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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 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Hydrogen permeability and stability of palladium films in a high pressure reactor

Palladium (Pd) thin films were fabricated by colloidal spray deposition (CSD) on substrates of porous yttrium stabilized zirconium oxide (YSZ). The films were sintered at 1140–1160 °C for 2–3 h in argon and had thickness of 5–11 μm. The hydrogen (H 2 ) permeation flux for the Pd film was measured with simulated feed gases (90% H 2 /He, syn-gas/steam, or syn-gas/steam with H 2 S) flowing on the film side and sweep gas (Ar) flowing on the substrate side. Here, the hydrogen flux with the Pd film was obtained by adjusting the flow rate and pressure of the gas. Hydrogen flux values of 121–173 cm 3 min -1 cm -2 were measured at 388–596 °C (feed: 90% H 2 /He at 200 mL min -1 ; sweep: Ar at 1400 mL min -1 ; and ΔP = ~170 psi), and the permeability was calculated and compared with literature values. Because Pd is known to be sensitive to some gases, the stability of Pd films was evaluated by examining the microstructures of samples after their exposure to gas mixtures containing CO, CO 2 , H 2 O, and H 2 S. From the results of stability tests in H 2 S-containing atmospheres, the Pd/Pd 4 S phase boundary was determined, and this measured boundary was compared to the Pd/Pd 4 S boundary calculated from the thermodynamic data in the literature.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Porosity evolution during heating of copper made from powder by friction extrusion

Here, friction extrusion was used to compact and extrude solid copper rod from feedstock powders. Following extrusion, considerable porosity was observed throughout the extrudate cross section due to the entrained porosity in the feedstock material and the extrusion process. The thermal stability of the extrudate was investigated via a series of heat treatments. Porosity evolution exhibited three distinct stages—an unchanged plateau (0°C–300°C) followed by an abrupt increase (400°C–500°C) and ultimately a reduction, as the temperature increases (>500°C). The peak porosity measured was ~25%. The underlying driving force for pore evolution is described as the competition between the internal pore pressure, material strength, and sintering kinetics, as a function of temperature. The observed porosity evolution and driving force are not expected to be limited to copper. Thus, this manuscript reveals an important consideration regarding elevated-temperature thermal stability as advanced manufacturing methods involving direct powder extrusion are explored.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Boosting the activity of non-platinum group metal electrocatalyst for the reduction of oxygen via dual-ligated atomically dispersed precursors immobilized on carbon supports

This paper describes the use of both atomically dispersed precursors (ADPs) and conductive carbon dispersion towards the synthesis of iron-based single atom electrocatalysts for the oxygen reduction reaction (ORR). For non-platinum group metal (non-PGM) catalysts, single iron, cobalt or manganese atoms coordinated with nitrogen are the most active structures towards the ORR. Achieving a high density of active sites made of single atoms is still challenging, requiring careful controls of pyrolysis to reduce the sintering of metal active sites. Herewith, we present a new strategy to synthesize iron-based single atom ORR electrocatalysts using a two pronged approach. We first designed a dual-ligated metal organic framework (MOF) precursor. This MOF was then immobilized onto Ketjen black carbon that serves as a conductive dispersion medium for creating the highly dispersed single atom sites. In this work, we demonstrate a near complete dispersion of the iron sites without obvious formation of nanoparticles. The activity of the resulting electrocatalyst exhibited an onset potential of 0.96 V and a half-wave potential of 0.84 V vs. reversible hydrogen electrode (RHE).

