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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 1,027 records · Page 57
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Graphitized hollow carbon spheres and yolk-structured carbon spheres fabricated by metal-catalyst-free chemical vapor deposition

Hard-sphere-templating method has been widely used to synthesize hollow carbon spheres (HCSs), in which the spheres were firstly coated with a carbon precursor, followed by carbonization and core removal. The obtained HCSs are generally amorphous or weakly graphitized (with the help of graphitization catalysts). In this work, we report on the fabrication of graphitized HCSs and yolk–shell Au@HCS nanostructures using a modified templating method, in which smooth, uniform graphene layers were grown on SiO 2 spheres or Au@SiO 2 nanoparticles via metal-catalyst-free chemical vapor deposition (CVD) of methane. Furthermore, our work not only provides a new method to fabricate high-quality, graphitized HCSs but also demonstrates a reliable approach to grow quality graphene on oxide surfaces using CVD without the presence of metal catalysts.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Room-temperature fabrication of garnet-type solid-electrolyte: Optimizing particle size for high ionic conductivity

Dense and uniform Li 6.25 Al 0.25 La 3 Zr 2 O 12 (Al-doped LLZO) solid-electrolyte film of ~24 µm thickness is successfully fabricated by room temperature aerosol deposition (AD) method. The process optimization study revealed that careful control of particle size and morphology is one of critical determinants in the development of a compact AD membrane. Notably, our method facilitated an impressive ionic conductivity of approximately 10 –5 S cm –1 , bypassing the necessity for post-annealing processes, a milestone in itself. However, it is hypothesized that the attained conductivity is somewhat restrained by factors such as smaller grain size and potential surface degradation due to moisture exposure during fabrication, indicating avenues for further research. Looking forward, detailed investigations into the film's microstructure and its impact on transport properties will be a focal point, alongside potential enhancements through post-annealing and particle coating strategies. Finally, this research hints at a promising trajectory for the development of high-efficiency solid-state battery technology.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Scalable fabrication of a tough and recyclable spore-bearing biocomposite thermoplastic polyurethane

Thermoplastic polyurethanes (TPUs) are a class of versatile thermoplastic elastomers, but most of their products lack a proper recycling strategy or have no end-of-life solutions. To pursue a sustainable end-of-life solution for TPU-based products, self-disintegrating biocomposite TPUs have recently been developed by embedding spores of TPU-degrading bacteria into TPUs via melt extrusion. Herein, we improve upon spore-bearing biocomposites and demonstrate industrially relevant manufacturing conditions for fabricating biocomposite TPUs. To minimize the coloration of biocomposite TPUs, spore production was modified. The innate brown color of the resulting materials was diminished by reducing FeSO 4 in sporulation media, generating white spores without compromising spore productivity, viability, morphology or heat-shock tolerance. Biocomposite TPUs containing white spores displayed a 45 % increase in toughness compared to TPUs without spores, while retaining ∼ 90 % spore viability post processing. Furthermore, biocomposite TPU fabrication was demonstrated using a scalable continuous extruder followed by injection molding. Biocomposite TPUs generated by these industry-relevant processes exhibited comparable toughness improvement and spore viability to biocomposite TPU prepared using a lab scale microcompounder, while enhancing productivity by 30-fold. Finally, spore addition significantly improved the recyclability of biocomposite TPUs, enabling 80 % toughness retention after 5 rounds of iterative melt processing. Additionally, no negative effect on the lifespan of the generated TPUs was observed over 1 year of storage. Overall, this study confirms that spore-bearing biocomposite TPUs are promising for practical applications, offering an accessible method to enhance toughness and sustainability of commercial TPUs through the incorporation of spore-based living fillers.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Scaled-up fabrication of durable and porous adsorbent-coated minichannels on aluminum for CO 2 separation

