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At least 883 records · Page 49
All sourcesNASA NTRSDOE OSTI
DOE OSTI2013

LLNL HEPA Filter Support of Nuclear Facility Safety R&D (FY12)

The ceramic HEPA filter project has been a successful and innovative project. This report contains information from the work from FY12 funding, as well as remaining FY11 funding. Of note, a total of 12 patents for the ceramic HEPA filter program have been filed, and an additional record of invention has been prepared with a provisional patent to follow. This project supports development of a ceramic HEPA filter technology to benefit DOE nuclear facilities by providing lower life-cycle costs and reducing or eliminating costs associated with Safety Class and Safety Significant systems in nuclear facilities. The satisfactory performance of ceramic filters in a fire could significantly reduce costs of support systems associated with mitigating a release, such as fire suppression, fire detection and alarm, and internal building structure. In nuclear safety, the best way to provide protection to public, workers and the environment is to provide a barrier between the hazard and the receptors. A passive engineered design feature is the best barrier for that purpose. Advanced ceramic HEPA filters provide an excellent barrier between radioactive material in a nuclear facility and everything downwind. Both university (Cal Poly) student teams did very well. As summarized in this report, they successfully added and upgraded instrumentation and controls to the High Temperature Test Unit (HTTU) for the ceramic filter project. They also succeeded in adding viewing ports, remotely controlled closed circuit television, a flame impingement system and a helium filter gasket leak detection system. Details can be found in Ref. 3 - 6. The HTTU has flexible capabilities and can also be used to test other types of filters or filter components in the future, if so desired. At LLNL, research to improve filter media coating (Fig. 1) is being conducted to maintain filtration efficiency while improving performance (reducing pressure drop). Improvements in the individual filter element are necessary to maintain filtration efficiency while decreasing pressure drop. The path forward for an optimal ceramic HEPA filter meeting DOE’s needs is to improve the filtration media. This task utilized the LLNL/DOE developed innovations along with progress in previous activities to prepare multiple ceramic filter elements and refine the technical details for depositing advanced filtration materials to the ceramic filter to meet desired filter performance. The ceramics filter elements were tested for pressure drop at the required air flow rate using an air flow test system. The filtration efficiency and pressure drop of the ceramic filter elements will be measured as part of the development process.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Separated waste stream immobilization of iodine and off-gas caustic scrubber solution (Final Report)

In this work, the approach was to immobilize the CS solution in a glass-bonded composite of cancrinite/sodalite. The synthesis of ceramic waste forms was accomplished by low-temperature (~90°C) processes developed by the team in the framework of a previous NEUP project. By building on our earlier efforts for iodine waste forms, we minimized the schedule and technical risk while still providing novel process demonstrations for the off-gas waste forms. In the case of AgI-based sorbents, a proof-of-concept stripping process was shown to remove iodine from AgI by converting it to NaI(aq) followed by immobilization of these ions in iodosodalite (ISOD), which could be glass-bonded in the same way as for the CS solution cancrinite/sodalite powders.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Super Conducting REBCO Cable Wrapper

Future upgrades to CERN particle accelerator magnets require flat, high-temperature superconducting cables, created by wrapping brittle REBCO tape around a Rutherford copper core. Because current manual wrapping processes are time-consuming and prone to damaging the delicate ceramic tape, our team was tasked with automating the fabrication. We developed a modular, wrapping machine featuring adjustment for repeatable 10°to 45° wrap angles and a precise magnetic tensioning mechanism. While full-scale testing is pending final machined parts, our 3D-printed prototype successfully validates the system’s motion and sets the stage for future testing.

Gillen, Kameron [Northern Illinois U.]↗
NASA NTRS1982

Energy efficient engine high pressure turbine ceramic shroud support technology report

This work represents the development and fabrication of ceramic HPT (high pressure turbine) shrouds for the Energy Efficient Engine (E3). Details are presented covering the work performed on the ceramic shroud development task of the NASA/GE Energy Efficient Engine (E3) component development program. The task consists of four phases which led to the selection of a ZrO2-BY2O3 ceramic shroud material system, the development of an automated plasma spray process to produce acceptable shroud structures, the fabrication of select shroud systems for evaluation in laboratory, component, and CF6-50 engine testing, and finally, the successful fabrication of ZrO2-8Y2O3/superpeg, engine quality shrouds for the E3 engine.

