SEARCH · Engineering Papers

Results for “sintering”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 757 records · Page 42

All sources NASA NTRS DOE OSTI

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↗

NASA NTRS2018

Demonstration of Subscale Cermet Fuel Specimen Fabrication Approach Using Spark Plasma Sintering and Diffusion Bonding

Nuclear thermal propulsion (NTP) has the potential to expand the limits of human space exploration by enabling crewed missions to Mars and beyond. The viability of NTP hinges on the development of a robust nuclear fuel material that can perform in the harsh operating environment (> or = 2500K, reactive hydrogen) of a nuclear thermal rocket (NTR) engine. Efforts are ongoing to develop fuel material and to assemble fuel elements that will be stable during the service life of an NTR. Ceramic-metal (cermet) fuels are being actively pursued by NASA Marshall Space Flight Center (MSFC) due to their demonstrated high-temperature stability and hydrogen compatibility. Building on past cermet fuel development research, experiments were conducted to investigate a modern fabrication approach for cermet fuel elements. The experiments used consolidated tungsten (W)-60vol%zirconia (ZrO2) compacts that were formed via spark plasma sintering (SPS). The consolidated compacts were stacked and diffusion bonded to assess the integrity of the bond lines and internal cooling channel cladding. The assessment included hot hydrogen testing of the manufactured surrogate fuel and pure W for 45 minutes at 2500 K in the compact fuel element environmental test (CFEET) system. Performance of bonded W-ZrO2 rods was compared to bonded pure W rods to access bond line integrity and composite stability. Bonded surrogate fuels retained structural integrity throughout testing and incurred minimal mass loss.

Barnes, Marvin W.↗

NASA NTRS2018

Massively Expanded NEA Accessibility via Microwave-Sintered Aerobrakes

The availability of a wide range of natural resources among the near-Earth asteroid (NEA) population offers the opportunity to utilize these resources in the service of making access to most of the Solar System much easier than any classical approach which relies solely upon structural, heat-shield, life support and propellant materials lifted from Earth.We have concentrated our attention on the two main factors that influence the application and utility of in situ aerobrake manufacture on near-earth asteroids. The first of these is the use of microwave sintering in the fabrication of aerocapture heatshields for retrieval of asteroidal materials into Earth orbit; the second is assessment of the performance of these aerocapture devices, including making very large numbers of NEAs accessible as sources of essential materials to support space exploration and exploitation.

Lewis, John S.↗

NASA NTRS2019

Evaluation of an Alternate Method for Determining Yield Strength Offset Values for Selective Laser Sintered Polymeric Materials

Due to the unique characteristics of Additively Manufactured (AM) polymeric materials, typical mechanical strength characterization methods such as those commonly used for traditionally-processed polymers or composite materials can produce results that do not accurately represent material capabilities. In order to characterize mechanical properties of these materials, new test and analysis methods are required. As part of the National Aeronautics and Space Administration (NASA) Advanced Composites Project (ACP), Boeing has evaluated true yield testing as an alternative or complimentary test to 0.2% offset yield testing for determining appropriate yield strength values of polymer materials. Previous testing has shown high strain, low modulus polymer materials such as selective laser sintered (SLS) Nylon 11 at elevated temperatures produce large variations in yield strength. The true yield test method was successful in finding the applied strain level when yield commences and appears to offer an increase in data robustness.

Henry, Chelsey↗

DOE OSTI2017

Reactive sintering of ceramic lithium ion electrolyte membranes

Disclosed herein are methods for making a solid lithium ion electrolyte membrane, the methods comprising combining a first reactant chosen from amorphous, glassy, or low melting temperature solid reactants with a second reactant chosen from refractory oxides to form a mixture; heating the mixture to a first temperature to form a homogenized composite, wherein the first temperature is between a glass transition temperature of the first reactant and a crystallization onset temperature of the mixture; milling the homogenized composite to form homogenized particles; casting the homogenized particles to form a green body; and sintering the green body at a second temperature to form a solid membrane. Solid lithium ion electrolyte membranes manufactured according to these methods are also disclosed herein.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2018

Machining induced fissures in relation to microstructure of sintered U3Si2 fuel pellets

