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At least 1,009 records · Page 56
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Development of Agile and Cost Effective Routes for Manufacturing Reliable Ceramic Components for SOFC Systems

Additive manufacturing routes were explored and developed to enable the low to medium volume manufacturing of ceramic components with a short lead time, flexibility for iterative design, and without the high CAPEX and tooling costs associated with green machining or injection molding. Agile manufacturing route of gelcasting and 3D printing were selected and work focused on the production of ceramic manifold components utilized in the balance of plant for Saint-Gobain’s all ceramic SOFC stack. This work showed that both gelcasting and a specific version of 3D printing were able to create parts with the proper fidelity and at lower cost than traditional powder processing followed by green machining.

36 MATERIALS SCIENCE↗
NASA NTRS1995

On-line removal of volatile fatty acids from CELSS anaerobic bioreactor via nanofiltration

The CELSS (controlled ecological life support system) resource recovery system, which is a waste processing system, uses aerobic and anaerobic bioreactors to recover plants nutrients and secondary foods from the inedible biomass. The anaerobic degradation of the inedible biomass by means of culture of rumen bacteria,generates organic compounds such as volatile fatty acids (acetic, propionic, butyric, VFA) and ammonia. The presence of VFA in the bioreactor medium at fairly low concentrations decreases the microbial population's metabolic reactions due to end-product inhibition. Technologies to remove VFA continuously from the bioreactor are of high interest. Several candidate technologies were analyzed, such as organic solvent liquid-liquid extraction, adsorption and/or ion exchange, dialysis, electrodialysis, and pressure driven membrane separation processes. The proposed technique for the on-line removal of VFA from the anaerobic bioreactor was a nanofiltration membrane recycle bioreactor. In order to establish the nanofiltration process performance variables before coupling it to the bioreactor, a series of experiments were carried out using a 10,000 MWCO tubular ceramic membrane module. The variables studied were the bioreactor slurry permeation characteristics, such as, the permeate flux, VFA and the nutrient removal rates as a function of applied transmembrane pressure, fluid recirculation velocity, suspended matter concentration, and process operating time. Results indicate that the permeate flux, VFA and nutrients removal rates are directly proportional to the fluid recirculation velocity in the range between 0.6 to 1.0 m/s, applied pressure when these are low than 1.5 bar, and inversely proportional to the total suspended solids concentration in the range between 23,466 to 34,880. At applied pressure higher than 1.5 bar the flux is not more linearly dependent due to concentration polarization and fouling effects over the membrange surface. It was also found that the permeate flux declines rapidly during the first 5 to 8 hours, and then levels off with a diminishing rate of flux decay.

Colon, Guillermo↗
DOE OSTI2019

A review of computational modeling techniques in study and design of shape memory ceramics

Shape memory ceramics are a unique family of shape memory materials with a wide variety of applications, such as ultra-high energy dissipation and high-temperature actuation. Along with significant progress in the experimental study of zirconia-based shape memory ceramics in recent years, computational simulations have exhibited powerful capabilities in revealing nano/microstructure-dependent deformation and failure mechanisms in these materials. In this work, we review the recent progress in understanding the phase transformation behavior in shape memory ceramics, focusing on computational modeling of zirconia-based ceramics. Electronic structure calculations have provided new data on the phase stability and surface properties of shape memory ceramics. At the nanometer length scale, molecular dynamics simulations have captured fundamental information about martensitic phase transformation and the effects of grain boundaries and defects on mechanical response of bi- and polycrystalline zirconia-based ceramics. At the micrometer length scale, advanced phase-field models have shown the ability to predict morphological evolution of microstructures and the corresponding mechanical responses in good agreement with experimental observations. Despite the recent multiscale computational advancements, further developments are required to establish processing-structure-property-performance relations that will lead to reliable and practical strategies for designing zirconia-based (or other) ceramics with improved and sustained shape memory responses. This article critically reviews current computational modeling techniques and provides an outlook for the study and design of the next generation of shape memory ceramics.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Radiation Effects in Innovative Structural Materials

