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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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A high-voltage, high-current, solid-state closing switch uses a field-effect transistor (e.g., a MOSFET) to trigger a high-voltage stack of thyristors. The switch can have a high hold-off voltage, high current carrying capacity, and high time-rate-of-change of current, di/dt. The fast closing switch can be used in pulsed power applications.
This report presents the work of developing a high temperature heat transfer and thermal storage fluid using low-cost chlorides salts as the basic components. Eutectic mixture of two or three chlorides salts could form a molten salt that can meet the expectation of low freezing point, high boiling point, and low corrosion to high temperature metals. The report includes two parts. Part-A presents the important principles of selecting appropriate constituent chloride salts for the eutectic mixture to have desired thermophysical properties and low corrosion to high temperature metals. Some selections of salt mixtures are listed for theoretical and experimental studies. Thermal and transport properties and heat transfer of four selected mixtures of chloride salts are presented at the end of Part-A. Detailed studies to the corrosion mechanism/behavior of metals in the selected salt mixture at high temperatures are presented in Part-B. Conditioning and purification to the salts are also introduced in Part-B, which is critical to keep the selected chloride salts to have low corrosion to metals at high temperatures.
Electrolytes connect the two electrodes in a lithium battery by providing Li + transport channels between them. Advanced electrolytes are being explored with high-nickel cathodes and the lithium-metal anode to meet the high energy density and cycle life goals, but the origin of the performance differences with different electrolytes is not fully understood. Here, the mechanisms involved in protecting the high-capacity, cobalt-free cathode LiNiO 2 with a model high-voltage electrolyte (HVE) are delineated. The kinetic barrier posed by a thick surface degradation layer with poor Li + -ion transport is found to be the major contributor to the fast capacity fade of LiNiO 2 with the conventional carbonate electrolyte. In contrast, HVE reduces the side reactions between the electrolyte and the electrodes, leading to a thinner nano-interphase layer comprised of more beneficial species. Crucially, the HVE leads to a different surface reorganization pathway involving the formation of a thinner nanoscale LiNi 2 O 4 spinel phase on the LiNiO 2 surface. Finally, with a high 3D Li + -ion and electronic conductivity, the spinel LiNi 2 O 4 reorganization nanolayer preserves fast Li + transport across the cathode–electrolyte interface, reduces reaction heterogeneity in the electrode and alleviates intergranular cracking within secondary particles, resulting in superior long-term cycle life.
A pre-deformation process was employed for a TiAl alloy via high-temperature torsion, in which the stability of the constituent phases was tailored, resulting in enhanced hardening capability and ductility via a gradient microstructure. A sample with a pre-torsion of 360° exhibited a yield strength of 475 MPa and an ultimate tensile strength of 592 MPa, with a tensile ductility of 47% at 850 °C. The tensile properties were significantly enhanced compared with the as-forged sample, which exhibited values of 395 MPa, 494 MPa, and 4.6%, respectively. The physical mechanisms for the significant enhancement of the mechanical property of the TiAl alloys were studied in-depth via of transmission electron microscopy, electron-backscattered diffraction, and high-energy X-ray diffraction techniques. The high strength is mainly attributed to the twin structure formed during torsion, while high fracture elongation correlates to the recrystallization of the γ phase at twin-twin sections and the load partitioning regulated by a hierarchical microstructure. When the tensile micro-strains along the loading direction and transverse direction in the γ phase of the pre-deformed TiAl alloy, a higher mechanical performance was obtained. Moreover, the fracture mode of the pre-torsional tensile sample is a combination of pores and cleavage facets which resulted from the microstructure after torsion. Finally, the gradient twin structure approach in this study provides a strategy for developing TiAl alloys with exceptionally high-temperature tensile property, and the results of the micromechanical behavior-microstructure-property relationship may improve the understanding of the plastic deformation of TiAl alloys.
