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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 955 records · Page 53
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Mechanical Behavior of Additively Manufactured Molybdenum and Fabrication of Microtextured Composites

Refractory metals are a class of high-melting-temperature materials suitable for use in extreme environment applications. Interestingly, during additive manufacturing many pure refractory metals exhibit a switch from (001) to (111) build direction fiber preference with increasing surface energy density. Here we exploit this solidification physics to fabricate material with “mesoscale composite” engineered structures consisting of features with contrasting (001) and (111) build direction microtextures. Separately, elevated temperature tensile testing of EBM fabricated material with a randomized distribution of mixed (001)/(111)-fiber grains is shown to exhibit excellent properties. These results are utilized to build a crystal plasticity model for evaluating the local inelastic response of the composite mesoscale structures. Analysis of printed microstructures and microstructure-scale simulations indicate that both macro-scale and localized material behavior may be tailored. This strategy can be potentially used to synthesize materials with optimized performance for high-temperature applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Microstructure and Elevated Temperature Flexure Testing of Tungsten Produced by Electron Beam Additive Manufacturing

Abstract Due to their superior high-temperature thermomechanical capabilities, sputter erosion durability, and excellent resistance to hydrogen isotopes, tungsten materials have garnered significant interest in fusion nuclear applications. However, low room-temperature ductility and complex machining strategies present significant challenges for traditional fabrication. Electron beam powder bed fusion (EB-PBF) shows promise in manufacturing pure tungsten via high thermal energy input, elevated build temperature, and a tightly controlled high-vacuum environment. This work explores the process, structure, and property relationship of pure tungsten fabricated by EB-PBF, where 99.8% relative density was achieved with reduced cracking by isolating the build substrate and optimizing the print parameter suite. Optical and electron imaging revealed that the microstructure contained equiaxed grains along the build direction, with subgrains present in all inspected grains. Flexural testing at ambient and elevated temperatures demonstrated high ductility at 900°C and flexural strength of 470 MPa at room temperature of additively manufactured tungsten.

Zhang, Haozhi↗
DOE OSTI2024

Enhanced Mechanical Properties and Wear Resistance of FeCrAl Alloys at ~ 300°C and Higher Temperatures

Abstract Worldwide, light water reactors (LWRs) have been using zirconium (Zr)-based alloys for the cladding of the uranium dioxide fuel for more than 6 decades. Zr alloys oxidize rapidly in the presence of water and steam at temperatures > 450°C; therefore, they do not respond well to scenarios of loss of coolant accidents. There is a global effort by nuclear materials technologists to find more robust or stronger cladding materials for LWRs. One option is to use an iron-chromium-aluminum (FeCrAl) alloy since they have excellent resistance to high temperature oxidation and superior mechanical properties at LWR operation temperatures. Results show that (1) FeCrAl alloys have better mechanical properties than Zr alloy and are orders of magnitude more resistant to creep at temperatures higher than LWR normal operation conditions. (2) FeCrAl alloys have better resistance to fretting wear than Zr alloys at the normal operation conditions of LWRs.

Materials Science↗
DOE OSTI2025

Chloride Molten Salt Electrolysis Enables Integrated and Energy-Efficient Process for NdFeB Magnet Fabrication

Rare-earth elements (REEs) have been identified by NATO, the USDOE, and USGS as critical materials, i.e., materials which have significant demand yet pose supply-chain risks. Many of the existing processes for separations, metallization, and final parts production used across the REE supply chain involve energy intensive steps. For example, neodymium (Nd or NdPr) is produced using oxyfluoride electrolysis of Nd 2 O 3 , which requires hydrofluoric acid to produce a key electrolyte component (NdF 3 ) and generates undesired perfluorocarbon (PFC) gases. Such challenges make securing a resilient supply chain for NdFeB permanent magnets in countries like the United States prohibitively difficult. Here, we propose a chloride-based MSE process that circumvents these challenges, delivering high-purity NdPr from a (NdPr)Cl 3 feed from upstream REE separations. This eliminates environmentally-damaging steps of oxalate or carbonate precipitation and calcination, and enables superior production rates due to greater solubility of (NdPr)Cl 3 in chloride melts compared to Nd 2 O 3 . We show that CMSE generates high-purity NdPr (99.4 wt.%) while being energy-efficient (~ 6 kWh/kg-Nd). NdPr from CMSE was used to fabricate a NdFeB magnet with an excellent maximum energy product (> 40 MGOe), comparable to commercially available NdFeB magnets. This establishes CMSE as a leading approach for integrated, energy-efficient NdFeB magnet production.

