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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 937 records · Page 52
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Material Extrusion Printing of Poly(Acrylonitrile‐Styrene‐Acrylate) and Poly(Acrylonitrile‐Butadiene‐Styrene) Structures Reinforced with Poly(Phenylene Oxide) Additives for Improved Thermomechanical Properties and their Surface Analysis by Time‐of‐Flight Secondary Ion Mass Spectrometry

Fused filament fabrication offers the ability to 3D print complex geometries made from plastic filament materials; however, these parts are mechanically outperformed by parts created by traditional fabrication methods. To overcome this challenge, a high-performance polymer poly(2,6-dimethyl-1,4-phenylene oxide) (PPO) is incorporated as an additive into two common engineering thermoplastics, poly(acrylonitrile-styrene-acrylate) (ASA) and poly(acrylonitrile-butadiene-styrene) (ABS). Structures printed from these polymer blends are more mechanically robust compared to those prepared from the parent polymers, with low loading levels (1–5 wt%) of PPO improving the elastic strength by up to ≈30% relative to the parent terpolymers. Even at higher loading levels (10 and 20 wt% PPO), there is no evidence of additive aggregation in the model thin films, which is supported by compositional analysis of the copolymers and chemical analysis via time-of-flight secondary ion mass spectrometry. The enhancements in mechanical properties of ASA and ABS blends appear to be a consequence of homogeneous incorporation of the PPO additive. In conclusion, this work explores expanding materials-property space using miscible blends of engineering thermoplastics to improve mechanical performance as a general approach to overcoming challenges with parts created by melt-based material extrusion printing.

additive manufacturing↗
DOE OSTI2025

3D Printing of Highly Porous Polypropylene Separators for Lithium‐Ion Batteries Using Fused Deposition Modeling and Thermally Induced Phase Separation

Appearing as one of the key-components of lithium-ion batteries (LIBs), this work specifically focuses on the additive manufacturing (AM) of custom-shape separators, facilitated by the filament material extrusion process, also called fused deposition modeling (FDM). The development and optimization of composite thermoplastic filament feedstocks combining polypropylene and paraffin wax, followed by the 3D printing of the separator membranes is shown. A post-processing step, based on thermal induced phase separation (TIPS), is introduced to promote porosity formation through removal of the paraffin wax sacrificial phase within the 3D printed items. Separators with different polypropylene/paraffin wax ratios are developed and the impact on printability, mechanical strength, porosity, and electrochemical performances, is thoroughly discussed. X-ray micro-computed tomography is employed to assess the geometric fidelity and to detect printing defects in a complex 3D lattice structure. The performance of the 3D printed porous separators is also compared to a commercial separator. This pioneering research establishes a foundation for the creation of porous separators that can adapt to and conform into 3D printed battery architectures with novel form factors, and also creates opportunities for the use of FDM and TIPS for a wide range of applications that employ porous structures beyond the energy storage field.

3D printing↗
DOE OSTI2022

A Coupled Small and Wide-Angle X-Ray Scattering Study of Phase Transformation Mechanisms in U-6Wt Pct Nb

The elevated temperature phase transformation kinetics of U-6wt%Nb in both wrought and cast conditions were investigated using in-situ high energy synchrotron X-ray scattering. The evolution of the phase content, γ-phase composition, and microstructure morphology was determined through the analysis of simultaneously collected wide-angle diffraction and small-angle scattering (SAXS) data. The results of the wide-angle scattering analysis, especially the phase fractions and average composition of the γ-phase, provide model parameters to enable a quantitative analysis using the SAXS data. Greater clarity regarding the kinetics of different precipitation mechanisms, namely the continuous precipitation (CP) of α-U within the γ-phase matrix and the discontinuous (DP) grain boundary precipitation of a lamellar microstructure, consisting of α-U and Nb-rich γ-phase are obtained from the coupled measurement modes. These results indicate that the CP mechanism is responsible for the initial precipitation of α-U at all temperatures considered. Near the nose in the time-temperature-transformation (TTT) diagram at ~798 K, both mechanisms are active during the early stages of phase transformation. However, the DP mechanism has an increasingly long incubation period with decreasing temperature below the TTT nose. In conclusion, the average interlamellar spacing obtained from the SAXS analysis increases with time, providing further evidence of the so-called divergent DP behavior previously observed in U-6wt%Nb alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Design of a supervisory control system for autonomous operation of advanced reactors