Refractory High Entropy Alloys (RHEAs) and Refractory Complex Concentrated Alloys (RCCAs) are high-temperature structural alloys ideally suited for use in harsh environments. While these alloys have shown promising structural properties at high temperatures that exceed the practical limits of conventional alloys, such as Ni-based superalloys, exploration of the complex phase-space of these materials remains a significant challenge. We report on a high-throughput alloy processing and characterization methodology, leveraging laser-based metal additive manufacturing (AM) and mechanical testing techniques, to enable rapid exploration of RHEAs/RCCAs. We utilized in situ alloying and compositional grading, unique to AM processing, to rapidly-produce RHEAs/RCCAs using readily available and inexpensive commercial elemental powders. We demonstrate this approach with the MoNbTaW alloy system, as a model material known for having exceptionally high strength at elevated temperature when processed using conventional methods (e.g., casting). Microstructure analysis, chemical composition, and strain rate dependent hardness of AM-processed material are presented and discussed in the context of understanding the structure-properties relationships of RHEAs/RCCAs.
Rapid experimentation and characterization are ever-present needs in the discovery of high entropy alloys. High entropy alloy systems are difficult to survey with systematic composition sweeps using traditional synthesis methods. The number of distinct compositions in even a four-element system is experimentally intractable. Exploration of these, and higher-element systems, necessitates thermodynamic prediction coupled with an automated sample creation method and a rapid screening methodology to effectively down-select alloys with targeted properties. As a result, a high-throughput method for evaluating the oxidation performance of refractory high entropy alloys was developed and tested. The six-element system of aluminum, chromium, molybdenum, niobium, tantalum, and titanium was evaluated for single phase stability and short-duration oxidation resistance. Target compositions were initially determined via thermodynamic predictions of single-phase stability across a wide temperature range. A twenty-five-sample build plate was produced using directed energy deposition additive manufacturing. After fabrication, the twenty-five 1 cm 3 samples were heat treated and characterized for composition and phase identification. The build plate was exposed to a high temperature oxidizing environment at 1000 °C for three hours. After oxidation, the composition, morphology, and chemistry of the oxides formed were characterized. Of the twenty-five samples produced, nine exhibited a favorable oxidation response, from which a single-phase BCC alloy at a composition of Al 13 Cr 7 Mo 19 Nb 18 Ta 26 Ti 17 was identified as the alloy with the most protective oxidation coating with a thin, adherent oxide scale. Finally, the complete experimental down-selection—from machine setup to final alloy identification—required approximately 45 labor hours, demonstrating a rapid validation for alloy discovery.
We report ion irradiation has long been used as a surrogate for neutron irradiation experiments which are comparatively slower, more expensive, and often can leave materials activated and difficult to handle post-irradiation. However, with the growing use of combinatorial synthesis methods and high-throughput, automated characterization techniques, ion irradiation facilities will need to upgrade their capabilities to be able to accommodate these new material platforms. To address this challenge, a high-throughput ion irradiation system has been developed at the University of Wisconsin-Madison Ion Beam Laboratory (IBL). The system is capable of accommodating large sample arrays of arbitrary geometries and heat samples individually using an infrared laser to enable high-temperature, high-throughput ion irradiation while mitigating the risk of annealing the irradiation damage in nearby samples. To control stage motion, laser power, and beam current measurement, among other tasks, the program Chronos was developed which enables automated high-throughput irradiation experiments.
Abstract We report on the high-resolution imaging and molecular dynamics simulations of a 3D-printed eutectic high-entropy alloy (EHEA) Ni 40 Co 20 Fe 10 Cr 10 Al 18 W 2 consisting of nanolamellar BCC and FCC phases. The direct lattice imaging of 3D-printed samples shows the Kurdjumov–Sachs (K–S) orientation relation {111} FCC parallel to {110} BCC planes in the dual-phase lamellae. Unlike traditional iron and steels, this alloy shows an irreversible BCC-to-FCC phase transformation under high pressures. The nanolamellar morphology is maintained after pressure cycling to 30 GPa, and nano-diffraction studies show both layers to be in the FCC phase. The chemical compositions of the dual-phase lamellae after pressure recovery remain unchanged, suggesting a diffusion-less BCC–FCC transformation in this EHEA. The lattice imaging of the pressure-recovered sample does not show any specific orientation relation between the two resulting FCC phases, indicating that many grain orientations are produced during the BCC–FCC phase transformation. Molecular dynamics simulations on phase transformation in a nanolamellar BCC/FCC in K–S orientation show that phase transformation from BCC to FCC is completed under high pressures, and the FCC phase is retained on decompression aided by the stable interfaces. Our work elucidates the irreversible phase transformation under static compression, providing an understanding of the orientation relationships in 3-D printed EHEA under high pressures.
