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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

Multiscale mechanical design of the lightweight, stiff, and damage-tolerant cuttlebone: A computational study

Cuttlebone, the endoskeleton of cuttlefish, offers an intriguing biological structural model for designing low-density cellular ceramics with high stiffness and damage tolerance. Cuttlebone is highly porous (porosity ~93%) and lightweight (density less than 20% of seawater), constructed mainly by brittle aragonite (95 wt%), but capable of sustaining hydrostatic water pressures over 20 atmospheres and exhibits energy absorption capability under compression comparable to many metallic foams (~4.4 kJ/kg). Here, in this work, we computationally investigate how such remarkable mechanical efficiency is enabled by the multiscale structure of cuttlebone. Using the common cuttlefish, Sepia Officinalis, as a model system, we first conducted high-resolution synchrotron micro-computed tomography (µ-CT) and quantified the cuttlebone's multiscale geometry, including the 3D asymmetric shape of individual walls, the wall assembly patterns, and the long-range structural gradient of walls across the entire cuttlebone (ca. 38 chambers). The acquired 3D structural information enables systematic finite-element simulations, which further reveal the multiscale mechanical design of cuttlebone: at the wall level, wall asymmetry provides optimized energy absorption while maintaining high structural stiffness; at the chamber level, variation of walls (number, pattern, and waviness amplitude) contributes to progressive damage; at the entire skeletal level, the gradient of chamber heights tailors the local mechanical anisotropy of the cuttlebone for reduced stress concentration. Our results provide integrated insights into understanding the cuttlebone's multiscale mechanical design and provide useful knowledge for the designs of lightweight cellular ceramics.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Development of a silicon carbide ceramic based counter-flow heat exchanger by binder jetting and liquid silicon infiltration for concentrating solar power

A silicon carbide ceramic counter-flow heat exchanger with integrated headers was printed by binder jetting additive manufacturing process. Multiple phenolic binder infiltration cycles (3 or 5) followed by pyrolysis were conducted to increase the net carbon content of the printed SiC specimens. Subsequently, to attain full densification, silicon melt infiltration was used. The microstructure and mechanical properties were comprehensively characterized on the densified material. The chemical compositions and visual distribution of the various regions in the specimens were determined via scanning electron microscopy, while X-ray diffraction and synchrotron µ-computed tomography were used to provide a quantitative assessment of the volume fractions of the identified phase regions. Microhardness measurements showed dependence on the local microstructure. The fracture strength of the material was correlated with the specimen density and agreed with the reported values in the literature. High-temperature exposure at 750 °C for up to 200h did not degrade the strength for the specimens with three phenolic-binder infiltrations; however, the strengths degraded for ones with five phenolic-binder infiltrations. The associated fracture toughnesses of the specimens were ~3.4 MPam 1/2 at room temperature and 750°C, and the thermal conductivities varied from >150 W/mK at room temperature to ~45 W/mK at 750°C. Hence, this study validated the use of the binder-jetting printed SiC ceramic materials for high-temperature heat exchanges. Lastly, we also present in this work the first successful fabrication of a binder-jetting printed one-piece dense SiC ceramic heat exchanger body with unblocked channels that can be used for the flow of heat transfer fluids.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Influence of crystal structure on constitutive anisotropy of silica sand at particle-scale

In spite of recent advanced geotechnical research regarding the influence of particle-scale morphology and fabric on the constitutive behavior of silica sands, there is still no published literature that investigated the influence of crystal structure of sand particles on their constitutive behavior. The main constituent of silica sand particles is quartz mineral, which has a trigonal crystal system and hexagonal lattice. This paper investigates the influence of quartz crystal structure on the constitutive response of silica sand particles using 3D X-ray diffraction (3DXRD), synchrotron micro-computed tomography (SMT), and 3D finite element (FE) analysis. Here, unconfined uniaxial compression experiments on single particles of synthetic silica cubes exposed the notion of constitutive anisotropy caused by the crystal structure of quartz. Since the silica cubes have simple regular geometry (1 mm) 3 , they were loaded in different directions with respect to their crystal local planes. The crystal structure was also identified for a natural silica sand specimen composed of 2705 particles and loaded in confined uniaxial compression. Physical limitations of the experimental measurements made a strong case for the use of 3D FE analysis to study how the change in crystal local orientation of individual sand particles can fundamentally produce anisotropy in the constitutive response of natural sand specimens. The 3D FE analysis was validated to accurately model the crystal-based constitutive anisotropy in silica particles using the results of the silica cube experiments. The analysis was then executed on 3D FE meshes that closely matched the physical shape and fabric of the 2705 particles in the natural sand specimen. Both the experiments and 3D FE analysis showed that the crystal structure of quartz essentially causes a directional anisotropy in the constitutive behavior of silica particles.

58 GEOSCIENCES↗
DOE OSTI2025

Influence of gradation on shear behavior and pore water response of sand

Here, this paper examines the influence of particle size distribution (PSD) on the shearing behavior of sand using axisymmetric triaxial compression (ATC) testing in conjunction with 3D imaging using synchrotron micro-computed tomography (SMT). Angular sand was sieved to obtain a narrow gradation (uniform) and a wide gradation (non-uniform) with uniformity coefficients (C u ) of 1.2 and 3.0, respectively. Experiments were conducted under drained conditions and a constant effective cell pressure (σ$^{'}_3$) of 50 kPa at low and high back pressures (BP). Results of paired ATC-SMT were analyzed in terms of global constitutive behavior, strain localization, and localized flow characteristics. A new particle tracking algorithm is developed to expose strain localization. Relative particle translation gradient (RPTG) results revealed that gradation affects how early the shear band develops and a tendency for narrow gradation to exhibit varying degrees of diffused shear band at high axial strain (ε 1 ) even though a clear single shear band was observed at the peak strength. Geometric tortuosity (τ) is used as a quantitative parameter to assess flow changes and the efficiency of the flow path. Representative elementary volumes (REVs) inside and outside the shear band were analyzed and the results showed a variation in flow path characteristics where wide gradation specimens had preferential flow paths.

