on the development of networks of contiguous cracks during pyrolysis, thereby allowing further impregnation to attain nearly-full densification. The present study employs in-situ x-ray computed tomography (XCT) to reveal in three dimensions the evolution of matrix structure during pyrolysis of a SiC-based preceramic polymer to 1200 °C. Observations are used to guide the development of a taxonomy of crack geometries and crack structures and to identify the temporal sequence of their formation. A quantitative analysis is employed to characterize effects of local microstructural dimensions on the conditions required to form cracks of various types. Complementary measurements of gas evolution and mass loss of the preceramic polymer during pyrolysis as well as changes in mass density and Young's modulus provide context for the physical changes revealed by XCT. Furthermore, the findings provide a foundation for future development of physics-based models to guide composite fabrication processes.

36 MATERIALS SCIENCE↗
DOE OSTI2014

A High Power Density Intermediate-Temperature Solid Oxide Fuel Cell with Thin (La 0.9 Sr 0.1 ) 0.98 (Ga 0.8 Mg 0.2 )O 3-δ Electrolyte and Nano-Scale Anode

Solid oxide fuel cells (SOFCs) with thin (La0.9Sr0.1)0.98Ga0.8Mg0.2O3-δ (LSGM) electrolytes are primary candidates for achieving high (> 1 W cm-2) power density at intermediate (< 650 °C) temperatures. Although high power density LSGM-electrolyte SOFCs have been reported, it is still necessary to develop a fabrication process suitable for large-scale manufacturing and to minimize the amount of LSGM used. Here we show that SOFCs made with a novel processing method and a Sr0.8La0.2TiO3-α (SLT) oxide support can achieve high power density at intermediate temperature. The SLT support is advantageous, especially compared to LSGM supports, because of its low materials cost, electronic conductivity, and good mechanical strength. The novel process is to first co-fire the ceramic layers – porous SLT support, porous LSGM layer, and dense LSGM layer – followed by infiltration of nano-scale Ni into the porous layers. Low polarization resistance of 0.188 Ωcm2 was achieved at 650 °C for a cell with an optimized anode functional layer (AFL) and an (La,Sr)(Fe,Co)O3 cathode. Maximum power density reached 1.12 W cm-2 at 650 °C, limited primarily by cathode polarization and ohmic resistances, so there is considerable potential to further improve the power density.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Effect of an oxide layer on high velocity impact of tantalum particles characterized using molecular dynamics

Micro-cold spray, also commonly referred to as the aerosol deposition method or vacuum kinetic spraying, is a process for depositing nanostructured films of metals and ceramics by impacting solid nanoparticles at high velocity onto a substrate at room temperature and at low pressures. Tantalum films deposited by micro-cold spray are desirable because tantalum is non-reactive to certain molten metals and can therefore serve as a non-reactive barrier coating. However, unlike most other metals deposited by micro-cold spray, tantalum quickly forms an oxide layer when exposed to air. In the deposition of films using traditional cold spray with much larger particles, native oxides must fracture for particle–substrate bonding to occur. Furthermore, the fraction of the particle that is oxidized in micro-cold spray and the strain rates experienced by the particles upon impact are both much larger than in cold spray, suggesting that the role of the oxide on film deposition may be distinct. The effect of this oxide layer on particle deformation and adherence to a substrate under high strain rates is studied using molecular dynamics simulations. The effect of oxide layer thickness, particle diameter, and impact velocity are examined.

42 ENGINEERING↗
DOE OSTI2021

Design of High-Voltage Stable Hybrid Electrolyte with an Ultrahigh Li Transference Number