A hybrid-electric propulsion system is an enabling technology to make the aircraft more fuel saving, quieter, and lower carbide emission. In this article, a megawatt (MW) scale power inverter based on a three-level active neutral-point-clamped (3L-ANPC) topology will be developed. To achieve high efficiency, the switching devices operating at carrier frequency in the power converter are configured by the emerging silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors, while the conventional silicon (Si) insulated-gate bipolar transistors are selected for switches operating at the fundamental output frequency. To obtain high power density, dc bus voltage is increased from the conventional 270 V to medium voltage of 2.4 kV to reduce cable weight. Also, unlike the traditional 400 Hz dominated aircraft ac systems, the rated fundamental output frequency here is boosted to 1.4 kHz to drive the high-speed motor, which helps further to reduce the motor weight. Main hardware development and control modulation strategies are presented. Experimental findings are presented to verify the performance of this MW-scale medium-voltage “SiC+Si” hybrid 3L-ANPC inverter. It is shown that the 1-MW 3L-ANPC inverter can achieve a high efficiency of 99% and a high power density of 12 kVA/kg.
The Material Plasma Exposure eXperiment (MPEX) device is a linear plasma device developed to perform plasma material interaction experiments under the conditions prototypic of a fusion reactor divertor. MPEX has multiple systems that must be precisely aligned to the plasma axis, including an electron cyclotron heating system that emits up to 400 kW of microwave power into the vacuum vessel. Five distinct systems require precise alignment on the MPEX device, thus requiring four bellows, all of which are adjacent to the plasma at a relatively high heat flux of approximately 47 kW/m2 and microwave power regions. The MPEX high heat flux bellows (HHFB) is designed to deliver 6 degrees of freedom positioning. The HHFB includes titanium–zirconium–molybdenum (TZM) inserts that are brazed into a Glidcop AL-15 body using a high-temperature braze alloy, thus blocking direct line of sight to an edge-welded bellows from the plasma and microwave screen to block microwaves from the bellows. Further, a custom ConFlat knife edge is machined into the Glidcop AL-15, so the vacuum flanges do not need a braze or weld joint on the vacuum interface. Fingerstock or copper mesh is used to restrict microwave power from entering the interstitial space between the water-cooled Glidcop AL-15 body and edge-welded bellows. Glidcop AL-15 was selected as the material of choice for the water-cooled body because it can maintain mechanical integrity at elevated temperatures, and it also allows for a high-temperature braze. TZM was selected for its machinability and compatibility with vacuum and plasma requirements. A test article is also being considered for a similarly shaped component, the MPEX limiter, that will demonstrate the integrity of the braze joint under high thermal load. Results from this testing will be extrapolated to deduce the lifetime and integrity of the HHFB design.
Fundamental high pressure/high temperature forced convection experiments have been conducted in support of the development of a Very High Temperature Reactor (VHTR) with a prismatic core. The experiments utilize a high temperature/high pressure gas flow test facility constructed for forced convection and natural circulation experiments. The test section has a single 16.8 mm ID flow channel in a 2.7 m long, 108 mm OD graphite column with four 2.3kW electric heater rods placed symmetrically around the flow channel. This experimental study presents the role of buoyancy forces in enhancing or reducing convection heat transfer for helium at high pressures up to 70 bar and high temperatures up to 873 degrees K. Wall temperatures have been compared among 10 cases covering the inlet Re numbers ranging from 500 to 3,000. Downward flows display higher and lower wall temperatures in the upstream and downstream regions, respectively, than the upward flow cases due to the influence of buoyancy forces. In the entrance region, convection heat transfer is reduced due to buoyancy leading to higher wall temperatures, while in the downstream region, buoyancyinduced mixing causes higher convection heat transfer and lower wall temperatures. However, their influences are reduced as the Reynolds number increases. This experimental study is of specific interest to VHTR design and validation of safety analysis codes.
