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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 865 records · Page 48
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Carbon Fiber Prepreg Recycling- Automated Perform Manufacturing Equipment (Final Technical Report)

Discontinuous fiber composites have a compelling business case as related to light metals such as aluminum and magnesium machined or die cast components. DFC’s have been in commercial production using carbon fiber/epoxy prepreg for both commercial aircraft and for military applications for a number of years and their usage is expanding into automotive and consumer goods components. Reasons for this include significantly lower cost as compared to continuous fiber composites easier design and understanding of the material by metal traditionalists, higher degree of part complexity with relatively simple and low cost molds when compared to high-pressure die casting, and potential for near zero waste. IACMI’s 10-year goals of reduction in carbon fiber reinforced plastics manufacturing cost by 25%, reduction in their embodied energy by 50%, and recyclability of 95% can all be advanced through robust recycling. With recycling We have shown that a 15% contribution in manufacturing cost reduction is feasible, that a significant reduction in embodied energy (over 90% for the recycled fraction) is achievable, and that when combined with primary pyrolysis recycling, the 95% target can be met. Large-scale application of advanced composites began with the aerospace industry, and CRTC’s location in Washington State provided access to a waste stream of nearly 900 tonnes/year that was going to landfill. As the aerospace industry has automated parts production, their material forms have become significantly easier to recycle, and some evidence of this exists for the future automotive and wind turbine components as well. CRTC decided to focus on re-purposing the carbon fiber/epoxy aerospace scrap streams through materials reformatting and reuse, and not on primary recycling (pyrolysis mainly) as this technology is commercially available. The main reasons for this were that it offers a route to effective use of the most widely available and consistent feedstock called edge-trim, as well as allows creation of complex and low-cost parts using rapid and cost-effective compression molding technologies. The reasons also include leading the way for potential automotive pre-preg recycling as the combination of roughly 85% virgin pre-preg and 15% recycled pre-preg directly supports IACMI’s goals and enables significant part cost reduction and a path to zero-waste composite manufacturing at the OEMs or Tier 1’s. The purpose of the project was to develop equipment and technology to transform continuous fiber pre-preg in roll forms into smaller chip-format DFC feedstock, and to determine impacts on moldability and performance based on lessons learned along the path. The availability of scrap from pre-preg manufacturers was a significant value to the program even though the aerospace pre-preg is designed to be autoclave molded thus has handling, tackiness, and processing factors that are not ideal for DFCs. The scope of the project was to develop a Phase 1 system that could identify and resolve some of the major hurdles, determine where to focus effort on building a commercial-scale Phase 2 system, and develop technology for handling a wide variety of incoming scrap materials to produce the most usable product. A chopping system was developed and reduced to practice via an experimental approach that enabled all forms of scrap coming from the pre-preg manufacturers and some forms of the scrap coming from OEM production lines to be very effectively re-purposed. The systems that were developed were not considered to be production robust but rather identified and resolved some of the major technical hurdles, and demonstrated the path towards effective full-scale commercialization.

36 MATERIALS SCIENCE↗
NASA NTRS1989

TBCs for better engine efficiency

State-of-the-art thermal barrier coatings (TBCs) developed for aircraft engines can achieve both hot-section component operating temperature reductions and superior oxidation resistance. Such TBCs typically consist of two layers: a metallic, often NiCrAlY 'bond' inner layer in contact with the superalloy structural component, and an outer, insulating ceramic layer. A ceramic frequently used in this role due to its high durability is plasma-sprayed ZrO2, partially stabilized with 6-8 wt pct Y2O3. TBCs can also be useful in nonaircraft gas turbines, which frequently use highly contaminated fuels.

Brindley, William J.↗
NASA NTRS1974

Metal-matrix composites: Status and prospects

Applications of metal matrix composites for air frames and jet engine components are discussed. The current state of the art in primary and secondary fabrication is presented. The present and projected costs were analyzed to determine the cost effectiveness of metal matrix composites. The various types of metal matrix composites and their characteristics are described.

