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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 973 records · Page 54
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Additive-Free Formic Acid Dehydrogenation Using a Pincer- Supported Iron Catalyst

The iron complex ( iPr PN Me P)Fe(H) 2 (CO) ( iPr PN Me P = CH 3 N(CH 2 CH 2 P i Pr 2 ) 2 ), which features a pincer ligand with a tertiary amine, can give up to 100,000 turnovers for additive-free formic acid dehydrogenation (FADH). This is two orders of magnitude higher than any previously reported base metal system. Furthermore, mechanistic studies reveal the catalytic reaction pathway and provide guidance for the development of improved catalytic systems for additive-free FADH.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Intramolecular 1,2 C-H Addition of o -Methyl Groups to Form Unique Ruthenium Pincer Tuck-in Complexes

New RPN H P ligands containing 2,4-xylyl (4mXPN H P) and mesityl (MesPN H P) groups on the phosphorus atoms were synthesized. 4mXPN H P reacts with [(cymene)RuCl 2 ] 2 followed by PMe 3 to produce κ 3 -4mXPN H PRu(PMe 3 )Cl 2 . MesPN H P reacts with [(cymene)RuCl 2 ] 2 to produce monomeric κ 3 -MesPN H PRuCl 2 that reacts with CO forming κ 3 -MesPN H PRu(CO)Cl 2 . Surprisingly, dehydrohalogenation of these complexes results in the activation of ortho methyl groups of the pincer ligands, rather than formation of κ 3 -RPNPRuLCl complexes. This results from transient κ 3 -RPNPRuLCl formation followed by 1,2-addition of an ortho C-H bond across the Ru-amide bond. The transient amide complex of κ 4 -4mXPN H PRu(PMe 3 )Cl was trapped with CO forming κ 3 -4mXPNPRu(PMe 3 )(CO)Cl. In contrast, κ 4 -MesPNHPRu(CO)Cl does not react with ligands to trap the expected amide complex of reverse C-H addition. Instead, CO and PMe 3 displace the chloride ligand forming cationic complexes. In both cases, hemi-lability of the pincer ligand was observed spectroscopically. In conclusion, the new complexes serve as precursors to moderately active catalysts for the acceptorless dehydrogenative coupling of n-butanol.

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

Additive‐Free Aqueous MXene Inks for Thermal Inkjet Printing on Textiles

Abstract Direct printing of functional inks onto flexible substrates allows for scalable fabrication of wearable electronics. However, existing ink formulations for inkjet printing require toxic solvents and additives, which make device fabrication more complex, limit substrate compatibility, and hinder device performance. Even water‐based carbon or metal nanoparticle inks require supplemental surfactants, binders, and cosolvents to produce jettable colloidal suspensions. Here, a general approach is demonstrated for formulating conductive inkjet printable, additive‐free aqueous Ti 3 C 2 T x MXene inks for direct printing on various substrates. The rheological properties of the MXene inks are tuned by controlling the Ti 3 C 2 T x flake size and concentration. Ti 3 C 2 T x ‐based electrical conduits and microsupercapacitors (MSCs) are printed on textile and paper substrates by optimizing the nozzle geometry for high‐resolution inkjet printing. The chemical stability and electrical properties of the printed devices are also studied after storing the devices for six months under ambient conditions. Current collector‐free, textile‐based MSCs show areal capacitance values up to 294 mF cm −2 (2 mV s −1 ) in poly(vinyl alcohol)/sulfuric acid gel electrolyte, surpassing reported printed MXene‐based MSCs and inkjet‐printed MSCs using other 2D nanomaterials. This work is an important step toward increasing the functional capacity of conductive inks and simplifying the fabrication of wearable textile‐based electronics.

Uzun, Simge↗
DOE OSTI2023

Rheology guiding the design and printability of aqueous colloidal composites for additive manufacturing

