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At least 109 records · Page 6

Advanced Materials Development under NASA’s Hybrid Thermally Efficient Core (HyTEC) Project

The Hybrid Thermally Efficient Core (HyTEC) project aims to develop small core turbofan engine technologies that will enable fuel burn reductions, additional use of electric airplane systems through power extraction, and to advance engine operability and compatibility with sustainable aviation fuels. As such, a portfolio of technologies that contribute to raising the pressure, temperature and efficiency of turbofan engine cores needs developed. Included in HyTEC’s technology portfolio to enable these advancements are enhanced combustor liner materials and higher temperature capable turbine blades and vanes manufactured using ceramic matrix composites (CMCs) and environmental barrier coatings (EBCs). These technologies are being developed and tested in laboratory-scale relevant environments to advance the technology readiness level (TRL) to 4 or 5, before moving into an engine core demonstrator to raise the TRL to 6. A new natural gas/oxygen burner rig facility will be used to simulate turbine engine relevant environments at the laboratory/coupon scale. In addition, improvements to enable sub-element, and more complex component testing in NASA Glenn’s combustor facility (CE-5) will be presented.

Ceramic Matrix Composites (CMCs)↗

Theoretical and Computational Studies of Rare Earth Substitutes: A Test-bed for Accelerated Materials Development

Hard permanent magnets in wide use typically involve expensive Rare Earth elements. In this effort, we investigated candidate permanent magnet materials which contain no Rare Earths, while simultaneously exploring improvements in theoretical methodology which enable the better prediction of magnetic properties relevant for the future design and optimization of permanent magnets. This included a detailed study of magnetocrystalline anisotropy energies, and the use of advanced simulation tools to better describe magnetic properties at elevated temperatures.

36 MATERIALS SCIENCE↗

NASA's Additive Manufacturing Development Materials Science to Technology Infusion - Connecting the Digital Dots

At NASA, the first steps of the Journey to Mars are well underway with the development of NASA's next generation launch system and investments in research and technologies that should increase the affordability, capability, and safety of exploration activities. Additive Manufacturing presents a disruptive opportunity for NASA to design and manufacture hardware with new materials at dramatically reduced cost and schedule. Opportunities to incorporate additive manufacturing align very well with NASA missions and with most NASA programs related to space, science, and aeronautics. The Agency also relies on many partnerships with other government agencies, industry and academia.

Vickers, John↗

A full-scale fire program to evaluate new furnishings and textile materials developed by the National Aeronautics and Space Administration

A program of experimental fires was carried out to establish the advantages offered by new materials for improved fire safety. Four full-scale bedrooms, differing only in the materials used to furnish them, were built and burned to provide comparative data on the fire hazards produced. Cost and availability differences were not considered. The visual evidence provided by TV and photographic coverage of the four experimental room fires showed clearly that the rooms responded very differently to a common ignition condition. Resistance to the ignition and spread of fire was substantially improved in the rooms furnished completely or partially with the new materials.

Hillenbrand, L. J.↗

Flame Resistant Fibrous Materials Development

Since 1973, Albany International Research Co. has been engaged by NASA-JSC under Contract No. NAS9-13673 to conduct studies aimed at developing fibers and flexible structures made therefrom which would provide improved flame resistance over existing commercially available materials in oxygen enriched atmospheres. A portion of the crew bay area life support system and crew equipment for the space shuttle was initially designed to function at a 30% oxygen, 70% nitrogen atmosphere at 9 psia pressure. This oxygen concentration imposed certain fire safety and smoke generation requirements which could not be completely met by commonly accepted textiles. Potentially useful new polymers were investigated both for fire safety and mechanical properties. During the course of the work, three candidate fibers were studied and evaluated and the results of each of these efforts are summarized.