Source record↗
DOE OSTI2021

Uncovering electronic and geometric descriptors of chemical activity for metal alloys and oxides using unsupervised machine learning

Here, we show that unsupervised machine learning (ML) using principal component analysis (PCA) provides a straightforward pathway for developing accurate and interpretable electronic-structure descriptors of the chemical and catalytic properties of materials. We demonstrate the approach by finding chemisorption descriptors for metal alloys and surface oxygens on metals and metal oxides. In both cases, the principal component (PC) descriptors yield ML models that predict the material’s chemical properties with competitive accuracy compared to ML models built using established descriptors. Importantly, interpreting the electronic-structure patterns captured by each PC descriptor via signal reconstruction suggests potential design motifs for future electronic-structure descriptor design and allows us to identify links between a material’s geometric and catalytic properties. Ultimately, we show that the unsupervised ML approach provides a route to find electronic-structure descriptors of the catalytic properties of materials that readily connect to geometric structure and composition.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Solid Electrolyte Interphase Formation at the Ionic Liquid Electrolyte—Lithium-Metal Interface Using an Ab Initio Molecular Dynamics Approach

An interfacial study is performed using ab initio molecular dynamics (AIMD) simulations to elucidate the electrochemical interfacial stability of an ionic liquid (IL) as component of an electrolyte in contact with a Li-metal anode when an additive, vinylene carbonate (VC), is added to the electrolyte. The IL electrolyte is composed of 1-butyl-1-methylpyrrolidinium bis(fluoro-sulfonyl)-imide (PYR14 + FSI − ) with lithium bis(trifluoromethane-sulfonyl)imide salt (Li + TFSI − ) in a 8:2 concentration ratio. Reactions observed at the interface electrolyte/Li-metal during the AIMD simulations are verified by electronic structure calculations using density functional theory calculations considering a continuum solvent model. We found that the addition of VC to the IL prevents further reduction of the counter-ion TFSI − and retards reduction of FSI − in comparison to the case when the additive VC is absent. The PYR14 + reduction is never observed with or without the additive. The 1st, 2nd, and 3rd electron affinities of the PYR14 + are −0.08, −0.36 and −3.65 eV, indicating little to large repulsive behavior against electrons. The opposite is observed for the two negative ions, FSI − and TFSI − , which yield 1st electron affinities of 1.73 and 1.83 eV, respectively. Reactions obtained under open circuit conditions. Dissociation mechanisms are presented for all IL components reduced at the IL/Li-metal interface.

Electrochemistry↗
NASA NTRS1990

Observations and models of star formation in the tidal features of interacting galaxies

Multi-color surface photometry (BVri) is presented for the tidal features in a sample of interacting galaxies. Large color variations are found between the morphological components and within the individual components. The blue colors in the primary and the tidal features are most dramatic in B-V, and not in V-i, indicating that star formation instead of metallicity or age dominates the colors. Color variations between components is larger in systems shortly after interaction begins and diminishes to a very low level in systems which are merged. Photometric models for interacting systems are presented which suggest that a weak burst of star formation in the tidal features could cause the observed color distributions. Dynamical models indicate that compression occurs during the development of tidal features causing an increase in the local density by a factor of between 1.5 and 5. Assuming this density increase can be related to the star formation rate by a Schmidt law, the density increases observed in the dynamical models may be responsible for the variations in color seen in some of the interacting systems. Limitations of the dynamical models are also discussed.

Wallin, John F.↗
DOE OSTI2022

A Carboranyl Electrolyte Enabling Highly Reversible Sodium Metal Anodes via a “Fluorine‐Free” SEI

Abstract Realization of practical sodium metal batteries (SMBs) is hindered due to lack of compatible electrolyte components, dendrite propagation, and poor understanding of anodic interphasial chemistries. Chemically robust liquid electrolytes that facilitate both favorable sodium metal deposition and a stable solid‐electrolyte interphase (SEI) are ideal to enable sodium metal and anode‐free cells. Herein we present advanced characterization of a novel fluorine‐free electrolyte utilizing the [HCB 11 H 11 ] 1− anion. Symmetrical Na cells operated with this electrolyte exhibit a remarkably low overpotential of 0.032 V at a current density of 2.0 mA cm −2 and a high coulombic efficiency of 99.5 % in half‐cell configurations. Surface characterization of electrodes post‐operation reveals the absence of dendritic sodium nucleation and a surprisingly stable fluorine‐free SEI. Furthermore, weak ion‐pairing is identified as key towards the successful development of fluorine‐free sodium electrolytes.