Advanced reactors to be deployed in the coming decades will face deregulated energy markets, and may adopt flexible operation to boost profitability. To aid in the transition from baseload to flexible operation paradigm, autonomous operation is sought. This work focuses on the control aspect of autonomous operation. Specifically, a hierarchical control system is designed to support constraint enforcement during routine operational transients. Within the system, data-driven modeling, physics-based state observation, and classical control algorithms are integrated to provide an adaptable and robust solution. A 320 MW Fluoride-cooled High-temperature Pebble-bed Reactor is the design basis for demonstrating the proposed control system. The hierarchical control system consists of a supervisory layer and low-level layer. The supervisory layer receives requests to change the system's operating conditions (e.g., the current reactor power to meet a load -follow), and accepts or rejects them based on constraints that have been assigned. Constraints are issued to keep the plant within an optimal operating region. The low-level layer interfaces with the actuators of the system to fulfill requested changes, while maintaining tracking and regulation duties. Further, to accept requests at the supervisory layer, the Reference Governor algorithm was adopted. To model the dynamics of the reactor, a system identification algorithm, Dynamic Mode Decomposition, was utilized. To estimate the evolution of process variables that cannot be directly measured (e.g., the propagation of delayed neutron precursors), the Unscented Kalman Filter, incorporating a nonlinear model of nuclear dynamics, was adopted. The composition of these algorithms led to a numerical demonstration of constraint enforcement during a 40% power drop transient (at a rate of 5 %/min). Uncontrolled secondary-side temperatures were successfully constrained. Adaptability of the proposed system was demonstrated by modifying the constraint values, and enforcing them during the transient. Robustness was also demonstrated by enforcing constraints under noisy environments.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

A scoping review of non-destructive testing (NDT) techniques in building performance diagnostic inspections

Understanding building envelope thermodynamics is an essential foundation of building sciences, mainly due to the envelope’s role as a boundary layer for exterior environments, as well as a container and regulator of internal microclimates. This paper presents a scoping literature review of select Non-destructive Testing (NDT) techniques for building envelope scanning and surveying for thermodynamic diagnostics. The investigation focuses specifically on reviewing six NDT techniques: Ground Penetrating Radar (GPR), Light Detection and Ranging (LiDAR)/Laser Scanning, Thermography, Ultrasound, Close-Range Photogrammetry and Through Wall Imaging Radar (TWIR). The aim is to identify knowledge gaps in terms of their use in accurately characterizing envelope compositions for further integration in Building Energy Modeling (BEM). Each technique was evaluated according to set categories imbibed from the American Society of Heating, Refrigerating, and Air Conditioning Engineering (ASHRAE) Standard 211P that showcase the technique’s ability to extract various relevant information. A framework is then developed to inform users on how to use hybrid NDT-based workflows applied in building envelope energy audits. The study concludes by discussing possibilities of utilizing NDT in large-scale audit automation, BEM integration, and developing built environment policies focusing on increasing existing building performance through retrofitting design.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Ca-isotopes as a robust tracer of magmatic differentiation