A method was developed to fabricate zeolite 13X adsorbent-coated minichannels on aluminum for CO₂ adsorption applications in this study. It emphasizes the innovative use of aluminum as a substrate, which offers airtight assembly, paving the way for highly efficient adsorption systems. An optimized coating process was developed using a slurry of Zeolite 13X, yeast, sugar, and xanthan gum, resulting in durable and highly porous layers that enhance CO₂ capture performance. A PETG peeler was designed to remove the top layer of the yeast-engineered adsorbent coatings, revealing a super porous and foamy structure. The teeth of the peeler were designed and fabricated for high repeatability and rapid prototyping. Breakthrough experiments were conducted on the scaled-up adsorbent bed using gas mixtures of 80% CO₂, 20% N₂, and 20% CO₂, 80% N₂ to represent different industrial scenarios. The performance of the bed was evaluated at flow rates of 160 and 190 cm³ min -1 using a Raman Laser Gas Analyzer (RLGA), demonstrating stable adsorption without degradation across multiple cycles. Computational modeling of integral transport phenomena under the chosen experimental conditions was pursued using gPROMS ProcessBuilder™, and the modeling results were compared with those from the tests for adsorption time, which resulted in an error margin of 2% to 9% for the breakthrough time, confirming the easy reproducibility of the design through modeling. This research advances CO₂ capture technologies by providing an effective and scalable solution for producing aluminum-based adsorbent coated beds, supporting industrial carbon capture efforts.

CO2 capture↗
DOE OSTI2024

High plasticity in refractory composite fabrication by ultrasonic additive manufacturing

Refractory metal composites are desirable for use in extreme environments that require materials with high specific strengths and resilience to external environments such as that found in nuclear and aerospace. However, due to the high melting temperature of refractories, liquid state joining processes such as welding remains difficult. Ultrasonic additive manufacturing (UAM) provides a potential route for processing refractory composites because it is a solid-state (i.e., no-melting) process and allows for intermittent machining operations to be performed between welds. Further, to demonstrate refractory composite fabrication, this study utilized UAM to machine a cavity to locate and sequester a Mo foil in a Zircaloy-4 (Zry-4) baseplate and additively build over the top with Zry-4 foils, thereby embedding the Mo in Zry-4 matrix. Significant deformation of the Zry-4 microstructure was observed: this deformation caused adiabatic heating and subsequent dynamic recrystallization through the transformation from α→β and then back to α as the material cooled. Flexural testing of the Zr–Mo composite revealed no delamination or failure, but the strength was not as expected, falling lower than a cold-worked Zry-4 sample. Finite element analysis supported that some bonding must have existed between the Zry-4 and Mo. There was indeed an interdiffusion zone at the Zry-4 foil–Mo foil interface, observing a metastable body-centered cubic β-Zr lathe. It was determined that sufficient strain energy was present to encourage the nucleation of the β-Zr grain along α-Zr grains. Future work is warranted to investigate UAM for refractory composite fabrication.

36 MATERIALS SCIENCE↗
DOE OSTI2018

An ant-nest-like cathode substrate for lithium-sulfur batteries with practical cell fabrication parameters

We report that electrochemical performances of lithium-sulfur batteries have received much progress in recent years. However, their practical deployment encounters challenges with respect to optimizing the cell-fabrication parameters (e.g., amounts of the active material and electrolyte). We present here an “ant-nest-like” cathode substrate with unique architecture to synchronously attain high electrochemical performance and necessary cell-fabrication parameters. The cells with a high sulfur loading (11.5 mg cm -2 ), a high sulfur content (75 wt.%), and a low electrolyte/sulfur ratio (9 μL mg -1 ) display a high areal capacity and energy density of, respectively, 7 mA h cm -2 and 14 mW h cm -2 with a capacity retention of 70% after 150 cycles. Moreover, the cells exhibit a low self-discharge behavior with a low self-discharge constant of 0.0013 per day and a long rest period of one month. Lastly, these dynamic and static electrochemical stabilities are attributed to the ant-nest-like structure and low surface area of the cathode substrate that allows, respectively, the accommodation and encapsulation of a high amount of active material and reduces the consumption of electrolyte.

