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DOE OSTI2025

Redox-Induced Microstructure and Phase Dynamics in Nickel: Insights from In Situ Synchrotron X-ray Diffraction

Using in situ synchrotron X-ray diffraction, we interrogate the microstructural and phase evolution of polycrystalline nickel (Ni) during redox cycling in O 2 , H 2 , and H 2 O environments. Oxidation in O 2 promotes strong (111) texturing in both the NiO overlayer and the underlying Ni substrate. However, this crystallographic alignment is lost following reduction in H 2 and subsequent reoxidation, demonstrating irreversible microstructural changes. H 2 exposure leads to proton dissolution into the Ni lattice, triggering a localized phase transition from face-centered cubic (FCC) to hexagonal close-packed (HCP) Ni in hydrogen-saturated regions. In H 2 O-containing atmospheres, dissociative H 2 O adsorption produces protons that permeate the NiO layer, forming γ-NiOOH within the NiO lattice and HCP Ni beneath the NiO overlayer as protons accumulate. Kinetic analysis via the Johnson-Mehl-Avrami–Kolmogorov model uncovers distinct growth mechanisms: preoxidized Ni surfaces follow one-dimensional (1D) kinetics for NiO, γ-NiOOH, and HCP growth, whereas pristine Ni exhibits three-dimensional (3D) kinetics due to island-like nucleation and growth of NiO. Furthermore, these results highlight the critical interplay between H 2 O dissociation, hydrogen permeation, and redox-driven phase transformations, with practical implications in engineering nickel-based catalysts and hydrogen storage systems through controlled microstructural and phase evolution.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Focused Ion Beam Tomography of Alloy 617 Corroded in Molten Chloride Salt

Materials qualification of reactor structural materials is a critical step in rapid implementation of advanced nuclear reactor technologies, particularly to assess the corrosion performance in these designs. Accelerated qualification of reactor structural materials requires incorporating powerful computational toolsets, such as phase field modelling in the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework, to predict the evolution of structural materials due to corrosion. Accordingly, computational toolsets will require experimental data generated at appropriate length scales to validate accuracy. Focused ion beam (FIB) provides a high degree of control over manipulation of materials for analytical purposes, including capturing data on the evolution in the microstructure and elemental composition of materials at the mesoscale, an appropriate length scale for phase field modelling of intergranular diffusion phenomena using the MOOSE framework. For instance, the FEI Helios G4 UX dual beam plasma FIB microscope at the Irradiated Materials Characterization Laboratory (IMCL) is capable of backscatter diffraction (EBSD) and energy-dispersive x-ray spectroscopy (EDS) documenting the evolution in the microstructure and elemental composition, respectively. The Helios can perform EDS and EBSD three-dimensionally (3D) using tomography, which is then combined using different software packages to visualize 3D volumes correlating elemental composition to microstructural data. The purpose of this investigation was to develop a streamlined characterization and data processing workflow for 3D tomography studies on the FEI Helios G4 plasma FIB. The investigation is segmented into three parts: 1) Optimizing the data collection workflow, 2) identifying appropriate data processing and visualization software (i.e. DREAM.3D, MIPAR, and VGStudioMax), and 3) establishing an infrastructure for public release. The optimization of the data collection workflow is in collaboration with members of the U220 department to setup formal training on the tomography operation of the G4, through ThermoFisher Scientific, and exploring DREAM.3D, MIPAR, and VGStudioMax data processing/visualization software packages. VGStudioMax currently demonstrates the most promise for future use. Optimization of the data collection and processing workflow is still ongoing. A collaboration with INL High Performance Computing (HPC) established an open-source license for expediting the public release of FIB tomography datasets through HPC. FIB tomography data generated by the G4 will provide comprehensive data for validating 3D phase field mesoscale modelling tools within the MOOSE framework for accelerated qualification of reactor structural materials.

