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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 1,009 records · Page 56
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Merging of Thin- and Thick-Film Fabrication Technologies: Toward Soft Stretchable “Island-Bridge” Devices

Soft stretchable thick–thin-film devices are prepared by merging different fabrication technologies with different functional materials. The new “island–bridge” devices rely on screen-printed thick-film island electrodes, connected by thin-film serpentine interconnects. Furthermore, such a hybrid fabrication process enables to realize high-performance stretchable materials toward a new class of soft electronics with new capabilities that cannot be achieved via individual fabrication routes.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Millimeter-Thick Liquid Crystalline Elastomer Actuators Prepared by-Surface-Enforced Alignment

Here, liquid crystalline elastomers (LCE) are thermally cyclable, compliant actuators with compelling mechanical properties. The large and programmable deformation of LCE has led to numerous functional examinations spanning optics, medical devices, and robotics. A well-established method to prepare complex LCE actuators is to utilize surface-enforced photoalignment. Herein, a facile and scalable approach is reported to circumvent the physical limits of surface-enforced alignment (e.g., samples that are 50 µm or less) to amplify the achievable force output in LCE. Applying an approach termed direct layering, the thermomechanical response of LCE elements prepared with +1 disclination patterns in a range of compositions and thicknesses is contrasted. The design and preparation of +1 disclination patterns and arrays is explored to assess the contribution of sample geometry and overlap to deformation and force output. The methodology detailed in this contribution allows for the preparation of elements ≈1 mm in thickness that are capable of actuating large objects. Furthermore, the fabrication of these elements uniquely enables the realization of mechanical instabilities to hasten the actuation rate in response to thermal change and to enable leaping.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Thickness-Dependent Thermal Conductivity and Phonon Mean Free Path Distribution in Single-Crystalline Barium Titanate

Nanosized perovskite ferroelectrics are widely employed in several electromechanical, photonics, and thermoelectric applications. Scaling of ferroelectric materials entails a severe reduction in the lattice (phonon) thermal conductivity, particularly at sub-100 nm length scales. Such thermal conductivity reduction can be accurately predicted using the information of phonon mean free path (MFP) distribution. The current understanding of phonon MFP distribution in perovskite ferroelectrics is still inconclusive despite the critical thermal management implications. Here, high-quality single-crystalline barium titanate (BTO) thin films, a representative perovskite ferroelectric material, are grown at several thicknesses. Using experimental thermal conductivity measurements and first-principles based modeling (including four-phonon scattering), the phonon MFP distribution is determined in BTO. The simulation results agree with the measured thickness-dependent thermal conductivity. The results show that the phonons with sub-100 nm MFP dominate the thermal transport in BTO, and phonons with MFP exceeding 10 nm contribute ≈35% to the total thermal conductivity, in significant contrast to previously published experimental results. The experimentally validated phonon MFP distribution is consistent with the theoretical predictions of other complex crystals with strong anharmonicity. This work paves the way for thermal management in nanostructured and ferroelectric-domain-engineered systems for oxide perovskite-based functional materials.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Ultra-thick, Low-Tortuosity, and Mesoporous Wood Carbon Anode for High-Performance Sodium-Ion Batteries

Sodium-ion batteries (SIBs) have attracted extensive interest in the past few years because of the low cost and abundance of sodium resources and hence the potential for grid scale energy storage. Developing low cost electrode materials, particularly anode materials, is the key for further promoting the application of SIBs. Here, we for the first time report a self-standing porous carbon anode directly from natural wood for SIBs, which processes following advantages: (i) ultra-thick carbon anode with a high areal capacity, for example a capacity of 13.6 mAh cm-2 was delivered when the thickness reached 0.85 mm; (ii) low tortuosity, where numerous inherited aligned channels in the wood carbon provide a rapid ion transport path; (iii) porous nature enables a fast ion transfer between the carbon electrode and the electrolyte; (iv) 100% utilization of the wood carbon that conductive additives, binders, and current-collectors are not needed; v) when coupling a Na3V2(PO4)3 cathode with the wood carbon anode, a high capacity of 80 mAh g-1 was obtained at 0.5 C rate (base on cathode) and excellent cycling stability of 300 cycles was also achieved, which demonstrated the promising performance of earth-abundant wood derived carbon material.

Shen, Fei↗
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 OSTI2018

Fuel film thickness measurements using refractive index matching in a stratified-charge SI engine operated on E30 and alkylate fuels

This paper shows fuel film measurements in a spark-ignited direct injection engine using refractive index matching (RIM). The RIM technique is applied to measure the fuel impingement of a high research octane number gasoline fuel with 30 vol% ethanol content at two intake pressures and coolant temperatures. Measurements are conducted for an alkylate fuel at one operating case, as well. It is shown that the fuel volume on the piston surface increases for lower intake pressure and lower coolant temperature and that the alkylate fuel shows very little spray impingement. The fuel films can be linked to increased soot emissions. A detailed description of the calibration technique is provided and measurement uncertainties are discussed. The dependency of the RIM signal on refractive index changes is measured. The RIM technique provides quantitative film thickness measurements up to 0.9 µm in this engine. Finally, for thicker films, semi-quantitative results of film thickness can be utilized to study the distribution of impinged fuel.