Nelson, W. A.↗
NASA NTRS1991

Combustion synthesis of TiB2-Al2O3-Al composite materials

The oxide-aluminum exothermic reduction reaction is presently used in the combustion-synthesis of ceramic/metal composites. An excess of Al is used in the reacting materials, which rapidly generate enough heat to exceed Al's melting point. The molten Al thus evolved is allowed to infiltrate the porous ceramic matrix as the exothermic reaction proceeds; this feature of the process turns the disadvantage of high porosity levels in combustion-synthesized materials into an advantage. Attention is given to the system obtained with 3TiO2 + 3B2O3 + (10-x)Al starting materials.

Feng, H. J.↗
NASA NTRS1992

Laboratory studies on cometary crust formation: The importance of sintering

It is demonstrated by experiments and theoretical considerations that sintering processes, so far used to describe the densification of metal and ceramic powders, are relevant for icy materials and therefore probably also for comets. A theoretical model is presented which describes the evolution of so called sinter necks, the contact zone between ice particles. With this model the strength increase of a porous, loosley packed icy body is calculated in which the sinter necks grow by evaporation and condensation of water vapor at a constant temperature. Experiments with ice powders validate the model qualitatively. An increase in strength up to a factor of four is observed during isothermal sintering. In order to check the relevance of the experimental results and the basic theoretical ideas with respect to real comets, more exact theories and improved experiments taking into account additional mass transport mechanisms are needed.

Ratke, L.↗
NASA NTRS1996

Evaluation of Student Outcomes in Materials Science and Technology

This paper specifies 14 benchmarks and exit standards for the introduction of Materials Science and Technology in a secondary school education. Included is the standard that students should be able to name an example of each category of technological materials including metals, glass/ceramics, polymers (plastics) and composites. Students should know that each type of solid material has specific properties that can be measured. Students will learn that all solid materials have either a long range crystalline structure or a short range amorphous structure (i.e., glassy). They should learn the choice of materials for a particular application depends on the properties of the material, and the properties of the material depends on its crystal structure and microstructure. The microstructure may be modified by the methods by which the material is processed; students should explain this by the example of sintering a ceramic body to reduce its porosity and increase its densification and strength. Students will receive exposure to the world of work, post secondary educational opportunities, and in general a learning that will lead to a technologically literate intelligent citizen.

Piippo, Steven↗
NASA NTRS2006

Development of a Thin Gauge Metallic Seal for Gas Turbine Engine Applications to 1700 F

The goal of doubling thrust-to-weight ratio for gas turbine engines has placed significant demands on engine component materials. Operating temperatures for static seals in the transition duct and turbine sections for instance, may well reach 2000 F within the next ten years. At these temperatures conventional age-hardenable superalloys lose their high strength via overaging and eventual dissolution of the gamma precipitate, and are well above their oxidation stability limit. Conventional solid-solution-strengthened alloys offer metallurgical stability, but suffer from rapid oxidation and little useful load bearing strength. Ceramic materials can theoretically be used at these temperatures, but manufacturing processes are in the developmental stages.

England, Raymond O.↗
NASA NTRS2008

Stable Electrical Operation of 6H-SiC JFETs and ICs for Thousands of Hours at 500 C

The fabrication and testing of the first semiconductor transistors and small-scale integrated circuits (ICs) to achieve up to 3000 h of stable electrical operation at 500 C in air ambient is reported. These devices are based on an epitaxial 6H-SiC junction field-effect transistor process that successfully integrated high temperature ohmic contacts, dielectric passivation, and ceramic packaging. Important device and circuit parameters exhibited less than 10% of change over the course of the 500 C operational testing. These results establish a new technology foundation for realizing durable 500 C ICs for combustion-engine sensing and control, deep-well drilling, and other harsh-environment applications.

Neudeck, Philip G.↗
DOE OSTI2013

Low-cost method for fabricating palladium and palladium-alloy thin films on porous supports

A process for forming a palladium or palladium alloy membrane on a ceramic surface by forming a pre-colloid mixture comprising a powder palladium source, carrier fluid, dispersant and a pore former and a binder. Ultrasonically agitating the precolloid mixture and applying to a substrate with an ultrasonic nozzle and heat curing the coating form a palladium-based membrane.