Tomich, Anton W.↗
DOE OSTI2022

A Carboranyl Electrolyte Enabling Highly Reversible Sodium Metal Anodes via a “Fluorine-Free” SEI

Realization of practical sodium metal batteries (SMBs) is hindered due to lack of compatible electrolyte components, dendrite propagation, and poor understanding of anodic interphasial chemistries. Chemically robust liquid electrolytes that facilitate both favorable sodium metal deposition and a stable solid-electrolyte interphase (SEI) are ideal to enable sodium metal and anode-free cells. Herein we present advanced characterization of a novel fluorine-free electrolyte utilizing the [HCB 11 H 11 ] 1- anion. Symmetrical Na cells operated with this electrolyte exhibit a remarkably low overpotential of 0.032 V at a current density of 2.0 mA cm -2 and a high coulombic efficiency of 99.5 % in half-cell configurations. Additionally, surface characterization of electrodes post-operation reveals the absence of dendritic sodium nucleation and a surprisingly stable fluorine-free SEI. Furthermore, weak ion-pairing is identified as key towards the successful development of fluorine-free sodium electrolytes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2011

Low-Speed Fan Noise Attenuation from a Foam-Metal Liner

A foam-metal liner for attenuation of fan noise was developed for and tested on a low-speed fan. This type of liner represents a significant advance over traditional liners, due to the possibility of placement in close proximity to the rotor. An advantage of placing treatment in this region is that the acoustic near field is modified, thereby inhibiting the noise-generation mechanism. This can result in higher attenuation levels than could be achieved by liners located in the nacelle inlet. In addition, foam-metal liners could potentially replace the fan rub strip and containment components, ultimately reducing engine components and thus weight, which can result in a systematic increase in noise reduction and engine performance. Foam-metal liners have the potential to reduce fan noise by 4 dB based on this study.

Sutliff, Daniel L.↗
DOE OSTI2025

FreeMHD: Validation and verification of the open-source, multi-domain, multi-phase solver for electrically conductive flows

The extreme heat fluxes in the divertor region of tokamaks may require an alternative to solid plasma-facing components, for the extraction of heat and the protection of the surrounding walls. Flowing liquid metals are proposed as an alternative, but raise additional challenges that require investigation and numerical simulations. Free surface designs are desirable for plasma-facing components, but steady flow profiles and surface stability must be ensured to limit undesirable interactions with the plasma. Previous studies have mainly used steady-state, 2D, or simplified models for internal flows and have not been able to adequately model free-surface liquid metal (LM) experiments. Therefore, FreeMHD has been recently developed as an open-source magnetohydrodynamics (MHD) solver for free-surface electrically conductive flows subject to a strong external magnetic field. The FreeMHD solver computes incompressible free-surface flows with multi-region coupling for the investigation of MHD phenomena involving fluid and solid domains. The model utilizes the finite-volume OpenFOAM framework under the low magnetic Reynolds number approximation. FreeMHD is validated using analytical solutions for the velocity profiles of closed channel flows with various Hartmann numbers and wall conductance ratios. Next, experimental measurements are then used to verify FreeMHD, through a series of cases involving dam breaking, 3D magnetic fields, and free-surface LM flows. These results demonstrate that FreeMHD is a reliable tool for the design of LM systems under free surface conditions at the reactor scale. Furthermore, it is flexible, computationally inexpensive, and can be used to solve fully 3D transient MHD flows.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2007

Stainless Steel NaK-Cooled Circuit (SNaKC) Fabrication and Assembly

An actively pumped Stainless Steel NaK Circuit (SNaKC) has been designed and fabricated by the Early Flight Fission Test Facility (EFF-TF) team at NASA's Marshall Space Flight Center. This circuit uses the eutectic mixture of sodium and potassium (NaK) as the working fluid building upon the experience and accomplishments of the SNAP reactor program from the late 1960's The SNaKC enables valuable experience and liquid metal test capability to be gained toward the goal of designing and building an affordable surface power reactor. The basic circuit components include a simulated reactor core a NaK to gas heat exchanger, an electromagnetic (EM) liquid metal pump, a liquid metal flow meter, an expansion reservoir and a drain/fill reservoir To maintain an oxygen free environment in the presence of NaK, an argon system is utilized. A helium and nitrogen system are utilized for core, pump, and heat exchanger operation. An additional rest section is available to enable special component testing m an elevated temperature actively pumped liquid metal environment. This paper summarizes the physical build of the SNaKC the gas and pressurization systems, vacuum systems, as well as instrumentation and control methods.