As uranium silicide (U3Si2) becomes a more desired fuel replacement for uranium dioxide in light water reactors, it is import to understand the fabrication process. Moreover, it is important to understand how the as-sintered microstructure of the fuel pellet affects the final product; uranium silicide fuel pellets are currently fabricated using a powder metallurgy process. Pellet quality and integrity is a concern as any unwanted defects may cause adverse irradiation behavior. Thus, pellets need to remain relatively free of defects (surface chipping, cracking, undesired microstructure, etc.) in order to be placed into a fuel assembly. Recently, it was observed that uranium silicide fuel pellets developed surface fissures on the machined surface after a centerless grinding process. Initial observations indicate a relation between microstructure and machining induced fissures; in essence, fissures on the machined surface are only observed in pellets containing a non-uniform texture (fine grains surrounding coarse grains). Experiments have been focused on determining the cause(s) of the non-uniform texture. Once the cause was determined and grain size was reproduced, samples with a coarse-grained microstructure, along with samples containing a fine-grained microstructure were centerless ground to confirm the relation between surface fissures and microstructure. Samples were also subjected to microscopic analysis, grain size analysis, and x-ray diffraction (XRD).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Cost-effective solid state reactive sintering method for protonic ceramic fuel cells

The present invention relates to a protonic ceramic fuel cell and a method of making the same. More specifically, the method relates to a cost-effective route which utilizes a single moderate-temperature (less than or equal to about 1400° C.) sintering step to achieve the sandwich structure of a PCFC single cell (dense electrolyte, porous anode, and porous cathode bone). The PCFC layers are stably connected together by the intergrowth of proton conducting ceramic phases. The resulted PCFC single cell exhibits excellent performance (about 450 mW/cm2 at about 500° C.) and stability (greater than about 50 days) at intermediate temperatures (less than or equal to about 600° C.). The present invention also relates to a two step method for forming a PCFC, and the resulting PCFC.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2020

High density UO 2 and high thermal conductivity UO 2 composites by spark plasma sintering (SPS)

Embodiments of the invention are directed to a method for production of a nuclear fuel pellet by spark plasma sintering (SPS), wherein a fuel pellet with more than 80% TD or more than 90% TD is formed. The SPS can be performed with the imposition of a controlled uniaxial pressure applied at the maximum temperature of the processing to achieve a very high density, in excess of 95% TD, at temperatures of 850 to 1600° C. The formation of a fuel pellet can be carried out in one hour or less. In an embodiment of the invention, a nuclear fuel pellet comprises UO 2 and a highly thermally conductive material, such as SiC or diamond.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Solvent-Free and Non-Sintered 500 Wh/kg All Solid-State Battery

Navitas teamed up with UMD and ORNL to establish a reliable scientific research team. The project addressed processing limitations of state-of-the-art solid electrolytes by extending solvent-free electrode fabrication technology to the scalable production of cathode/solid electrolyte laminates. The innovation started with a solid-state sulfide electrolyte (LiPS) with Cl stabilization able to meet the keystone conductivity challenge in a film of practical thickness (μ 50 µm). The electrolyte was based on a composite of PTFE, and stabilized LiPSCl. With optimization, the ionic conductivity reached 3.3 ×10 -3 S/cm. The solid electrolyte with as low as 0.4% binder allowed long term cycling (> 500 cycles) of Li/SSE/Li cell at > 4 mA/cm 2 with the utilization of Li > 80%. The Li and SSE interfaces were successfully protected with LiF-rich SEI layer. NCM811cathode active materials were coated with a thin layer of Al 2 O 3 (5 nm). The free standing cathode film was fabricated through dry-process with Al2O3-coated NCM811, LiPSCl, active carbon, and small amount PTFE. The all-solid-state batteries were laminated with free standing surface coated NCM811 cathode film, free standing LiPSCl SSE film, and surface protected Li anode together in a single lamination step, and demonstrated high specific capacity (> 200 mAh/g) with coulombic efficiency > 99.5%. The all-solid-state batteries through solvent-free and no-sintering process are promising for large format cell with 500 Wh/Kg specific energy density.

25 ENERGY STORAGE↗

DOE OSTI2022

Slides for MS&T2022: Carbon-Carbon Composites from 3D Printed Preforms Graphitized by Electric Field Assisted Sintering

Formation of Carbon-Carbon (C-C) composite materials requires putting a carbon fiber preform through a cycle of densification, carbonization, and graphitization. This cycle is then repeated until the desired properties are achieved. The graphitization phase is particularly energy demanding as it involves heating the components to in excess of 2000°C. In traditional furnaces this is also quite time consuming as typical heating rates are low, and the actual heat treatment may be limited by component dimensions, as heat is conducted throughout the part primarily by thermal diffusion. Joule heating by means of Electric Field Assisted Sintering (EFAS) systems enables high heating rates and causes the part to be heated from the inside, which eliminates the thermal diffusion time constraint. In our process, C-C composites are formed by pyrolyzation of 3D-printed carbon fiber preforms, vacuum infiltration of naphthalene based mesophase pitch, and carbonization. The part is then graphitized in the EFAS system. By this method graphitization of the composite matrix was achieved in less than an hour. A part density of greater than 1.6g/cc (up to 1.9g/cc demonstrated) was achieved after only two rounds of infiltration and a single graphitization. Overall the process took less than a week which is significantly faster than traditional methods. Optical microscopy and XRD results are discussed to elucidate the internal porosity and characterize the degree of graphitization. Testing was performed showing the impact on fiber direction to electrical and thermal properties of the final part.