Materials science↗
DOE OSTI2021

Total Blood Mercury Predicts Methylmercury Exposure in Fish and Shellfish Consumers

Abstract Many studies evaluating methylmercury (MeHg) toxicity rely on whole blood total mercury (THg) measurements to estimate MeHg exposure. However, whole blood THg includes other forms of mercury (Hg), such as inorganic Hg, which have different exposure sources and toxicological effects than MeHg. Therefore, estimating the whole blood MeHg/THg ratio is critical to predicting MeHg exposure and, subsequently, efforts to establish an exposure–response relationship for use in risk assessment. A large, representative dataset (National Health and Nutrition Examination Survey (NHANES) 2011–2016) was used to determine the whole blood MeHg/THg ratio among (a) self-reported fish and shellfish consumers, ≥ 15 years of age (the “full adult” population ( N = 5268 training dataset; N = 2336 test dataset)) and (b) female fish and shellfish consumers, 15–44 years of age (the “women of reproductive age” population ( N = 1285 training dataset; N = 560 test dataset)). Unadjusted and adjusted linear and spline models with direct measurements for both THg and MeHg were evaluated. The mean whole blood MeHg/THg ratio was 0.75 (95% confidence interval (CI): 0.74, 0.75). This ratio was significantly higher among those with higher THg concentrations. All models exhibited excellent fit (adjusted R 2 from 0.957 to 0.982). Performance was slightly improved in spline versus linear models. For the full adult population and women of reproductive age, the unadjusted spline model predicted whole blood MeHg concentrations of 5.65 µg/L and 5.55 µg/L, respectively, when the THg concentration was 5.80 µg/L. These results suggest that whole blood THg is a good predictor of whole blood MeHg among fish and shellfish consumers.

Wells, Ellen M.↗
DOE OSTI2024

ESM data downscaling: a comparison of super-resolution deep learning models

Abstract Climate projections at fine spatial resolutions are required to conduct accurate risk assessment for critical infrastructure and design adaptation planning. Generating these projections using advanced Earth system models (ESM) requires significant computational resources. To address this issue, various statistical downscaling techniques have been introduced to generate fine-resolution data from coarse-resolution simulations. In this study, we evaluate and compare five deep learning-based downscaling techniques, namely, super-resolution convolutional neural networks, fast super-resolution convolutional neural network ESM, efficient sub-pixel convolutional neural network, enhanced deep residual network (EDRN), and super-resolution generative adversarial network (SRGAN). These techniques are applied to a dataset generated by the Energy Exascale Earth System Model (E3SM), focusing on key surface variables such as surface temperature, shortwave heat flux, and longwave heat flux. Models are trained and validated using paired fine-resolution (0.25 $$^{\circ }$$ ∘ ) and coarse-resolution (1 $$^{\circ }$$ ∘ ) monthly data obtained from a 9-year simulation. Next, blind testing is performed using monthly data obtained from two different years outside of the training and validation set. To evaluate the efficiency of each technique, different statistical metrics are used, including mean squared error (MSE), peak signal-to-noise ratio (PSNR), structural similarity index measure (SSIM), and learned perceptual image patch similarity (LPIPS). The results show that EDRN outperforms other algorithms in terms of PSNR, SSIM, and MSE, but struggles to capture fine-scale features in the data. In contrast, SRGAN, a generative model that uses perceptual loss, excels in capturing fine details at boundaries and internal structures, resulting in lower LPIPS than other methods.

Pawar, Nikhil M. (ORCID:0000000211613289)↗
DOE OSTI2020

The practice and economics of hybrid poplar biomass production for biofuels and bioproducts in the Pacific Northwest

Hybrid poplar demonstration-scale farms were managed in Oregon, Washington, Idaho, and California to establish management practices, yields, harvesting methods, and the economics of biomass production. Yield during the 2-year establishment cycle averaged 3.5 dry Mg ha –1 year –1 increasing to 11.6 Mg ha –1 year –1 in the ensuing 3-year coppice cycle. Populus deltoides (Bartram ex Marsh.) × P. maximowiczii (Henry) varieties preformed best in Oregon during the coppice cycle with the best variety producing 18.1 Mg ha –1 year –1 , while P. ×generosa (Henry) varieties maximized yields in Washington at 22.1 Mg ha –1 year –1 . P. ×canadensis (Moench) varieties excelled in Idaho and California with upper yields of 13.6 Mg ha –1 year –1 and 12.9 Mg ha –1 year –1 , respectively. Stands were cut with a single-pass harvester 2 years after planting and a second time after 3 years of coppice growth; material capacity, limited by poor ground conditions, varied between 21.7 to 31.3 green Mg h –1 . Chemical composition averaged 1.87% inorganics, 7.74% extractives, 26.90% lignin, 38.07% glucan, 13.66% xylan, 1.61% galactan, 1.14% arabinan, and 2.76% mannan. Production costs (USD) projected over a 20-year rotation of six coppice cycles were $71.81 Mg –1 in Washington, $89.91 Mg –1 in Oregon, $98.76 Mg–1 in Idaho, and 179.07 Mg–1 in California. Here, land rental, establishment, crop care, harvest, transportation, and land restoration, respectively, accounted for 23%, 5%, 19%, 30%, 17%, and 6% of total feedstock cost. Farms were successfully restored to conditions existing before poplar conversion. In the absence of fertilization, increases in soil pH and decreases in nitrate-nitrogen, zinc, iron, and organic matter were consistently noted but could not be associated with poplar production alone.