The large mass difference (~10%) between the two most abundant isotopes of calcium, 40 Ca and 44 Ca, gives Ca great potential in tracking mass-dependent fractionation during magmatic processes. Resolvable Ca-isotope fractionation during fractional crystallization of magma, particularly by feldspar in evolved melts, has been theoretically inferred but not robustly tested in nature. To further explore the effects of magmatic differentiation on Ca-isotope systematics, we studied the late-Permian alkaline igneous suite of the Øyangen Caldera, Oslo Rift, Norway, consisting of volcanic and intrusive units ranging from basanitic to rhyolitic compositions. Major and trace element variations and modeling demonstrate that the main series of samples (N = 21), including basanites, ring-dyke syenites, and central-dome syenites, likely documents a co-genetic and closed-system fractional crystallization sequence. Our data show minimal δ 44/40 Ca variation (< 0.05 ‰) in the intermediate magma and a marked increase in δ 44/40 Ca in the felsic magma of the Øyangen Caldera (from 0.62 ± 0.02 ‰ to 1.15 ± 0.03 ‰ relative to Ca standard, SRM915a). The systematic increase is best explained by equilibrium isotopic fractionation dominated by alkali feldspar in the fractionating mineral assemblage. This is further supported by strong correlations between δ 44/40 Ca, CaO, and Eu/Eu* in the main-series samples. Implementing a Monte Carlo approach, isotopic modeling of the liquid line of descent using Rayleigh fractionation is highly consistent with the observed Ca-isotope evolution. For the first time, we confirm prominent Ca stable isotope fractionation in felsic-stage differentiation of alkaline magma and constrain the isotope fractionation factors of plagioclase and K-feldspar. Integrated with extant estimations on mineral fractionation factors from the literature, our results suggest increasing fractionation effects of rock-forming minerals with decreasing Ca content. Finally, the affirmation of significant Ca-isotope fractionation in alkaline magma by feldspar empowers the application of Ca as a versatile tracer of crustal evolution, allowing further tests in other magmatic conditions across various planetary objects.

58 GEOSCIENCES↗
DOE OSTI2023

Mechanisms of dissolution from gibbsite step edges elucidated by ab initio molecular dynamics with enhanced sampling

Surface reactions underpin our collective understanding of mineral dissolution. This impacts a range of predictive geochemical models (for weathering, the fate and transport of metals) as well as industrial utilization of minerals. Yet atomistic details are rarely known due to the complex mineral/fluid interfacial environment. There is significant need to understand the mechanistic details of dissolution reactions and how they depend on surface morphology and solution conditions. This work utilizes surface pit models in conjunction with changes to solution composition that mimic pH to explore surface detachment of aluminate from gibbsite, which is a primary source of Al in soils and within the industrial processing of aluminum. Ab initio molecular dynamics simulations with enhanced sampling has been used to explore the detailed process of the detachment, the results of which indicate two potential pathways that are differentiated based upon the extent of water hydration. Here, the heights of the energy barriers depend upon the local morphology which influence the number of bridges (quasi-)simultaneously broken (1 or 2) or the Al-O coordination of the neighboring aluminum atoms (5 or 6) at the armchair edge. pH effects are significant, with a nearly 50% reduction in barrier height under alkaline conditions that are relevant to geothermal fluids and Al extraction from minerals.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

High entropy alloys as catalysts: A focused review

A brief literature review of recent experimental and computational efforts on the use of high entropy alloys (HEAs) as catalysts is presented, while also sharing some perspectives and future insights. To fully broach the vast compositional possibilities of HEA materials, integrating computational modeling with high-throughput experimental synthesis and validation is necessary to accelerate their design and development. Once identified, specific HEAs can be a class of materials for the next generation of catalysts when addressing global challenges related to energy independence, commodity chemical production, environmental remediation, abating emissions, and modernized domestic supply chain resilience.