Coskren, R. J.↗

Hanford WTP LAW Melter Startup and Tuning Feed Material Development - 17065

The U.S. Department of Energy's (DOE) Hanford Site in southeast Washington state is home to 56 million gallons of chemical and radioactive waste stored in underground tanks, the result of more than four decades of plutonium production. To address this challenge, the U.S. Department of Energy contracted Bechtel National, Inc., to design and build the world's largest radioactive waste treatment plant. The Hanford Tank Waste Treatment and Immobilization Plant (WTP) will use vitrification to immobilize most of Hanford's waste. Vitrification involves blending the waste with glass-forming materials, and heating it to high temperature to form molten glass, then pouring it into stainless steel containers. In this glass form, its radioactivity will decay over hundreds to thousands of years. In advance of full operation of WTP, a sequential process of commissioning will be undertaken to ensure the plant operates safely and within design requirements. The first phase of WTP operations will focus on the Low-Activity Waste (LAW) Vitrification Facility and its supporting facilities and systems. Commissioning of the LAW Facility will employ a progressive approach to address the complexity of system operation and introduction of hazards. This approach starts with introduction of low hazard and simple testing configurations, and incrementally increasing the complexity and hazardous makeup of testing feed materials, culminating in fully integrated treatment of radioactive tank waste during hot commissioning. Testing with simulants that are chemically similar to radioactive tank waste introduces significant chemical hazards into treatment systems in the form of nitrogen oxides (NOx) and anhydrous ammonia. A method of testing to allow tuning and demonstration of equipment and to develop operator proficiency prior to introducing these chemical hazards was deemed necessary. To that end, the development and testing of a new 'tuning feed' material is in progress. The tuning feed is important because its use will enable the first-time integration of all LAW Facility process systems. The tuning feed must include key physical and chemical characteristics that correspond to the commissioning simulant and low activity tank waste, without the inherently hazardous materials or toxic off-gas constituents that result from tank waste treatment. Tuning feed is being developed to provide representative melter feed rheology, glass chemistry, cold cap formation, and off-gas generation rate in order to predict system response to actual tank waste to the extent practical. The tuning feed must also be compatible with process equipment and other process streams that will be encountered during the cold commissioning testing program. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Advanced Nuclear Fuels and Materials Development and Philosophy of the DOE Advanced Fuels Campaign

The mission of the Advanced Fuels Campaign (AFC) is to perform Research, Development, and Demonstration (RD and D) activities for advanced fuel forms (including cladding) to enhance the performance and safety of the nation's current and future reactors; enhance proliferation resistance of nuclear fuel; effectively utilize nuclear energy resources; and address longer-term waste management challenges. This includes development of a state-of-the art Research and Development (R and D) infrastructure to support the use of a 'goal-oriented science-based approach.' AFC uses this approach to develop a fundamental understanding of fuel and cladding fabrication methods and performance under irradiation, enabling the pursuit of multiple fuel forms for future fuel cycle options. This approach includes fundamental experiments, theory, and advanced modeling and simulation. One of the most challenging aspects of AFC is the management, integration, and coordination of major R and D activities across multiple organizations. AFC interfaces and collaborates with other Fuel Cycle Technologies (FCT) campaigns, universities, industry, various DOE programs and laboratories, federal agencies (e.g., Nuclear Regulatory Commission [NRC]), and international organizations. Key challenges are the development of fuel technologies to enable major increases in fuel performance (safety, reliability, power and burnup) beyond current technologies, and development of characterization methods and predictive fuel performance models to enable more efficient development and licensing of advanced fuels. AFC is challenged with the research and development of fuels for two different reactor technology platforms, namely transmutation fuel for non-water cooled reactors and advanced fuel development for light water reactor (LWR) systems. This presentation will provide an overview of the Advanced Fuel Campaign activities including the near term activities in advanced nuclear fuel system research and development as well as highlighting general activities pursued to improve the study, modeling, and simulation of irradiated nuclear materials. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A Full-Scale Fire Program to Evaluate New Furnishings and Textile Materials Developed by the National Aeronautics and Space Administration