Considering the high energy consumption during processing, and the low compliance and adhesion of ceramic electrolytes, the integration of polymer into ceramic electrolytes provides a way to mitigate the interfacial issues. However, the severe ion concentration gradient, low ionic conductivity, and instability toward Li metal and high-voltage cathodes become the major concerns in applying hybrid electrolytes. In this work, we report a single-ionconducting hybrid electrolyte (SIE-LLZO) with 64 wt % Li 7 La 3 Zr 2 O 12 (LLZO) particles embedded in a fluoroboron-centered Li-conductive polymer framework (LiBFSIE). The SIE-LLZO electrolyte exhibited a high Li transference number of 0.94 and electrochemical stability up to 5.6 V vs Li/Li + . Promising averaged Coulombic efficiencies of 99.97% and 99.91% were achieved in cells with LiNi 0.8 Co 0.15 Al 0.05 O 2 and LiNi 0.6 Mn 0.2 Co 0.2 O2 cathodes for 400 and 200 cycles, respectively. Finally, the Li-conducting pathway in the hybrid electrolyte was further investigated by a 6 Li-to- 7 Li isotope replacement method, indicating that Li transport mainly relies on the LLZO and interface between LiBFSIE and LLZO.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Thermodynamic equilibrium and kinetic fundamentals of oxide dissolution in aqueous solution

Dissolution of oxides in aqueous solutions is fundamentally important for a range of applications and a critical process that determines the chemical durability of industrial ceramics, the performance of nuclear waste forms, and the chemical weathering of minerals. The thermodynamic equilibrium and kinetics of dissolution reactions are key to determining the rate at which oxides dissolve. The increase in collaborative research across disciplines in materials research necessitates a common background to tackle shared scientific problems across different fields. This review selectively examines the fundamentals of dissolution theories that have been developed in chemistry, geochemistry, and materials science, and assembles them into a single collective document for the broader materials science community. Applications of the theories are highlighted using examples from specific areas, but can be similarly applied to other areas. Challenges and future research needs for a predictive-level understanding are discussed in light of the current literature.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2013

Composite Synthesis Methodology Development: Nanocrvstalline SiC and Ti 3 SiC 2 Alloys for Reactory Materials – Outline of initial synthesis capabilities M4CT-13PN0405034

We have identified three initial preceramic polymers to help produce the SiC-based alloys for this project and have developed simple processing steps to make SiC-based alloy ceramics. The use of unfilled SMP-10 (Polycarbosilane) or SMP-877 (Methyl-Polycarbosilane) is not feasible due to the large mass losses that occur during pyrolysis. The pre-gelling steps below save time when those two polymers are filled with powders. The use of SL-MS30 provides us with a SiC-filled polymer that can be used to test out the CNT mats without further complications due to other powders.

36 MATERIALS SCIENCE↗
DOE OSTI2021

CFA-17-12798: Nanostructured Ceramic Membranes for Enhanced Tritium Management

This project focuses on the novel use of interfacial hydrated layers in ionic conducting ceramic materials for tritiated water (HTO) adsorption and recovery. Low-temperature water adsorption properties of nanoscale structured ceramics combined with hydrogen isotope exchange in their hydrated layers could provide a low-cost and transformative avenue to address tritium management challenges.

08 HYDROGEN↗
DOE OSTI2020

Electrothermal Phenomena in Ferroelectrics

Physical properties of lead-zirconate-titanate (PZT) ceramics change according to the initial electric poling process and electrical boundary conditions. This paper reports the electrothermal, piezothermal, and piezoelectric coupling phenomena in ferroelectrics from thermodynamics viewpoints, in particular, thermal property differences between unpoled and poled PZT’s in the poling direction for open circuit and short circuit conditions. We propose a new terminology, “secondary electrothermal” coupling factor kλ, which is analogous to the electromechanical coupling factor k, relating the elastic compliances under short- and open-circuit conditions, in order to explain the fact that the short-circuit condition exhibited the larger thermal diffusivity than the open-circuit condition. On the other hand, the unpoled specimen exhibits the lowest thermal diffusivity. This tutorial paper was authored for providing comprehensive knowledge on equilibrium and time-dependent thermodynamics in ferroelectrics.

Uchino, Kenji (ORCID:0000000316517912)↗
NASA NTRS1982

Advanced Materials Technology

Composites, polymer science, metallic materials (aluminum, titanium, and superalloys), materials processing technology, materials durability in the aerospace environment, ceramics, fatigue and fracture mechanics, tribology, and nondestructive evaluation (NDE) are discussed. Research and development activities are introduced to the nonaerospace industry. In order to provide a convenient means to help transfer aerospace technology to the commercial mainstream in a systematic manner.