Vat photopolymerization (VP) and direct ink write (DIW) additive manufacturing (AM) provide complex geometries with precise spatial control employing a vast array of photo-reactive polymeric systems. Although VP is recognized for superior resolution and surface finish, DIW provides versatility for higher viscosity systems. However, each AM platform presents specific rheological requirements that are essential for successful 3D printing. First, viscosity requirements constrain VP polymeric materials to viscosities below 10 Pa s. Thus, this requirement presents a challenging paradox that must be overcome to attain the physical performance of high molecular weight polymers while maintaining suitable viscosities for VP polymeric materials. Second, the necessary rheological complexity that is required for DIW pastes requires additional rheological measurements to ensure desirable thixotropic behavior. Further, this manuscript describes the importance of rheological measurements when designing polymeric latexes for AM. Latexes effectively decouple the dependency of viscosity on molecular weight, thus enabling high molecular weight polymers with low viscosities. Photo-crosslinking of water-soluble monomers and telechelic oligomeric diacrylates in the presence of the latex enables the fabrication of a scaffold, which is restricted to the continuous aqueous phase and effectively surrounds the latex nanoparticles enabling the printing of otherwise inaccessible high molecular weight polymers. Rheological testing, including both steady and oscillatory shear experiments, provides insights into system properties and provides predictability for successful printing. This perspective article aims to provide an understanding of both chemical functionality (photo- and thermal-reactivity) and rheological response and their importance for the successful design and evaluation of VP and DIW processable latex formulations.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Tailoring the γ-γ'-γ" dual superlattice microstructure of INCONEL® 725 by high temperature aging and Nb/Ta additions for superior creep properties

Next-generation energy systems require superior resistance to creep deformation due to the considerably prolonged exposure times at operating stress and temperature. To improve the elevated temperature properties of INCONEL® 725 (IN725), a corrosion resistant alloy, several variants with different Ti/Al ratio and judicious amounts of Nb and Ta were made. Furthermore, a high temperature aging (HTA) heat treatment, designed to promote favorable precipitate phase formation, was explored. These adjustments allowed to tailor the amount and type of precipitate strengthening which led to significant increases in time to failure. The Ti/Al ratio was used to favor the formation of γ' or γ" precipitates. Compact morphology precipitates, consisting of γ' precipitates surrounded by a γ" shell, were formed in alloys with a low Ti/Al ratio. The HTA increased the creep life of various alloy formulations up to a maximum improvement of 371% as compared to the standard aging heat treatment. The Nb and Ta additions had a similar effect on increasing creep life by promoting and stabilizing γ" precipitation. The positive effect of the additions was even more pronounced when coupled with the HTA. A phase stability study with up to 10,000 h exposure at 700°C revealed that the compact morphology helped in slightly reducing coarsening of the γ' precipitates, although the effect on creep was not significant. The findings of this study enable design of dual superlattice alloys through microstructural engineering that yields superior performance and can be applied to a wide range of alloys in the IN718 and derivatives family.

Antonov, Stoichko↗
DOE OSTI2025

Measurement of $t\overline{t}$ production in association with additional b -jets in the eμ final state in proton–proton collisions at $\sqrt{s}$ = 13 TeV with the ATLAS detector

This paper presents measurements of top-antitop quark pair ($t\overline{t}$) production in association with additional b-jets. The analysis utilises 140 fb -1 of proton–proton collision data collected with the ATLAS detector at the Large Hadron Collider at a centre-of-mass energy of 13 TeV. Fiducial cross-sections are extracted in a final state featuring one electron and one muon, with at least three or four b-jets. Results are presented at the particle level for both integrated cross-sections and normalised differential cross-sections, as functions of global event properties, jet kinematics, and b-jet pair properties. Observable quantities characterising b-jets originating from the top quark decay and additional b-jets are also measured at the particle level, after correcting for detector effects. The measured integrated fiducial cross sections are consistent with $t\overline{t}$$b\overline{b}$ predictions from various next-to-leading-order matrix element calculations matched to a parton shower within the uncertainties of the predictions. State of-the-art theoretical predictions are compared with the differential measurements; none of them simultaneously describes all observables. Differences between any two predictions are smaller than the measurement uncertainties for most observables.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

Search for new physics in top quark production with additional leptons in proton-proton collisions at $\sqrt{s} = $ 13 TeV using effective field theory

Events containing one or more top quarks produced with additional prompt leptons are used to search for new physics within the framework of an effective field theory (EFT). The data correspond to an integrated luminosity of 41.5 fb$^{−1}$ of proton-proton collisions at a center-of-mass energy of 13 TeV at the LHC, collected by the CMS experiment in 2017. The selected events are required to have either two leptons with the same charge or more than two leptons; jets, including identified bottom quark jets, are also required, and the selected events are divided into categories based on the multiplicities of these objects. Sixteen dimension-six operators that can affect processes involving top quarks produced with additional charged leptons are considered in this analysis. Constructed to target EFT effects directly, the analysis applies a novel approach in which the observed yields are parameterized in terms of the Wilson coefficients (WCs) of the EFT operators. A simultaneous fit of the 16 WCs to the data is performed and two standard deviation confidence intervals for the WCs are extracted; the standard model expectations for the WC values are within these intervals for all of the WCs probed.[graphic not available: see fulltext]