25 ENERGY STORAGE↗
DOE OSTI2016

A miniature electron ionization source fabricated using microelectromechanical systems ($\mathrm{MEMS}$) with integrated carbon nanotube ($\mathrm{CNT}$) field emission cathodes and low-temperature co-fired ceramics ($\mathrm{LTCC}$)

The use of microelectromechanical systems (MEMS) components in miniature mass spectrometers is particularly attractive due to their small size and scalable manufacturing capability. Our group has pioneered the development of miniature electron ionization sources combining MEMS fabricated structures with integrated carbon nanotube (CNT) cold-cathode field emitters. However, until now they have been of limited use due to the limited ability to direct the ions into a mass analyzer. In this work, we design a miniature ion source using a microfabricated MEMS device and a low temperature co-fired ceramic (LTCC) carrier that includes electrical connections, ion optics for directing ions out of the device, and a sample inlet. Here we present the design and fabrication of the ion source; simulate the energy and angular dispersion; and experimentally determine the energy and angular dispersion.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Fabrication and durability characterization of superhydrophobic and lubricant-infused surfaces

Hypothesis: Practical applications of non-wetting surfaces require good mechanical durability in the wet environments for which they are intended to be used. Durability of non-wetting surfaces is influenced by the surface features, interaction with the functionalization agent, and the lubricant properties that can be tuned independently to identify optimal combination. Experiments: In this study, superhydrophobic and lubricant-infused surfaces are fabricated on copper tubes using chemical etching and electrodeposition texturing techniques, six different functionalizing agents, and five different infused lubricants. Through 180 fabrication combinations and 102 durability tests, each parameter is systematically studied for contributions to initial non-wetting behavior and its durability in heated, wet environment, under high-energy water jet impingement, and under accelerated flow conditions. Findings: Among the adsorbing and curing functionalization agents investigated, n-Hexadecyl mercaptan that belongs to the sulfhydryl group and Sylgard-184, respectively, showed high durability in heated water immersion and under jet impingement tests. For lubricant-infused surfaces, lubricants with high surface tension demonstrated high durability in heated water immersion test, whereas durability in hydrodynamic conditions is closely correlated to lubricant viscosity. Results showed that a lubricant-infused surface will maintain its non-wetting properties in dropwise condensation conditions for approximately 1.5 years.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Fabrication of yeast engineered porous 13X adsorbent layers for CO 2 capture

This study investigates a novel environmentally friendly coating technique using yeast fermentation to obtain super porous Zeolite 13X adsorbent layers through freeze-drying technique for CO 2 capture applications. Several mass ratios of sugar to yeast were used to control the porosity and pore sizes in the adsorbent layer. A unique peeling process was integrated to obtain foamy, hollow structures to have deeper layer accessibility of adsorbent for adsorption applications. These coated adsorbent layers were experimentally characterized as a function of the mass ratio of sugar to yeast and adsorbent solid fraction. Scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and Fourier-transform infrared spectroscopy (FT-IR) are used to analyze the coated layers. Here, the void fraction for coated samples is found to vary between 0.48 and 0.56, making the samples applicable for adsorption applications. Adsorption performance experiments are performed to test the coated samples' performance compared to 13X powder. Due to their simplistic fabrication, cost-effectiveness, rapid pore formation, and high adsorption capacity, these porous 13X layers hold potential for large-scale fabrication and CO 2 capture applications.

