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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 829 records · Page 46
All sourcesNASA NTRSDOE OSTI
DOE OSTI2012

Current Status of Ti PM: Progress, Opportunities and Challenges

Utilization of titanium components made by powder metallurgy methods has had limited acceptance largely due to the high cost of titanium (Ti) powder. There has been renewed interest in lower cost powder and several Ti reduction methods that produce a particulate product show promise. This talk summarizes work done at Oak Ridge National Laboratory to consolidate these lower cost powders into mill products. Press and sinter consolidation, hot isostatic pressing (HIP) and direct roll consolidation to make sheet have been explored. The characteristics of the consolidated products will be described as a function of the consolidation parameters. Research sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Industrial Technologies Program, under contract DE-AC05-00OR22725 with UT-Battelle, LLC.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Fabrication of advanced accident tolerant U-Si fuel forms

Prospective advanced accident tolerant UN-USi fuel forms for light-water reactors are being studied at Los Alamos National Laboratory. In this paper we present a recent effort to fabricate and characterize U{sub 3}Si{sub 5} and UN-U{sub 3}Si{sub 5} fuel. The U{sub 3}Si{sub 5} is prepared by arc-melting stoichiometric amounts of uranium and silicon metals. The arc melting process consists of cutting U metal plate into small pieces that can be placed in a tri-arc furnace for melting. The material is slowly heated until a uniform melt of the U and Si is achieved. The fabrication of the U{sub 3}Si{sub 5} pellets followed a conventional cold-press and sinter process. As for the fabrication of UN-U{sub 3}Si{sub 5}, the uranium nitride (UN) feedstock powder was synthesized using carbothermic reduction nitridation. The UN is milled and sieved to sub-74 μm. The UN was mixed with EBS (ethylene bis-stearamide) and milled for 45 minutes. The UN-EBS was combined with 10 wt.% U{sub 3}Si{sub 5} powder (equivalent to 15 vol.% in UN) and additional EBS. The fabrication of the UN-U{sub 3}Si{sub 5} pellets followed a conventional cold-press and sinter process similar to that used to fabricate the U{sub 3}Si{sub 5} pellets. A sample UN-U{sub 3}Si{sub 5} pellet was cross-sectioned, ground, and polished for optical microscopy. The UN and U{sub 3}Si{sub 5} phases are apparent as well as pores and micro-cracks. The affect of micro-cracking on fuel performance is unknown and should be assessed during post-irradiation examination.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Comparison of High Level Waste Glass Feeds Containing Frit and Glass Forming Chemicals - 16154

This study compares the impact of frit and glass forming-chemicals on high level waste feed melting behavior. Feeds formulated to yield high-boron (lower waste loading) and low-boron (higher waste loading) glass compositions were prepared by blending a simulated high-level waste with glass-forming additives either in the form of chemicals or pre-melted as glass frit. The feeds were pressed into cylindrical disc-shaped pellets using a die tool and a hydraulic press. Each pellet was heat-treated in a high-temperature furnace equipped with a window to view the pellet's response to increasing temperature, usually up to 1100 deg. C, until the pellet turned into a molten glass droplet. A camera mounted in front of the viewing window was used to take high-quality pictures at predetermined intervals. Images were analyzed using a program that calculated the pellet profile area and volume as functions of temperature. The analyses are used to determine characteristic temperatures and associated volume expansions including foam onset and collapse. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2010