09 BIOMASS FUELS↗
DOE OSTI2023

Towards an Integrated Process for CO 2 Capture and Utilization: Cultivation of Scenedesmus acutus Using Gaseous CO 2 and NH 3

Integrating CO 2 scrubbing from flue gas with its utilization in algae cultivation represents a potential means of lowering the cost of CO 2 capture. Towards this goal, this study sought to assess the feasibility of using gaseous a CO 2 /NH 3 stream, derived from CO 2 capture using aqueous ammonia, as a C- and N-source for algae cultivation. Scenedesmus acutus was cultured in 800 mL photobioreactors using gaseous CO 2 /NH 3 in mole ratios varying from 7 to 18. Excellent growth of Scenedesmus acutus was observed, the average growth rate for CO 2 /NH 3 = 10 of 0.171 ± 0.015 g/L·day exceeding that obtained using 1% CO 2 /N 2 and urea as the N-source (0.099 ± 0.28 g/L·day). Under optimal growth conditions (CO 2 /NH 3 mole ratio of 10), CO 2 utilization ranged from 57% to 72%, while the NH 3 utilization was >90%. The CO 2 /NH 3 feed rate was also found to exert a significant effect on algae productivity, excessive feed rates leading to accumulation of NH 3 in the culture at concentrations that were toxic to the algae. Consequently, to avoid the toxic effects of high NH 3 concentrations (>2.0 mM), it proved necessary to balance the NH 3 supply with the algae growth rate so that excessive NH 3 accumulation was prevented. This indicates that for practical applications, a CO 2 /NH 3 feed control strategy would be required that takes into account the ammonium ion concentration in solution and the pH so as to avoid significant concentrations of free NH 3 . Furthermore, analysis of the harvested biomass revealed a high protein (≥ 47 wt%) and a low ash content (< 3.6 wt%), suggesting it would be well suited for use as animal feed or as a feedstock for the production of bioplastics.

03 NATURAL GAS↗
DOE OSTI2021

Wafer-scale quasi-layered tungstate-doped polypyrrole film with high volumetric capacitance

Layered materials are particularly attractive for supercapacitors because of their unique physical, electrical and chemical properties. In this work, we demonstrate a facile and scalable electrochemical deposition method for wafer-scale synthesis of quasi-layered tungstate-doped polypyrrole films (named TALPy) with controllable thickness and size. The as-prepared TALPy film exhibits a high gravimetric density and excellent volumetric capacitance, exceeding many high-performing carbon- and polymer-based film electrodes. Based on combined results of ex-situ X-ray diffraction (XRD), Raman and X-ray photoelectron spectroscopy (XPS), it is determined that TALPy stores charge through an ion intercalation process accompanied by change in oxidation states of polypyrrole backbone, which is referred as intercalation pseudocapacitance. All these results suggest the great promise of electrochemical deposition as a scalable and controllable bottom-up approach for synthesizing quasi-layered conductive organic-inorganic hybrid films for electrochemical energy storage applications with high volumetric performance.

36 MATERIALS SCIENCE↗
DOE OSTI2022

High temperature ceramic thermal insulation material

Flexible and lightweight thermal insulation materials with hierarchical microstructures are ubiquitous in thermal management and protection systems. Ceramic aerogels promise high-temperature thermal insulation but lack mechanical robustness, while the fibrous materials with excellent mechanical elasticity display modest thermal insulation. Here we describe flexible hierarchical superhydrophobic ceramic insulation nanocomposites through the densified architectured hierarchical nanostructures, radiative insulation coating, and interfacial cross-linking among composites. The lightweight flexible ceramic nanocomposites exhibit a density of 0.13 g/cm 3 , high-temperature fire resistance with thermal conductivity of 0.024 W/(m·K), and super-hydrophobicity with the water contact angle of 152°. The mechanical robustness and high-temperature thermal insulation of ceramic nanocomposites, together with its soundproof performance, shed light on the low-cost flexible insulation materials manufacturing with scalability for high-temperature thermal insulation applications under high mechanical loading conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2024