Adsorbent coating↗
DOE OSTI2026

Siloxane-modified polycarbosilane flexible Prepregs for fabrication of ceramic matrix composites via compression molding and PIP densification

For this work, the development of ceramic matrix composites (CMCs) using 5 harness satin carbon fiber fabric impregnated with commercial polycarbosilane precursor plasticized by siloxane copolymer was investigated aiming to improve wetting behavior and shape conformability. The polycarbosilane precursor and polysiloxane plasticizer were mixed at varying weight ratios to obtain flexible preceramic resin prepreg cloths. 13 plies of preceramic polymer prepreg cloths were stacked in 0/90° layup and cured by compression molding, followed by densified via PIP process. The CMCs were densified with eight PIP cycles followed by final crystallization at 1600 °C. The CMCs made with 10 wt% polysiloxane loading showed lower viscosity of the prepreg resin as well as higher strength and displacement to failure compared to those fabricated from unplasticized polycarbosilane prepolymer. In contrast, at higher concentration of plasticizer, viscosity of the prepreg resin increased, and the CMC became more brittle; however, it exhibited considerably higher thermal conductivity.

Carbosilane↗
DOE OSTI2018

Characterization of Inconel 625 fabricated using powder-bed-based additive manufacturing technologies

The purpose of this study was to perform a comparative analysis of powder-bed-based additive manufacturing (AM) technologies during the production of metallic components using Inconel 625 powder material. The AM technologies explored in this study include electron beam powder bed fusion (EPBF), laser powder bed fusion (LPBF), and binder jetting technology. Samples were fabricated in two build directions (X and Z build orientations) for this evaluation process, where all specimens underwent a hot isostatic pressing (HIP) post-process. The comparison was made in terms of microstructure and mechanical properties including ultimate tensile strength (UTS), yield strength (YS), percent elongation, and modulus of elasticity (E). Microstructural characterization showed evidence of equiaxed grain formation for binder jetting and LPBF parts, whereas EPBF parts displayed a more columnar grain formation parallel to the build direction. Six specimens were tested per technology, three built in the X orientation and three built in the Z orientation. All six specimens were built in a single run of each AM machine. Results indicated that all three technologies are capable of meeting the minimum requirements of the ASTM F3056-14 standard for parts produced in the X orientation, with properties that are similar to wrought Inconel 625. In the Z orientation, however, only LPBF was able to meet the minimum standard requirements. Through the comparative analysis of the mechanical properties, here this work showed that LPBF outperformed the other technologies in a majority of the evaluated properties, followed by EPBF and binder jetting. An analysis of the fracture surfaces of tensile specimens was also performed, and it indicated ductile fracture (dimple rupture) for the specimens produced with all three of the AM technologies studied. Nevertheless, the characterization also showed certain differences in the fractured surfaces, such as the presence of un-sintered powder particles for the binder jetting processed Inconel 625, or the development of the so called woody structure for the EPBF processed material. This study can be used to determine distinct characteristics between the three powder-bed-based technologies for the fabrication of Inconel 625 that can further include other technologies and materials using similar approaches.

36 MATERIALS SCIENCE↗
DOE OSTI2017

A novel method combining additive manufacturing and alloy infiltration for NdFeB bonded magnet fabrication

In this paper, binder jetting additive manufacturing technique is employed to fabricate NdFeB isotropic bonded magnets, followed by an infiltration process with low-melting point eutectic alloys [i.e., Nd 3 Cu 0.25 Co 0.75 (NdCuCo) and Pr 3 Cu 0.25 Co 0.75 (PrCuCo)]. Densification and mechanical strength improvement are achieved for the as-printed porous part. Meanwhile, the intrinsic coercivity H ci is enhanced from 732 to 1345 kA/m and 1233 kA/m after diffusion of NdCuCo and PrCuCo, respectively. This study presents a novel method for fabricating complex-shaped bonded magnets with promising mechanical and magnetic properties.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Mechanical behavior and shear band of a powder-metallurgy-fabricated CoCrFeMnNi high-entropy alloy during high strain-rate deformation