42 ENGINEERING↗
DOE OSTI2022

UO 2 -liquid metal suspension fuel concept for enhanced passive safety of LWRs: A heat pipe case study

This work proposes a novel fuel concept for use in light-water type reactors (LWRs): UO 2 particles suspended in a low-melting-point liquid metal (LM). This new fuel form offers lower energy density and higher thermal conductivity, thus enhancing the fuel’s thermal performance compared to sintered UO 2 pellets. Two candidate alloys for the LM are proposed based on previous studies into accident-tolerant fuels: Bi-Pb-Sn and Pb-Sn. Ten research questions are provided to guide future development of this fuel. A simple heat pipe model was constructed by coupling a reactor physics code to a heat transport code and other physics modules. Scoping calculations were performed on this model core as a preliminary investigation into five of the research questions. A fuel with 13 wt% UO 2 was shown to maintain a steady-state peak coolant channel wall temperature below 400 °C, and maintain criticality via self-regulating reactivity feedback. Shortcomings of the present model are discussed in this work, along with proposed future model improvements and fuel development. The appendix provides an example of a reactor concept that could be developed to utilize this fuel, but more modeling and experimental work are needed before a full reactor concept can be developed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Sensitivity of UO 2 fuel performance to microstructural evolutions driven by dilute additives

Use of dilute additives to nuclear fuel is being considered to increase the security of commercial fuel management through traceability of fabricated fuel elements. Taggants, as additives are denoted when included for traceability purposes, may also improve fuel performance, as demonstrated in Cr-containing uranium dioxide as described in the literature, and they may also improve fuel safety. In fact, studies have shown that some additives affect fuel material properties such as grain size and density after sintering. Given the possible range of elements that could be used as additives, the impact of such fuel property variations on the fuel’s thermomechanical behavior becomes relevant. These effects can be evaluated through a sensitivity study of standard fuel models to analyze changes in these properties using a fuel performance code. In this work, the BISON code is being used to investigate these effects through a 2D axisymmetric model of smeared UO 2 fuel pellets and ZIRLO® cladding under realistic pressurized water reactor core irradiation conditions. Here, randomly sampled densities and grain sizes within specified ranges are used as input parameters in the simulations, and several fuel model-related outputs are evaluated. The thermomechanical response of the cladding is also addressed in this study. The simultaneous variation of both input parameters offers a more comprehensive path to identify key sensitivities. Outputs explored include temperature, fission gas release, creep, and radial stress. Results show that although most of these outputs are sensitive to grain size to a certain extent, density mainly affects fuel temperature and elastic strain. Furthermore, sensitivities can vary depending on the radial position within the fuel pellet.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Modeling and design of a separate effects irradiation test targeting fission gas release from Cr-doped UO 2

Fission gas release (FGR) from nuclear fuel during operation can diminish heat transfer properties across the pellet-cladding gap and increase the fuel rod internal pressure, thereby posing a concern to fuel reliability and safety during an accident. Enlarging the fuel grain size, which has been shown to improve fission gas retention, can be achieved by doping the fuel feedstock prior to sintering. In this work, the BISON fuel performance code was used to predict FGR from undoped and chromia-doped UO 2 (referred to as Cr-doped UO 2 ) fuel specimens with different grain sizes and across various temperatures. The BISON models identified the irradiation conditions for which FGR is most significant, and a separate effects irradiation experiment in the High Flux Isotope Reactor (HFIR) was then developed targeting those conditions. Further, the experiment leveraged the MiniFuel irradiation capability at Oak Ridge National Laboratory and consisted of 12 fuel specimens of varying grain size and Cr content. A coupling scheme between BISON FGR results and the ANSYS finite element thermal model used for experiment design was formulated to predict cumulative FGR from each fuel specimen based on expected irradiation temperature histories. The fuel samples were fabricated and characterized as a part of this work, and the fuel compositions modeled in BISON were representative of the specimens used in the experiment. This combined modeling and experimental effort aims to study the effect of fuel grain size and Cr content on FGR and to provide simulated BISON FGR results that can be used for future model validation activities.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Accelerated test protocols to predict service life and durability of solid oxide fuel cells