Copeland-Johnson, Trishelle↗

DOE OSTI2024

Influence of porous aluminosilicate grain size materials in experimental and modelling Cs + adsorption kinetics and wastewater column process

This paper focuses on the influence of the grain size of a geopolymer based adsorbent on its Cs + adsorption performances both in batch and fixed-bed process. The geopolymer phase was used as a binder to support NaY zeolite particle in a 20 wt% charged porous composite with 160 m 2 .g –1 of porous surface area. These samples were shaped with three grain sizes (50 /100/500 µm) to remove 80–90 mg/g of Cs + in batch and column operations. After their microstructural and porous characterizations, their efficiency and adsorption characteristics were investigated through adsorption isotherms and kinetic in the two processes. While the grain size has no influence on the maximal extraction capacity of the adsorbent, it strongly affects the sorption kinetic. By coupling experimental data and a modelling approach, the complex sorption mechanism was highlighted, suggesting a new insight of the contaminant sorption kinetic. Then, comparison of batch and column adsorption experiments illustrates the detailed explanation of various process parameters for column study. The results show challenges for fixed-bed column utilization by the choice of the appropriate grain size as a compromise between the material sorption kinetic and hydrodynamic considerations. Furthermore, this is of high importance to more accurately optimize the design of column adsorption to assess the transport of Cs+ in multi-porous tailored grain size materials.

36 MATERIALS SCIENCE↗

DOE OSTI2021

The changing nature of hydroclimatic risks across South Africa

We present results from large ensembles of projected twenty-first century changes in seasonal precipitation and near-surface air temperature for the nation of South Africa. These ensembles are a result of combining Monte Carlo projections from a human-Earth system model of intermediate complexity with pattern-scaled responses from climate models of the Coupled Model Intercomparison Project Phase 5 (CMIP5). These future ensemble scenarios consider a range of global actions to abate emissions through the twenty-first century. We evaluate distributions of surface-air temperature and precipitation change over three sub-national regions: western, central, and eastern South Africa. In all regions, we find that without any emissions or climate targets in place, there is a greater than 50% likelihood that mid-century temperatures will increase threefold over the current climate’s two-standard deviation range of variability. However, scenarios that consider more aggressive climate targets all but eliminate the risk of these salient temperature increases. A preponderance of risk toward decreased precipitation (3 to 4 times higher than increased) exists for western and central South Africa. Strong climate targets abate evolving regional hydroclimatic risks. Under a target to limit global climate warming to 1.5 °C by 2100, the risk of precipitation changes within South Africa toward the end of this century (2065–2074) is commensurate to the risk during the 2030s without any global climate target. Thus, these regional hydroclimate risks over South Africa could be delayed by 30 years and, in doing so, provide invaluable lead-time for national efforts to prepare, fortify, and/or adapt.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Thermal management of a high temperature sodium sulphur battery stack

The sodium sulfur battery is an advanced secondary battery with high potential for grid-level storage due to their high energy density, low cost of the reactants, and high open-circuit voltage. However, as the operating temperature of the battery is high (about 300 °C), effective thermal management is required to prevent thermal runaway under high current density operation. Here, to develop efficient thermal management strategies, a detailed, thermo-electrochemical, non-isothermal, distributed dynamic model of a sodium-sulfur battery stack is developed. Models of three thermal management strategies are developed and analyzed in this work: active cooling, passive cooling, and hybrid cooling. The active cooling strategy uses air as the cooling medium whereas, the passive cooling strategy uses a phase change material. In the hybrid cooling strategy, both active and passive cooling strategies are used. Due to the high operating temperature of the sodium sulfur batteries, the rejected heat can be utilized effectively and consequently a high variability in the heat rejection rate may not be acceptable. Performance of these strategies is analyzed under high current density operation by evaluating the variability in the cell temperature during charge/discharge cycles, temperature difference between the cells based on their locations, and variability in the heat rejection rate. The phase change-based hybrid thermal management strategy with an embedded controller maintained the temperature variation within ±/- 2.8 °C. Considering the tradeoff between the capital cost for PCM, fan power requirement, and variability in the heat rejection rate, the optimal quantity of the PCM and the maximum air velocity for the maximum current density of 260 mA/cm 2 (0.55 C-rate) were found be 0.74 g/Wh and 3 m/s, respectively.