High-entropy alloys (HEAs) fabricated by powder metallurgy are considered to exhibit extremely-great potential application values in the field for high-speed impact deformation due to their uniform microstructures and compositions. The mechanical behavior of a powder-metallurgy-fabricated (PM) CoCrFeMnNi HEA was investigated at room temperature with strain rates ranging from 1200 s -1 to 2800 s -1 . It was found that the serration behavior and shear localization of the alloy under dynamic conditions occurred. Results also indicated that the serrated flow took place in the PM CoCrFeMnNi HEA during mechanical deformation at high strain rates (>1000 s -1 ) and became more pronounced as the strain rate increased. Furthermore, it was determined that the yield-strength values of the PM CoCrFeMnNi HEA were sensitive to strain rates, where the values increased from 500 MPa to 700 MPa when the strain rates increased from 1200 s -1 to 2800 s -1 . Shear bands with a width of about 20 μm were generated in the PM CoCrFeMnNi HEA after the shear stress reached a maximum value of 635 MPa, which corresponded to a nominal strain of about 8.71. Nanotwins and ultrafine-equiaxed grains with a diameter of about 150 nm also developed at the core of the shear band during deformation. The results revealed that the strength of the shear band was much higher than that of the matrix grain. Nanotwins in the shear band were composed of a single face-centered-cubic (FCC) structure with the twin plane of ($\bar{1}$1$\bar1$), which could be formed via a rotational dynamic recrystallization (RDR).

36 MATERIALS SCIENCE↗
DOE OSTI2025

High temperature tensile properties of H13 tool steel fabricated via binder jet additive manufacturing

H13 is one of the most used steels for hot work tooling applications like die casting. Binder jet additive manufacturing (BJAM) offers a cost-effective solution to fabricate tools with performance enhancing features like internal cooling channels. While full densification of BJAM H13 has been demonstrated in the literature, the room and high temperature tensile properties of the material, and the effect of post-process treatments like hot isostatic pressing (HIP), and heat treatment (HT) are unknown. Here we use HIP+HT to obtain a combination of ultimate tensile strength (UTS) and elongation to failure that is superior to H13 fabricated via laser powder bed fusion and wire arc additive manufacturing. HIP+HT BJAM H13 has a superior UTS (1836 MPa) compared with conventionally processed (1671 MPa) H13 but has lower plastic elongation. We report that as-sintered samples have an extensive network of continuous grain boundary (GB) carbides that contribute to brittle fracture. HIP+HT results in partial dissolution of GB carbides and formation of a fine martensitic microstructure resulting in superior tensile strength and elongation compared with as-sintered H13. We use thermo-kinetic calculations to rationalize the effects of HIP+HT on microstructure and properties.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Densification, microstructure, and mechanical properties of Mo–30W alloys fabricated from conditioned powders

Refractory alloys, such as molybdenum-based systems, are attracting growing interest for applications in extreme environments, such as in the nuclear and aerospace industries. Recent advances in sintering technologies, coupled with mechanical alloying, have enabled the tailored design of these alloys by leveraging powder characteristics to control final microstructures and mechanical properties. In this study, Mo-30W alloys were fabricated using electric field-assisted sintering (EFAS) from ball-milled powders with and without hydrogen treatment to investigate the influence of surface oxides on material properties and sintering behavior. The results revealed that samples processed from as-ball-milled powder contained a high density of oxides within the microstructure, whereas oxide presence was significantly reduced in samples fabricated from hydrogen-treated powders. Interestingly, the two powder types led to opposite trends in grain size distribution: samples from untreated powders exhibited grain refinement from sample periphery to the center, while samples from hydrogen-treated powders showed grain coarsening toward the center. This behavior is attributed to temperature gradients present during sintering due to electrical percolation pathway differences during Joule heating. The powder surface oxides may have influenced the temperature distribution and grain evolution. Microhardness profiles measured along both axial and thickness directions were consistent with the grain size distribution. Furthermore, oxide films on powder surfaces have delayed densification by hindering particle necking and atomic diffusion during sintering.