Godfroy, Thomas J.↗
DOE OSTI2025

Performance improvement of proton exchange membrane water electrolysis by surface modification of porous transport layers

Proton exchange membrane water electrolysis (PEMWE) is a promising option for hydrogen production from a variety of energy sources. Cost-effective production of hydrogen with PEMWE requires reduction of costly precious metals as well as optimization of the components and interfaces in the cell. The interface between the platinum-coated titanium porous transport layer (PTL) and catalyst layer (CL) significantly impacts the performance of the electrolyzer cell. Here, we report on two PTL modification methods, mechanical abrasion and chemical etching, which we find improve PEMWE performance by lowering the resistance of the PTL/CL interface. The PTL surface modifications enabled performance improvements up to 77 mV at 4 A cm −2 and reduction of the high frequency resistance, demonstrating that the resistance of the PTL/CL interface is a significant factor in the cell performance. The PTL surface roughness was varied using abrasive materials ranging from 0.1 to 140 μm in grain sizes and chemical etching was found to also increase the surface roughness. The surface roughness was quantified using confocal laser microscopy and the surface oxidation was measured using X-ray photoemission spectroscopy. These results demonstrate that both increasing surface roughness and oxide removal contribute to lowering the PTL/CL interfacial resistance and increasing cell performance.

08 HYDROGEN↗
DOE OSTI2022

Three-Electrode Study of Electrochemical Ionomer Degradation Relevant to Anion-Exchange-Membrane Water Electrolyzers

Among existing water electrolysis (WE) technologies, anion-exchange-membrane water electrolyzers (AEMWEs) show promise for low-cost operation enabled by the basic solid-polymer electrolyte used to conduct hydroxide ions. The basic environment within the electrolyzer, in principle, allows the use of non-platinum-group metal catalysts and less-expensive cell components compared to acidic-membrane systems. Nevertheless, AEMWEs are still underdeveloped, and the degradation and failure modes are not well understood. To improve performance and durability, supporting electrolytes such as KOH and K 2 CO 3 are often added to the water feed. The effect of the anion interactions with the ionomer membrane (particularly other than OH – ), however, remains poorly understood. We studied three commercial anion-exchange ionomers (Aemion, Sustainion, and PiperION) during oxygen evolution (OER) at oxidizing potentials in several supporting electrolytes and characterized their chemical stability with surface-sensitive techniques. We analyzed factors including the ionomer conductivity, redox potential, and pH tolerance to determine what governs ionomer stability during OER. Specifically, we discovered that the oxidation of Aemion at the electrode surface is favored in the presence of CO 3 2– /HCO 3 – anions perhaps due to the poor conductivity of that ionomer in the carbonate/bicarbonate form. Sustainion tends to lose its charge-carrying groups as a result of electrochemical degradation favored in basic electrolytes. PiperION seems to be similarly negatively affected by a pH drop and low carbonate/bicarbonate conductivity under the applied oxidizing potential. Furthermore, the insight into the interactions of the supporting electrolyte anions with the ionomer/membrane helps shed light on some of the degradation pathways possible inside of the AEMWE and enables the informed design of materials for water electrolysis.

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

Combined Plasmonic Au-nanoparticle and Conducting Metal Oxide High-temperature Optical Sensing with LSTO

<span style="color: rgba(0, 0, 0, 0.79); font-family: &quot;Source Sans Pro&quot;, source-sans-pro, museo_sans300, museo-sans, Arial, sans-serif; font-size: 16px; background-color: rgb(255, 255, 255);">Fiber optic sensor technology offers several advantages for harsh-environment applications. However, the development of optical gas sensing layers that are stable under harsh environmental conditions is an ongoing research challenge. In this work, electronically conducting metal oxide lanthanum-doped strontium titanate (LSTO) films embedded with gold nanoparticles are examined as a sensing layer for application in reducing gas flows at high temperature (600–800 °C). A strong localized surface plasmon resonance (LSPR) based response to hydrogen is demonstrated in the visible region of the spectrum, while a Drude free electron-based response is observed in the near-IR. Characteristics of these responses are studied both on planar glass substrates and on silica fibers. Charge transfer between the oxide film and the gold nanoparticles is explored as a possible mechanism governing the Au LSPR response and is considered in terms of the corresponding properties of the conducting metal oxide-based matrix phase. Principal component analysis is applied to the combined plasmonic and free-carrier based response over a range of temperatures and hydrogen concentrations. It is demonstrated that the combined visible and near-IR response of these films provides improved versatility for multiwavelength interrogation, as well as improved discrimination of important process parameters (concentration and temperature) through application of multivariate analysis techniques.</span>

Wuenschell, Jeffrey K.↗
DOE OSTI2026

Recovery of terephthalic acid from solar PV backsheets using waste solvent from distilled spirits production