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2023

Searches for additional Higgs bosons and for vector leptoquarks in $ττ$ final states in proton-proton collisions at $\sqrt{s}$ = 13 TeV

Three searches are presented for signatures of physics beyond the standard model (SM) in $ττ$ final states in proton-proton collisions at the LHC, using a data sample collected with the CMS detector at $\sqrt{s}$ = 13 TeV, corresponding to an integrated luminosity of 138 fb -1 . Upper limits at 95% confidence level (CL) are set on the products of the branching fraction for the decay into $τ$ leptons and the cross sections for the production of a new boson $\phi$, in addition to the H(125) boson, via gluon fusion (gg$\phi$) or in association with b quarks, ranging from $\mathcal{O}$(10 pb) for a mass of 60 GeV to 0.3 fb for a mass of 3.5 TeV each. The data reveal two excesses for gg$\phi$ production with local $p$-values equivalent to about three standard deviations at m $\phi$ = 0.1 and 1.2 TeV. In a search for $t$-channel exchange of a vector leptoquark U 1 , 95% CL upper limits are set on the dimensionless U 1 leptoquark coupling to quarks and $τ$ leptons ranging from 1 for a mass of 1 TeV to 6 for a mass of 5 TeV, depending on the scenario. In the interpretations of the $M^{125}_{h}$ and $M^{125}_{h,EFT}$ minimal supersymmetric SM benchmark scenarios, additional Higgs bosons with masses below 350 GeV are excluded at 95% CL.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Additivity, Haag duality, and non-invertible symmetries

The algebraic approach to quantum field theory focuses on the properties of local algebras, whereas the study of (possibly non-invertible) global symmetries emphasizes global aspects of the theory and spacetime. We study connections between these two perspectives by examining how either of two core algebraic properties — “additivity” or “Haag duality” — is violated in a 1+1D CFT or lattice model restricted to the symmetric sector of a general global symmetry. For the Verlinde symmetry of a bosonic diagonal RCFT, we find that additivity is violated whenever the symmetry algebra contains an invertible element, while Haag duality is violated whenever it contains a non-invertible element. We find similar phenomena for the Kramers-Wannier and Rep(D 8 ) non-invertible symmetries on spin chains.

Discrete Symmetries↗
DOE OSTI2020

Design complexity and performance analysis in additively manufactured heat exchangers

The main objective of this research is to investigate the tradeoffs between design complexity and thermal performance in additively manufactured metallic heat exchangers. Such heat exchangers have become a favorite topic for investigation in various fields ranging from air conditioning to aircraft gas turbine engines. In particular, high manufacturing cost has emerged as the major drawback in broad applications of manifold-microchannel heat exchanger (MMHXs). The possibility of cost-effective manufacturing has generated wide interest in applying additive manufacturing (AM) for fabricating MMHXs. Furthermore, AM technologies will provide an opportunity for enhanced design and superior heat transfer performance. In this study, innovative MMHXs are designed and fabricated through selective laser melting. An experimental setup was designed to measure pressure drop and heat transfer for the developed MMHXs with a wide range of Reynolds numbers. Furthermore, the coefficient of performance was calculated based on the heat flow rate, air pressure drop, and air flow rate. Measurement results demonstrated that in some scenarios adding more internal features, i.e., increasing design complexity, does not necessarily improve the MMHX performance.

10 SYNTHETIC FUELS↗
DOE OSTI2024

Additive friction stir deposition induced stress ripples in aluminum alloy

In additive manufacturing, modification of the viscosity of softened or molten metal plays a significant role in the development of mechanical properties distribution. Similar to soft polymers, molten or softened metal usually exhibits vastly different viscoelastic properties. During scratching tests, viscoelastic polymers undergo spatiotemporal stress development and relaxation, causing stress ripples to form on their surfaces. Here, it is observed that friction stir-based solid-state manufacturing can yield similar stress ripples on softened aluminum alloys due to the linear motion of the deposition tool. Softened aluminum alloys exhibit viscoelastic and viscoplastic responses similar to polymeric material during the solid-state deposition process. In the final product, residual stress ripples appear on the surface of the metal alloy due to periodic residual stress relaxation, leading to oscillatory behavior from the bulk mechanical properties of the material. The orientation of the in-built stress pattern formed in the bulk of the additively manufactured metal alloy underneath the visually evident onion ring-like surface pattern formation is diametrically in the opposite direction. The experimentally observed results are consistent with analytical calculation and numerical simulations in terms of behaviors.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Autonomous direct freeform fabrication strategy for multi-axis additive manufacturing