Performance tests and analyses are critical to effective high-performance computing software development and are central components in the design and implementation of computational algorithms for achieving faster simulations on existing and future computing architectures for large-scale application problems. In this article, we explore performance and space-time trade-offs for important compute-intensive kernels of large-scale numerical solvers for partial differential equations (PDEs) that govern a wide range of physical applications. We consider a sequence of PDE-motivated bake-off problems designed to establish best practices for efficient high-order simulations across a variety of codes and platforms. We measure peak performance (degrees of freedom per second) on a fixed number of nodes and identify effective code optimization strategies for each architecture. In addition to peak performance, we identify the minimum time to solution at 80% parallel efficiency. The performance analysis is based on spectral and p-type finite elements but is equally applicable to a broad spectrum of numerical PDE discretizations, including finite difference, finite volume, and h-type finite elements.
High-entropy oxides (HEOs) composed of multiple metal elements have attracted great attention as anode materials for lithium-ion batteries (LIBs) due to the synergistic effects of various metal species. However, the practical applications of HEOs are still plagued by poor conductivity, unstable solid electrolyte interphase (SEI) and poor cycling stability. In this work, nanosized (FeCoNiCrMn) 3 O 4 HEO (NHEO) is prepared successfully by the NaCl-assisted mechanical ball-milling strategy. Novelly, polyacrylonitrile (PAN) is used as the binder and then in situ thermochemically cyclized to construct a cyclized PAN (cPAN) outer layer onto NHEO (NHEO-cPAN). The in situ formed cPAN coating not only improves the electrical conductivity, but also reinforces the structural and interfacial stability, and thereby, the resulted NHEO-cPAN electrode exhibits significantly enhanced rate and cyclic performance. Specifically, NHEO-PAN500 electrode delivers a high reversible capacity of 560 mAh g –1 at 5 A g –1 and a high-capacity retention of 83% over 800 cycles at 3 A g –1 . Furthermore, the structural evolution and electrochemical behavior of NHEO-PAN electrode during discharge/charge is systematically investigated by operando X-ray diffraction, in situ impedance spectroscopy and ex situ high-resolution transmission electron microscopy. Therefore, this work provides new insights into the engineering of electrode and interphase for high-performance HEO electrode materials, potentially enlightening the practical applications of HEO-based LIBs.
High-nickel LiNi 1–x–y Mn x Co y O 2 and LiNi 1–x–y Co x Al y O 2 cathodes are receiving growing attention due to the burgeoning demands on high-energy-density lithium-ion batteries. The presence of both cobalt and manganese in them, however, triggers multiple issues, including high cost, high toxicity, rapid surface deterioration, and severe transition-metal dissolution. Herein, a Co- and Mn-free ultrahigh-nickel LiNi 0.93 Al 0.05 Ti 0.01 Mg 0.01 O 2 (NATM) cathode that exhibits 82% capacity retention over 800 deep cycles in full cells, outperforming two representative high-Ni cathodes LiNi 0.94 Co 0.06 O 2 (NC, 52%) and LiNi 0.90 Mn 0.05 Co 0.05 O 2 (NMC, 60%) is presented. It is demonstrated that a titanium-enriched surface along with aluminum and magnesium as the stabilizing ions in NATM not only ameliorates unwanted side reactions with the electrolyte and structural disintegrity, but also mitigates transition-metal dissolution and active lithium loss on the graphite anode. As a result, the graphite anode paired with NATM displays an ultrathin (≈8 nm), monolayer anode-electrolyte interphase architecture after extensive cycling. Furthermore, NATM displays considerably enhanced thermal stability with an elevated exothermic temperature (213 °C for NATM vs 180 and 190 °C for NC and NMC, respectively) and remarkably reduced heat release. This work sheds light on rational compositional design to adopt ultrahigh-Ni cathodes in lithium-based batteries with low cost, long service life, and improved thermal stability.