CMPLE: Correlation Modeling to Decode Photosynthesis Using the Minorize–Maximize Algorithm

In plant genomic experiments, correlations among various biological traits (phenotypes) give new insights into how genetic diversity may have tuned biological processes to enhance fitness under diverse conditions. Consequently, knowing how the correlations are affected by genetic (G) and environmental (E) factors helps develop climate-resilient plants. However, the current literature lacks any method for assessing the effect of predictors on pairwise correlations among multiple phenotypes together with easily interpretable model parameters. To address this need, we propose to model pairwise correlations directly in terms of G and E and develop a computationally efficient inference procedure. Two major novelties in our methodology are (1) the use of a composite pairwise likelihood method to avoid the positive definiteness restriction on the correlation matrix and (2) the use of a novel Minorize–Maximize (MM) algorithm for the efficient estimation of a large number of parameters. The proposed method shows excellent numerical performance on synthetic datasets. Here, the analysis of the motivating data on cowpea reveals that the rates of solar energy storage by photosynthesis (the aggregate trait) are differentially affected by different genetic loci through two distinct processes: “photoinhibition” which results from photodamage caused by excess light, and “photoprotection” which protects plants from photodamage but also results in energy loss.

Correlation modeling↗
DOE OSTI2021

On the Order Parameter of the Continuous Phase Transition in the Classical and Quantum Mechanical Limits

The mean field theory is revisited in the classical and quantum mechanical limits. Taking into account the boundary conditions at the phase transition and the third law of the thermodynamics the physical properties of the ordered and disordered phases were reported. The equation for the order parameter predicts the occurrence of a saturation of Ψ 2 = 1 near Θ S , the temperature below the quantum mechanical ground state is reached. The theoretical predictions are also compared with high resolution thermal expansion data of SrTiO 3 monocrystalline samples and other some previous results. An excellent agreement has been found suggesting a universal behavior of the theoretical model to describe continuous structural phase transitions.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Microstructural Development in Inconel 718 Nickel-Based Superalloy Additively Manufactured by Laser Powder Bed Fusion

Excellent weldability and high temperature stability make Inconel 718 (IN718) one of the most popular alloys to be produced by additive manufacturing. Here in this study, we investigated the effects of laser powder bed fusion (LPBF) parameters on the microstructure and relative density of IN718. The samples were fabricated with independently varied laser power (125 - 350W), laser scan speed (200 - 2200 mm/s), and laser scan rotation (0° - 90°). Archimedes’ method, optical microscopy, and scanning electron microscopy were employed to assess the influence of LPBF parameters on the relative density and microstructure. Optimal processing windows were identified for a wide range of processing parameters and relative density greater than 99.5% was achieved using volumetric energy density between 50 and 100 J/mm3. Microstructural features including melt pool geometry, lack of fusion defect, keyhole porosity, and sub-grain cellular microstructure were examined and quantified to correlate to LPBF parameters. A simple empirical model was postulated to relate relative sample density and LPBF volumetric energy density. Melt pool dimensions were quantitatively measured and compared to estimations based on Rosenthal solution, which yielded a good agreement with the width, but underestimated the depth, particularly at high energy input, due to lack of consideration for keyhole mode. In addition, the sub-grain cellular-dendritic microstructure in the as-built samples was observed to decrease with increasing laser scan speed. Quantification of the sub-micron cellular-dendritic microstructure yielded estimated cooling rate in the order of 10 5 – 10 7 K/s.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Cs 3 Bi 2 I 9 -hydroxyapatite composite waste forms for cesium and iodine immobilization

Perovskite-based ceramic composites were developed as potential waste form materials for immobilizing cesium (Cs) and iodine (I) with high waste loadings and chemical durability. The perovskite Cs 3 Bi 2 I 9 has high Cs (22 wt%) and I (58 wt%) content, and thus can be used as a potential host phase to immobilize these critical radionuclides. In this work, the perovskite Cs 3 Bi 2 I 9 phase was synthesized by a cost effective solution-based approach, and was embedded into a highly durable hydroxyapatite matrix by spark plasma sintering to form dense ceramic composite waste forms. The chemical durabilities of the monolithic Cs 3 Bi 2 I 9 and Cs 3 Bi 2 I 9 -hydroxyapatite composite pellets were investigated by static and semi-dynamic leaching tests, respectively. Cs and I are incongruently released from the matrix for both pure Cs 3 Bi 2 I 9 and composite structures. The normalized Cs release rate is faster than that of I, which can be explained by the difference in the strengths between Cs-I and Bi-I bonds as well as the formation of insoluble micrometer-sized BiOI precipitates. The activation energies of elemental releases based on dissolution and diffusion-controlled mechanisms are determined with significantly higher energy barriers for dissolution from the composite versus that of the monolithic Cs 3 Bi 2 I 9 . The ceramic-based composite waste forms exhibit excellent chemical durabilities and waste loadings, commensurate with the state-of-the-art glass-bonded perovskite composites for I and Cs immobilization.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