25 ENERGY STORAGE↗

DOE OSTI2022

Estimating biofuel contaminant concentration from 4D ERT with mixing models

Here, we present the results of a lab-scaled feasibility study to assess the performance of electrical resistivity tomography for detection, characterization, and monitoring of fuel grade ethanol releases to the subsurface. Further, we attempt to determine the concentration distribution of the ethanol from the electrical resistivity tomography data using mixing-models. Ethanol is a renewable fuel source as well as an oxygenate fuel additive currently used to replace the known carcinogen methyl tert-butyl ether; however, ethanol is preferentially biodegraded and a cosolvent. When introduced to areas previously impacted by nonethanol-based fuels, it will facilitate the persistence of carcinogenic fuel compounds like benzene and ethylbenzene, as well as remobilize them to the ground water. These compounds would otherwise be retained in the soil column undergoing active or passive remediation processes such as soil vapor extraction or natural attenuation. Here, we introduce ethanol to a saturated Ottawa sand in a tank instrumented for four-dimensional geoelectrical measurements. Forward model results suggest pure phase ethanol released into a water saturated silica sand should present a detectable target for electrical resistivity tomography relative to a saturated silica sand only. We observe the introduction of ethanol to the closed hydraulic system and subsequent migration over the duration of the experiment. One-dimensional and three–dimensional temporal data are assessed for the detection, characterization, and monitoring of the ethanol release. Results suggest one-dimensional geoelectrical measurements may be useful for monitoring a release, while three-dimensional geoelectrical field imaging would be useful to characterize, monitor, and design effective remediation approaches for an ethanol release, assuming field conditions do not preclude the application of geoelectrical methods. We then attempt to use predictive mixing models to calculate the distribution of ethanol concentration within the measurement domain. For this study we examine four different models: a nested parallel mixing model, a nested cubic mixing model, the complex refractive index model (CRIM), and the Lichtenecker-Rother (L-R) model. The L-R model, modified to include an electrical formation factor geometry term, provided the best agreement with expected EtOH concentrations.

09 BIOMASS FUELS↗

DOE OSTI2024

Multiphysics Co-Optimization Design and Analysis of Double-Side Cooled Silicon Carbide-Based Power Module: Preprint

With the rapid growth of Electric Vehicles (EVs) and Hybrid Electric Vehicles (HEVs), much more rigorous design targets have been set for automotive power electronics, including high power density, high reliability, and low cost. Novel power module and inverter technologies based on wide bandgap (WEG) semiconductors have been developed to meet these design targets, while providing optimal power semiconductor operating temperature and promising thermomechanical performance. Compared with conventional cooling techniques which are normally applied only on one side of power module, double-side cooling approach is now believed to be the solution to enable high power density and low thermal resistance of WEG semiconductor-based power electronics. In this work, we develop a three-phase power module that is double-sided cooled using dielectric fluid jet impingement. In each phase, four silicon carbide (SiC) power semiconductors are bonded to copper busbars without electrical insulation layers. A finite element analysis (FEA) model is created for thermal and thermomechanical analysis. Based on FEA modeling results, we select particular dimensions for a parametric study to optimize thermal and mechanical performance. Using a multi-objective genetic algorithm (MOGA)-based optimization method, we have minimized the maximum junction temperature and thermal stresses within the power module. The multiphysics co-optimization approach has enabled an efficient design process of power modules with greatly reduced computational cost, as compared to conventional processes that rely on exhaustive numerical simulations and iterations.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Mechanical and Thermal Properties of Low-Density Al 20+x Cr 20-x Mo 20-y Ti 20 V 20+y Alloys