Fabrication and Comparison of Fuels for Advanced Gas Reactor Irradiation Tests

As part of the program to demonstrate TRISO-coated fuel for the Next Generation Nuclear Plant, a series of irradiation tests of Advanced Gas Reactor (AGR) fuel are being performed in the Advanced Test Reactor (ATR) at the Idaho National Laboratory. In the first test, called “AGR-1,” graphite compacts containing approximately 300,000 coated particles were irradiated from December 2006 until November 2009. Development of AGR-1 fuel sought to replicate the properties of German TRISO-coated particles. No particle failures were seen in the nearly 3-year irradiation to a burn up of 19%. The AGR-1 particles were coated in a two-inch diameter coater. Following fabrication of AGR-1 fuel, process improvements and changes were made in each of the fabrication processes. Changes in the kernel fabrication process included replacing the carbon black powder feed with a surface-modified carbon slurry and shortening the sintering schedule. AGR-2 TRISO particles were produced in a six-inch diameter coater using a change size about twenty-one times that of the two-inch diameter coater used to coat AGR-1 particles. Changes were also made in the compacting process, including increasing the temperature and pressure of pressing and using a different type of press. Irradiation of AGR-2 fuel began in late spring 2010. Properties of AGR-2 fuel compare favorably with AGR-1 and historic German fuel. Kernels are more homogeneous in shape, chemistry and density. TRISO-particle sphericity, layer thickness standard deviations, and defect fractions are also comparable. In a sample of 317,000 particles from deconsolidated AGR-2 compacts, 3 exposed kernels were found in a leach test. No SiC defects were found in a sample of 250,000 deconsolidated particles, and no IPyC defects in a sample of 64,000 particles. The primary difference in properties between AGR-1 and AGR-2 compacts is that AGR-2 compacts have a higher matrix density, 1.6 g/cm3 compared to about 1.3 g/cm3 for AGR-1 compacts. Based on fuel properties, excellence performance is expected for the AGR-2 UCO fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

An overview of switchgrass phenotypes variability across diverse populations and their implications for conversion to fuels

There have been substantial changes to the human lifestyle over the past two centuries, which are reflected in the amount of fuel we consume to power our day-to-day needs. The way we use these resources has indeed manifested in an overdependence on non-renewable energy sources, such as coal and petroleum, for generating electricity and powering our transportation needs. There is a pressing need to explore alternative ways of fueling our current lifestyle without impacting the environment. Biofuels have long been touted as a sustainable solution for use as drop-in fuels in aviation and maritime applications. Still, they have yet to establish themselves as a competitive commercial alternative, necessitating further research and development. Lignocellulosic biomass is an underutilized resource that is widely accessible for the commercial processing of renewable biofuels. Bioenergy crops, such as switchgrass (Panicum virgatum L.), which can be cultivated on marginal lands with minimal competition for agricultural land, are an ideal and promising candidate for bulk-scale biofuel synthesis. Over the past 30 years, significant progress has been made in breeding and genetically modifying these grasses to enhance their drought resilience and subsequent yields. However, discrepancies in biomass composition can lead to irregular feedstocks for downstream operations, which in turn affect overall production targets for biofuels. Here, this review examines the variability in switchgrass (P. virgatum L.) biomass phenotypes across diverse populations and plant components, and their implications for biofuel conversion. The study highlights significant variations in biomass yield, composition, and cell wall chemistry both between switchgrass genotypes and within individual cultivars. Key findings include differences in cellulose, hemicellulose, and lignin content between leaves and stems, which affect biomass digestibility and ethanol yield. The review also discusses the impact of lignin chemistry, particularly the syringyl/guaicyl (S/G) ratio, on the efficiency of biomass saccharification. Furthermore, it explores how these variations respond differently to various pretreatment techniques, affecting overall biofuel production. We conclude that understanding and quantifying this variability is crucial for optimizing switchgrass as a feedstock for commercial biofuel production, thereby potentially addressing the pressing need for sustainable energy sources in sectors such as aviation.