42 - ENGINEERING↗
DOE OSTI2022

Fragmentation of the edge of a terminated Cu nanolayer within a Nb matrix upon annealing

Here, we investigate the evolution of the tip of a terminated Cu nano-layer embedded within a Nb matrix upon annealing at 800°C. The tip of the terminated Cu layer fragments progressively into a series of single-crystal Cu particles upon continued annealing. This finding shows that layer fragmentation is the second step, after layer pinchoff, in the thermal coarsening of nanolayered metal composites. Comparison to prior phase-field modeling permits us to infer that the mobility at 800°C of Cu-Nb, as modeled by the Cahn-Hillard equation, is M(c)=(M 0 = 7.3 ± 3.6 nm 5 / s • eV) |1 – c 2 |, where the order parameter, c, is 1 for Cu and -1 for Nb.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Behavior of astatine and bismuth in non-conventional solvents: Extraction into imidazolium-based ionic liquid and methyl anthranilate with active pharmaceuticals binary mixtures from nitric acid media

Astatine is one of the least chemically studied elements and its behavior in the presence of non- conventional solvents has not been investigated before. This work considers both hydrophobic ionic liquids and binary mixtures as alternatives to conventional solvents. The study is based on the extraction of astatine and bismuth (target material required to produce astatine) into imidazolium-based ionic liquid, and binary mixtures formed by active pharmaceuticals (ibuprofen, lidocaine) and a food grade ingredient (methyl anthranilate). It is shown that both the ionic liquid and binary mixtures can successfully extract At from nitric acid media, but extraction of Bi into the ionic liquid is very inefficient, resulting in a good separation factor for these two elements in the entire studied acidity range. Extraction of At into binary mixtures is very efficient, having distribution ratio values as high as 1000, while the behavior of Bi under these conditions depends on the composition of the mixture. Furthermore, a mathematical model has been developed to fit both At and Bi experimental data and applied to determine corresponding thermodynamic extraction constants.

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

Interzeolite Transformation through Cross-Nucleation: A Molecular Mechanism for Seed-Assisted Synthesis

Polymorph selection and efficient crystallization are central goals in zeolite synthesis. Crystalline seeds are used for both purposes. While it has been proposed that zeolite seeds induce interzeolite transformation by dissolving into structural units that promote nucleation of the daughter crystal, the seed’s structural elements do not always match those of the target zeolite. This discrepancy raises the question of how the seed promotes the daughter phase. Here, we present the first molecularly resolved investigation of seed-assisted zeolite synthesis. Using molecular simulations, we reproduce the experimental finding that a parent zeolite can promote the nucleation of a daughter zeolite even when it lacks common composite building units (CBUs) or crystal planes. Modeling the seed-assisted synthesis of an AFI-type zeolite using zeolite CHA, our simulations indicate that stand-alone CBUs from the parent seed do not facilitate daughter crystal formation. However, introducing the intact seed significantly reduces the synthesis time, supporting that seed integrity is key to increased efficiency. This reduction arises from the cross-nucleation of the AFI-type zeolite on the CHA (001) face. We find that parent and daughter zeolites are connected by an interfacial transition layer with an order distinct from that of both zeolites. Simulations reveal that cross-nucleation occurs over a broad range of synthesis conditions. We argue that cross-nucleation would be most favorable for zeolite pairs that share crystalline planes such as those forming intergrowths. In conclusion, our findings suggest that the prevalence of intergrowths with a common lattice plane in zeolite synthesis is likely a kinetic effect of accelerated cross-nucleation.

Crystallization↗
DOE OSTI2023

Changes in Tropical Cyclones Undergoing Extratropical Transition in a Warming Climate: Quasi-Idealized Numerical Experiments of North Atlantic Landfalling Events

The current study extends earlier work that demonstrated future extratropical transition (ET) events will feature greater intensity and heavier precipitation to specifically consider potential changes in the impacts of landfalling ET events in a warming climate. A quasi-idealized modeling framework allows comparison of highly similar present-day and future event simulations; the model initial conditions are based on observational composites, increasing representativeness of the results. The future composite ET event features substantially more impactful weather conditions in coastal areas, with heavier precipitation and greater storm intensity. Specifically, a Category 2 present-day storm attained Category 4 Saffir-Simpson intensity in the future simulation and maintained greater intensity throughout the entire life cycle, although the storm undergoes less reintensification during the post-ET process, a result of reduced baroclinic conversion. These findings suggest increased potential for coastal hazards due to stronger tropical cyclone winds and heavier rainfall, leading to more severe coastal flooding and storm surge.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Supercurrent decay in ballistic magnetic Josephson junctions