Refractory high-entropy alloys (RHEAs) Al 20+x Cr 20-x Mo 20-y Ti 20 V 20+y ((x, y) = (0, 0), (0, 10), and (10, 15)) were computationally studied to obtain a low density and a better mechanical property. The density functional theory (DFT) method was employed to compute the structural and mechanical properties of the alloys, based on a large unit cell model of randomly distributed elements. Debye–Grüneisen theory was used to study the thermal properties of Al 20+x Cr 20-x Mo 20-y Ti 20 V 20+y . The phase diagram calculation shows that all three RHEAs have a single body-centered cubic (BCC) structure at high temperatures ranging from 1000 K to 2000 K. The RHEA Al 30 Cr 10 Mo 5 Ti 20 V 35 has shown a low density of 5.16 g/cm 3 and a hardness of 5.56 GPa. The studied RHEAs could be potential candidates for high-temperature application materials where high hardness, ductility, and low density are required.

36 MATERIALS SCIENCE↗

NASA NTRS1981

Information and display requirements for aircraft terrain following

The display design procedure for manned vehicle systems, is applied and validated, for a particular scenario. The scenario chosen is that of zero visibility high speed terrain following (V = 466 ft/sec, H = 200 ft) with an A-10 aircraft. The longitudal (linearized) dynamics are considered. The variations in (command path over) terrain pi(t) are modeled as a third order random process. The display design methodology is based on the optimal control model of pilot response, and employs this model in various ways in different phases of the design process. The overall methodology indicates that the design process is intended as a precursor to manned simulation. It provides a rank ordering of candidate displays through a three level process.

Kleinman, D. L.↗

NASA NTRS1985

Modeling and analysis of pinhole occulter experiment: Initial study phase

The feasibility of using a generic simulation, TREETOPS, to simulate the Pinhole/Occulter Facility (P/OF) to be tested on the space shuttle was demonstrated. The baseline control system was used to determine the pointing performance of the P/OF. The task included modeling the structure as a three body problem (shuttle-instrument pointing system- P/OP) including the flexibility of the 32 meter P/OF boom. Modeling of sensors, actuators, and control algorithms was also required. Detailed mathematical models for the structure, sensors, and actuators are presented, as well as the control algorithm and corresponding design procedure. Closed loop performance using this controller and computer listings for the simulator are also given.

Vandervoort, R. J.↗

NASA NTRS1984

Observations of electron beams in the low-latitude boundary layer

ISEE 1 electron spectrometer observations are used to study the electron distribution function in the low latitude boundary layer (LLBL) of the magnetosphere in the sunward direction. The study included 43 examples of well-defined layers. Using three-dimensional, model-independent distribution functions of electrons observed in the boundary layer, beams of field-aligned electrons with typically 100 eV energy maximums, streaming in either one, or both, directions have been identified. The phase densities in the LLBL and at lower altitudes are similar, and the beams observed in the LLBL are identified with those observed at lower altitudes. They form an important component of the plasma electrons in the LLBL, which otherwise resembles a mixture of magnetosheath-like and magnetospheric electrons.

Ogilvie, K. W.↗

NASA NTRS1992

Interplanetary program to optimize simulated trajectories (IPOST). Volume 4: Sample cases

The Interplanetary Program to Optimize Simulated Trajectories (IPOST) is intended to support many analysis phases, from early interplanetary feasibility studies through spacecraft development and operations. The IPOST output provides information for sizing and understanding mission impacts related to propulsion, guidance, communications, sensor/actuators, payload, and other dynamic and geometric environments. IPOST models three degree of freedom trajectory events, such as launch/ascent, orbital coast, propulsive maneuvering (impulsive and finite burn), gravity assist, and atmospheric entry. Trajectory propagation is performed using a choice of Cowell, Encke, Multiconic, Onestep, or Conic methods. The user identifies a desired sequence of trajectory events, and selects which parameters are independent (controls) and dependent (targets), as well as other constraints and the cost function. Targeting and optimization are performed using the Standard NPSOL algorithm. The IPOST structure allows sub-problems within a master optimization problem to aid in the general constrained parameter optimization solution. An alternate optimization method uses implicit simulation and collocation techniques.