Kousika, Rohit [Univ. of Tennessee, Knoxville, TN ↗
DOE OSTI2018

Sugar yield and composition of tubers from Jerusalem Artichoke ( Helianthus tuberosus ) irrigated with saline waters

Abstract Currently, major biofuel crops are also food crops that demand fertile soils and good‐quality water. Jerusalem artichoke ( Helianthus tuberosus , Asteraceae) produces high tonnage of tubers that are rich in sugars, mainly in the form of inulin. In this study, plants of the cultivar “White Fuseau” grown under five salinity levels were evaluated for tuber yield. Results indicated that this cultivar is moderately salt‐tolerant if the goal is tuber production. Hydraulic pressings of the tubers produced juice that contained 15% (wet weight) or 55% (dry weight) free sugars, with 70% of these in the form of inulin and the rest as fructose, sucrose, and glucose. Importantly, salinity did not affect the total free sugar or inulin content of the tubers. Tubers were composed of about 12% dry washed bagasse (wet weight) or 44% (dry matter basis) and bagasse retained such high quantities of free sugars after pressing that washing was required for complete sugar recovery. Chemical composition analysis of tuber bagasse suggested that it had low lignin content (11–13 wt%), and its structural sugar composition was similar to chicory root bagasse. Because of the high hemicellulose and pectin content of the bagasse, adding xylanase and pectinase to cellulase substantially improved sugar yields from enzymatic hydrolysis compared to at the same protein loading as cellulase alone. In addition to the high total sugar yield of tuber, these first findings on the sugar and lignin content and enzymatic hydrolysis of tuber bagasse can lead to low‐cost production of ethanol for transportation fuels.

Bhagia, Samarthya↗
DOE OSTI2026

Distinct Melt Infusion Architectures of Antiperovskite Solid Electrolytes

Antiperovskite solid electrolytes are an emerging class of lithium‐ion conductors distinguished by their unusually low melting points, enabling scalable, low‐temperature processing routes not accessible to most solid electrolytes. In this work, we synthesize phase‐pure chloride (Cl), bromide (Br), and mixed halide (ClBr) variants of antiperovskites and investigate their ionic conductivities in both powder and hot‐pressed forms. Hot pressing significantly enhances conductivity across all compositions, while energy‐dispersive X‐ray spectroscopy (EDS) of the mixed halide system reveals halide surface migration during densification. We further investigate the melt‐infiltration behavior of these electrolytes into substrates relevant to solid‐state battery architectures, including Al and Cu current collectors, conventional NMC and LFP cathodes, and a foamed NMC cathode with a highly porous architecture. The foamed cathode enables deep and uniform electrolyte penetration, highlighting the role of electrode architecture in facilitating melt infiltration. Across all substrates, electrolyte halide chemistry strongly influences wetting behavior, penetration depth, and resulting microstructural morphology. Together, these results establish clear processing–structure relationships for melt‐infiltrated antiperovskite solid electrolytes and demonstrate how electrolyte chemistry and electrode architecture govern interfacial morphology during integration, providing practical guidelines for processing and structural design in solid‐state battery systems.

antiperovskite↗
DOE OSTI2022

Bioenergy Underground: Challenges and opportunities for phenotyping roots and the microbiome for sustainable bioenergy crop production

Abstract Bioenergy production often focuses on the aboveground feedstock production for conversion to fuel and other materials. However, the belowground component is crucial for soil carbon sequestration, greenhouse gas fluxes, and ecosystem function. Roots maximize feedstock production on marginal lands by acquiring soil resources and mediating soil ecosystem processes through interactions with the microbial community. This belowground world is challenging to observe and quantify; however, there are unprecedented opportunities using current methodologies to bring roots, microbes, and soil into focus. These opportunities allow not only breeding for increased feedstock production but breeding for increased soil health and carbon sequestration as well. A recent workshop hosted by the USDOE Bioenergy Research Centers highlighted these challenges and opportunities while creating a roadmap for increased collaboration and data interoperability through standardization of methodologies and data using F.A.I.R. principles. This article provides a background on the need for belowground research in bioenergy cropping systems, a primer on root system properties of major U.S. bioenergy crops, and an overview of the roles of root chemistry, exudation, and microbial interactions on sustainability. Crucially, we outline how to adopt standardized measures and databases to meet the most pressing methodological needs to accelerate root, soil, and microbial research to meet the pressing societal challenges of the century.