36 MATERIALS SCIENCE↗
DOE OSTI2024

3D-ink-printing of monocrystalline YBCO superconductor

Single-crystal microstructure can bring high performance for many materials includingpiezoelectrics1, 2, semiconductors3, 4, and cuprate superconductors5. Unlike single-crystal metalsthat can be machined into complex components6, most single-crystal ceramics are limited to theshape of thin films or plates due to their brittleness. However, more designs of advanced devicesneed to break these geometric limitations. 3D-ink-printing can efficiently fabricate complex architectured ceramics, but the microstructure is polycrystals. Here, for the first time, we demonstrate a route to grow single-crystal on 3D printed ceramic-YBa2Cu3O7-x (YBCO)superconductors that can simultaneously have complex architectures and high critical currentdensity. An ink containing precursor powders was 3D extruded and sintered to obtain polycrystalYBCO micro-lattices. A single-crystal seed is then utilized to grow single crystal on 3D-printedmicro-lattices by melt growth method. We found that the geometric details of 3D printed microlatticecan survive after it went through liquid + solid phase region above its peritectic temperature.More complex YBCO single-crystal parts, such as horizontal and toroidal coils, were thensuccessfully fabricated. In addition, Origami can be implemented on our 3D printed sample to increase their complexity. This research provides a new way to develop superconducting devicessuch as undulators for synchrotron radiation and microwave cavities for dark-matter axion search7.We expect this new process will inspire more studies about 3D printing of single-crystal ceramics. For example, 3D printing of BaTiO3 can be developed to grow a single crystal8 for the applications of dielectric capacitors and transducers.

43 PARTICLE ACCELERATORS↗
NASA NTRS2009

Survey Analysis of Materials Processing Experiments Aboard STS-47: Spacelab J

This Technical Memorandum (TM) is a survey outline of materials processing experiments aboard Space Shuttle Mission STS-47: Spacelab J, a joint venture between NASA and the National Space Development Agency of Japan. The mission explored materials processing experiments including electronics and crystal growth materials, metals and alloys, glasses and ceramics, and fluids. Experiments covered include Growth of Silicone Spherical Crystals and Surface Oxidation, Growth Experiment of Narrow Band-Gap Semiconductor Lead-Tin-Tellurium Crystals in Space, Study on Solidification of Immiscible Alloys, Fabrication of Very-Low-Density, High-Stiffness Carbon Fiber/Aluminum Hybridized Composites, High Temperature Behavior of Glass, and Study of Bubble Behavior. The TM underscores the historical significance of these experiments in the context of materials processing in space.

Sharpe, R. J.↗
DOE OSTI2026

Hybrid Additive Manufacturing and Electric Field-Assisted Sintering of High-temperature Heat Exchangers via Sacrificial Channel Molds

A hybrid manufacturing approach, integrating additive manufacturing (AM) with powder methodology via electric field-assisted sintering (EFAS), was developed for the fabrication of high-temperature compact heat exchangers (CHX) from refractory metals. The methodology employed additively manufactured sacrificial channel molds (SCMs) as shapeholders for CHX channels, which were embedded in metal powders using EFAS. Following embedding, the SCMs were chemically dissolved to form the internal channel network. SCMs were fabricated using both digital light processing (DLP) and direct ink writing (DIW) from chemically reactive, calcium-based ceramic feedstocks with varying ratios of Al2O3 reinforcement. The microstructure, phase composition, and dissolution behavior of both as-printed and embedded SCMs were investigated. The shrinkage behavior of the SCMs embedded in refractory metals, as well as the interfacial characteristics between the SCMs and metal matrix, were studied. The results showed that the SCMs containing sufficient chemical reactive ceramics dissolved effectively before and after embedding. The as-printed SCMs retained the phase composition of their feedstocks, but the embedded SCMs containing calcium-based ceramics and Al2O3 exhibited the formation of calcium aluminates due to high temperature exposure during embedding. Most SCMs exhibited a cellular Al2O3 network filled with Ca-rich ceramics. Shrinkage after embedding was strongly dependent on SCM density, with lower density SCMs exhibiting greater shrinkage. A thin SCM-affected zone was observed at the metal matrix surface, characterized by increased porosity compared to the bulk matrix. This effect was attributed to infiltration of the SCM materials into powder particle boundaries under pressure, followed by their removal during dissolution. This study demonstrates the feasibility of manufacturing CHXs from hard-to-process refractory metals for use in harsh environments.

36 - MATERIALS SCIENCE↗
DOE OSTI2018

New surface characterization tools for alumina based refractory material exposed to cavitation - Image analysis and pattern recognition approach

Highlights: • Surface degradation was monitored via mass loss measurement. • Observation of surface damage destruction was done using image analysis. • Shape parameters of surface defects change during cavitation. • Shape parameters changes are correlated to mass loss measurements. - Abstract: The aim of this study was to examine the influence of cavitation erosion on the morphology of defects formed on the surfaces of alumina-based materials. The alumina-based samples were exposed to cavitation erosion for 42 min. The damages that occurred were monitored at predefined time intervals by measuring the mass loss and observing the sample surfaces. Digital images of surfaces were processed using an image analysis software package to define morphological characteristics of the damages occurred. The calculated morphological parameters were subjected to analysis by pattern recognition techniques to correlate the appearance of particular morphological characteristics with the behavior of the material during cavitation erosion. The newly established method in describing cavitation erosion which uses pattern recognition approach for treatments of morphological parameters calculated for damages by image analysis tools gave the results efficient for material characterization as the traditional one.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Evaluation of Iron‐Phosphate Glass–Ceramic Waste Form for Electrorefiner Salt Waste Simulant Dechlorinated With Phosphoric Acid

