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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 991 records · Page 55
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Thick Binder-Free Electrodes for Li-Ion Battery Fabricated Using Templating Approach and Spark Plasma Sintering Reveals High Areal Capacity

The templating approach is a powerful method for preparing porous electrodes with interconnected well-controlled pore sizes and morphologies. The optimization of the pore architecture design facilitates electrolyte penetration and provides a rapid diffusion path for lithium ions, which becomes even more crucial for thick porous electrodes. In this work, NaCl microsize particles are used as a templating agent for the fabrication of 1 mm thick porous LiFePO 4 and Li 4 Ti 5 O 12 composite electrodes using spark plasma sintering technique. These sintered binder-free electrodes are self-supported and present a large porosity (40%) with relatively uniform pores. The electrochemical performances of half and full batteries reveal a remarkable specific areal capacity (20 mA h cm -2 ), which is 4 times higher than those of 100 µm thick electrodes present in conventional tape-casted Li–ion batteries (5 mA h cm -2 ). The 3D morphological study is carried out using full field transmission X-ray microscopy in microcomputed tomography mode to obtain tortuosity values and pore size distributions leading to a strong correlation with their electrochemical properties. These results also demonstrate that the coupling between the salt templating method and the spark plasma sintering technique turns out to be a promising way to fabricate thick electrodes with high energy density.

25 ENERGY STORAGE↗
DOE OSTI2018

Fabrication of Sub-Micrometer-Thick Solid Electrolyte Membranes of β-Li 3 PS 4 via Tiled Assembly of Nanoscale, Plate-Like Building Blocks

Here solid electrolytes represent a critical component in future batteries that provide higher energy and power densities than the current lithium-ion batteries. The potential of using ultrathin films is among the best merits of solid electrolytes for considerably reducing the weight and volume of each battery unit, thereby significantly enhancing the energy density. However, it is challenging to fabricate ultrathin membranes of solid electrolytes using the conventional techniques. Here, a new strategy is reported for fabricating sub-micrometer-thick membranes of β-Li 3 PS 4 solid electrolytes via tiled assembly of shape-controlled, nanoscale building blocks. This strategy relies on facile, low-cost, solution-based chemistry to create membranes with tunable thicknesses. The ultrathin membranes of β-Li 3 PS 4 show desirable ionic conductivity and necessary compatibility with metallic lithium anodes. The results of this study also highlight a viable strategy for creating ultrathin, dense solid electrolytes with high ionic conductivities for the next-generation energy storage and conversion systems.

25 ENERGY STORAGE↗
DOE OSTI2015

Fabrication of co-continuous poly(ε-caprolactone)/polyglycolide blend scaffolds for tissue engineering

The apparent inability of a single biomaterial to meet all the requirements for tissue engineering scaffolds has led to continual research in novel engineered biomaterials. One method to provide new materials and fine-tune their properties is via mixing materials. Here in this study, a biodegradable powder blend of poly(ε-caprolactone) (PCL), polyglycolide (PGA), and poly(ethylene oxide) (PEO) was prepared and three-dimensional interconnected porous PCL/PGA scaffolds were fabricated by combining cryomilling and compression molding/polymer leaching techniques. The resultant porous scaffolds exhibited co-continuous morphologies with ~50% porosity. Mean pore sizes of 24 and 56 μm were achieved by varying milling time. The scaffolds displayed high mechanical properties and water uptake, in addition to a remarkably fast degradation rate. The results demonstrate the potential of this fabrication approach to obtain PCL/PGA blend scaffolds with interconnected porosity. In general, these results provide significant insight into an approach that will lead to the development of new composites and blends in scaffold manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Dual material fused filament fabrication of composite core‐shell structures with improved impact resistance and interfacial adhesion