Reliable accelerated test protocols are needed for solid oxide fuel cell research to facilitate rapid learning on key durability issues, identify potential modes of failure expeditiously, and eventually predict the calendar lifetime of an electrochemical cell. In this work, solid oxide fuel cells operated at a constant current density were compared to cells undergoing accelerated measurements, which are composed of intermittent current injection to the cell. A general accelerated test profile was developed by cycling a solid oxide fuel cell from open circuit to a predetermined operating current density that is the same as the current density during a steady-state operation, to accelerate the local redox environment. The following parameters were studied: current density, operation temperature, moist level, sintering temperature, cycling current, cycling frequency, and operation time. Up to 1,320,000 cycles were generated in this work. The cell degradation was accelerated by nearly 10 times, suggesting the feasibility of using this protocol for acceleration test to predict life performance and durability of solid oxide fuel cells.

08 HYDROGEN↗
DOE OSTI2020

3D printed transparent ceramic YAG laser rods: Matching the core-clad refractive index

Yttrium Aluminum Garnet (YAG) solid state laser gain media rods with an active Neodymium-doped core and an optically-clear cladding region were additively manufactured via direct-ink-writing (DIW), followed by sintering and hot isostatic pressing to form fully dense optical ceramics. Lutetium and Gadolinium were chosen as optically-inert co-doping ions in the clad to match the increase in refractive index caused by the Neodymium in the core. Additionally, either 11.6% Lutetium or 3.8% Gadolinium can be used to match the index change from 2% neodymium; however, differences in diffusion distances across the core-clad interface lead to large fluctuations in index in that region. These index fluctuations can be minimized either by matching dopants with similar diffusion distances, or by implementing a gradual gradient in the doping profile, possible through DIW, rather than a sharp compositional interface attainable via more standard fabrication methods. This improvement in index homogeneity resulted in a 40% improvement in lasing performance compared with that of a core-clad rod fabricated with a sharp interface between the doped and undoped regions.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Unraveling the multi-step crystallization mechanism of polytetrafluoroethylene, modified polytetrafluoroethylene, and their nanocomposites with boron nitride nanobarbs: Experimental insights and theoretical analysis

The non-isothermal crystallization behavior and kinetics of polytetrafluoroethylene (PTFE) composites with boron nitride nanobarb (BNNB), a new generation nanostructure with unique surface morphology and mechanical “barbs” have been analyzed, understanding these properties is essential for their high-end applications as thermal interface materials (TIM) for microwave, 5G and microelectronic devices. The analysis of the crystallization parameters includes crystallization onset, peak and end temperatures, crystallization half-life and overall crystallinity of PTFE, modified PTFE and their BNNB composites. The results were further analyzed using theoretical models such as the combined Avrami-Ozawa model. It was found that BNNB supports crystallization in the modified PTFE but shows minimal effect on the crystallization of PTFE. Due to the limitation of the classical theoretical models used above in fully characterizing the multi-step crystallization process of PTFE, an in-depth analysis using the model-free advanced isoconversional computation was used to characterize the PTFE crystallization based on the evolution of activation energy with fractional crystallinity and for the first time with temperature. Three kinetic regions were identified in the crystallization mechanism. Here, this study investigated the molecular organization and microstructural evolution of PTFE, modified PTFE and their composites during non-isothermal crystallization using advanced X-ray scattering measurements. An insight into the changes undergone by the material's microstructural units including crystallite size and morphology, lamellar thickness and lamellar interfacial layer thickness, and crystallographic phase dynamics during non-isothermal cooling from the melt, was provided here in this work. The effect of copolymer modification of PTFE and the inclusion of pristine and functionalized BNNB (a thermally conductive and electrically insulating ceramic) are both new investigations that provide valuable knowledge for the development of materials with strong matrix-nanofiller interaction and guidance for optimizing sintering and cooling cycles, two key steps in PTFE processing that largely affect the material microstructural features. Overall, the result of the three-part investigation demonstrates that BNNB supports crystallization in the modified PTFE up to 20 wt% concentration and at low and high cooling rates typically used in the industrial processing of PTFE.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Post-landing major element quantification using SuperCam laser induced breakdown spectroscopy