09 BIOMASS FUELS↗
DOE OSTI2022

Coefficient of Thermal Expansion Evolution during Ratchet Growth of PBX 9502 and Neat TATB

The Plastic-Bonded Explosive (PBX) 9502 is comprised of the insensitive high explosive TATB (triamino trinitrobenzine) crystals coated in FK-800 polymer binder and isostatically pressed. The TATB crystals have a graphitic, plate-like morphology and possess significant thermal and mechanical anisotropy. Compactions of neat TATB or TATB-based composites (like PBX 9502) have been shown to have TATB crystals that are oriented during the pressing process giving rise to TATB texture and resulting in micro- and macro-scale anisotropy of the compaction. Thermal cycling of the compactions results in irreversible volume expansion (or ratchet growth) likely by creating stress points on the microscale. However, the actual mechanism behind this expansion is not fully understood. Previous characterization of the ratchet growth phenomenon has focused on the magnitude of the irreversible strain as measured before and after a thermal cycle. In the work presented here, we analyze the evolving thermal expansion behavior during the ascending and descending temperature ramps and compare differences observed due to the presence/absence of binder in the compaction.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2025

Extrusion‐Spheronization of Mock Energetic Materials

The primary method for producing plastic bonded explosive (PBX) granules, or “prills”, has remained relatively unchanged for 70 years despite the complex nature of the process. In this work, we demonstrate the feasibility of using an extrusion‐spheronization technique to produce prills for PBX applications. We begin by detailing an inert formulation with similar properties of PBXs and then demonstrate the extrusion‐spheronization processing of these materials. A study is then performed where the spheronization process time of the extruded materials is varied and the resultant prills are morphologically characterized. Further, these prills are then pressed into high‐density articles and subject to compression testing to elucidate trends in process, properties, and performance. It was found that, for our formulation (95 wt.% melamine/5 wt.% polymer binder) and process, a spheronization time of 60 s yielded relatively uniform particles that exhibited improved poured, tapped, and pressed densities. Mechanical strength did not have a strong trend with process time as all spheronized materials had similar peak compression stress at failure. After further optimization, extrusion‐spheronization may be a promising path for future PBX formulation.

extrusion spheronization↗
DOE OSTI2026

Extrusion‐Spheronization of Energetic Materials

The prevailing method to produce plastic‐bonded explosive (PBX) molding powder, or “prills”, is a complex, multiphase, and bespoke process that was developed by the high explosives (HEs) manufacturing industry several decades ago. This work demonstrates the utility of a simpler, widely‐used mechanical process—extrusion‐spheronization—to produce PBX prills. We begin by detailing precautions taken to enable safe remote operation of extrusion‐spheronization equipment with HE. We then perform a study investigating the effect of lacquer solvent composition on the particle packing, pressed density, and compressive strength properties of a 95 wt.% TATB/5 wt.% polymer binder formulation akin to PBX 9502. It was found that increased composition of low vapor pressure solvents caused prolonged retention of the solvent, resulting in tackier materials that would agglomerate and form larger prills. The larger prills also led to lower poured density and tapped density of HE prills and compressive strength of pressed PBX articles. The samples prepared with a 75% propyl acetate/25% butyl acetate lacquer solvent composition exhibited the highest compressive strength. However, it is believed that the prill packing and compressive strength properties are primarily driven by the prill size rather than the chemical composition of the lacquer itself. Extrusion‐spheronization remains a promising method to reliably and repeatably produce HE prills that is less sensitive to feedstock or process variation than traditional methods.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Lightweight TiC–(Fe–Al) ceramic–metal composites made in situ by pressureless melt infiltration