The plans for the present series of full-scale experimental fires were initiated at the suggestion of NASA following the presentation of a film and discussion illustrating Battelle-Columbus' recent work in fire research. That film showed bedroom-type fires carried out as a part of a program to determine the influence of the cyclic characteristics of real fires under limited ventilation on the burning and pyrolysis properties of the room furnishings. A new series of fires was suggested by NASA designed to show the performance of new fire resistant and fire retardant materials by providing comparative fire and smoldering environmental conditions. More recently, the goal for the new series of fires was written in a meeting with NASA personnel and others at Battelle on May 3 and 4, 1972. The goal was as follows: To establish the need for special materials of improved fire safety in domiciliary settings of public concern, and to assess, in a professionally acceptable manner, the potential of materials arising from the new space-age technology for this purpose. It was anticipated that some new materials arising from the space-age technology and not yet available through conventional commercial channels might provide significant improvements in fire safety if the best of the commercially available materials showed important shortcomings in this area. It was the intent of this program to assess the benefits that could accrue from the use of these new materials. Fire safety is a matter requiring the evaluation of a number of factors. For example, fire resistance and fire spread, visibility during the fire, toxicity of evolved gases, and the fire-fighting problem that is created must be evaluated before the relative hazard can be assessed. The plan of the program provided for sampling and instrumentation to evaluate these factors, consistent with the goal of technological utilization that has been specified. Arrangements were made with the Columbus Fire Department to use an existing six-story concrete building', designed and used as a fire training tower, as the site for the experimental fires. The visual evidence provided by TV and photographic coverage of the four experimental room fires showed clearly that the rooms responded very differently to a common ignition condition. In particular: (1) The Typical room, furnished from conventional retail sources, ignited easily and burned rapidly so that after 8 minutes the contents of the room were nearly destroyed. (2) The Improved room, furnished with materials selected as being among the best commercially available, showed substantial improvement over the Typical room in that there was slower fire spread. However, the relatively complete destruction of the room contents that resulted, and the large amounts of smoke, made it clear that substantial further improvements were needed. This fire was stopped after 29 minutes. (3) The Space-age room, furnished completely with new materials that were not yet commercially available, did not ignite under the common ignition condition and soon demonstrated the substantial improvement in fire resistance available for those components close to the ignition source. A second and larger ignition arrangement showed that this room can burn, but the difficulty with which this was brought about confirmed the improved fire resistance available with use of these materials. (4) The Mixed room ensemble, furnished with 'materials identical to the Typical room except for the substitution of the bed from the Space-age room, illustrated the improvement in control of fire spread available by careful placement of fire materials in the important paths of fire development of an otherwise ordinary room. The most significant hazards at early times in each fire were due to the rapid rise in heat flux and the abrupt obscuration of vision by smoke. The most consistent toxicity hazard was due to CO and its importance would depend on the ability of the occupant to survive the initial heat and smoke menace which characterized each fire room. Other gases and vapors were shown to reach hazardous levels in certain fire rooms and, again, their significance to an occupant, would relate to the times in which such hazards occurred, and probably to the synergistic nature of the hazard arising from mixtures of such gases. Fire retardant items in the room are caused to pyrolyze by the heat of burning from other items in the room and so contribute to combustible and toxic vapor accumulations, even though they may not have entered into the burning process. This effect of a mixture of combustible materials to produce burning and pyrolysis not characteristic of any one item individually we have chosen to call the "ensemble effect". Further full-scale fire trials may be expected to show the significant changes that control the burning and pyrolytic processes and in that event a programmed fire chamber should be developed to yield realistic laboratory results.

Hillenbrand, L. J.↗

Insights into the Enhanced Oxidative Thermal Stability of Nanoparticle Organic Hybrid Materials Developed for Carbon Capture and Energy Storage

Due to the growing need for Direct Air Capture (DAC) and integrated carbon capture and conversion technologies, CO 2 capture materials that can withstand a wide range of environmental conditions, including fluctuating ambient temperatures and high concentrations of oxidizing agents (i.e., oxygen and moisture), are critically needed. Liquid-like Nanoparticle Organic Hybrid Materials (NOHMs) have been proposed as candidates for DAC and electrolyte additives enabling sustainable energy storage (i.e., integrated CO 2 capture and conversion and flow batteries). Liquid-like NOHMs functionalized with an ionic bond have been shown to display greatly enhanced oxidative thermal stability compared to the untethered polymer. However, these studies were limited in terms of reaction conditions and the detailed mechanisms of the oxidative thermal degradation were not reported. In this work, a kinetic thermal degradation analysis was performed on NOHM-I-HPE and the neat polymer, Jeffamine M2070 (HPE), in both non-oxidative and oxidative conditions. NOHM-I-HPE displayed similar thermal stability to the untethered polymer in a nitrogen environment, but interestingly, the thermal stability of the ionically tethered polymer was significantly enhanced in the presence of air. This observed enhancement of oxidative thermal stability is attributed to the orders of magnitude larger viscosity of the liquid-like NOHMs compared to untethered polymer and the bond stabilization of the ionically tethered polymer in the NOHMs canopy. Further, spectroscopic analyses of the liquid residue revealed that in the presence of oxygen, the degradation of HPE and NOHM-I-HPE occurs through the formation of trace amounts of carbonyls. This study illustrated that NOHMs can serve as functional materials for sustainable energy storage applications because of their excellent oxidative thermal stability.