The extreme radiation environments and demanding structural conditions of next-generation fission and proposed fusion reactors will require high performance materials with very high radiation resistance. Although conventional structural materials such as ferritic/ martensitic steels offer several attractive features, there is value in exploring alternative materials systems that may offer unprecedented radiation stability while also offering good thermomechanical properties. As noted elsewhere, options for designing radiation resistance include (a) the traditional approach of introducing a very high sink strength for recombination of radiation-induced vacancies and interstitials (e.g., Ti-modified stainless steels or 'nano-cluster-strengthened ferritic alloys', (b) utilizing materials with immobile vacancies at the operating temperature (e.g., silicon carbide), and (c) utilizing certain classes of materials that inherently exhibit superior resistance to radiation defect retention and accumulation (e.g., ferritic steels). Three relatively new but promising structural materials systems were selected for investigation, based on their favorable unirradiated mechanical properties and potential for good stability under irradiation: High entropy alloys (HEAs), bulk metallic glass (BMG), and MAX phase ceramics. The high configurational entropy in HEAs might alter point defect (solute and radiation defects) diffusion processes, thus potentially enhancing the recombination of radiation-produced damage. Therefore, HEAs offer the potential of a new class of materials for radiation resistance category (c) mentioned previously. A variety of BMGs such as Zr{sub 52.5}Cu{sub 17.9}Ni{sub 14.6}Al{sub 10}Ti{sub 5} offer good mechanical properties including fracture toughness values that may exceed 100 MPa-m{sup 1/2} and near net shape fabrication potential. The lack of crystallinity in BMGs prohibits the formation of conventional Frenkel pair defects under irradiation and therefore offer the possibility of another new material system for radiation resistance category (c). MAX phase ceramics (e.g., Ti{sub 3}SiC{sub 2}, Ti{sub 3}AlC{sub 2}, Ti{sub 2}AlC) have good mechanical properties and contain a nano-laminate structure that could provide a very high point defect sink strength. Due to their refractory nature, many of the MAX phase ceramics may exhibit negligible vacancy mobility up to high temperatures. Therefore, MAX phase ceramics offer the potential to provide radiation resistance in either categories (a) and (b), depending on the operating temperature. For this study, a novel 27%Fe-27%Mn-28%Ni-18%Cr single phase face centered cubic high entropy alloy was synthesized that exhibited good strength and ductility over a wide temperature range. Zr{sub 52.5}Cu{sub 17.9}Ni{sub 14.6}Al{sub 10}Ti{sub 5} (BAM-11) was selected as a prototypic advanced BMG. Several MAX phase ceramics (e.g., Ti{sub 3}SiC{sub 2}, Ti{sub 3}AlC{sub 2}, Ti{sub 2}AlC) that have good unirradiated thermal and mechanical properties were also investigated. The irradiation damage behaviors of these three novel materials systems have been studied after fission neutron at ∼75 deg. C up to 1 dpa and Ni ion irradiation at 25- 700 deg. C up to 30 dpa (lower temperatures and doses for the BMGs). All three sets of materials generally exhibited good radiation stability within certain temperature regimes. For example, the BMG exhibited only minor (<10%) change in strength that appeared to saturate after a dose of ∼1 dpa. A key shortcoming of current BMGs are that they can not be used at temperatures >>300 deg. C due to glass to crystalline transition at elevated temperature. The MAX phase ceramics irradiated at 400-700 deg. C appeared to be in the 'low temperature' regime where vacancies are immobile and therefore the radiation hardening saturated at relatively low doses. The Ti{sub 3}SiC{sub 2} MAX phase exhibited the best overall radiation stability over a wide temperature range. The HEA exhibited fine scale dislocation loop formation, no observable cavity swelling and reduced amounts of Cr depletion compared to traditional austenitic Fe-Cr-Ni alloys after ion irradiation, which suggests suppressed point defect and solute diffusion behavior. (authors)

36 MATERIALS SCIENCE↗
DOE OSTI2015

Quantitative phase separation in multiferroic Bi{sub 0.88}Sm{sub 0.12}FeO{sub 3} ceramics via piezoresponse force microscopy

BiFeO{sub 3} (BFO) is a classical multiferroic material with both ferroelectric and magnetic ordering at room temperature. Doping of this material with rare-earth oxides was found to be an efficient way to enhance the otherwise low piezoelectric response of unmodified BFO ceramics. In this work, we studied two types of bulk Sm-modified BFO ceramics with compositions close to the morphotropic phase boundary (MPB) prepared by different solid-state processing methods. In both samples, coexistence of polar R3c and antipolar P{sub bam} phases was detected by conventional X-ray diffraction (XRD); the non-polar P{sub nma} or P{sub bnm} phase also has potential to be present due to the compositional proximity to the polar-to-non-polar phase boundary. Two approaches to separate the phases based on the piezoresponse force microscopy measurements have been proposed. The obtained fractions of the polar and non-polar/anti-polar phases were close to those determined by quantitative XRD analysis. The results thus reveal a useful method for quantitative determination of the phase composition in multi-phase ceramic systems, including the technologically most important MPB systems.