Charles P. Blankenship↗
NASA NTRS1985

Destabilization of yttria-stabilized zirconia induced by molten sodium vanadate-sodium sulfate melts

The extent of surface destabilization of ZrO2 - 8 wt percent Y2O3 ceramic disks was determined after exposure to molten salt mixtures of sodium sulfate containing up to 15 mole percent sodium metavanadate (NaVO3) at 1173 K. The ceramic surface was observed to transform from the cubic/tetragonal to monoclinic phase, concurrent with chemical changes in the molten salt layer in contact with the ceramic. Significant attack rates were observed in both pure sulfate and metavanadate sulfate melts. The rate of attack was found to be quite sensitive to the mole fraction of vanadate in the molten salt solution and the partial pressure of sulfur trioxide in equilibrium with the salt melt. The observed parabolic rate of attack is interpreted to be caused by a reaction controlled by diffusion in the salt that penetrates into the porous layer formed by the destabilization. The parabolic rate constant in mixed sodium metavanadate - sodium sulfate melts was found to be proportional to the SO3 partial pressure and the square of the metavanadate concentration. In-situ Raman spectroscopic measurements allowed simultaneous observations of the ceramic phases and salt chemistry during the attack process.

Nagelberg, A. S.↗
NASA NTRS1992

Removing Undesired Fine Powder From Silicon Reactor

Fluidized-bed reactor produces highly pure polycrystalline silicon particles with diameters approximately greater than 400 micrometers. Operates by pyrolysis of silane in reaction zone, which is bed of silicon seed particles fluidized by flow of silane and carrier gas. Above reaction zone, gas mixture flows rapidly enough to entrain silicon powders, but not larger seed and product particles. Entrained particles swept out of reactor. Applicable to other processes such as production of fine metal and ceramic powders where control of sizes of product needed.

Flagella, Robert N.↗
NASA NTRS2000

Internally Cooled Monolithic Silicon Nitride Aerospace Components

A set of rapid prototyping (RP) processes have been combined with gelcasting to make ceramic aerospace components that contain internal cooling geometry. A mold and core combination is made using a MM6Pro (Sanders Prototyping, Inc.) and SLA-250/40 (3Dsystems, Inc.). The MM6Pro produces cores from ProtoBuild (trademarked) wax that are dissolved in room temperature ethanol following gelcasting. The SLA-250/40 yields epoxy/acrylate reusable molds. Parts produced by this method include two types of specimens containing a high density of thin long cooling channels, thin-walled cylinders and plates, as well as a model hollow airfoil shape that can be used for burner rig evaluation of coatings. Both uncoated and mullite-coated hollow airfoils has been tested in a Mach 0.3 burner rig with cooling air demonstrating internal cooling and confirming the effectiveness of mullite coatings.

Best, Jonathan E.↗
DOE OSTI2022

Tritium Transport Modeling at the Pore Scale in Ceramic Breeder Materials Using TMAP8

Fusion reactors depend on the blanket material to breed and release tritium at the same rate or faster than it is consumed by the fusion reaction. Cellular ceramic breeders (CCBs) are dense materials that can maintain a high tritium breeding ratio while promoting tritium release because of highly connected pores. Assessing the tritium breeding capabilities of these materials requires a combination of extensive experimental and modeling efforts. In this work, we develop and calibrate a multiphysics model of tritium transport. This novel model accounts for ceramic and pore diffusion, trapping and detrapping, and several surface reactions at the pore surface. We perform a sensitivity analysis and calibrate the model by comparing its predictions against experimental measurements of deuterium absorption. The calibrated model is then used to model tritium absorption in samples with different pore microstructures to investigate the effect of pore interconnectivity on tritium absorption. The model is part of the development of the multiscale, multiphysics framework for tritium transport [i.e., the Tritium Migration Analysis Program (TMAP8)], which is itself built on top of the finite-element multiphysics framework multiphysics object-oriented simulation environment (MOOSE). This study demonstrates some of TMAP8’s capabilities and is the first step toward assessing the tritium breeding capabilities of ceramic breeder material designs.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Modeling Microwave-Enhanced Chemical Vapor Infiltration Process for Preventing Premature Pore Closure