The mechanical performance of parts produced by fused filament fabrication (FFF) has been limited due to the presence of voids and poor interlayer welding. Recent advancements in FFF have enabled the fabrication of void-free objects with strong interlayer welding through the use of semicrystalline polymer shells such as high-density polyethylene (HDPE) along with a high viscosity core polymer like acrylonitrile-butadiene-styrene (ABS). Furthermore, the zero-shear viscosity (η0) of ABS is three orders of magnitude higher than HDPE making the ABS-HDPE core-shell configuration preferable. ABS holds the shape by preventing bulk flow and part bending while HDPE promotes full surface contact across the layers. Most polymers, however, are immiscible which causes a weak weld line along the core-shell interface. Herein, maleic anhydride (MAH) is grafted to the butadiene segment of the ABS core thereby compatibilizing the interface with HDPE, improving the interfacial adhesion. Attenuated total reflectance-Fourier transform infrared spectroscopy was employed to confirm successful grafting. Using a custom-made die affording the core-shell structure, the ABS-g-MAH is shown to improve the impact resistance by 253% and 16% compared to neat HDPE and ABS specimens, respectively. Additionally, a 10% increase compared to the unmodified ABS-HDPE core-shell configuration is observed.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Hybrid of multi‐dimensional fillers for thermally enhanced polyamide 12 composites fabricated by selective laser sintering

Abstract Selective laser sintering (SLS) is an additive manufacturing technology that can provide a novel strategy to manufacture complex polymer‐based composites with tailored properties. In this study, polyamide 12 (PA12) composite powders based on Al 2 O 3 , boron nitride (BN), and carbon nanotubes (CNTs) were prepared via a two‐step mixing approach. Morphology characterization techniques indicated that the fillers were uniformly dispersed in the PA12 matrix as expected. Under the optimum 3D‐printing parameters, the fabrication of SLS parts with high filler loading could be obtained. With 40 wt% Al 2 O 3 , 8 wt% BN, and 2 wt% CNT hybrid fillers, the thermal conductivity of PA12 composites could reach 1.09 W/mK. It could be attributed to the synergistic effect of multi‐dimensional fillers to form dense and continuous thermal conduction paths. The factors influencing the performance of PA12 composites such as melting and crystallization behaviors, dielectric properties, and mechanical properties were also discussed. The results show that these composites have favorable dielectric and mechanical properties. Overall, the PA12 composites fabricated by SLS technology in this study exhibit excellent thermal management ability.

Yuan, Yue↗
DOE OSTI2025

Toward Standardized Microscale Tensile Testing for Two‐Photon Polymerization‐Fabricated Materials in Liquid

Two-photon polymerization (TPP) enables the fabrication of intricate 3D microstructures with submicron precision, offering significant potential in biomedical applications like tissue engineering. In such applications, to print materials and structures with defined mechanics, it is crucial to understand how TPP printing parameters impact the material properties in a physiologically relevant liquid environment. Herein, an experimental approach utilizing microscale tensile testing (μTT) for the systematic measurement of TPP-fabricated microfibers submerged in liquid as a function of printing parameters is introduced. Using a diurethane dimethacrylate-based resin, the influence of printing parameters on microfiber geometry is first explored, demonstrating cross-sectional areas ranging from 1 to 36 μm 2 . Tensile testing reveals Young's moduli between 0.5 and 1.5 GPa and yield strengths from 10 to 60 MPa. The experimental data show an excellent fit with the Ogden hyperelastic polymer model, which enables a detailed analysis of how variations in writing speed, laser power, and printing path influence the mechanical properties of TPP microfibers. The μTT method is also showcased for evaluating multiple commercial resins and for performing cyclic loading experiments. Collectively, this study builds a foundation toward a standardized microscale tensile testing framework to characterize the mechanical properties of TPP printed structures.

mechanical characterization↗
DOE OSTI2023

A Platform for Atomic Fabrication and In Situ Synthesis in a Scanning Transmission Electron Microscope