The SuperCam instrument on the Perseverance Mars 2020 rover uses a pulsed 1064 nm laser to ablate targets at a distance and conduct laser induced breakdown spectroscopy (LIBS) by analyzing the light from the resulting plasma. SuperCam LIBS spectra are preprocessed to remove ambient light, noise, and the continuum signal present in LIBS observations. Prior to quantification, spectra are masked to remove noisier spectrometer regions and spectra are normalized to minimize signal fluctuations and effects of target distance. In some cases, the spectra are also standardized or binned prior to quantification. To determine quantitative elemental compositions of diverse geologic materials at Jezero crater, Mars, we use a suite of 1198 laboratory spectra of 334 well-characterized reference samples. The samples were selected to span a wide range of compositions and include typical silicate rocks, pure minerals (e.g., silicates, sulfates, carbonates, oxides), more unusual compositions (e.g., Mn ore and sodalite), and replicates of the sintered SuperCam calibration targets (SCCTs) onboard the rover. For each major element (SiO 2 , TiO 2 , Al 2 O 3 , FeO T , MgO, CaO, Na 2 O, K 2 O), the database was subdivided into five “folds” with similar distributions of the element of interest. One fold was held out as an independent test set, and the remaining four folds were used to optimize multivariate regression models relating the spectrum to the composition. We considered a variety of models, and selected several for further investigation for each element, based primarily on the root mean squared error of prediction (RMSEP) on the test set, when analyzed at 3 m. In cases with several models of comparable performance at 3 m, we incorporated the SCCT performance at different distances to choose the preferred model. Shortly after landing on Mars and collecting initial spectra of geologic targets, we selected one model per element. Subsequently, with additional data from geologic targets, some models were revised to ensure results that are more consistent with geochemical constraints. The calibration discussed here is a snapshot of an ongoing effort to deliver the most accurate chemical compositions with SuperCam LIBS.

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

Additive manufacturing of highly dense anisotropic Nd–Fe–B bonded magnets

Extrusion based big area additive manufacturing process is utilized for fabrication of dense anisotropic bonded magnets. High loading fraction (≥70 vol%) of magnequench anisotropic Nd–Fe–B powder in nylon is used for preparing anisotropic bonded magnets. A higher energy product of ~143.2 kJ/m 3 is obtained for the post printed magnetic field aligned at 1 Tesla. These findings make an important step towards the fabrication of gap magnets with energy product between ferrite and Nd–Fe–B sintered magnets. Finally, printed bonded magnets exhibited better thermal stability, mechanical properties and superior magnetic properties compared to commercial injection molded magnets.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Additive manufacturing of three-dimensional (3D)-architected CoCrFeNiMn high- entropy alloy with great energy absorption

In this study, we developed an approach to additive manufacturing of three-dimensional (3D)-architected CoCrFeNiMn high-entropy alloys by direct ink writing combined with thermal sintering. The 3D-architected CoCrFeNiMn lattices exhibit the outstanding energy absorption capacity that expands the envelope of existing architected materials. Such a high-energy absorption ability originates from the bend-dominated deformation mode of the 3D-architecture as well as the fully-annealed homogeneous microstructure of equiaxed grains, which collectively lead to remarkable strain hardening upon deformation. Our study provides a new avenue for 3D-printing advanced architected materials with extreme mechanical energy absorption for a myriad of structural applications.

mechanical property↗
DOE OSTI2020

Measurement of flow properties coupled to experimental and numerical analyses of dense, granular flows for solar thermal energy storage