Lightweight ceramic–metal (cermet) composites combine stiffness and hardness with fracture toughness and ductility. TiC and Al are ideal pairs among lightweight cermet composites because of their relatively high strength-to-weight ratios, but these materials are difficult to process in solid state or with Al melt infiltration without making an aluminum carbide phase, which is detrimental to mechanical properties. Here, Fe is added to a TiC powder preform to reduce the activity of Al with TiC during Al melt infiltration and to aid in pressing TiC preforms, making a lightweight TiC–(Fe–Al) composite while avoiding other, unwanted phases. The composites are made by first pressing TiC powder mixed with Fe followed by Al melt infiltration; the result is a composite with high TiC content in a two-phase matrix, both of which are Fe–Al-based. The composite has low density, low porosity, high hardness, no detectable Al 4 C 3 phase with X-ray diffraction and retains shape well during infiltration.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Characterizing mechanical and microstructural properties of novel montmorillonite-rich polyethylene composites

Montmorillonite (MMT) clays are important industrial materials used as catalysts, chemical sorbents and fillers in polymer–clay nanocomposites. The layered structure of these clays has motivated research into further applications of these low-cost materials, including use as ion exchange media and solid-state ionic conductors. In these applications, the mechanical properties of MMT are key when considering long-term, reliable performance. Previous studies have focused on the mechanical properties of nanocomposites with MMT as the minority component or pure MMT thin films. In this work, the microstructure and mechanical properties of pure MMT and majority MMT/polyethylene composites pressed into dense pellets are examined. Characterization methods such as X-ray diffraction, atomic force microscopy and scanning electron microscopy together with nanoindentation reveal important structure–property relationships in the clay-based materials. Here, utilizing these techniques, we have discovered that MMT processing impacts the layered microstructure, chemical stability and, critically, the elastic modulus and hardness of bulk MMT samples. Particularly, the density of the pellets and the ordering of the clay platelets within them strongly influence the elastic modulus and hardness of the pellets. By increasing pressing force or by incorporating secondary components, the density, and therefore mechanical properties, can be increased. If the layered structure of the clay is destroyed by exfoliation, the mechanical properties will be compromised. Understanding these relationships will help guide new studies to engineer mechanically stable MMT-based materials for industrial applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Development of coal-derived carbon-based structural unit as a potential new building material

Coal combustion for energy has not only wasted the hydrogen-rich volatile matters but also results in CO 2 emission causing serious environmental issues. An integrated coal pyrolysis and solvent extraction process under elevated temperatures in an inert atmosphere is implemented to convert as-mined coal from Wyoming Powder River Basin to functional carbon elements such as pyrolysis char (PC). This paper presents the development and fabrication of new carbon-based structural unit (CSU) using pulverized PC and two coal-derived pitches (mesophase pitch and tar pitch) to attain high compressive strength greater than 30 MPa, low thermal conductivity less than 0.30 W/m.K, and low density less than 1.25 g/cm 3 . CSUs have the potential to overcome the current challenges with cement and concrete through pressurized fabrication followed by carbonization. This study aims to develop CSU with nearly 100% coal-derived carbon material for structural application in buildings. The effects of pressing pressures, carbonization temperatures, and binder contents on the density and mechanical and thermal properties of CSU samples are investigated. The study concludes that mesophase pitch produces a better performance of CSU samples, a combination of 100 MPa pressing pressure and carbonization temperature of 900 ⁰C yields the highest compressive strength, and a 25% MP content is recommended for low-cost CSU fabrication. Furthermoer, CSU has a much lower density, lower thermal conductivity, higher compressive strength, and higher strength-to-density ratio than normal concrete.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Processing of crack-free high density polycrystalline LiTaO3 ceramics

Our work achieved high density (99.9%) polycrystalline LiTaO 3 . The keys to the high density without cracking were the use of LiF-assisted densification to maintain fine grain size as well as the presence of secondary lithium aluminate phases as grain growth inhibitors. The average grain size of the hot pressed polycrystalline LiTaO 3 is less than 5 μm, limiting residual stresses caused by the anisotropic thermal expansion. Dilatometry results clearly indicate liquid phase sintering via the added LiF sintering aid. Efficient liquid phase sintering allows densification during low temperature hot pressing. Electron microscopy confirmed the high-density microstructure. Furthermore, Rietveld analysis of neutron diffraction data revealed the presence of LiAlO 2 and LiAl 5 O 8 minority phases and negligible substitutional defect incorporation in LiTaO 3 .