Hong, P. E.↗

NASA NTRS1992

Interplanetary Program to Optimize Simulated Trajectories (IPOST). Volume 1: User's guide

IPOST is intended to support many analysis phases, from early interplanetary feasibility studies through spacecraft development and operations. The IPOST output provides information for sizing and understanding mission impacts related to propulsion, guidance, communications, sensor/actuators, payload, and other dynamic and geometric environments. IPOST models three degree of freedom trajectory events, such as launch/ascent, orbital coast, propulsive maneuvering (impulsive and finite burn), gravity assist, and atmospheric entry. Trajectory propagation is performed using a choice of Cowell, Encke, Multiconic, Onestep, or Conic methods. The user identifies a desired sequence fo trajectory events, and selects which parameters are independent (controls) and dependent (targets), as well as other constraints and the coat function. Targeting and optimization is performed using the Stanford NPSOL algorithm. IPOST structure allows sub-problems within a master optimization problem to aid in the general constrained parameter optimization solution. An alternate optimization method uses implicit simulation and collocation techniques.

Hong, P. E.↗

NASA NTRS1992

Three-dimensional numerical simulation of the 20 June 1991, Orlando microburst

On 20 June 1991, NASA's Boeing 737, equipped with in-situ and look-ahead wind-shear detection systems, made direct low-level penetrations (300-350 m AGL) through a microburst during several stages of its evolution. This microburst was located roughly 20 km northeast of Orlando International Airport and was monitored by a Terminal Doppler Weather Radar (TDWR) located about 10 km south of the airport. The first NASA encounter with this microburst (Event 142), at approximately 2041 UTC, was during its intensification phase. At flight level, in-situ measurements indicated a peak 1-km (averaged) F-factor of approximately 0.1. The second NASA encounter (Event 143) occurred at approximately 2046 UTC, about the time of microburst peak intensity. It was during this penetration that a peak 1-km F-factor of approximately 17 was encountered, which was the largest in-situ measurement of the 1991 summer deployment. By the third encounter (Event 144), at approximately 2051 UTC, the microburst had expanded into a macroburst. During this phase of evolution, an in-situ 1-km F-factor of 0.08 was measured. The focus of this paper is to examine this microburst via numerical simulation from an unsteady, three-dimensional meteorological cloud model. The simulated high-resolution data fields of wind, temperature, radar reflectivity factor, and precipitation are closely examined so as to derive information not readily available from 'observations' and to enhance our understanding of the actual event. Characteristics of the simulated microburst evolution are compared with TDWR and in-situ measurements.

Proctor, Fred H.↗

NASA NTRS1992

Interplanetary Program to Optimize Simulated Trajectories (IPOST). Volume 2: Analytic manual

The Interplanetary Program to Optimize Space Trajectories (IPOST) is intended to support many analysis phases, from early interplanetary feasibility studies through spacecraft development and operations. The IPOST output provides information for sizing and understanding mission impacts related to propulsion, guidance, communications, sensor/actuators, payload, and other dynamic and geometric environments. IPOST models three degree of freedom trajectory events, such as launch/ascent, orbital coast, propulsive maneuvering (impulsive and finite burn), gravity assist, and atmospheric entry. Trajectory propagation is performed using a choice of Cowell, Encke, Multiconic, Onestep, or Conic methods. The user identifies a desired sequence of trajectory events, and selects which parameters are independent (controls) and dependent (targets), as well as other constraints and the cost function. Targeting and optimization is performed using the Stanford NPSOL algorithm. IPOST structure allows subproblems within a master optimization problem to aid in the general constrained parameter optimization solution. An alternate optimization method uses implicit simulation and collocation techniques.

Hong, P. E.↗

NASA NTRS1993

Comparison of cross sections from the quasi-classical trajectory method and the j(z)-conserving centrifugal sudden approximation with accurate quantum results for an atom-rigid nonlinear polyatomic collision

We report the results of a series of calculations of state-to-state integral cross sections for collisions between O and nonvibrating H2O in the gas phase on a model nonreactive potential energy surface. The dynamical methods used include converged quantum mechanical scattering calculations, the j(z) conserving centrifugal sudden (j(z)-CCS) approximation, and quasi-classical trajectory (QCT) calculations. We consider three total energies 0.001, 0.002, and 0.005 E(h) and the nine initial states with rotational angular momentum less than or equal to 2 (h/2 pi). The j(z)-CCS approximation gives good results, while the QCT method can be quite unreliable for transitions to specific rotational sublevels. However, the QCT cross sections summed over final sublevels and averaged over initial sublevels are in better agreement with the quantum results.