We investigate transport properties of ballistic magnetic Josephson junctions and establish that suppression of supercurrent is an intrinsic property of the junctions, even in absence of disorder. By studying the role of ferromagnet thickness, magnetization, and crystal orientation we show how the supercurrent decays exponentially with thickness and identify two mechanisms responsible for the effect: (i) large exchange splitting may gap out minority or majority carriers leading to the suppression of Andreev reflection in the junction, (ii) loss of synchronization between different modes due to the significant dispersion of the quasiparticle velocity with the transverse momentum. Our results for Nb/Ni/Nb junctions are in good agreement with recent experimental studies. Our approach combines density functional theory and the Bogoliubov-de Gennes model and opens a path for material composition optimization in magnetic Josephson junctions and superconducting magnetic spin valves.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Theoretical insights into the surface physics and chemistry of redox-active oxides

Redox active oxides are ubiquitous in materials applications, including catalysis, photovoltaics, self-cleaning glasses, chemical sensors, and electronic components. Their utility derives from their unique ability to access multiple metal charge states within a finite energy window. However, this property also confounds our ability to study reducible oxides, because it leads to structural, compositional, and electronic complexities that elude simplistic models of materials structure and function. Oxygen vacancies play a critical role in shaping the functional properties of such oxides; most notably, they lead to mobile charge imbalances that impact surface processes at significant distances from the originating defect. Atomistic simulations are inherently equipped to illuminate these phenomena at a fundamental level; however, reducible oxides pose great challenges due to the high level of electron correlation needed to correctly describe them. Knowing how defects form, couple, propagate, agglomerate, or repel each other and influence the surface properties of reducible oxides is only now coming into the grasp of modern theory and simulation capabilities. This knowledge is also key to discovering and controlling emergent materials processes at nanometer scale and beyond. The manuscript was written with support of all three authors from U.S. Department of Energy (DOE), Office of Science, Office of Basic Energy Sciences, Division of Chemical Sciences, Geosciences, and Biosciences. Work by RR and VG was performed at Pacific Northwest National Laboratory (PNNL), which is a multi-program laboratory operated by Battelle for DOE under Contract DE AC05 76RL01830. AS was supported under Award DE-SC0007347.

Rousseau, Roger J.↗
DOE OSTI2021

Air separation via two-step solar thermochemical cycles based on SrFeO 3-δ and (Ba,La) 0.15 Sr 0.85 FeO 3-δ perovskite reduction/oxidation reactions to produce N 2 : rate limiting mechanism(s) determination

Two-step solar thermochemical cycles based on reversible reactions of SrFeO 3–δ and (Ba,La) 0.15 Sr 0.85 FeO 3–δ perovskites were considered for air separation. The cycle steps encompass (1) the thermal reduction of SrFeO 3–δ or (Ba,La) 0.15 Sr 0.85 FeO 3–δ perovskites driven by concentrated solar irradiation and (2) oxidation in air to remove O 2 and produce N 2 . Rate limiting mechanisms were examined for both reactions using a combination of isothermal and non-isothermal thermogravimetry for temperature-swings between 673 and 1373 K, heating rates of 10, 20, and 50 K min –1 , and O 2 pressure-swings between 20% O 2 /Ar and 100% Ar at atmospheric pressure. Evolved O 2 and associated lag due to transport behavior were measured with gas chromatography and used with measured sample temperatures to predict equilibrium compositions from a compound energy formalism thermodynamic model. Measured and predicted chemical equilibrium changes in deviation from stoichiometry were compared. Rapid chemical kinetics were observed as the samples equilibrated rapidly for all conditions, indicative that heat and mass transfer were the rate limiting mechanisms. Furthermore, the effects of bulk diffusion (or gas diffusion through the bed or pellet) were examined using pelletized and loose powdered samples and determined to have no discernable impact.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Spatially programmed alignment and actuation in printed liquid crystal elastomers