25 ENERGY STORAGE↗

Materials Development and Advanced Process Simulation for Additive Manufacturing with Fiber-Reinforced Thermoplastics (Final Technical Report)

DuPont, Local Motors, and the Composites Manufacturing and Simulation Center (CMSC) at Purdue worked together to advance process simulation capabilities for Additive Manufacturing (AM) and develop printable short fiber reinforced semi-crystalline engineering thermoplastics suitable for vehicle components. DuPont provided one candidate thermoplastic material, which was evaluated against the following three criteria: 1) Printability using extrusion additive manufacturing processes. 2) Suitability for vehicle applications based on mechanical coupon screening tests. 3) Predictive capability of process simulations. Indiana Manufacturing Institute provided modeling and simulation technology and access to Purdue’s lab scale AM printer. Local Motors provided mechanical property requirements and printed demonstration prototype components using their Thermwood Large Scale Additive Manufacturing (LSAM) printer. To meet the performance and cost requirements of the automotive industry, high fiber content semi-crystalline engineering materials are required. Printing experience and property data for a 50% by weight short glass fiber reinforced material were gathered. Further, material properties required for simulating the printing process with the glass-fiber reinforced material were characterized. Knowledge was acquired with regards to the processability and performance of this thermoplastic material. Predictions of part deformation and crystallinity level were verified against experimental observations. Any significant results other than verification of simulation, e.g., novel material identified here would be impactful.

36 MATERIALS SCIENCE↗

Developing Materials Processing to Performance Modeling Capabilities and the Need for Exascale Computing Architectures (and Beyond)

Additive Manufacturing techniques are presenting the Department of Energy and the NNSA Laboratories with new opportunities to consider novel component production and repair processes, and to manufacture materials with tailored response and optimized performance characteristics. Additive Manufacturing technologies already are being applied to primary NNSA mission areas, including Nuclear Weapons. These mission areas are adapting to these new manufacturing methods, because of potential advantages, such as smaller manufacturing footprints, reduced needs for specialized tooling, an ability to embed sensing, novel part repair options, an ability to accommodate complex geometries, and lighter weight materials. To realize the full potential of Additive Manufacturing as a game-changing technology for the NNSA’s national security missions; however, significant progress must be made in several key technical areas. In addition to advances in engineering design, process optimization and automation, and accelerated feedstock design and manufacture, significant progress must be made in modeling and simulation. First and foremost, a more mature understanding of the process-structure-property-performance relationships must be developed. Because Additive Manufacturing processes change the nature of a material’s structure below the engineering scale, new models are required to predict materials response across the spectrum of relevant length scales, from the atomistic to the continuum. New diagnostics will be required to characterize materials response across these scales. And not just models, but advanced algorithms, next-generation codes, and advanced computer architectures will be required to complement the associated modeling activities. Based on preliminary work in each of these areas, a strong argument for the need for Exascale computing architectures can be made, if a legitimate predictive capability is to be developed.

36 MATERIALS SCIENCE↗

Uranium Casting Materials Development: HfN Testing Summary

A total of four dip tests were performed on TerraPower provided HfN coated niobium coupons. However, in the first two tests, excessive oxidation of the charges materials led to inadequate contact between the HfN coated specimens and the molten alloy. The final two tests used a much higher ramp rate, which provided less time for oxidation of the melt. In both of these tests, the dipped specimens appeared fully intact and coated with metal alloy. The alloy could not be easily removed, suggesting either a mechanical interlocking or a chemical bonding. Due to shifting programmatic priorities, metallographic examination of the samples was not performed.

