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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Metallene-related materials for electrocatalysis and energy conversion

As a member of graphene analogs, metallenes are a class of two-dimensional materials with atomic thickness and well-controlled surface atomic arrangement made of metals or alloys. When utilized as catalysts, metallenes exhibit distinctive physicochemical properties endowed from the under-coordinated metal atoms on the surface, making them highly competitive candidates for energy-related electrocatalysis and energy conversion systems. Significantly, their catalytic activity can be precisely tuned through the chemical modification of their surface and subsurface atoms for efficient catalyst engineering. Here, this minireview summarizes the recent progress in the synthesis and characterization of metallenes, together with their use as electrocatalysts toward reactions for energy conversion. In the Synthesis section, we pay particular attention to the strategies designed to tune their exposed facets, composition, and surface strain, as well as the porosity/cavity, defects, and crystallinity on the surface. We then discuss the electrocatalytic properties of metallenes in terms of oxygen reduction, hydrogen evolution, alcohol and acid oxidation, carbon dioxide reduction, and nitrogen reduction reaction, with a small extension regarding photocatalysis. At the end, we offer perspectives on the challenges and opportunities with respect to the synthesis, characterization, modeling, and application of metallenes.

36 MATERIALS SCIENCE↗
NASA NTRS1999

Vacuum Plasma Spray (VPS) Forming of Solar Thermal Propulsion Components Using Refractory Metals

The Thermal Spray Laboratory at NASA's Marshall Space Flight Center has developed and demonstrated a fabrication technique using Vacuum Plasma Spray (VPS) to form structural components from a tungsten/rhenium alloy. The components were assembled into an absorber cavity for a fully-functioning, ground test unit of a solar then-nal propulsion engine. The VPS process deposits refractory metal onto a graphite mandrel of the desired shape. The mandrel acts as a male mold, forming the required contour and dimensions of the inside surface of the deposit. Tungsten and tungsten/25% rhenium were used in the development and production of several absorber cavity components. These materials were selected for their high temperature (greater than 25000 C [greater than 4530 F]) strength. Each absorber cavity comprises 3 coaxial shells with two, double-helical flow passages through which the propellant gas flows. This paper describes the processing techniques, design considerations, and process development associated with forming these engine components.

Zimmerman, Frank R.↗
NASA NTRS2002

An Assessment of the Residual Stresses in Low Pressure Plasma Sprayed Coatings on an Advanced Copper Alloy

Modeling studies were conducted on low pressure plasma sprayed (LPPS) NiAl top coat applied to an advanced Cu-8(at.%)Cr-4%Nb alloy (GRCop-84) substrate using Ni as a bond coat. A thermal analysis suggested that the NiAl and Ni top and bond coats, respectively, would provide adequate thermal protection to the GRCop-84 substrate in a rocket engine operating under high heat flux conditions. Residual stress measurements were conducted at different depths from the free surface on coated and uncoated GRCop-84 specimens by x-ray diffraction. These data are compared with theoretically estimated values assessed by a finite element analysis simulating the development of these stresses as the coated substrate cools down from the plasma spraying temperature to room temperature.

Raj, S. V.↗
NASA NTRS1976

Gas-path seal technology

Improved gas-path seals are needed for better fuel economy, longer performance retention, and lower maintenance, particularly in advanced, high-performance gas turbine engines. Problems encountered in gas-path sealing are described, as well as new blade-tip sealing approaches for high-pressure compressors and turbines. These include a lubricant coating for conventional, porous-metal, rub-strip materials used in compressors. An improved hot-press metal alloy shows promise to increase the operating surface temperatures of high-pressure-turbine, blade-tip seals to 1450 K (2150 F). Three ceramic seal materials are also described that have the potential to allow much higher gas-path surface operating temperatures than are possible with metal systems.

Zuk, J.↗
NASA NTRS2008

Durability Assessment of TiAl Alloys

The durability of TiAl is a prime concern for the implementation of TiAl into aerospace engines. Two durability issues, the effect of high temperature exposure on mechanical properties and impact resistance, have been investigated and the results are summarized in this paper. Exposure to elevated temperatures has been shown to be detrimental to the room temperature ductility of gamma alloys with the most likely mechanisms being the ingress of interstitials from the surface. Fluorine ion implantation has been shown to improve the oxidation resistance of gamma alloys, and ideally it could also improve the environmental embrittlement of high Nb content TiAl alloys. The effect of F ion implantation on the surface oxidation and embrittlement of a third generation, high Nb content TiAl alloy (Ti-45Al-5Nb-B-C) were investigated. Additionally, the ballistic impact resistance of a variety of gamma alloys, including Ti-48Al-2Cr- 2Nb, Ti-47Al-2Cr-2Nb, ABB-2, ABB-23, NCG359E, 95A and Ti-45Al-5Nb-B-C was accessed. Differences in the ballistic impact properties of the various alloys will be discussed, particularly with respect to their manufacturing process, microstructure, and tensile properties.