Lithium (Li)-excess transition metal oxide materials which crystallize in the cation-disordered rock salt (DRX) structure are promising cathodes for realizing low-cost, high-energy-density Li batteries. However, the state-of-the-art electrolytes for Li-ion batteries cannot meet the high-voltage stability requirement for high-voltage DRX cathodes, thus new electrolytes are urgently demanded. It has been reported that the solvation structures and properties of the electrolytes critically influence the performance and stability of the batteries. In this study, the structure–property relationships of various electrolytes with different solvent-to-diluent ratios are systematically investigated through a combination of theoretical calculations and experimental tests and analyses. This approach guides the development of electrolytes with unique solvation structures and characteristics, exhibiting high voltage stability, and enhancing the formation of stable electrode/electrolyte interphases. These electrolytes enable the realization of Li||Li 1.094 Mn 0.676 Ti 0.228 O 2 (LMTO) DRX cells with improved performance compared to the conventional electrolyte. Specifically, Li||LMTO cells with the optimized advanced controlled-solvation electrolyte deliver higher specific capacity and longer cycle life compared to cells with the conventional electrolyte. Additionally, the investigation into the structure–property relationship provides a foundational basis for designing advanced electrolytes, which are crucial for the stable cycling of emerging high-voltage cathodes.
Al alloys have widespread applications, but often suffer from low yield strength. Recently, nanotwinned Al-Fe solid solution alloys have shown high flow stress (>1.5 GPa), ascribed to nanograins with abundant incoherent twin boundaries and solute-stabilized 9R phase. However, the high temperature mechanical behaviors of high-strength twinned Al-Fe alloys remain unknown. In this study, we show that nanotwinned microstructures are stable up to 280 °C, followed by recrystallization at 300 °C. In-situ uniaxial compression tests in a scanning electron microscope show that the nanotwinned Al alloys retain their high flow stress of ~1.3 GPa when tested up to 200 °C, and substantial softening occurs at a test temperature of 300 °C. This work reveals the superb thermal stability and high temperature mechanical behaviors of the nanotwinned Al-Fe alloys, and offers a new perspective to design future strong and thermally stable nanostructured Al alloys.
A method for optimization of a high-stroke, high-frequency flexural bearing was completed. The main goal was to design a flexural bearing system as the energy restoration component of a one kW free piston linear engine alternator (LEA) operating at 90 Hz and maximum targeted displacement of 22 mm. Defined electricity output of 1 kW, with more than 30% efficiency, required engine operation under high speed and high stroke conditions. Under such challenging stroke and frequency requirements, a method of design was required to select between a wide range of parameters in flexural bearing design. A parametric CAD model was prepared and used in the optimization package of a finite element analysis (FEA) software. Four main parameters of flexural bearing geometry were identified and included the outer diameter, thickness, number of arms, and sweep angle of spiral cuts. Other design parameters including spiral gap width, shape factor and spiral start points angle were shown to be less important compared to these four main parameters in primary design and were examined separately. A neural network algorithm was used to investigate the interactions and effects of design parameters. The sensitivity of each parameter on output criteria such as maximum stress and natural frequency was examined and design charts developed. Methods for further modification of the spiral curve at end points were introduced to reduce the maximum stress level by up to 20%. Several steel alloys and a titanium-based alloy were identified as proper material candidates for high cycle applications and the final designed spring was manufactured and tested to validate the FEA results of axial stiffness and strain level throughout the flexure arms. The percent of the flexure’s moving mass was estimated to be 29% with FEA analysis and compared well with the experimental value of 31%. The stress/strain results of the FEA analysis matched with the experimental results – within ±5%.