Current research on solar photovoltaic (PV) recycling mainly focuses on recovering valuable metals and glass, often neglecting the polymeric components, particularly the backsheets, which are typically landfilled or thermally decomposed. This study explores an innovative approach to upcycle PV backsheets into value-added products, specifically terephthalic acid (TPA), using waste ethanol solvent from the distilled spirits industry. Experimental results show that increasing both exposure time and ethanol concentration significantly enhances backsheet delamination efficiency. Using waste ethanol, a maximum delamination efficiency of 80% was achieved at room temperature after 24 hours. In decomposition trials, both sodium hydroxide (NaOH) and potassium hydroxide (KOH) demonstrated comparable efficiencies (96.6–97.5%) over 8 and 24 hour reactions. With virgin ethanol, NaOH yielded 94–97.5% TPA recovery. Notably, using waste ethanol achieved a TPA recovery efficiency of 96.8%, underscoring the process's economic viability and sustainability. Analytical characterization of TPA recovered after 8 hours showed consistent spectral patterns across both alkalis and solvents, indicating a similar chemical environment and functional groups. The recovered TPA can be repolymerized into high-purity PET, suitable for manufacturing new PV backsheets. This work advances polymer-recycling by demonstrating that an industrial waste solvent (distilled-spirits ‘heads’) can replace virgin ethanol without loss in delamination performance or TPA yield. While PV backsheet PET is a modest share of global PET, using waste ethanol to upcycle this currently under-recycled stream demonstrates a transferable solvent-reuse pathway that can extend to higher-volume PET sources.

Nain, Preeti [Michigan State Univ., East Lansing, ↗
DOE OSTI2020

Facilitating hydrogen atom migration via a dense phase on palladium islands to a surrounding silver surface

Significance The energy efficiency of catalytic processes hinges on achieving high selectivity and activity; bimetallic catalysts have potential to increase both by exploiting different chemical properties of the components. Transport of intermediates between the two metals, for example, transport of hydrogen atoms for selective hydrogenation, is required to capitalize on this bifunctionality. A mechanism for the migration of hydrogen atoms to silver from palladium is demonstrated here. Dihydrogen first dissociates on palladium, then forms a dense hydrogen phase on the palladium island. The dense phase includes weakly bound hydrogen atoms that are nearly isoenergetic with hydrogen on silver, rendering migration nearly energy neutral. The efficiency for hydrogen migration across the palladium−silver is maximized for small ensembles of palladium atoms.

O’Connor, Christopher R.↗
DOE OSTI2022

Highly stable preferential carbon monoxide oxidation by dinuclear heterogeneous catalysts

Atomically dispersed catalysts have been shown highly active for preferential oxidation of carbon monoxide in the presence of excess hydrogen (PROX). However, their stability has been less than ideal. We show here that the introduction of a structural component to minimize diffusion of the active metal center can greatly improve the stability without compromising the activity. Using an Ir dinuclear heterogeneous catalyst (DHC) as a study platform, we identify two types of oxygen species, interfacial and bridge, that work in concert to enable both activity and stability. In conclusion, the work sheds important light on the synergistic effect between the active metal center and the supporting substrate and may find broad applications for the use of atomically dispersed catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Iron isotope fractionation between solid and liquid metal in the Fe-P±Ni system: Experimental constraints and implications for meteorites

Iron meteorites record a range of Fe isotope compositions that hold valuable information regarding the evolution of their parent bodies. Interpreting this isotopic variability, however, requires experimental constraints on the equilibrium isotope fractionation between phases. It is thought that the cores of many iron meteorite parent bodies experienced fractional crystallization, during which crystallization of solid iron-nickel occurs from an increasingly non-metal-rich liquid alloy. Phosphorus is one component of this alloy, and this study provides the first constraints on Fe-isotope fractionation between solid and liquid alloys in the Fe-Ni-P system. Experiments comprising Fe and P show a clear enrichment in the light isotopes of Fe in the liquid phase, which increases with the amount of phosphorus. Nickel-bearing samples are offset from the trend defined by Ni-free experiments, which is accounted for by the change in the solid alloy phase from a body-centered cubic to face-centered cubic structure upon the addition of Ni. The increasing light isotope enrichment of the liquid with increasing P content suggests interstitial solution of P, which is known to lengthen Fe-Fe bonds in Fe-P liquids (Waseda and Shiraishi 1977). Results suggest a negligible effect of P on Fe isotope fractionation during planetesimal core crystallization. Iron isotopes may, however, prove useful for identifying the petrogenesis of schreibersite in pallasites and iron meteorites.

58 GEOSCIENCES↗