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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 793 records · Page 44
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Ultrasonic Characterization of Material Properties in Metal Components Additively Manufactured by Powder Bed Fusion

We present the methodology for using pulsed-echo ultrasound to characterize the properties of additively manufactured (AM) metal components and their response to changes in the fabrication settings. We show how to accurately characterize anisotropy in these properties and when such characterization can be performed noninvasively. Our approach, when applied to 3D-printed stainless steel samples, reveals a significant heterogeneity between the surface and internal properties of the AM part and the anisotropy in material properties in the build and transverse directions.

Walton, Kenneth↗
DOE OSTI2026

From Powder to Power: Tailored Pre-Milling Strategy that Optimizes Microstructure for Efficient Hydrogen Evolution

The hydrogen evolution reaction (HER) plays a critical role in enabling large-scale electrolytic hydrogen production and advancing future technologies and fuel production. Among non-precious metals, NiMo-based catalysts are particularly attractive due to their capability to promote both water dissociation and hydrogen adsorption in alkaline media. However, conventional NiMo catalysts often suffer from incomplete alloying, particle aggregation, weak metal–support interactions, and surface oxidation, which significantly limit active site utilization, electronic conductivity, and long-term stability. Herein, we report a scalable, solid-state, two-step ball milling strategy for constructing an efficient NiMo/C catalyst for the HER. Pre-milling the metal precursors prior to carbon incorporation promotes efficient solid-state activation, leading to the formation of uniformly alloyed, ultrafine, and defect-rich Ni–Mo nanoparticles with robust metal–carbon interfacial anchoring. Benefiting from this integrated structural design, the optimized NiMo/C catalyst exhibits low overpotentials and Tafel slopes, reduced charge-transfer resistance, and excellent durability under alkaline conditions. Comprehensive structural and surface analysis reveal that the enhanced HER performance can be attributed to the synergistic interplay of homogeneous Ni–Mo alloying, uniform nanoparticle dispersion on a defect-rich carbon scaffold, enhanced accessibility of catalytically active sites, and optimized electronic coupling that stabilizes the catalyst surface. This work highlights the two-step solid-state ball milling strategy as a simple, robust, and scalable route for the preparation of effective and durable non-precious metal HER electrocatalysts, offering practical insights toward large-scale and inexpensive hydrogen production.

Yang, Xiaoxuan [Oak Ridge National Laboratory (ORN↗
DOE OSTI2023

Utah FORGE: Powder X-ray Diffraction Data from Well 16A(78)-32 Core

This dataset from Lawrence Livermore National Laboratory (LLNL) consists of four raw X-ray diffraction (XRD) scans and preliminary results of quantitative XRD analysis. The scanned samples were prepared from four subcores, which came from various depths of the FORGE well 16A(78)-32 core. Desired core lengths were selected from available core photos (on GDR), provided by FORGE personnel, and subcored at LLNL. The XRD scans were collected in May 2023 at LLNL as pre-experimental characterization data for these subcores, which will be used in core-flooding experiments at LLNL and in triaxial direct shear experiments at Los Alamos National Laboratory as part of DOE Project 5-2428. XRD scans are in RAW file format (e.g., FORGE-5477-full.raw) and are suitable for viewing and analysis using open-source quantitative XRD software (e.g., Profex; www.profex-xrd.org ) and/or other proprietary instrument software.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Data for: Ultrasonic characterization of material heterogeneities in stainless steel parts fabricated by powder bed fusion

These are the raw ultrasonic waveform files and nanoindentation measurements for three additively manufactured 316L stainless steel components with different fabrication parameters. Each part's length is divided into four segmented regions where their fabrication energy densities change. Part V+ begins at 33 J/mm^3 and increases in energy density by 3 J/mm^3 with each segment. Part C remains at a constant 33 J/mm^3 throughout the part. Part V- begins at 33 J/mm^3 and decreases in energy density by 3 J/mm^3 with each segment. We have found that the ultrasonic waves in regions with higher energy densities will traverse more quickly, as shown by the shorter time of flight, and vice versa. Similarly, nanoindentation measurements of reduced modulus and hardness follow this trend. We have measured the direction in which the parts were fabricated (build direction) and the segmented regions that are perpendicular to the build direction (transverse directions). The build direction longitudinal wave velocity measurements are considerably lower than their transverse direction counterparts, indicating anisotropy between the two directions. In Part C, we have removed material from one of its surfaces and recorded its ultrasonic and nanoindentation measurements with each material removal iteration. Changes in the material properties are more prominent by nanoindentation, suggesting material heterogeneity between the part's surface and interior. The README.txt file has information on how to navigate the files and process the data.