36 MATERIALS SCIENCE↗

DOE OSTI2022

High density UO2 and high thermal conductivity UO2 composites by spark plasma sintering (SPS)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

Creep and Tensile Properties of Direct Metal Laser Sintered (DMLS) Inconel 738LC Coupons and Comparison to Cast Properties

Due to the nature of sCO2 power cycles, a number of turbine parts must have good mechanical properties at elevated temperatures. For recompression cycles, the turbine inlet temperature is between 600°C - 750°C, which puts nearly all high-temperature turbine parts into a creep regime. The high-strength parts in these applications are often composed of materials having high nickel or chrome contents, and are often termed superalloys. At these temperatures, the blades must survive mechanical loads due to centrifugal stress and blade loading. While centrifugal stress is primarily a function of tip velocity and its associated centrifugal acceleration, blade loading is a function of power density. Since sCO2 turbomachinery is approaching the power density of rocket engines, blade loading tends to be quite large. Another result of this high power density is that blade passages for 1-10 MW turbines tend to be quite small, making conventional fabrication methods challenging and costly; this leads engineers to pioneer new techniques to address these challenges. The authors of the current work are addressing this challenge by applying additive manufacturing techniques in the production of a 10 MW radial inflow impeller. While a comprehensive database exists for the mechanical properties of forged and cast superalloys, data is sparse for superalloys fashioned by direct metal laser sintering (DMLS) or other additive manufacturing methods. For the remainder of this work, the term printed will refer to components manufactured using one of these processes for brevity. The current work stems from the desire to manufacture a radial inflow turbine impeller using additive manufactured (AM) Inconel 738. While Siemens has adopted the use of DMLS printed Inconel 738 for use in select aviation engine parts, creep and tensile properties have not been published to the extent needed to validate a given design. The current work will show creep and tensile properties of AM Inconel 738 in the horizontal and vertical build directions and their respective comparison to cast Inconel 738 properties.

wilkes, Jason↗

DOE OSTI2023

EXPERIMENTAL ANALYSIS OF SINGLE EVAPORATION TUBE UTILIZING SINTERED COPPER PARTICLE WICKING STRUCTURES

Wicking structures have been widely used within passive heat transfer devices with high heat fluxes, such as heat pipes, to enhance their thermal performance. While wicking structures promote capillary pumping of the working fluid as well as thin film evaporation, they can result in capillary evaporation and further enhances the evaporation heat transfer. In this study, a 0.5 mm thick layer of 105 microns sintered copper particles was added to the inner wall of a copper tube, aiming to enhance the heat transfer characteristics by taking advantage of capillary evaporation. Acetone was chosen as the working fluid, and the performance of an evaporation tube was tested for power inputs of 10, 30, 50, and 70 W. For each power input, trials were run at inclination angles varying from -90° and 90° to investigate the capillary effects. The temperature measurements showed that the temperature distribution along the evaporation tube is always downward sloping, meaning the temperature at the fluid inlet is larger than the outlet. Interestingly, the surface temperature at some locations is less than the outlet temperature, indicating the effect of capillary evaporation. In addition, a theoretical investigation was performed to investigate the effects of the particle size on the thermal performance of the evaporation tube and found that particle sizes affect capillary evaporation.

Wang, Pengtao↗

DOE OSTI2023

Method of controlled conversion of thermosetting resins and additive manufacturing thereof by selective laser sintering

The invention is directed to a method of controlled conversion of thermosetting resins and additive manufacturing thereof by selective laser sintering. Partial curing of a thermosetting formulation can be used to increase the T g of the resin and minimize the additional cure needed to cross-link a printed object. After printing, the partially cured material is finally cured via a slow temperature ramp maintained just below the material's evolving T g .

Campbell, C. Garrett↗

DOE OSTI2023

Reduced-temperature sintering of spinel-type coatings and layers with metallic alloy powder precursors

A method of forming a spinel coating on a substrate is disclosed including the steps of coating at least a portion of the substrate with a precursor including an alloy powder, and sintering the precursor at a temperature of less than 1000 degrees Celsius to form the spinel coating. The alloy powder used for the precursor can include particles having a particle size of less than 10 micrometers. The method can be utilized to form spinel coatings as contact surfaces between electrodes and interconnects of solid oxide fuel cell (SOFC) stacks.