42 ENGINEERING↗
DOE OSTI2018

Fracture Toughness of Thick Boride Layers Estimated by the Cross-Sectioned Scratch Test

New results about the fracture toughness (K{sub c}) of thick boride layers estimated by the cross-sectioned scratch test are presented in this study. The FeB-Fe{sub 2}B layers developed at the surface of borided AISI 1018 and AISI 1045 steels and the Fe{sub 2}B layer formed on the borided AISI 1045 steel exposed to a diffusion annealing process (DAP) were used for this purpose. The cross-sectioned scratch tests were performed with a Vickers diamond stylus drawn across the thick boride layer under a constant load to produce a half-cone-shaped fracture near to the top surface of the borided steels. The height of the half-cone-shaped fracture as a function of the cross-sectioned scratch loads was used to determine the fracture toughness of the FeB and Fe{sub 2}B layers. The results showed a fracture resistance of ∼2.8 MPa√m for the FeB layer formed at the surface of borided AISI 1045 steel. Likewise, the effect of the DAP on the surface of the borided AISI 1045 steel promoted the formation of an exclusively Fe{sub 2}B layer, with an increase in the fracture toughness of the whole boride layer around 5 MPa√m. Finally, the principle of the technique can be used to minimize the influence of the anisotropic properties on the fracture toughness along the depth of boride layers.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Friction Stir Lap Welding 0.8-mm-Thick 2024 Aluminum Alloy with the Assistance of Stationary Shoulder

In this work, 0.8-mm-thick 2024 aluminum alloy was friction stir lap welded with the assistance of a stationary shoulder system. The joint surface formation, microstructure and mechanical properties of the welded joints were studied. The results showed that sound joints without defect could be obtained at a wide parameter range because stationary shoulder increased the material flow during welding. The stationary shoulder decreased the joint roughness from 125.5 to 58.9 µm. A thickness reduction of 4% was achieved at a welding speed of 200 mm/min. The joint fabricated by the stationary shoulder system had superior lap shear properties compared to the joint fabricated using the conventional tool. A high failure load of 7440 N was achieved at welding speed of 200 mm/min. The joint presented tensile fracture mode and the fracture morphology showed typical ductile fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Through-Thickness Strain Gradient in a Hot-Rolled Al-Mg Alloy Obtained by Nanoindentation and Glancing Angle X-Ray Diffraction

Combined nanoindentation and glancing angle X-ray diffraction (GAXD) methods were used to study the mechanical properties of near-surface microstructures (NSMs) of a hot-rolled 5xxx aluminum alloy. Nanoindentations with a sharp indenter were carried out with penetration depth ranging from 250 nm to 4500 nm at the near-surface regions as well as the bulk of the hot-rolled alloy. The primary indentation parameter presented here was the hardness, given that plastic strain obtained from GAXD experiment could be correlated with the hardness value. Analysis of nanoindentation hardness results proved that NSMs of this alloy on average were harder than the bulk due to the presence of different surface features discussed here. The GAXD experiments were performed between a minimum incident angle 0.025°, equivalent to 765 nm penetration depth, and a maximum angle 1°, equivalent to 3000 nm penetration depth. The strain-induced broadening in the diffraction peaks was calculated by the Williamson–Hall technique. Both indentation hardness and glancing angle diffraction results confirmed strain gradient as a function of depth in the NSMs of the alloy. Both techniques also showed that the thickness of the subsurface layer (i.e., several micrometers below the surface) of hot-rolled sample was approximately 2.44 μm at the tested areas. Additionally, reported results provided evidence for the ability to use glancing angle X-ray diffraction as a nondestructive tool for the measurement of subsurface layers' thickness as well as microstrain (non-uniform or plastic strain) as a function of depth.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Effect of Specimen Thickness on Microstructural Changes During Oxidation of the NiCrW Alloy 230 at 950–1050°C