The chemical vapor infiltration (CVI) process involves infiltrating a porous preform with reacting gases that undergo chemical transformation at high temperatures to deposit the ceramic phase within the pores, ultimately leading to a dense composite. The conventional CVI process in composite manufacturing needs to follow an isothermal approach to minimize temperature differences between the external and internal surfaces of the preform, ensuring that reactive gases infiltrate internal pores before external surfaces seal. Here, this study addresses the challenge of premature pore closure in CVI processes through microwave heating. A frequency-domain microwave solver is developed in OpenFOAM to investigate volumetric heating mechanisms within the preform. Through numerical studies, we demonstrate the capability of microwave heating of creating an inside-out temperature inversion. This inversion accelerates reactions proximal to the preform center, effectively mitigating the risk of premature external pore closure and ensuring uniform densification. The results reveal a significant enhancement in temperature inversion when high-permittivity reflectors are incorporated to generate resonant waves. This microwave heating strategy is then coupled with high-fidelity direct numerical simulation (DNS) of reacting flow, enabling the analysis of resulting densification processes. The DNS includes detailed chemistry and realistic diffusion coefficients. The numerical results can be used to estimate the impact of microwave-induced temperature inversion on densification in productions.

42 ENGINEERING↗
DOE OSTI2024

Modeling Microwave-Enhanced Chemical Vapor Infiltration Process for Preventing Premature Pore Closure

The chemical vapor infiltration (CVI) process involves infiltrating a porous preform with reacting gases that undergo chemical transformation at high temperatures to deposit the ceramic phase within the pores, ultimately leading to a dense composite. The conventional CVI process in composite manufacturing needs to follow an isothermal approach to minimize temperature differences between the external and internal surfaces of the preform, ensuring that reactive gases infiltrate internal pores before external surfaces seal. This study addresses the challenge of premature pore closure in CVI processes through microwave heating. A frequency-domain microwave solver is developed in Open-FOAM to investigate volumetric heating mechanisms within the preform. Through numerical studies, we demonstrate the capability of microwave heating of creating an inside-out temperature inversion. This inversion accelerates reactions proximal to the preform center, effectively mitigating the risk of premature external pore closure and ensuring uniform densification. The results reveal a significant enhancement in temperature inversion when high-permittivity reflectors are incorporated to generate resonant waves. This microwave heating strategy is then coupled with high-fidelity direct numerical simulation (DNS) of reacting flow, enabling the analysis of resulting densification processes. The DNS simulation includes detailed chemistry and realistic diffusion coefficients. The numerical results can be used to estimate the impact of microwave-induced temperature inversion on densification in productions.

Ge, Wenjun↗
DOE OSTI2021

Direct ink writing of boron carbide monoliths

Direct ink writing – an extrusion-based additive manufacturing process – followed by pressureless sintering was investigated to produce boron carbide monoliths. The effects of ceramic powder loading and Pluronic binder concentration on the rheology of boron carbide pastes were studied and linked to both processing behaviour and final outcome in terms of sintered density and hardness. The effects of printing parameters, in particular orifice diameter and printing speed, were also investigated. Reducing the size of the extrusion nozzle from 584 μm to 406 μm led to significantly better shape retention, lower surface roughness, as well as higher density and hardness. A 203 μm printing orifice was also trialled but was unsuccessful due to faster drying kinetics that occurred with smaller ceramic struts resulting in rapid warping and nozzle clogging. Carbon-black – 8 wt% relative to B 4 C – acted as an effective sintering aid to increase both density and hardness. After optimisation of feedstock and printing parameters, few-layer samples (3–5 layers) had a density as high as ~ 97 % TD and a hardness of ~ 30 GPa. On the other hand, 18-layer specimens had a sintered density of ~ 87 % TD, despite a fully dense microstructure, due to the formation of a 3D array of inter-strut pores. Nevertheless, several issues that arose during manufacturing and post-processing were detrimental to the density and structural integrity of printed specimens; these issues were identified, discussed, and suggestions for future work are provided in this report.

36 MATERIALS SCIENCE↗