Draper, Susan L.↗
DOE OSTI2025

GRinding Automated Classification Engine

This work is an ML-driven framework for automated surface analysis of microscopy images. We create a training dataset by imaging stainless steel samples to benchmark four developed deep neural network architectures. These models, based on a YOLOv8n-cls backend, integrate image features and process metadata using various fusion methods to distinguish between acceptable and unacceptable surface finishes. This code is associated with publication "Classifying Alloy Surface Preparation Quality with Metadata-Infused Machine Learning for Rapid Alloy Discovery" for project APEX LDRD-ER (25-ERD-039)

Gongora, AldairE [Lawrence Livermore National Labo↗
DOE OSTI2023

Environmental Protection Coating System for Refractory Metal Alloys (EPCS for RMAs)

As part of ARPA-E’s Ultra High Temperature Impervious Materials Advancing Turbine Efficiency (UITIMATE) program, this project aims to develop an environmental protection coating system (EPCS) for refractory metal alloys (RMAs) – which will provide radical improvement in long term protection for ultra-high temperature refractory metal components in harsh gas-turbine environments. The drive for higher fuel efficiency and higher core power of gas turbines used in electric power generation and in aircraft propulsion requires higher peak operation temperatures. The temperature capability of state-of-the-art materials cannot meet the new requirements. Refractory metal alloys have desirable capabilities for achieving the required peak temperatures, but most of them are subject to oxidation in the gas turbine environment. Thus, there is a strong need to develop novel environmental protective coatings that enable the refractory metals to operate in an ultra-high temperature engine environment. This project is composed of four major technical innovations that can provide a potentially transformational solution in providing environmental protection for refractory metal alloys over a wide range of temperature. 1) Multi-layer self-healing environmental barrier coating (EBC) that provides protection against combustion gas environment. 2) Oxidation resistant diffusion barrier (DB) on the alloy surface to enhance coating stability. 3) Synergistic integration of the multi-layer self-healing EBC with the diffusion barrier to extend coating life. 4) Guidance of physics-based modeling to accelerate coating development and optimization. Our team has successfully developed a multi-layer self-healing environmental protection coating system (EPCS) that can provide oxidation protection for commercially available molybdenum based refractory metal alloys over a wide temperature range of up to 1600 °C for fuel-efficient gas turbine applications. The team also developed a multi-layer high temperature coating design tool to accelerate coating development and optimization based on physics-based modeling. The team also engaged RTX business unite, notable Pratt and Whitney, for future commercialization of this technology. The successful completion of this Phase I effort led to the selection of performing Phase II of the program. In Phase II, the team plans to apply the EPCS in the protection of a newly discovered molybdenum-based metal alloy which has the potential of superior high temperature properties to the commercial products. Th coating will be evaluated under test conditions and environment that mimic gas turbine operation.

36 MATERIALS SCIENCE↗
NASA NTRS1982

Compressor cascade performance deterioration caused by sand ingestion

Airfoil cascade erosion and performance deterioration was investigated in a gas particle cascade tunnel. The cascade blades were made of 2024 aluminum alloy and the solid particles used were quartz sand. The results of the experimental measurements are presented to show the change in the blade surface erosion, pressure distribution and the total loss coefficient with erosion. The surface quality of the blades exposed to particulate flows are changing the material surfaces. With time, the surface roughness increases and leads to a decrease in engine performance. It was found that the surface roughness values increase asymptotically to a maximum value with increased erosion. The experimental results indicate that the roughness parameters correlate well against the mass of particles impacting unit area of the surface. Such a correlation is useful in aerodynamics and performance computations in turbomachinery.