In Situ Scattering Studies of Crystallization Kinetics in a Phase-Separated Zr–Cu–Fe–Al Bulk Metallic Glass

In this work, thermal stability and the crystallization kinetics of a phase-separated Zr-Cu-Fe-Al bulk metallic glass were investigated using in situ high-energy synchrotron X-ray and neutron diffraction, as well as small-angle synchrotron X-ray scattering. It was revealed that this glass with excellent glass-forming ability possesses a two-step crystallization behavior. The crystalline products and their evolution sequence are more complicated than a homogeneous Zr-Cu-Al glass with average glass-forming ability. The experimental results indicate that a finely distributed nanometer-sized cubic Zr 2 Cu phase forms first and then transforms to a tetragonal Zr 2 Cu phase, while the matrix transforms to an orthorhombic Zr3Fe phase. The strength of the Zr-Cu-Fe-Al composite containing cubic Zr 2 Cu phase and glass matrix increases, and the plasticity also improves compared to the as-cast Zr-Cu-Fe-Al bulk metallic glass. Our results suggest that the formation of multiple and complex crystalline products would be the characteristics of the Zr-Cu-Fe-Al glass with better glass-forming ability. Our study may shed light on the synthesis of bulk-sized glass-nanocrystals composites of high strength and good plasticity.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Boosting High-Rate Zinc-Storage Performance by the Rational Design of Mn 2 O 3 Nanoporous Architecture Cathode

Manganese oxides are regarded as one of the most promising cathode materials in rechargeable aqueous Zn-ion batteries (ZIBs) because of the low price and high security. However, the practical application of Mn 2 O 3 in ZIBs is still plagued by the low specific capacity and poor rate capability. Herein, highly crystalline Mn 2 O 3 materials with interconnected mesostructures and controllable pore sizes are obtained via a ligand-assisted self-assembly process and used as high-performance electrode materials for reversible aqueous ZIBs. The coordination degree between Mn 2+ and citric acid ligand plays a crucial role in the formation of the mesostructure, and the pore sizes can be easily tuned from 3.2 to 7.3 nm. Ascribed to the unique feature of nanoporous architectures, excellent zinc-storage performance can be achieved in ZIBs during charge/discharge processes. The Mn 2 O 3 electrode exhibits high reversible capacity (233 mAh g -1 at 0.3 A g -1 ), superior rate capability (162 mAh g -1 retains at 3.08 A g -1 ) and remarkable cycling durability over 3000 cycles at a high current rate of 3.08 A g -1 . Moreover, the corresponding electrode reaction mechanism is studied in depth according to a series of analytical methods. These results suggest that rational design of the nanoporous architecture for electrode materials can effectively improve the battery performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Iron-Imprinted Single-Atomic Site Catalyst-Based Nanoprobe for Detection of Hydrogen Peroxide in Living Cells

Fe-based single-atomic site catalysts (SASCs), with the natural metalloproteases-like active site structure, have attracted widespread attention in biocatalysis and biosensing. Precisely, controlling the isolated single-atom Fe-N-C active site structure is crucial to improve the SASCs’ performance. In this work, we use a facile ion-imprinting method (IIM) to synthesize isolated Fe-N-C single-atomic site catalysts (IIM-Fe-SASC). With this method, the ion-imprinting process can precisely control ion at the atomic level and form numerous well-defined single-atomic Fe-N-C sites. The IIM-Fe-SASC shows better peroxidase-like activities than that of non-imprinted references. Due to its excellent properties, IIM-Fe-SASC is an ideal nanoprobe used in the colorimetric biosensing of hydrogen peroxide (H 2 O 2 ). Using IIM-Fe-SASC as the nanoprobe, in situ detection of H 2 O 2 generated from MDA-MB-231 cells has been successfully demonstrated with satisfactory sensitivity and specificity. This work opens a novel and easy route in designing advanced SASC and provides a sensitive tool for intracellular H 2 O 2 detection.

77 NANOSCIENCE AND NANOTECHNOLOGY↗