Here, the engineering of quantum materials requires the development of tools able to address various synthesis and characterization challenges. These include the establishment and refinement of growth methods, material manipulation, and defect engineering. Atomic-scale modification will be a key enabling factor for engineering quantum materials where desired phenomena are critically determined by atomic structures. Successful use of scanning transmission electron microscopes (STEMs) for atomic scale material manipulation has opened the door for a transformed view of what can be accomplished using electron-beam-based strategies. However, serious obstacles exist on the pathway from possibility to practical reality. One such obstacle is the in situ delivery of atomized material in the STEM to the region of interest for further fabrication processes. Here, progress on this front is presented with a view toward performing synthesis (deposition and growth) processes in a scanning transmission electron microscope in combination with top-down control over the reaction region. An in situ thermal deposition platform is presented, tested, and deposition and growth processes are demonstrated. In particular, it is shown that isolated Sn atoms can be evaporated from a filament and caught on the nearby sample, demonstrating atomized material delivery. This platform is envisioned to facilitate real-time atomic resolution imaging of growth processes and open new pathways toward atomic fabrication.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Nonradiative Recombination Dominates Voltage Losses in Cu(In,Ga)Se 2 Solar Cells Fabricated using Different Methods

Voltage losses reduce the photovoltaic conversion efficiency of thin‐film solar cells and are a primary efficiency limitation in Cu(In,Ga)Se 2 . Herein, voltage loss analysis of Cu(In,Ga)Se 2 solar cells fabricated at three institutions with variation in process, bandgap, absorber structure, postdeposition treatment (PDT), and efficiency is presented. Nonradiative voltage losses due to Shockley–Read–Hall charge carrier recombination dominate and constitute >75% of the total compared to <25% from radiative voltage losses. The radiative voltage loss results from nonideal absorption and carriers in band tails that stem from local composition‐driven potential fluctuations. It is shown that significant bulk lifetime improvements are achieved for all alkali PDT processed absorbers, chiefly associated with reductions in nonradiative recombination. Primary voltage loss contributions (radiative and nonradiative) change little across fabrication processes, but variation in submechanisms (bulk lifetime, net acceptor concentration, and interface recombination) differentiate nonradiative loss pathways in this series of solar cells.

14 SOLAR ENERGY↗
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

Synthesis of CdZnTeSe single crystals for room temperature radiation detector fabrication: mitigation of hole trapping effects using a convolutional neural network

In this article, we report the growth of Cd 0.9 Zn 0.1 Te 0.97 Se 0.03 (CZTS) wide bandgap semiconductor single crystals for room temperature gamma-ray detection using a modified vertical Bridgman method. Charge transport properties measured in the radiation detectors, fabricated from the grown CZTS crystals, indicated signs of hole trapping. Hole traps inhibit high-resolution radiation detection especially for energetic gamma rays. Machine learning (ML) applications are gaining tremendous mpetus in improving device and sensor performance by compensating for limi tations arising from such intrinsic material properties. In this article, we describe a deep convolutional neural network (CNN) that has demonstrated remarkable efficiency in identifying the energy of a gamma photon detected by a CZTS detector. The CNN has been trained using simulated data that resemble output pulses from actual CZTS detectors when exposed to 662-keV gamma photons. The device properties required for the simulation have been derived from radiation detection measurements on a real Cd 0.9 Zn 0.1 Te 0.97 Se 0.03 detector fabricated in our laboratory. The CNN has been trained with detector pulses arising through photoelectric (PE) and Compton scattering (CS) separately. The percentage error in predicting the detected energies, within an extremely small duration of 0.28 ms, was found to be lower than 0.1% for gamma energies above 50 keV and for training datasets con taining PE and CS events separately. The CNN was also validated for a mixed PE and CS dataset to obtain a prediction error of 1%. Additionally, the effect of detector resolution on the efficiency of the CNN was also explored.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Monofilamentary In Situ Fe/MgB{sub 2} Superconducting Wires Fabricated by Pellet-in-Tube Method