Granular flows of sintered bauxite proppants were researched along an inclined plane for solar thermal energy storage applications. Granular flow properties needed to drive numeric granular models were measured for improved numerical model predictions for Carbobead CP 50/140, 40/100, and 30/60 particles. Particle shape and size distributions were determined by coupling optical microscopy to an in-house image processing algorithm. The impulse excitation technique was used to measure elastic and shear moduli, and compute Poisson’s ratio. The coefficient of static sliding friction was measured using the slip-stick method, and the static rolling friction was determined from measured shear on particles positioned between two hot-pressed plates. The coefficient of restitution was measured by dropping particles on a surface and determining the kinetic energy before and after impact with the surface using high resolution particle tracking velocimetry. Particle size did not significantly impact the coefficients of restitution and static rolling friction, however, particle shape distribution resulted in a large variation in measurements. An inclined flow experiment was performed to characterize granular flows of Carbobead CP 30/60 particles using particle image velocimetry. Numerical models of the experiment using discrete element method were generated with the measured mechanical properties as inputs for comparison with experimental results. A constant directional torque rolling friction model best predicted bulk granular flow behavior. Furthermore, good agreement between the model and experiment was achieved at ambient, steady state conditions, with average velocity differences <10%.

14 SOLAR ENERGY↗
DOE OSTI2022

Temperature-dependent diffuse reflectance measurements of ceramic powders in the near- and mid-infrared spectra

Radiative properties are critical to quantify radiative energy fluxes between surfaces and in participating media. However, there is limited experimental data on temperature-dependent radiative properties of materials. Herein, this work focuses on experimentally measuring temperature-dependent diffuse reflectance in the near- and mid-infrared spectra (1–20 μm) for ceramic particles with applications as heat-transfer and thermal-storage media in concentrated solar power (CSP) plants. Specifically, a commercially available sintered bauxite proppant, ACCUCAST ID80, and its primary chemical constituents—alumina (Al 2 O 3 ) and silica (SiO 2 )—are measured in powder form using a Fourier transform infrared spectrometer (FTIR) coupled with a specialized diffuse reflectance accessory and a heated stage. Room-temperature diffuse reflectance measurements show increased absorption in tests with greater mass fractions of the ceramic samples. There is a strong correlation in the measured reflectance spectra of ACCUCAST with alumina and silica in the spectral range 2000–500 cm –1 (5–20 μm). Whereas, for shorter wavelengths (< 5 μm), the absorptance for ACCUCAST is greater than the absorptance for alumina and silica, indicating contributions from other chemical species present in the composite material. For the first time, temperature-dependent diffuse reflectance measurements are reported for ACCUCAST up to 1000 °C. These results are compared against those of alumina and silica through the calculation of a thermal emittance. All three materials exhibit a calculated emittance of ~0.9 at room temperature. However, this value decreases to ~0.6 for ACCUCAST and drops to less than 0.4 for alumina and silica at 1000 °C. Thermal cycling in air at 1000 °C resulted in a visible color change from dark grey to light orange for ACCUCAST and a subsequent larger increase in reflectance for wavelengths less than 5 μm as compared to ACCUCAST thermally cycled at 1000 °C in vacuum. Alumina and silica spectra proved to be largely unaffected by thermal cycling under atmospheric conditions. Overall, this study establishes a powerful technique for the characterization of radiative properties of particulate materials as a function of temperature and presents a detailed case study of ACCUCAST, a candidate for next-generation particle-based CSP.

14 SOLAR ENERGY↗
DOE OSTI2025

Large area transparent refractory aerogels with high solar thermal performance

Application of transparent silica aerogels in low-temperature solar thermal systems has led to major improvements in performance. In high temperature concentrating solar thermal (CST) systems, aerogels have yet to demonstrate the necessary scalability, durability, and performance to support their widespread deployment. Here, large-area transparent refractory aerogel tiles are synthesized and shown to achieve a record-high receiver figure-of-merit (FOM) at high temperatures. The work leverages a scaled-up process for sol–gel synthesis to control the density of the aerogels for improved solar transmittance and adapts a previous atomic layer deposition (ALD) technique with the aid of predictive reaction-transport modeling. After aging for 10 days at 700 °C, the large-area tiles exhibit a solar-weighted transmittance of 95.6 % and a thermal emittance of 0.31, corresponding to a FOM of 80 % at 100 suns and 700 °C. The observed sintering rates at 700 °C are comparably low to earlier one-inch aerogels, suggesting long-term stability under relevant operating conditions. Furthermore, the study indicates that refractory aerogels are scalable materials for efficient photothermal conversion at high temperatures.