Multi-axis additive manufacturing (M-AM) enables precise material deposition along both planar and curved layers, eliminating the need for support structures through a continuous material deposition approach. In contrast to conventional 2-dimensional planar layers constrained to a fixed building orientation, the deposition on freeform layers demands the specification of guided curves to determine material deposition directions which are no longer to be fixed to a build direction. There are challenges that arise when fabricating components with multiple “build” directions, necessitating the decomposition of geometries and the specification of guided curves for the resulting volumes. Furthermore, multi-axis systems introduce heightened challenges due to an increased degree of freedom in motion. Consequently, the potential risks of collision between the deposited geometry and the motion platform become a notable concern. This research proposes a freeform layering algorithm to address the challenge of seamless transitions between planar and curved layers in the process planning of M-AM. The algorithm computes 3D “printable” layers by leveraging topological information derived from the geometry to be built and integrates collision-free manufacturability considerations into the computational process. These accumulated volumes serve as a “substrate” and support volumes for subsequent deposition, allowing later layers to be built without the need for additional support material. In conclusion, the proposed method successfully devises a freeform layering approach suitable for intricate models that demand substantial support, thus enabling the fabrication of diverse geometries in a manner previously unachievable.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Fatigue crack growth resistance of a mesoscale composite microstructure Haynes 282 fabricated via electron beam melting additive manufacturing

Materials synthesis via additive manufacturing gives unprecedented control over the solidified microstructure. While a number of studies have demonstrated the ability to produce spatially varying microstructures, little work exists to understand the behavior of such “composite” materials. In this work, we utilized electron beam melting to process Ni-based superalloy Haynes 282 and produce compact tension samples with a spatially varying mesoscale structure. Fatigue crack growth experiments reveal that the crack growth rate is dependent on the degree of microstructural heterogeneity. This work demonstrates that the crack growth resistance can be tailored within a component using electron beam melting additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Experimental Examination of Additively Manufactured Patterns on Structural Nuclear Materials for Digital Image Correlation Strain Measurements

Abstract Background There are a limited number of commercially available sensors for monitoring the deformation of materials in-situ during harsh environment applications, such as those found in the nuclear and aerospace industries. Such sensing devices, including weldable strain gauges, extensometers, and linear variable differential transformers, can be destructive to material surfaces being investigated and typically require relatively large surface areas to attach (> 10 mm in length). Digital image correlation (DIC) is a viable, non-contact alternative to in-situ strain deformation. However, it often requires implementing artificial patterns using splattering techniques, which are difficult to reproduce. Objective Additive manufacturing capabilities offer consistent patterns using programmable fabrication methods. Methods In this work, a variety of small-scale periodic patterns with different geometries were printed directly on structural nuclear materials (i.e., stainless steel and aluminum tensile specimens) using an aerosol jet printer (AJP). Unlike other additive manufacturing techniques, AJP offers the advantage of materials selection. DIC was used to track and correlate strain to alternative measurement methods during cyclic loading, and tensile tests (up to 1100 µɛ) at room temperature. Results The results confirmed AJP has better control of pattern parameters for small fields of view and facilitate the ability of DIC algorithms to adequately process patterns with periodicity. More specifically, the printed 100 μm spaced dot and 150 μm spaced line patterns provided accurate measurements with a maximum error of less than 2% and 4% on aluminum samples when compared to an extensometer and commercially available strain gauges. Conclusion Our results highlight a new pattern fabrication technique that is form factor friendly for digital image correlation in nuclear applications.

Novich, K. A. (ORCID:0000000204466022)↗
DOE OSTI2025

Microstructural, Oxidation, and Mechanical Behavior of NbTi-Based Refractory Alloys with 5 to 10 Pct Co, Cr, and Ni Additions