Anisotropy↗
DOE OSTI2021

Local-Distance Seismic Event Relocation and Relative Magnitude Estimation, Applications to Mining Related Seismicity in the Powder River Basin, Wyoming

Recent efforts to characterize small ( M w < 3 ) seismic events at local distances have become more important because of the increased observation of human-triggered and induced seismicity and the need to advance nuclear explosion monitoring capabilities. The signals generated by low-magnitude seismic sources necessitate the use of nearby short-period observations, which are sensitive to local geological heterogeneity. Local to near-regional distance ( < 300 km ) surface and shear waves can dominate short-period observations from small, shallow seismic sources. In this work, we utilize these observations to estimate precise, relative locations and magnitudes of ~ 700 industrial mining events in Wyoming, using nearly 360,000 observations. The precise, relative location estimates (with formal location uncertainty estimates of less than 1 km) collapse a diffuse collection of mining events into discrete clusters associated with individual blasting operations. We also invert the cross-correlation amplitudes to estimate precise, relative moment magnitude estimates, which help validate and identify disparities in the event sizes reported by regional network catalogs. Joint use of multiple phases allows for the inclusion of more seismic events due to the increase in the number of observations. In some cases, using a single phase allowed us to relocate only 50% of the original reported seismic events within a cluster. Combining shear- and surface-wave phases increased the number of events to above 90% of the original events, allowing us to characterize a broader range of event sizes, source to station distances, and event distributions. This analysis takes a step toward making a fuller characterization of small industrial seismic events observed at local distances.

58 GEOSCIENCES↗
DOE OSTI2020

UFCC Calibration Measurements for Bulk U 3 O 8 Powder Samples

The uranium UF 6 coincidence counter (UFCC) was designed to measure 5A/B cylinders containing UF 6 in the passive neutron self-interrogation mode. The purpose of the present report is to extend the UFCC capability to other sample types such as oxides and liquids that might be found during verification activities. A 252 Cf source was introduced into the detector to make the active mode measurements possible, because only the UF 6 samples have adequate neutron emission for self-interrogation. The sample enrichments varied from 0.72% to 91% to establish the shape of the calibration curve and the measurement uncertainties. The measurements included the singles, doubles, and triples rates. The time correlations between the 252 Cf source and the induced fission reactions reduced the statistical error in the doubles and triples rates to be small enough for useful measurements in 5-10 minutes.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Shock and Reaction in Granular Bed of HMX-Aluminum Powders

Ignition and material response properties of aluminumized HMX heterogeneous explosive mixtures were explored in a series of planar impact experiments performed over multiple years. This work expands on previous work studying material response to impact in single-component HMX granular materials. The addition of nanometric aluminum is shown to affect the ignition sensitivity and growth to reaction from impact. The gas gun test results are presented here varying parameters of particle size, shock strength, and aluminum mass fraction.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Porosity Determination and Classification of Laser Powder Bed Fusion AlSi10Mg Dogbones Using Machine Learning [Slides]

Angular pores (lack of fusion) pores are more detrimental to the health of the part due to induced stress concentrations. Three types of porosity found in AM parts: keyhole porosity, gas porosity, and lack of fusion porosity. In this research, we address the question, "Which machine learning and/or machine vision techniques work best to segment porosity and determine the type of porosity observed in the sample?"

42 ENGINEERING↗
DOE OSTI2022

Transition Metal Oxide Powders Made from Flame Spray Pyrolysis for Li-Ion Batteries

In 2012 the U.S. Department of Energy introduced its EV Everywhere Grand Challenge, with a stated goal of enabling “plug-in electric vehicles (PEVs) that are as affordable and convenient for the American family as gasoline-powered vehicles by 2022.” This requires a reduction in battery costs from the current $500/kWh to around $125/kWh. Most approaches have been to eliminate vehicle weight through lightweighting and to improve the energy density of battery materials. But what if we were able to just make the materials cheaper instead? To this end we introduce a green, low-cost method of producing cathode materials using an integrated flame spray pyrolysis process.

25 ENERGY STORAGE↗