36 MATERIALS SCIENCE↗
DOE OSTI2017

An In Situ Formed, Dual-Phase Cathode with a Highly Active Catalyst Coating for Protonic Ceramic Fuel Cells

Composite cathodes of solid oxide fuel cells (SOFCs) are normally fabricated by mechanical mixing of electronic- and ionic-conducting phases. Here, a dual-phase SOFC cathode, composed of perovskite PrNi 0.5 Mn 0.5 O 3 (PNM) and exsoluted fluorite PrOx particles, produced in situ through a glycine–nitrate solution combustion process, is reported. When applied as the cathode for a BaZr 0.1 Ce 0.7 Y 0.1 Yb 0.1 O 3 -based protonic ceramic fuel cell, the hybrid cathode displays excellent electrocatalytic activity (area-specific resistance of 0.052 Ω cm 2 at 700 °C) and remarkable long-term stability when operated at a cell voltage of 0.7 V for ≈500 h using H 2 as fuel and ambient air as oxidant. The excellent performance is attributed to the proton-conducting BaPrO 3 -based coating and high-concentration oxygen vacancies of a Ba-doped PNM surface coating, produced by the reaction between the cathode and Ba from the electrolyte (via evaporation or diffusion), as confirmed by detailed X-ray photoelectron spectroscopy, Raman spectroscopy, and density functional theory-based calculations.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Polymer coatings on zirconia microspheres via rotating flow fluid dynamics

Conventional tristructural isotropic (TRISO) coatings for nuclear fuels require multi-step and expensive formation processes; any breakage of the coatings may lead to fission species release. Polymer derived ceramic (PDC) coatings can be a suitable alternative to address these issues. In this study, allylhydridopolycarbosilane (SMP-10) coatings were created on yttria stabilized zirconia (YSZ) microspheres using a Rotating Flow Fluid Dynamics (RFFD) coating method. The effects of curing temperature, rotation speed, and coating cycle/time on the coating were analyzed. Surface functionalization of YSZ microspheres with NaOH resulted in good adhesion between the polymer precursor and the YSZ kernel particles. Spectroscopy analysis revealed complete curing of SMP-10 coated YSZ at 160 °C. Rotation speed and coating time significantly affect the coating characteristics. After 3 cycles at lower rotation speed (50 rpm) for 10 min each, the coating obtained was uniform and homogeneous. In comparison, the coating showed almost 10 times less eccentricity at a high rotation speed of 300 rpm. Compared with the coatings prepared at 300 rpm condition, the coatings have higher sphericity and lower eccentricity at 50 rpm. Overall, this study provides a novel and effective route for fabricating and curing SMP-10 precursor coatings on YSZ microspheres.

Ravi, Nivetha [University of Alabama, Birmingham]↗
DOE OSTI2026

Iodine Capture with Copper-Electroplated Nickel Foams

This work explores the use of Ni0 foam scaffolds for Cu0 coatings for use as sorbents for iodine. The Cu0 electroplating was performed from aqueous copper(II) sulfate (CuSO4) solutions under different conditions to achieve a range of Cu0-layer thicknesses (4.89 ± 1.05 μm–57.32 ± 3.95 μm) with 900 A·m–2 current densities and coating times of 15–180 min. The thickest coatings resulted in Cu0-plated Ni0 foams with >89 mass % Cu0 in the final product. Iodine capture experiments showed very high Cu0 utilizations of 91.9–97.3 mass % at iodine loadings of 839–1774 mg·g–1 through the formation of CuI (marshite; space group F-43m). No evidence was found of iodine reactions taking place with the Ni0 scaffold, so it remained in iodine-loaded Cu-electroplated Ni foams as structural support to provide mechanical rigidity to the foams during the iodine loading process. Hot pressing of these materials can be used to create a CuI/Ni ceramic-metal composite waste form for disposal as demonstrated with spark plasma sintering.

Riley, Brian [Pacific Northwest National Laborator↗
DOE OSTI2021

Lithium cuprate, a multifunctional material for NO selective catalytic reduction by CO with subsequent carbon oxide capture at moderate temperatures

Li 2 CuO 2 was evaluated as a possible catalyst for the NO selective catalytic reduction (NO SCR) by CO. The initial idea was supported by ab initio thermodynamic analysis. This analysis showed that NO SCR was favored by using Li 2 CuO 2 as a catalyst, based on the calculated heat of reaction and Gibbs free energy. The NO SCR reaction was evaluated under dynamic, isothermal and cyclic conditions using different NO : CO ratios (2 : 1, 1 : 1 and 1 : 2). The dynamic and isothermal experiments showed that Li 2 CuO 2 does reduce NO in the presence of CO to reach higher conversions (>90%) between 400 and 450 °C. However, it must be mentioned that the catalytic process was reduced once some of the produced CO 2 was captured on the ceramic. At that point, Li 2 CuO 2 acts as a bifunctional material, catalyzing the NO SCR reaction and capturing some of the produced CO 2 . Moreover, cyclic experiments evidenced high NO reduction. Finally, a different set of experiments showed that this catalytic reduction performed differently if NO and CO were previously fed. Finally, when lithium cuprate is previously carbonated (initial CO feed), the catalytic reaction does not complete. In contrast, when there was a previous nitrate formation (initial NO feed), the reaction reached 100% efficiency.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1980