Zhu, Jiahong↗

DOE OSTI2026

Embedding Fiber Optic Sensors in Stainless Steel using Spark Plasma Sintering for Structural Health Monitoring in Harsh Environments

Embedded fiber optic sensors such as fiber Bragg gratings (FBGs) offer a unique route for distributed real-time in-situ imaging of various engineering parameters for numerous purposes. This study advanced the current sensor embedding approaches by exploring a spark plasma sintering (SPS)-assisted technology to embed FBGs in high-temperature structural materials and demonstrated the capability of temperature measurement. In this approach, single-mode FBGs were integrated into stainless steel (SS) 316L components using SPS, followed by the evaluation of the bonding quality between the FBGs and matrix, the optical attenuation of the fibers induced by embedding, and the sensing characters of the FBGs under temperature stimuli. The results demonstrated that superior bonding was achieved between the FBGs and highly-densified SS316L. Examination of the behavior of Bragg gratings validated signal fidelity after embedding. Real-time thermal imaging under temperature cycling using the FBGs demonstrated the effectiveness of the technique for smart materials manufacturing.

36 - MATERIALS SCIENCE↗

DOE OSTI2026

Mechanical Behavior of Neutron Irradiated Refractory Multi-Principal Element Alloys Processed via Spark Plasma Sintering

The search for advanced materials capable of withstanding the extreme conditions of Generation IV reactors is a critical area in materials science research. These reactors operate under severe environments, including high temperatures, corrosion, stress, and irradiation damage. Consequently, there is a need for innovative alloy systems to ensure the reliability and longevity of proposed Generation IV reactor components. Refractory multi-principal-element alloys (RMPEA) have emerged as a promising candidate due to their exceptional properties. These alloys, characterized by their composition of multiple principal elements in near-equiatomic ratios, exhibit superior resistance to irradiation damage, reduced void swelling, enhanced microstructural stability, and minimal irradiation-induced hardening. While initial studies on RMPEAs have shown promising results, most research has been limited to thin films, nanocrystalline microstructures, and ion irradiation, which do not accurately represent the behavior of bulk materials. To address this gap, our research focused on the neutron irradiation of bulk RMPEAs. We aim to conduct comprehensive post-irradiation examinations (PIE) of RMPEAs irradiated at the Advanced Test Reactor at Idaho National Laboratory. The RMPEAs were synthesized using spark plasma sintering (SPS) with mechanically alloyed metallurgical powder. The RMPEA specimens are a MoNbTi alloy system with additions of -Zr, and -ZrV. Furthermore, PIE consisted of mechanical testing and advanced materials characterization. The mechanical testing consisted of sub-sized tensile testing, micro- and nano- indentation. Microstructural characterization included scanning electron microscopy and transmission electron microscopy. Mechanical testing coupled with advanced microscopy techniques provides insight into phase morphology and its effects on the mechanical properties of the RMPEA specimens. The results indicate that both pristine and irradiated RMPEA specimens exhibited brittle behavior during tensile testing, which can be attributed to their heterogeneous microstructure. The SPS manufacturing process did not include any post treatment, which resulted in a heterogeneous microstructure. Energy-dispersive X-ray spectroscopy revealed the presence of intermetallic such as laves phases within the microstructure. Specifically, Ti-rich precipitates were observed in the MoNbTi specimen, while Mo-rich precipitates were found in the MoNbTiZrV specimen. Nano-hardness testing of pristine samples showed that the laves phases exhibited higher hardness values compared to the matrix phase, suggesting that precipitate hardening is likely the dominant hardening mechanism in these specimens. The results from this work will be used to build a finite element model to predict mechanical behavior of future MPEA compositions. Thus, enabling for a streamlined approach to developing novel MPEAs for the nuclear industry.

36 - MATERIALS SCIENCE↗

DOE OSTI2017

Measurement of O and Ti atom displacements in TiO 2 during flash sintering experiments

In-situ flash experiments on rutile TiO 2 were performed at the synchrotron at the Brookhaven National Laboratory. Pair distribution function analysis of total X-ray scattering measurements yielded mean-square atomic displacements of oxygen and titanium atoms during the progression of the 3 stages of flash. The displacements are measured to be far greater for oxygen atoms than for titanium atoms. Thus, these large displacements may signal an “elastic softening” of the lattice, which, recently, has been predicted as a precursor to the onset of flash.

36 MATERIALS SCIENCE↗