36 MATERIALS SCIENCE↗

Materials Development for Auxiliary Components for Large Compact Mo/Au TES Arrays

We describe our current fabrication process for arrays of superconducting transition edge sensor microcalorimeters, which incorporates superconducting Mo/Au bilayers and micromachined silicon structures. We focus on materials and integration methods for array heatsinking with our bilayer and micromachining processes. The thin superconducting molybdenum bottom layer strongly influences the superconducting behavior and overall film characteristics of our molybdenum/gold transition-edge sensors (TES). Concurrent with our successful TES microcalorimeter array development, we have started to investigate the thin film properties of molybdenum monolayers within a given phase space of several important process parameters. The monolayers are sputtered or electron-beam deposited exclusively on LPCVD silicon nitride coated silicon wafers. In our current bilayer process, molybdenum is electron-beam deposited at high wafer temperatures in excess of 500 degrees C. Identifying process parameters that yield high quality bilayers at a significantly lower temperature will increase options for incorporating process-sensitive auxiliary array components (AAC) such as array heat sinking and electrical interconnects into our overall device process. We are currently developing two competing technical approaches for heat sinking large compact TES microcalorimeter arrays. Our efforts to improve array heat sinking and mitigate thermal cross-talk between pixels include copper backside deposition on completed device chips and copper-filled micro-trenches surface-machined into wafers. In addition, we fabricated prototypes of copper through-wafer microvias as a potential way to read out the arrays. We present an overview on the results of our molybdenum monolayer study and its implications concerning our device fabrication. We discuss the design, fabrication process, and recent test results of our AAC development.

Finkbeiner, F. m.↗

Low-Thermal-Conductivity Pyrochlore Oxide Materials Developed for Advanced Thermal Barrier Coatings

When turbine engines operate at higher temperatures, they consume less fuel, have higher efficiencies, and have lower emissions. The upper-use temperatures of the base materials (superalloys, silicon-based ceramics, etc.) used for the hot-section components of turbine engines are limited by the physical, mechanical, and corrosion characteristics of these materials. Thermal barrier coatings (TBCs) are applied as thin layers on the surfaces of these materials to further increase the operating temperatures. The current state-of-the-art TBC material in commercial use is partially yttria-stabilized zirconia (YSZ), which is applied on engine components by plasma spraying or by electron-beam physical vapor deposition. At temperatures higher than 1000 C, YSZ layers are prone to sintering, which increases thermal conductivity and makes them less effective. The sintered and densified coatings can also reduce thermal stress and strain tolerance, which can reduce the coating s durability significantly. Alternate TBC materials with lower thermal conductivity and better sintering resistance are needed to further increase the operating temperature of turbine engines.

Bansal, Narottam P.↗

Investigative study of holographic recording materials development

The potential of certain cis-trans isomers and doped LiNbO3 for the holographic read/write/erase memory application was investigated. The cis-trans work involved the photochemical investigation of a number of potential materials as well as specific molecular engineering efforts on alpha-methyl stilbene and its derivatives. These efforts resulted in an increase in the change in index of refraction, and thereby, in potential recording utility, of an order of magnitude. The work on LiNbO3 was directed toward a preliminary investigation of the dynamics of the writing process. Several samples and a variety of writing conditions were investigated. An unexpected and as yet unexplained improvement in material behavior with continued recycling was observed. In addition, some effort was devoted to an analysis of the physical conditions under which several current theories of the optical damage process are valid.

Source record↗

Holographic recording materials development

The area of organic cis-trans photoisomerization systems for holographic memory applications was examined. Photochemical studies were made of stilbene, indigo, and thioindigo derivatives in solution and in a variety of polymer matrix materials, to optimize the photorefractive behavior of the chemical system as a whole. Lithium niobate was used to study the writing and reading efficiencies of thick phase holograms. Both phase-wave holograms and Fourier-transform holograms were employed, and a number of reconstruction techniques are discussed. The possibility of using cis-trans photoisomerization of appropriate organic chemicals as the basis for a holographic recording system is confirmed.

Source record↗

Nano-Composite Material Development for 3-D Printers

Graphene possesses excellent mechanical properties with a tensile strength that may exceed 130 GPa, excellent electrical conductivity, and good thermal properties. Future nano-composites can leverage many of these material properties in an attempt to build designer materials for a broad range of applications. 3-D printing has also seen vast improvements in recent years that have allowed many companies and individuals to realize rapid prototyping for relatively low capital investment. This research sought to create a graphene reinforced, polymer matrix nano-composite that is viable in commercial 3D printer technology, study the effects of ultra-high loading percentages of graphene in polymer matrices and determine the functional upper limit for loading. Loadings varied from 5 wt. % to 50 wt. % graphene nanopowder loaded in Acrylonitrile Butadiene Styrene (ABS) matrices. Loaded sample were characterized for their mechanical properties using three point bending, tensile tests, as well as dynamic mechanical analysis.

36 MATERIALS SCIENCE↗