36 MATERIALS SCIENCE↗
DOE OSTI2019

Production of Hydrogel Microneedles from Fish Scale Biopolymer

This work presents for the first time, a scalable, low cost method for producing hydrogel microneedles from fish scales derived biopolymer using a modified low temperature press method. The microneedles are made from cross-linked hydrolyzed collagen (HC). The suitability of the microneedles for drug loading were tested by loading with Ferrous gluconate. Force analysis carried out in compression mode showed that the microneedles could withstand up to 0.136 N per microneedle before fracture which is sufficient strength to pierce the skin. The cross-linked microneedles swelled to 340% of their original mass in PBS and within 24 h released 34.5% of the loaded drug, while the non cross-linked microneedles dissolved within minutes. Chemical testing of the released drug confirmed that the drug released retained its chemical structure by forming colored complex with acetylsalicylic acid and UV spectrometry was used to quantify the concentration released. FTIR analysis confirmed the modified structure of the polymer when cross-linked. This proposed method allows cross-linking at room temperature using a thermal press method which can be easily scaled up.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2011

Compaction of Titanium Powders

Accurate modeling of powder densification has been an area of active research for more than 60 years. The earliest efforts were focused on linearization of the data because computers were not readily available to assist with curve-fitting methods. In this work, eight different titanium powders (three different sizes of sponge fines<150 {micro}m,<75 {micro}m, and<45 {micro}m; two different sizes of a hydride-dehydride [HDH]<75 {micro}m and<45 {micro}m; an atomized powder; a commercially pure [CP] Ti powder from International Titanium Powder [ITP]; and a Ti 6 4 alloy powder) were cold pressed in a single-acting die instrumented to collect stress and deformation data during compaction. From these data, the density of each compact was calculated and then plotted as a function of pressure. The results show that densification of all the powders, regardless of particle size, shape, or chemistry, can be modeled accurately as the sum of an initial density plus the sum of a rearrangement term and a work-hardening term. These last two terms are found to be a function of applied pressure and take the form of an exponential rise.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Air and Argon Sintering Atmospheres on Properties and Hydrothermal Aging Resistance of Y-TZP Ceramics

In this work, we investigated the role of sintering atmosphere and temperature on low-temperature degradation of 3 mol.% yttria tetragonal zirconia polycrystals ceramics. Green compacts were prepared by die-pressing followed by cold isostatic pressing at 200 MPa. The green bodies were sintered between the temperature range of 1250 and 1500 °C in air and argon gas atmosphere. Sintered samples were tested to determine bulk density, Young’s modulus, Vickers hardness and fracture toughness. The results revealed that the mechanical properties of air-sintered samples were better than that of argon-sintered samples sintered at 1400 °C and below while the argon sintering marginally improves the fracture toughness and hardness when sintered at 1450 °C and above. FESEM images showed that the tetragonal grain size was similar when sintered in argon atmosphere. However, regardless of sintering atmosphere, grain growth was inevitable as the sintering temperature was increased. Hydrothermal aging test in superheated steam was performed in an autoclave at temperature of 180 °C and 10 bar pressure up to 12 h. Effect of aging on tetragonal-to-monoclinic phase transformation was measured by using x-ray diffraction. The phase transformation was found to be strongly influenced by the sintering temperature and sintering atmosphere. The sample sintered at 1500 °C in argon atmosphere exhibited rapid phase transformation compared to air atmosphere, while the samples sintered at or below 1400 °C in argon showed no phase transformation after 12-h exposure in steam environment.

36 MATERIALS SCIENCE↗