Tabakoff, W.↗
DOE OSTI2021

Control of the Plasma-Material Interface for Long Pulse Optimization in EAST and KSTAR

This project's major goal was to understand and control the plasma-material interface to improve long pulse discharge and performance in the EAST and KSTAR devices, emphasizing the unique strengths of each machine. In particular, MIT has developed implanted depth markers to diagnose the net erosion of high-Z materials. The goals included the characterization and utilization of these markers in various high-Z materials of interest, including TZM, tungsten, and refractory metal base high entropy alloys.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1986

Advanced rotary engine components utilizing fiber reinforced Mg castings

Under a two-phase program sponsored by NASA, the technology for producing advanced rotary engine components utilizing graphite fiber-reinforced magnesium alloy casting is being developed. In Phase I, the successful casting of a simulated intermediate housing was demonstrated. In Phase II, the goal is to produce an operating rotor housing. The effort involves generation of a material property data base, optimization of parameters, and development of wear- and corrosion-resistant cast surfaces and surface coatings. Results to date are described.

Goddard, D.↗
NASA NTRS1991

Alkali metal compatibility testing of candidate heater head materials for a Stirling engine heat transport system

The authors describe work performed as part of the 25-kWe advanced Stirling conversion system project. Liquid alkali metal compatibility is being assessed in an ongoing test program to evaluate candidate heater head materials and fabrication processes at the temperatures and operating conditions required for Stirling engines. Specific materials under evaluation are alloy 713LC, alloy 713LC coated with nickel aluminide, and Udimet 720, each in combination with Waspaloy. The tests were run at a constant 700 C. A eutectic alloy of sodium and potassium (NaK) was the working fluid. Titanium sheet in the system was shown to be an effective oxygen getter. Metallographic and microchemical examination of material surfaces, joints, and their interfaces revealed little or no corrosion after 1000 h. Tests are in progress, with up to 10,000 h exposure.

Noble, Jack E.↗
NASA NTRS1994

High Performance Arcjet Engines

This effort sought to exploit advanced single crystal tungsten-tantalum alloy material for fabrication of a high strength, high temperature arcjet anode. The use of this material is expected to result in improved strength, temperature resistance, and lifetime compared to state of the art polycrystalline alloys. In addition, the use of high electrical and thermal conductivity carbon-carbon composites was considered, and is believed to be a feasible approach. Highly conductive carbon-carbon composite anode capability represents enabling technology for rotating-arc designs derived from the Russian Scientific Research Institute of Thermal Processes (NIITP) because of high heat fluxes at the anode surface. However, for US designs the anode heat flux is much smaller, and thus the benefits are not as great as in the case of NIITP-derived designs. Still, it does appear that the tensile properties of carbon-carbon can be even better than those of single crystal tungsten alloys, especially when nearly-single-crystal fibers such as vapor grown carbon fiber (VGCF) are used. Composites fabricated from such materials must be coated with a refractory carbide coating in order to ensure compatibility with high temperature hydrogen. Fabrication of tungsten alloy single crystals in the sizes required for fabrication of an arcjet anode has been shown to be feasible. Test data indicate that the material can be expected to be at least the equal of W-Re-HfC polycrystalline alloy in terms of its tensile properties, and possibly superior. We are also informed by our colleagues at Scientific Production Association Luch (NP0 Luch) that it is possible to use Russian technology to fabricate polycrystalline W-Re-HfC or other high strength alloys if desired. This is important because existing engines must rely on previously accumulated stocks of these materials, and a fabrication capability for future requirements is not assured.

Kennel, Elliot B.↗
DOE OSTI2023

Interfacial alloying between lead halide perovskite crystals and hybrid glasses

The stellar optoelectronic properties of metal halide perovskites provide enormous promise for next-generation optical devices with excellent conversion efficiencies and lower manufacturing costs. However, there is a long-standing ambiguity as to whether the perovskite surface/interface (e.g. structure, charge transfer or source of off-target recombination) or bulk properties are the more determining factor in device performance. Here we fabricate an array of CsPbI 3 crystal and hybrid glass composites by sintering and globally visualise the property-performance landscape. Our findings reveal that the interface is the primary determinant of the crystal phases, optoelectronic quality, and stability of CsPbI 3 . In particular, the presence of a diffusion “alloying” layer is discovered to be critical for passivating surface traps, and beneficially altering the energy landscape of crystal phases. However, high-temperature sintering results in the promotion of a non-stoichiometric perovskite and excess traps at the interface, despite the short-range structure of halide is retained within the alloying layer. By shedding light on functional hetero-interfaces, our research offers the key factors for engineering high-performance perovskite devices.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Thermal analyses of high-power advanced thermoacoustic radioisotope power system for future space exploration missions