Thin monofilamentary Fe/MgB{sub 2} superconducting wires without barriers are investigated by means of electrical transport measurements and surface and structural analysis methods. Small diameter wires are fabricated by pellet-in-tube method (PeIT) to obtain a high uniform initial filling density and heat treated as a function of various sintering temperatures and times. The results are discussed in terms of the grain connectivity, Fe{sub 2}B phase formation, and the relation between wire diameter and sintering conditions. We suggest that PeIT has a crucial importance to achieve homogeneous initial filling density, which leads to the fabrication of uniform long-length MgB{sub 2} wires.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

A Comparative Study on Microstructures, Magnetic Features and Morphologies of Ternary Fe–Co–Ni Alloy Thin Films Electrochemically Fabricated at Different Deposition Potentials

Electrochemically fabricated ternary Fe–Co–Ni alloy thin films with different chemical compositions were obtained at different deposition potentials. An increase in the deposition potential increased the Ni content while it decreased the Co and Fe contents in the film structure. An anomalous co-deposition behaviour was also studied and the anomalous order of co-deposition was found to be Fe–Ni > Co–Ni > Fe–Co irrespective of deposition potential. Structural characterizations confirmed the presence of single face-centred cubic (fcc) phase structure with [111] preferred crystallographic orientation for all films. The size of the crystallites and the texture degree increased with increasing applied deposition potential. Smaller globular particles occurred on the surface structure of the film fabricated at higher deposition potentials compared to those grown at lower deposition potentials. A decrement detected in the coercive field with increasing applied deposition potential was related to the variations occurred in the chemical composition and the particle size.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Influence of the Solvent on the Structure and Morphology of Nanoparticles Fabricated by Laser Ablation of Bulk Magnesium Targets

Ultrafine powders and colloid solutions of nanoparticles are fabricated by nanosecond pulsed laser ablation (a Nd:YAG laser, 1064 nm, 7 ns, 150 mJ, and 20 Hz) of metallic magnesium targets in water and organic solvents of different polarities (ethyl alcohol, ethyl acetate, and n-hexane). The morphology, dimensional characteristics, composition, and structure of the particles are studied by the methods of transmission electron microscopy, x-ray diffraction, and Fourier-transform infrared spectroscopy depending on the solvent used. For the first time it has been demonstrated that nanostructures of magnesium oxyhydroxide Mg{sub 5}O(OH){sub 8} are formed during the ablation in water. It is established that in organic solvents, formation of hexagonal and cubic magnesium oxides is possible. Nanoparticles fabricated by the ablation in less thermostable solvents – ethyl acetate and hexane – contain carbonates.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2017

Microstructures and Microhardness Properties of CMSX-4{sup ®} Additively Fabricated Through Scanning Laser Epitaxy (SLE)

Epitaxial CMSX-4{sup ®} deposition is achieved on CMSX-4{sup ®} substrates through the scanning laser epitaxy (SLE) process. A thorough analysis is performed using various advanced material characterization techniques, namely high-resolution optical microscopy, scanning electron microscopy, energy-dispersive x-ray spectroscopy, x-ray diffraction, and Vickers microhardness measurements, to characterize and compare the quality of the SLE-fabricated CMSX-4{sup ®} deposits to the CMSX-4{sup ®} substrates. The results show that the CMSX-4{sup ®} deposits have smaller primary dendritic arm spacing, finer γ/γ′ size, weaker elemental segregation, and higher microhardness compared to the investment cast CMSX-4{sup ®} substrates. The results presented here demonstrate that CMSX-4{sup ®} is an attractive material for laser-based AM processing and, therefore, can be used in the fabrication of gas turbine hot-section components through AM processing.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Study on Microstructures and Mechanical Properties of Foam Titanium Carbide Ceramics Fabricated by Reaction Sintering Process