Liquid crystal elastomers (LCEs) exhibit reversible shape morphing behavior when cycled above their nematic-to-isotropic transition temperature. During extrusion-based 3D printing, LCE inks are subjected to coupled shear and extensional flows that can be harnessed to spatially control the alignment of their nematic director along prescribed print paths. Here, we combine experiment and modeling to elucidate the effects of ink composition, nozzle geometry, and printing parameters on director alignment. From rheological measurements, we quantify the dimensionless Weissenberg number ( Wi ) for the flow field each ink experiences as a function of printing conditions and demonstrate that Wi is a strong predictor of LCE alignment. We find that director alignment in LCE filaments printed through a tapered nozzle varies radially when Wi < 1, while it is uniform when Wi ≫ 1. Based on COMSOL simulations and in operando X-ray measurements, we show that LCE inks printed through nozzles with an internal hyperbolic geometry exhibit a more uniform director alignment for a given Wi compared to those through tapered nozzles. Concomitantly, the stiffness along the print direction and actuation strain of printed LCEs increases substantially under such conditions. By varying Wi during printing through adjusting the flow rate “on the fly”, LCE architectures with uniform composition, yet locally encoded shape morphing transitions can be realized.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Hanford Tank Waste Matrix Impact on Ion Exchange Performance Using Crystalline Silicotitanate

The removal of radiocesium from Hanford tank waste supernate is a critical step in preparing feed for low-activity waste immobilization. This study evaluated cesium ion exchange performance using crystalline silicotitanate (CST) media in a series of tests designed to evaluate the influence of waste matrix variability on capacity and kinetics. Tank waste supernate subsampled from five Hanford double-shell tanks encompassed a range of sodium, hydroxide, nitrate, and nitrite concentrations in order to assess the impact of feed variability on the performance of the ion exchange system. Both equilibrium and dynamic ion exchange tests were conducted to quantify cesium distribution coefficients and breakthrough behavior under prototypic operating conditions. Results indicated that effective cesium capacity varied by up to a factor of five across the matrices tested, with higher sodium concentrations significantly reducing uptake. Kinetic behavior was similarly matrix-dependent, with solution viscosity contributing to a twofold variation in mass-transfer rates. These results demonstrate the strong dependence of CST ion exchange performance on waste composition and must be incorporated into predictive models for future treatment system design and optimization.

Westesen, Amy M.↗
DOE OSTI2026

Heavy dark matter in rapidly evolving massive stars

We study the impact of heavy dark matter (DM) captured in massive stars via scattering(s) with the star constituents. We focus on the first stars and use stellar evolution simulations to track down how DM capture evolves over time from the zero-age main sequence to the late metal-rich stages of stellar evolution. During the early hydrogen-helium-dominated phase, the capture process is well described by scattering with two targets. As a star evolves, metal production leads to the formation of a dense core surrounded by a lighter envelope. The core significantly enhances the capture of ultra-heavy DM; in this case, three distinct nuclear species are required to accurately describe multiple-scattering capture. We use the Eddington inversion method to obtain a realistic DM velocity distribution, better suited when the star is near the center of a halo, than the widely used Maxwell-Boltzmann distribution. We find that heavy DM would be able to thermalize and achieve capture-annihilation equilibrium within a massive star's lifetime for regions of the parameter space not excluded by direct detection. For non-annihilating DM, because of the high amount of targets available for capture and despite massive stars being short-lived, it would even be possible for DM to achieve self-gravitation and collapse to a black hole, which eventually could swallow the star from within before the expected end of the star's life, for non-excluded regions of the parameter space. Our results highlight the dependence of DM capture on the stellar evolutionary stage, composition, and halo location, demonstrating that accurate modeling of massive stars is essential for constraining heavy DM with primordial stellar populations.

dark matter theory↗