Aerogels↗
DOE OSTI2022

Experimental characterization of extreme temperature granular flows for solar thermal energy transport and storage

High-temperature, dense granular flows along an inclined plane were considered for solar thermal energy transport and storage with sintered bauxite particles. A series of experiments was performed for particle inlet temperatures of ~ 200, 400, 600, and 800 °C to understand the mechanisms of granular flows at extreme temperatures. Mass flow rates were measured using a load cell and free-surface velocities were measured and computed using particle image velocimetry. Surface temperatures were measured using infrared cameras. A significant decrease in steady-state particle mass flow rate was observed with increasing temperature due to changing flow properties. A decrease in bulk particle free-surface velocities was observed at higher temperatures. Free-surface velocity measurement error between experiments were within 20% of the average. The particle surface temperatures decreased from inlet to outlet with larger gradients at higher temperatures observed due to increasing convection and radiative heat losses. Here, a decrease in temperature was observed along the side walls due to a decrease in particle velocities.

14 SOLAR ENERGY↗
DOE OSTI2024

The evolution of model Rh/Fe 3 O 4 (001) catalysts in hydrogen environments

Single metal atoms dispersed on oxides are a new emerging class of catalysts owing to their unique electronic and chemical properties. Here, in this study, we have prepared a series of model single-atom catalysts possessing well-characterized Rh sites that include Rh adatoms (Rh ad ), mixed surface layers with octahedrally-coordinated Rh (Rh oct ), as well as metallic Rh clusters and nanoparticles (Rh met ) on Fe 3 O 4 (001). Using X-ray photoelectron spectroscopy (XPS) and scanning tunneling microscopy (STM), we investigated the activity of such model systems towards H2 and their stability in reducing environments. Our results show that the atomically dispersed Rhad and Rhoct species do not activate H 2 , which would result in the formation of surface hydroxyls on Fe 3 O 4 (001). In contrast, the presence of Rh met in H 2 results in the formation of hydroxyls and subsequent etching of the Fe 3 O 4 (001) at higher temperatures (≥ 500 K) due to water formation via the Mars-van Krevelen mechanism. Additionally, such surface etching leads to the release of the Rh oct from the surface lattice and their sintering to Rh met . To bridge the material gap between the surface science models and high surface area catalysts, we perform parallel studies on powder Rh/Fe 3 O 4 catalysts. The XPS characterization shows remarkable similarities between these systems. Further, our surface science studies provide an atomistic picture of the behavior of high surface area catalysts in the H 2 atmosphere.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Evolution of Ni-Mo/MgO during catalytic methane pyrolysis to produce base-growth nanotubes

Catalytic pyrolysis of methane is a promising approach for affordable hydrogen production without CO 2 emissions. While this process is thermodynamically appealing compared to steam reforming, the high stability of methane requires severe conditions, making catalyst stability challenging. Here, we report the behavior of a highly promising Ni-Mo/MgO catalyst, which greatly outperforms its Ni/MgO, Mo/MgO, and Ni-Mo/SiO 2 counterparts at atmospheric pressure. At 800°C, nearly 229 g of carbon nanotubes per gram of Ni are produced. We propose that this superior performance results from the phase evolution of the catalyst, which exsolves stable nickel catalyst particles under reaction conditions. We further reveal that molybdenum carbide formation reduces sintering and adheres the active catalytic particles to the support throughout the reaction, enabling catalyst reuse. Several characterization techniques (same-spot TEM, XPS, XRD, and Raman) are employed to examine catalyst morphology at every step, fostering a deeper understanding of its catalytic activity and stability.

36 MATERIALS SCIENCE↗