NbTi-based refractory alloys with additions of Co, Cr, and Ni represent an interesting medium-entropy alloy system with potential for protective oxide film formation, high strength, and ductility. This study investigates the microstructural evolution, oxidation behavior, and mechanical properties of NbTi-based alloys containing 5 to 10 at. pct Co, Cr, and Ni. CALPHAD predictions suggest that this composition range can be heat treated to obtain a predominantly body-centered cubic matrix phase. Mechanical properties, including microhardness, yield strength, maximum strength, and specific strength are evaluated through isothermal compression tests conducted between room temperature and 800 °C. The oxidation kinetics of these alloys are assessed through discontinuous oxidation tests. Parabolic oxidation kinetics were observed for NbTi–10Ni and NbTi–5Co, while linear oxidation kinetics were found for NbTi–10Cr and NbTi–10(CoCrNi). Microstructures and oxide layers are characterized using X-ray diffraction, electron backscatter diffraction, energy-dispersive X-ray spectroscopy, and scanning electron microscopy. All alloys exhibit significant mechanical softening between room temperature and 800 °C, with elastic-perfectly plastic flow observed at 800 °C. The addition of 10 pct Cr to NbTi resulted in two BCC phases up to 1050 °C, conflicting with CALPHAD predictions of a single-phase solid solution at this temperature, and resulting in higher flow stress at 800 °C. NbTi–10(CoCrNi) exhibited the lowest flow stress at 800 °C despite having more ‘cocktail effect’ potential and insufficient molar fractions of Co, Cr, or Ni to form a desirable protective oxide film.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Full-Strength Additive Manufacturing of Pure Aluminum Alloy 7075 Using Liquid Metal Jet Printing

Additive manufacturing (AM) of high-strength aluminum alloys can produce high-performance aerospace and biomedical parts with unique geometries and functions. However, many high-performance alloy systems such as AA 7075 pose challenges during AM due to thermal cycles that cause hot cracking, limiting AM to casting-friendly alloys. Stock AA 7075 alloy poses additional challenges due to the excessive growth of insoluble precipitates during casting and needs to be thermomechanically processed to obtain acceptable mechanical properties. Here, this work uses liquid metal jet printing to produce high-resolution pure AA 7075 parts at high strength (593 MPa) and ductility (10 pct), surpassing the specific strength of any type of steel. The parts are printed by depositing fine droplets on a high-temperature substrate that reduces cooling rates, preventing hot cracking. The results show that fully dense, crack-free parts can only be printed at substrate temperatures of 500 °C with a cooling rate threshold of < 2000 K/s to prevent cracking and < 500 K/s to eliminate porosity. The tensile strength, microhardness, and ductility of the parts matched or were beyond the wrought alloy specifications after heat treatment, possibly due to high solidification rates that produce finer insoluble precipitates. Our results indicate that many challenging high-performance alloy systems can now be 3D printed based on the critical thresholds for cooling rates using any AM method that can satisfy these conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The Addition of Boron to Melt-Spun Fe-6.5%Si Ribbons

Fe-6.5%Si has higher electrical resistivity, lower magnetocrystalline anisotropy, and lower magnetostriction than traditional Fe-3.2%Si silicon steel. The reduced iron losses of Fe-6.5%Si render it a highly favorable candidate for high-speed motors and transformers. However, large-scale production of wide Fe-6.5%Si tape by rapid solidification can be challenging mainly because of its high melting point. In this work, boron is alloyed to Fe-6.5%Si to reduce its melting temperature and interfacial energy to improve the alloy’s processability. Boron additions from 0.01 wt.% to 2.24 wt.% into Fe-6.5%Si and its effect on ribbon thickness, grain size, magnetic, and mechanical properties were studied. Further, minor boron alloying significantly changed the melt pool stability and wetting on the quench wheel and in turn increased the quench rate with minimum impact on the magnetic saturation and ductility. Boron addition of < 0.06 wt.% was also found beneficial to the magnetic property of the alloy by lowering both its hysteresis and eddy current losses.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Image-Based Fracture Surface Defect Characterization Methods for Additively Manufactured Ti-6Al-4V Tested in Fatigue

Abstract Fatigue initiation in additively manufactured samples/parts often occurs at processed-induced defects such as lack-of-fusion (LoF), keyhole, or other morphological/microstructural defects that have unique characteristics and measurable qualities. Attempts at identifying and minimizing such defects have utilized optimized processing conditions along with in situ and ex situ characterization that includes metallography and/or X-ray computed tomography (XCT). This paper highlights the benefits of using fracture surface analyses to detect and quantify defects that may not be detected by metallography/XCT due to sectioning and resolution limits. In addition to using manual quantification of fatigue initiating LoF and keyhole defects on fracture surfaces, image-based machine learning using convolutional neural networks such as U-Net were also used to automate the process. Statistical analyses were used to identify the extreme cases of defects that initiated and accelerated fatigue and to model the distribution of defect size and shape characteristics to distinguish the type of defect. Initial results show agreement between trained machine learning models and ground truth data in defect segmentation, and the distributions of defect characteristics are distinguishable to particular process-induced defect types.

Materials Science↗