Schwenke, David W.↗

NASA NTRS1993

Detailed study of oxidation/wear mechanism in lox turbopump bearings

Wear of 440C angular contact ball bearings of the phase 2 high pressure oxygen turbopump (HPOTP) of the space shuttle main engine (SSME) has been studied by means of various advanced nondestructive techniques (NDT) and modeled with reference to all known material, design, and operation variables. Three modes dominating the wear scenario were found to be the adhesive/sheer peeling (ASP), oxidation, and abrasion. Bearing wear was modeled in terms of the three modes. Lacking a comprehensive theory of rolling contact wear to date, each mode is modeled after well-established theories of sliding wear, while sliding velocity and distance are related to microsliding in ball-to-ring contacts. Microsliding, stress, temperature, and other contact variables are evaluated with analytical software packages of SHABERTH(TM)/SINDA(TM) and ADORE(TM). Empirical constants for the models are derived from NIST experiments by applying the models to the NIST wear data. The bearing wear model so established precisely predicts quite well the average ball wear rate for the HPOTP bearings. The wear rate has been statistically determined for the entire population of flight and development bearings based on Rocketdyne records to date. Numerous illustrations are given.

Chase, T. J.↗

NASA NTRS1995

Electrolyte management considerations in modern nickel hydrogen and nickel cadmium cell and battery designs

In the early 1980's the NASA Lewis group addressed the topic of designing nickel hydrogen cells for LEO applications. As published in 1984, the design addressed the topics of gas management, liquid management, plate expansion, and the recombination of oxygen during overcharge. This design effort followed principles set forth in an earlier Lewis paper that addressed the topic of pore size engineering. At about that same time, the beneficial effect on cycle life of lower electrolyte concentrations was verified by Hughes Aircraft as part of a Lewis funded study. A succession of life cycle tests of these concepts have been carried out that essentially verified all of this earlier work. During these past two decades, some of the mysteries involved in the active material of the nickel electrode have been resolved by careful research efforts carried out at several laboratories. At The Aerospace Corporation, Dr. Zimmerman has been developing a sophisticated model of an operating nickel hydrogen cell which will be used to model certain mechanisms that have contributed to premature failures in nickel hydrogen and nickel cadmium cells. During the course of trying to understand and model abnormal nickel hydrogen cell behaviors, we have noted that not enough attention has been paid to the potassium ion content in these cells, and more recently batteries. Several of these phenomenon have been well known in the area of alkaline fuel cells, but only recently have they been examined as they might impact alkaline cell designs. This paper will review three general areas where the potassium ion content can impact the performance and life of nickel hydrogen and nickel cadmium devices, Once these phenomenon are understood conceptually, the impact of potassium content on a potential cell design can be evaluated with the aid of an accurate model of an operating cell or battery. All three of these areas are directly related to the volume tolerance and pore size engineering aspects of the components used in the cell or battery design: (1) The gamma phase uptake of potassium ion can result in a lowering of the electrolyte concentration. This leads to a higher electrolyte resistance as well as electrolyte diffusional limitations on the discharge rate. This phenomenon will also impact the response of the cell to a reconditioning cycle. (2) The impact of low level shunt currents in multi-cell con figurations will result in the movement of potassium ion from one part of the battery to another. This will impact the electrolyte volume/vapor pressure relationships within the cell or battery. (3) The transport of water vapor from place to place under the driving force of a tempetature gradient has already impacted cells for the case where water vapor is condensed on a colder cell wall. The paper will explore the convective and diffusive movement of gases saturated with water vapor from a warmer plate pack to a cooler one - both with and without liquid communication.

Thaller, L. H.↗