Development of fire-resistant, low smoke generating, thermally stable end items for commercial aircraft and spacecraft using a basic polyimide resin

A terpolyimide precursor was developed which can be foamed by microwave methods and yields foams possessing the best seating properties. A continuous process, based on spray drying techniques, permits production of polyimide powder precursors in large quantities. The constrained rise foaming process permits fabrication of rigid foam panels with improved mechanical properties and almost unlimited density characteristics. Polyimide foam core rigid panels were produced by this technique with woven fiberglass fabric bonded to each side of the panel in a one step microwave process. The fire resistance of polyimide foams was significantly improved by the addition of ceramic fibers to the powder precursors. Foams produced from these compositions are flexible, possess good acoustical attenuation and meet the minimum burnthrough requirements when impinged by high flux flame sources.

Gagliani, J.↗
NASA NTRS1979

The evaluation of ceramic turbine stators

A ceramic turbine stator evaluation program administered by the NASA Lewis Research Center and supported by the Department of Energy is outlined. The objectives of the program are to evaluate the durability of ceramic stators over a highly dynamic automotive gas turbine duty cycle and to assess the capability of current ceramic design methodology to predict the durability of the stators over the selected duty cycle for times in excess of 200 hours. The program also provides an assessment of the ability of the ceramic industry to fabricate complex geometry monolithic stators by near-net-shape forming processes. A summary of results obtained to date is presented and future plans are discussed.

Fisher, E. A.↗
NASA NTRS1980

Extraterrestrial materials processing and construction

Three different chemical processing schemes were identified for separating lunar soils into the major oxides and elements. Feedstock production for space industry; an HF acid leach process; electrorefining processes for lunar free metal and metal derived from chemical processing of lunar soils; production and use of silanes and spectrally selective materials; glass, ceramics, and electrochemistry workshops; and an econometric model of bootstrapping space industry are discussed.

Criswell, D. R.↗
NASA NTRS1983

Progress in net shape fabrication of alpha SiC turbine components

The development status of component technology in an automotive gas turbine Ceramic Applications in Turbine Engines program is discussed, with attention to such materials and processes having a low cost, net shape fabrication potential as sintered alpha-SiC that has been fashioned by means of injection molding, slip casting, and isostatic pressing. The gas turbine elements produced include a gasifier turbine rotor, a turbine wheel, a connecting duct, a combustor baffle, and a transition duct.

Storm, R. S.↗
NASA NTRS1985

Temperature-Gradient Furnace for Solidification Experiments

Gradients are controllable from zero to 500 degrees C/cm. Typical temperature profile superimposed on partial cross section of furnace. Steepness of gradient varied by adjusting flow of energy to and from different zones of furnace. Specimen placed in ampoule moved inside ceramic tube according to needs of experiment. Furnace provides axial temperature profiles for material processing experiments.

Aldrich, B. R.↗
NASA NTRS1986

NDE of advanced ceramics

Radiographic, ultrasonic, and scanning laser acoustic microscopy (SLAM) techniques were used to characterize silicon nitride and silicon carbide modulus-of-rupture test specimens in various stages of fabrication. Conventional and microfocus X-ray techniques were found capable of detecting minute high-density inclusions in as-received powders, green compacts, and fully densified specimens. Significant density gradients in sintered bars were observed by radiography, ultrasonic velocity, and SLAM. Ultrasonic attenuation was found sensitive to microstructural variations due to grain and void morphology and distribution. SLAM was capable also of detecting voids, inclusions, and cracks in finished test bars. Consideration is given to the potential for applying thermoacoustic microscopy techniques to green and densified ceramics. Some limitations and the detection probability statistics of the aforementioned nondestructive evaluation (NDE) processes are also discussed.

Klima, S. J.↗
NASA NTRS1991

NDE of ceramics and ceramic composites

Although nondestructive evaluation (NDE) techniques for ceramics are fairly well developed, they are difficult to apply in many cases for high probability detection of the minute flaws that can cause failure in monolithic ceramics. Conventional NDE techniques are available for monolithic and fiber reinforced ceramic matrix composites, but more exact quantitative techniques needed are still being investigated and developed. Needs range from flaw detection to below 100 micron levels in monolithic ceramics to global imaging of fiber architecture and matrix densification anomalies in ceramic composites. NDE techniques that will ultimately be applicable to production and quality control of ceramic structures are still emerging from the lab. Needs are different depending on the processing stage, fabrication method, and nature of the finished product. NDE techniques are being developed in concert with materials processing research where they can provide feedback information to processing development and quality improvement. NDE techniques also serve as research tools for materials characterization and for understanding failure processes, e.g., during thermomechanical testing.

Vary, Alex↗