36 - MATERIALS SCIENCE↗
DOE OSTI2026

Topology-driven compressive behavior of Inconel 718 lattice structures with Z-strut reinforcement fabricated by laser powder bed fusion

This study investigates the compressive deformation behavior and mechanical performance of Inconel 718 lattice structures fabricated by laser powder bed fusion (LPBF). Four unit-cell topologies—BCC, FCC, BCCZ, and FCCZ—were designed with a unit-cell size of 3 mm and fabricated under identical process conditions to isolate the effect of topology. Measured relative densities ranged from 14.65% to 17.72%. Compressive testing showed that Z-strut-reinforced topologies (BCCZ: 54.6 MPa; FCCZ: 80.2 MPa) exhibited higher strength than their unreinforced counterparts, which may be associated with mixed-mode deformation behavior enabled by the vertically aligned Z-struts. Finite element simulations and Digital Image Correlation (DIC) analysis support the observation of a transition from node-dominated deformation in BCC/FCC to mixed-mode deformation in BCCZ/FCCZ. These findings suggest that unit-cell topology is a key design variable for tailoring deformation mechanisms in LPBF lattice structures.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Characterization and mechanical properties of cladded stainless steel 316L with nuclear applications fabricated using electron beam melting

The ability to fabricate or join components of 316 L austenitic stainless steel using additive manufacturing (AM) processes such as laser and electron beam melting (EBM®) offers several advantages including enhanced part complexity, narrow or absent heat affected zones, increased part precision, avoidance of filler materials (such as traditional welds), and the ability to create metallurgically sound bonds. These attributes can contribute to improved mechanical properties of the fabricated components and component repair in nuclear, aerospace, and chemical industries. In the present work, we report that austenitic 316 L stainless steel additively manufactured by EBM exhibits a 76% increase in the yield strength and a corresponding increase of 29% in the ultimate tensile strength in contrast to the wrought substrate and commercial forged 316 L stainless steel. The EBM clad 316 L stainless steel elongation was 36%. The wrought substrate equiaxed grain size was ~30 μm in contrast to elongated, columnar grains ~0.1 mm wide and >1 mm in length for the EBM cladding. Transmission Electron Microscopy (TEM) analysis revealed that these columnar grains, which exhibited very straight, and presumably special grain boundaries having a very high (100) texture, contained a variety of sub-grain microstructures consisting of low-angle sub-grain boundaries containing dislocation tangles and stacking-fault arrays, and homogeneously distributed Cr 23 C 6 carbide precipitates, with no preferential carbide precipitation on either the straight, special columnar grain boundaries, or the very low-angle sub-grain boundaries. This observation and the formation of hierarchical microstructures which produce high strength and possibly corrosion resistance as a consequence of the absence of grain boundary carbide precipitation, illustrate the prospects for AM as a novel concept for achieving grain boundary engineering to promote high-strength and corrosion resistant alloys for high-temperature, corrosive environments, including elevated temperature nuclear reactor applications.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Performance of a ferritic/martensitic steel for nuclear reactor applications fabricated using additive manufacturing

Ferritic/martensitic (FM) steels are being targeted for use in a range of advanced reactor concepts as cladding and structural components. FM steels for nuclear reactor applications have historically been produced using traditional methods (e.g., casting and forging), but recently, additive manufacturing processes have become of interest for making FM-based components. Here, the laser-blown-powder additive manufacturing process was used to fabricate an FM steel, HT9, followed by microstructural and mechanical performance evaluations to determine the viability of future use of additive manufacturing for FM-based component fabrication. Results showed that the as-built condition formed a layered structure with alternating layers of δ-ferrite and martensite, which resulted in anisotropic engineering and true-stress, true-strain mechanical performance. Post-build normalizing and tempering treatments alerted the prior austenite grain size and precipitate distributions, and drove the mechanical performance to near-isotropic properties that mimic wrought-processed properties. Overall, the resulting microstructures in all conditions were rationalized in the context of multi-pass welding and the synergies are discussed.

36 MATERIALS SCIENCE↗