The importance of glass and glass–ceramic nuclear waste forms has been reaffirmed in recent years by the growing interest in nuclear power as a reliable energy source. Determination of processing methods for the disposal of halide-containing wastes will be essential for the advancement of nuclear technologies such as non-aqueous fuel reprocessing. Phosphate-based dechlorination and subsequent vitrification of radioactive salt waste into an iron-phosphate waste form have been identified as a potential processing scheme for electrochemical processing waste. The impact of H 3 PO 4 -based dechlorination of complex salt mixtures on the vitrification process and structure of the final iron-phosphate waste form has not yet been investigated. In this work, iron-phosphate glass–ceramics were made from simulant salt waste (48LiCl–33KCl–19NaCl mol%) dechlorinated with the H3PO4-based method. The glass-forming region was compared to that of traditionally prepared Na 2 O–Fe 2 O 3 –P 2 O 5 systems. For a candidate glass-forming composition, the processing scheme presented here was determined to favor Fe 3+ species. The O/P molar ratio was consistent for the candidate composition when dechlorinated at 400°C and 600°C in air and argon environments, indicating glass network connectivity was maintained despite variations in processing parameters. The results presented here validate processing schemes requiring iron-phosphate waste form synthesis following H 3 PO 4 -based dechlorination.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Power Electronics Module with Integrated Ceramic Heat Exchanger

NREL, in partnership with Synteris and Packet Digital, has developed a 3D-printable ceramic package for power electronic modules to improve their thermal management, power density, performance, and lifetime. Existing power modules contain flat ceramic substrates that serve as both the electrically insulating component and thermal conductor that transfer the large heat outputs of these devices. The team has developed an additive manufacturing process that replaces the traditional insulating metalized substrate, substrate attach, and baseplate/heat exchanger with an additively-manufactured ceramic packaging that acts as both an electrical insulator and heat exchanger for better thermal management. The design, manufacturability, and function of this power module will be discussed.

25 ENERGY STORAGE↗
DOE OSTI2014

Crystallite-growth, phase transition, magnetic properties, and sintering behaviour of nano-CuFe{sub 2}O{sub 4} powders prepared by a combustion-like process

The synthesis of nano-crystalline CuFe{sub 2}O{sub 4} powders by a combustion-like process is described herein. Phase formation and evolution of the crystallite size during the decomposition process of a (CuFe{sub 2})—precursor gel were monitored up to 1000 °C. Phase-pure nano-sized CuFe{sub 2}O{sub 4} powders were obtained after reaction at 750 °C for 2 h resulting in a crystallite size of 36 nm, which increases to 96 nm after calcining at 1000 °C. The activation energy of the crystallite growth process was calculated as 389 kJ mol{sup −1}. The tetragonal⇄cubic phase transition occurs between 402 and 419 °C and the enthalpy change (ΔH) was found to range between 1020 and 1229 J mol{sup −1} depending on the calcination temperature. The optical band gap depends on the calcination temperature and was found between 2.03 and 1.89 eV. The shrinkage and sintering behaviour of compacted powders were examined. Dense ceramic bodies can be obtained either after conventional sintering at 950 °C or after a two-step sintering process at 800 °C. Magnetic measurements of both powders and corresponding ceramic bodies show that the saturation magnetization rises with increasing calcination-/sintering temperature up to 49.1 emu g{sup −1} (2.1 µ{sub B} fu{sup −1}), whereas the coercivity and remanence values decrease. - Graphical abstract: A cheap one-pot synthesis was developed to obtain CuFe{sub 2}O{sub 4} nano-powders with different crystallite sizes (36–96 nm). The optical band gaps, phase transition temperatures and enthalpies were determined depending on the particle size. The sintering behaviour of nano CuFe{sub 2}O{sub 4} was studied in different sintering procedures. The magnetic behaviour of the nano-powders as well as the corresponding ceramic bodies were investigated. - Highlights: • Eco-friendly and simple synthesis for nano CuFe{sub 2}O{sub 4} powder using starch as polymerization agent. • Monitoring the phase evolution and crystallite growth kinetics during the synthesis. • Determination of the optical band gap, phase transition temperature, and enthalpy change. • Sintering behaviour of nano-sizes CuFe{sub 2}O{sub 4}. • Magnetic behaviour of CuFe{sub 2}O{sub 4} powders and ceramics depending on their particle size.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