This paper presents the results of 3-D thermal analyses of the heat source assembly of a 440 We advanced radioisotope power system (RPS) for future space exploration missions. This high thermal efficiency RPS employs a heat source assembly of eight Step 2 General Purpose Heat Source (GPHS) modules and four Thermoacoustic Power Converter (TAPC) units. Each unit is thermally coupled to two GPHS modules. Here, the analyses investigated the temperatures of the Iridium (Ir) alloy cladding of the 238 PuO 2 fuel pellets and the surface of the Fine Weave Pierced Fabric (FWPF) aeroshell in the GPHS modules to ensure reliable operation and safety in case of an unlikely reentry. Conductive coupling of the GPHS modules to the heater heads of the TAPC units produces relatively uniform axial and azimuthal distributions of heat flux and temperature. However, for this case the temperature of the Ir alloy cladding is lower than the desired values of 1173 K to maintain sufficient ductility. Adding a 5 mm wide He filled gap and decreasing the thickness of the graphite sleeve to 10 mm increased Ir cladding temperature to 1197–1174 K, which are in the desired range. The maximum surface temperatures of the FWPF graphite aeroshell of 1022–1131 K is well below the NASA specified limit of 1373 K. In addition, the total mass of the heat source assembly decreased by 19.6 kg, ~43% saving compared to original design.

42 ENGINEERING↗
NASA NTRS1974

Examination of the influence of coatings on thin superalloy sections. Volume 1: Description and analysis

The effects of an aluminide coating and of section thickness were investigated on two cast nickel-base superalloys. Cast section thickness ranged from 0.038 cm to 0.15 cm. Simulated engine exposures in a jet fuel burner rig with cyclic air cooling were studied. The effects of surface machining before coating and re-machining and re-coating after exposures were examined. The properties evaluated included tensile strength, stress rupture, high-cycle mechanical fatigue, and thermal fatigue. A metallurgical analysis was made of the microstructures of the coated and uncoated alloy.

Kaufman, M.↗
NASA NTRS1987

Observations of directional gamma prime coarsening during engine operation

Two alloys with negative mismatch parameters, NASAIR 100 and a modified NASAIR 100 called Alloy 3 were run as turbine blades in an experimental ground based Garret TFE731 engine for up to 200 hr. The directional coarsening of gamma prime (rafting) that developed during engine testing was analyzed and compared to previous research from laboratory tests. The blades were found to be rafted normal to the centrifugal stress axis over much of the span, but near the surfaces, the blades were found to be rafted parallel to the centrifugal stress axis for certain cycles. Representative photomicrographs of the blades and the effects of stress and temperature on raft formation are shown.

Draper, Susan L.↗
DOE OSTI2022

Measurement of High Density Electrons Above a Helium Film on an Amorphous Metal Substrate

Here we have measured two-dimensional electron systems bound to a thin helium film supported by a metallic substrate. We report on our measurement of electron density obtained via a Kelvin probe technique. The underlying metallic substrate is an amorphous metallic alloy (TaWSi), which can support large uniform densities due to its low surface roughness and homogeneous work function. We find that this substrate is able to support high enough densities that the electrons are expected to be Fermi-degenerate.

42 ENGINEERING↗
DOE OSTI2020

Predicting metal–metal interactions. I. The influence of strain on nanoparticle and metal adlayer stabilities

Strain-engineering of bimetallic nanomaterials is an important design strategy for developing new catalysts. In this paper, we introduce an approach for including strain effects into a recently introduced, density functional theory (DFT)-based alloy stability model. The model predicts adsorption site stabilities in nanoparticles and connects these site stabilities with catalytic reactivity and selectivity. Strain-based dependencies will increase the model’s accuracy for nanoparticles affected by finite-size effects. In addition to the stability of small nanoparticles, strain also influences the heat of adsorption of epitaxially grown metal-on-metal adlayers. In this respect, we successfully benchmark the strain-including alloy stability model with previous experimentally determined trends in the heats of adsorption of Au and Cu adlayers on Pt (111). For these systems, our model predicts stronger bimetallic interactions in the first monolayer than monometallic interactions in the second monolayer. We explicitly quantify the interplay between destabilizing strain effects and the energy gained by forming new metal–metal bonds. While tensile strain in the first Cu monolayer significantly destabilizes the adsorption strength, compressive strain in the first Au monolayer has a minimal impact on the heat of adsorption. Hence, this study introduces and, by comparison with previous experiments, validates an efficient DFT-based approach for strain-engineering the stability, and, in turn, the catalytic performance, of active sites in bimetallic alloys with atomic level resolution.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