Foam titanium carbide (TiC) ceramics with a three-dimensional network structure were fabricated by the reaction sintering process, in which polyurethane foam was taken as the template, and TiO{sub 2} and phenolic resin were used as the reactants. Phase, microstructures and fracture morphologies of foam TiC ceramics were characterized by x-ray diffraction (XRD) and scanning electron microscopy (SEM), respectively. The results show that when the mass ratios of phenolic resin and TiO{sub 2} (F/T) are (0.8-1.2): 1, foam TiC ceramics with pure TiC phase can be formed. As the F/T ratios increase, crystal lattice parameters of fabricated foam TiC ceramics become bigger. When the value of F/T decreases from 1.2 to 0.8, grain size of TiC grows larger and microstructures get denser; meanwhile, the compressive strength increases from 0.10 to 1.05 MPa. Additionally, either raising the sintering temperatures or extending holding time can facilitate the completion of the reaction process and increase the compressive strength.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Fabrication and Properties of Composite Artificial Muscles Based on Nylon and a Shape Memory Alloy

This paper focuses on the design, fabrication and investigation of the mechanical properties of new artificial muscles formed by twisting and annealing. The artificial muscles designed by twisting nylon have become a popular topic in the field of smart materials due to their high mechanical performance with a large deformation and power density. However, the complexity of the heating and cooling system required to control the nylon muscle is a disadvantage, so we have proposed a composite artificial muscle for providing a direct electricity-driven actuation by integrating nylon and a shape memory alloy (SMA). In this paper, the design and fabrication process of these composite artificial muscles are introduced before their mechanical properties, which include the deformation, stiffness, load and response, are investigated. The results show that these composite artificial muscles that integrate nylon and a SMA provide better mechanical properties and yield up to a 44.1% deformation and 3.43 N driving forces. The good performance and direct electro-thermal actuation make these composite muscles ideal for driving robots in a method similar to human muscles.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Fabrication of Ta-Reinforced Cu-Based Bulk Metallic Glass Composites by High-Pressure Torsion

Ex situ Cu{sub 54}Zr{sub 22}Ti{sub 18}Ni{sub 6} matrix bulk metallic glass composites (BMGCs) reinforced with Ta particles (10–30 vol.%) were fabricated by high-pressure torsion (HPT) under applied pressure of 6 GPa for 1–3 turns at temperatures of 25 or 200 °C. The densification, structure, thermal, and mechanical properties of BMGC samples were investigated by Archimedes densitometry, optical microscopy, x-ray diffraction, differential scanning calorimetry, small punch test, and microhardness measurements. Near full-density BMGC disks (relative densities higher than 0.97) are fabricated using HPT, irrespective of the processing strain and temperature. The microhardness of BMGCs is improved by increasing the number of turns, or the processing temperature due to the improvement in the deformation degree of both the amorphous and Ta particles as well as the reduction in the interlayer spacing of Ta particles. Nevertheless, there is an optimal amount of Ta which gives rise to the peak hardness in the BMGC samples, depending on the amount of imposed strain during HPT. The results of small punch test indicate that the addition of Ta to the monolithic BMG and increasing the HPT temperature significantly enhance the fracture load and deflection.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Performance of Nd-Fe-B Magnets Fabricated by Hot Isostatic Pressing and Low-Temperature Sintering

Magnetic properties and microstructure of Nd-Fe-B sintered magnets fabricated by hot isostatic pressing (HIP) were studied. For comparison, magnets were also fabricated by vacuum sintering. The density reached 7.58 g/cm{sup 3} for the magnets HIP-sintered at 1123 K. The density of the magnets vacuum-sintered at 1123 K was much lower, which is of about 6.92 g/cm{sup 3}. While the density of magnets vacuum-sintered at 1318 K was the same as the HIP-sintered magnets, the sintering temperature was significantly decreased to 1123 K. In addition, the average grain size decreased from 9 to 6 μm, which has enhanced coercivity. Therefore, the coercivity increased from 1067.7 to 1238.5 kA/m, which is 16% higher than the vacuum-sintered magnets. HIP is a promising method to obtain high density and high coercivity Nd-Fe-B sintered magnets.

36 MATERIALS SCIENCE↗