An accurate procedure for predicting oxidation-induced damage and lifetime limits is crucial for the reliable operation of high-temperature metallic components in practical applications. In order to develop a predictive oxidation lifetime model for Ni–Cr alloys, specimens of wrought NiCrW alloy 230 with different thicknesses were cyclically oxidized in air at 950–1050°C for up to 3000 h. After prolonged exposure, two types of carbides as well as a Cr-rich nitride (π-phase) precipitated in the γ-Ni matrix. In the case of oxidation-induced loss of Cr from the alloy resulted in the formation of subscale zones, which were free of the Cr-rich carbide and nitride but also of the Ni-W rich M 6 C. The width of the M 6 C-free zone was smaller than that free of the Cr-rich precipitates. Thermodynamic and diffusion calculations of the observed time- and temperature-dependent Cr depletion processes identified that back diffusion of C occurred which resulted in an increased volume fraction of M 23 C 6 in the specimen core. Moreover, with increasing time and temperature, the amount of π-phase in the specimen core increased. The subscale depletion of the initially present Cr-nitrides and the formation of Cr-nitrides in the specimen center is believed to be related to a mechanism which is qualitatively similar to that described for the Cr carbide enrichment. However, with increasing time and decreasing specimen thickness, N uptake from the atmosphere becomes apparent. As a result, the precipitates present in the specimen center eventually consisted almost exclusively of nitrides.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Impact of Backing Plate and Thermal Boundary Conditions for High-Speed Friction Stir Welding of 25-mm Thick Aluminum Alloy 7175-T79

Here this study demonstrates high-speed (150 mm/min) single pass friction stir butt joining of 25 mm thick aluminum alloy 7175-T79. To understand the impact of quenching and cooling rate on process responses, joint strength, and grain size distributions across the weld thickness, we performed a series of friction stir welding (FSW) trials in air and with a trailing water spray using steel and composite backing plates (BP). Welds made in air and trailing water spray exhibit significantly different hardness distributions across the nugget, heat affected zone (HAZ), and HAZ minimum hardness as evidenced by detailed microhardness mapping. The effect of trailing water spray (TWS) on joint efficiency overshadows the influence of BP composition due to the vastly different contribution to quenching. TWS also resulted in a multifaceted effect on FSW such as lowering processing temperature, increasing X and Z forces while lowering Y force, and narrow heat affecting zone. Finally, digital image correlation (DIC)-based fracture mode analysis and grain size measurements correlate with the hardness distribution.

42 ENGINEERING↗
DOE OSTI2019

New results on asymmetric thick branes

This work deals with the presence and stability of thick brane solutions in the warped five dimensional braneworld scenario with a single extra spatial dimension of infinite extent. We combine two distinct procedures that give rise to new possibilities, allowing that we describe models of asymmetric thick branes, with the asymmetry being controlled by a single real parameter. We illustrate the main results with some distinct models, which show that the method works for both standard and generalized models, and the solutions are gravitationally stable against small perturbations of the metric.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2017

Effect of TiO 2 particle size and layer thickness on mesoscopic perovskite solar cells

Mesoporous TiO 2 (mp-TiO 2 ) layers are commonly used as electron transport layers in perovskite solar cells, which help to extract electrons from the perovskite light-absorbing layer and transport them to the electrodes. We investigated the effects of the layer thickness of mp-TiO 2 and particle size of TiO 2 on photovoltaic properties, in terms of the surface area of the mp-layer and the interfacial areas of the TiO 2 nanoparticles in the mp-layer. Various mp-TiO 2 layers with thicknesses of 150, 250, and 400 nm and particle sizes of 25 nm and 41 nm were prepared to compare the photovoltaic properties of such layer-containing perovskite solar cells. Time-resolved photoluminescence decay and impedance studies showed that interfacial resistance as well as perovskite-to-TiO 2 charge injection are important factors affecting photovoltaic performance. The deterioration of the photovoltaic parameters with increasing TiO 2 /TiO 2 interfacial area also confirms that the interfacial series resistance that arises from these connections should be reduced to enhance the performance of mesoscopic perovskite solar cells.

14 SOLAR ENERGY↗
DOE OSTI2019

A New Computational Method for Membrane Compressibility: Bilayer Mechanical Thickness Revisited

Because lipid bilayers can bend and stretch in ways similar to thin elastic sheets, physical models of bilayer deformation have utilized mechanical constants such as the moduli for bending rigidity (κ C ) and area compressibility (K A ). However, the use of these models to quantify the energetics of membrane deformation associated with protein-membrane interactions, and the membrane response to stress is often hampered by the shortage of experimental data suitable for the estimation of the mechanical constants of various lipid mixtures. Although computational tools such as molecular dynamics simulations can provide alternative means to estimate K A values, current approaches suffer significant technical limitations. Here, in this study, we present a novel, to our knowledge, computational framework that allows for a direct estimation of K A values for individual bilayer leaflets. The theory is based on the concept of elasticity and derives K A from real-space analysis of local thickness fluctuations sampled in molecular dynamics simulations. We explore and validate the model on a large set of single and multicomponent bilayers of different lipid compositions and sizes, simulated at different temperatures. The calculated bilayer compressibility moduli agree with values estimated previously from experiments and those obtained from a standard computational method based on a series of constrained tension simulations. We further validate our framework in a comparison with an existing polymer brush model and confirm the polymer brush model’s predicted linear relationship with proportionality coefficient of 24, using elastic parameters calculated from the simulation trajectories. The robustness of the results that emerge from the method allows us to revisit the origins of the bilayer mechanical (compressible) thickness and in particular its dependence on acyl-chain unsaturation and the presence of cholesterol.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

When physics-informed data analytics outperforms black-box machine learning: A case study in thickness control for additive manufacturing

Aerosol jet printing (AJP) has emerged as a promising noncontact additive manufacturing method for high-resolution printing for a wide range of material systems. A key challenge limiting the broader adoption of AJP in the material science community is the lack of methods to precisely control thickness. Herein, we develop a model-based design of experiment (MBDoE) framework that integrates physics-informed models, nonlinear regression, and information criteria to postulate, select and calibrate the best model to describe and optimize the AJP manufacturing process. Starting with already available data from system commissioning (e.g., prior single variable sensitivity analysis), four candidate physics-informed models are postulated and trained. MBDoE identifies a single additional optimal experiment to validate these predictive models with quantified uncertainties, which are then used to determine the best experimental conditions to control printed film thickness. As a comparative benchmark, the analysis is repeated using the same dataset with nonparametric Gaussian process regression (GPR) model that does not incorporate physical information. Using MBDoE principles, we find that only five experiments are necessary to calibrate the nonlinear physics-informed parametric model, and with said limited data, this model outperforms the black-box machine learning GPR model. This key result underscores an emerging trend in the data science community: incorporating physical information into predictive models often drastically reduces the data requirements. Leveraging MBDoE further increased the data efficiency. By design, the proposed data science framework is general in nature and can be easily extended to other experimental and additive manufacturing systems beyond AJP.

Aerosol jet printing↗
DOE OSTI2022

Influence of carrier trapping on radiation detection properties in $\mathrm{CVD}$ grown 4H-SiC epitaxial layers with varying thickness up to 250 µm

We report low doped n-type 4H-SiC epitaxial layers of thickness 50, 150, and 250 µm grown by hot wall chemical vapor deposition were used to fabricate Ni/4H-SiC Schottky radiation detectors. The epitaxial layers were grown on the (0001) face of highly conductive bulk 4H-SiC substrates 8° offcut towards the $\langle 11\bar{2}1\rangle$ direction. The 50, 150, and 250 µm thick epilayer detectors, under optimized settings, showed energy resolutions of 2.0%, 0.78%, and 0.63%, respectively for 5.48 MeV alpha particles. Deep level transient spectroscopy studies showed that the observed variation in the detector resolution is linked to the defect parameters in the devices. Least-squares fitting of the bias dependence of the charge collection efficiency according to a drift-diffusion model, revealed minority carrier diffusion lengths of 16, 10, and 9.2 µm, respectively, implying that the detectors are not limited by minority carrier trapping. The detector performance was observed to be primarily dependent on the concentration and capture cross-sections of the lifetime killing electron traps Z 1/2 and EH 6/7 .

36 MATERIALS SCIENCE↗
DOE OSTI2023

Non-planar growth of high Al-mole-fraction AlGaN on patterned GaN platforms for mitigating strain-induced cracks beyond the critical layer thickness

Non-planar growth of Al x Ga 1-x N epitaxial layers with an average alloy composition up to Al-mole-fraction of x ~ 0.21 was performed on patterned c-plane GaN on (0001) sapphire substrates with stripe-shaped mesa structures. This approach successfully realized the growth of crack-free AlGaN layers on the top of mesas with layer thicknesses greater than the expected critical layer thickness by relaxing the in-plane stress on the top of the mesa. The effectiveness of the relaxation strongly depends on the width and depth of the stripe mesa. In conclusion, the relaxation of in-plane stress and resultant suppression of cracks in AlGaN layer are qualitatively discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Antiferromagnet thickness dependence and rotatable spins in exchange biased CoO/Fe films

The emergence of exchange bias and coercivity enhancement has been investigated in epitaxial CoO/Fe films with varied antiferromagnet (AF) thicknesses, even smaller than the critical value where the frozen CoO spins are detectable. Vector magnetometry and first-order reversal curve (FORC) measurements reveal different CoO thickness dependence of the exchange bias and coercivity enhancement, including the evolution of magnetization reversal from a high coercivity, low bias phase due to rotatable CoO moments to a high bias, low coercivity phase due to frozen CoO moments. Furthermore, the AF domain state is found to be metastable, which can be reoriented by external and exchange fields prior to the appearance of frozen spins, pointing to a generic origin of the training effect. Monte Carlo simulations show that the AF anisotropy energy barrier and the rotatable spins induced by magnetic field and exchange interaction at the interface are responsible for the observed effects.

36 MATERIALS SCIENCE↗