Computed tomography↗
DOE OSTI2025

Influence of Initial fabric and water-wetting on particle fracture and force chain evolution in natural silica sand

Particle fracture has a significant influence on the engineering behavior of granular materials. However, the combined influence of the initial fabric and wetting on particle fracture and force chain evolution in granular materials, particularly in sands, remains insufficiently explored in the current literature. Here, in this paper, one-dimensional (1D) confined compression experiments were conducted on dry and wet specimens, and particle-level fracture was captured using three-dimensional (3D) in-situ Synchrotron Micro-Computed Tomography (SMT). A quantitative assessment of particle fracture revealed that wet specimens, which have disturbed fabric, exhibited a higher fracture percentage in comparison to dry specimens. Complementary 3D finite element (FE) simulations were performed using dry and wet (only solid fabric was considered and the influence of pore water is not considered) sand assemblies to assess interparticle contact forces and particle-scale stress distributions within the specimens. Force chain analysis was subsequently conducted, encompassing quantification of interparticle forces, characterization of force network structures, and monitoring the dynamic evolution of force chains under different strain levels. The results show that the specimens with disturbed fabric led to a more dynamic and less persistent force network, more fabric instability, and thus more reorganization of force chain structures. In addition, the frequent rearrangement of the force network in the presence of water (with reduced inter-particle contact friction) likely exacerbates localized stress concentrations, promoting failure in previously unengaged or weakly connected particles. The results reported in this paper offer a new insight into how the initial fabric and wetting cause different fracture behavior. The findings can also pave the way for more in-depth future investigations into the mechanics governing particle fracture in granular assemblies.

Finite element analysis↗
DOE OSTI2025

Surface smoothing for laser powder-bed Ti-6Al-4V by a transient liquid phase

Surface roughness is the primary driver of fatigue for additively manufactured metals. To address surface roughness, this work introduces a new method to smooth features beyond line-of-sight without material removal. The method applies a coating that triggers local surface remelting by activating a eutectic reaction during heat treatment. The associated liquid phase then wets and isothermally solidifies into a smoother surface. For Ti-6Al-4V fabricated with laser powder bed fusion, samples with and without TLP smoothing (using a Cu coating) were characterized with a suite of techniques, including mechanical testing, electron backscatter diffraction, synchrotron X-ray tomography, and fractography. TLP smoothing reduced surface roughness by 80% and amplified compressive residual stress at the surface by about 50%. With statistically equivalent virtual microstructures, crystal plasticity scrutinized the roles of phases, porosity, and surface roughness. Although the tensile strain-to-failure was reduced to 1% strain, the TLP smoothing process increased high-cycle fatigue strength by about 20% compared to control samples, pointing to future opportunities to optimize the new process through various coating compositions and heat treatment schedules. Overall, this work establishes a new paradigm for treating surfaces of materials for smoothness and compressive residual stress.

Additive manufacturing↗
DOE OSTI2023

Two-layer cathode architecture for high-energy density and high-power density solid state batteries

Solid state batteries with high-energy density and high-power density require the development of thick and energy dense cathodes. Structured cathode electrodes with a double-layer configuration were enabled using a freeze tape casting technique. A bottom dense layer was utilized to enhance the energy density whereas a top porous layer with vertically aligned walls was utilized to enhance the power density. The porous structure of the power layer was achieved by ice templating this layer on top of the densified energy layer of the cathode. This configuration was found to better utilize the active material of the cathodes and was optimized using numerical simulation and computer modeling. Cells with Li metal anode and LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) at approximately 5 and 20 mg/cm 2 were cycled at 70 °C at different C-rates. Poly(ethylene oxide) (PEO) with lithium bis-trifluoromethanesulfonimide (LiTFSI) was used for the catholyte and the solid-state electrolyte. The structured cathodes exhibited more than double capacity values as well as better Coulombic efficiency compared to non-structured (single-layer) thick cathodes. In conclusion, synchrotron X-ray tomography and scanning electron microscopy were used to characterize the microstructure of the cathodes.

25 ENERGY STORAGE↗
DOE OSTI2020

Fractal breakage of porous carbonate sand particles: Microstructures and mechanisms

In situ, three-dimensional (3D) characterizations of particle breakage in porous carbonate sands are presented, for the first time, with synchrotron-based micro computed tomography. Evolution of grain-scale characteristics are identified and quantified via elaborate image processing and topology analyses. The sequential 3D images reveal distinctly different fracture mechanisms for carbonate sands from silica sands. The angular shape of carbonate sand particles facilitates bending fracture, and particles with a lower sphericity and a higher porosity are more prone to break. 3D crack networks extracted from fractured particles imply considerable cleavage along initial pores. The fractal dimension of crack networks increases with external loading due to crack branching via cleavage. The resultant fragment size distribution also appears fractal and the fractal feature is valid down to the breakage limit of calcium carbonate. Crack propagation along the initial pores reduces the energy barrier for particle breakage and thus fracture strength of particles

Carbonate sands↗
DOE OSTI2020

Deformation Precursors to Catastrophic Failure in Rocks

Forecasting the timing of catastrophic failure, such as crustal earthquakes, has been a central concern for centuries. Such forecasting requires identifying signals that evolve or accelerate in the precursory phase leading to failure, and the subset of signals that may be detected in the crust. We develop machine learning models to predict the proximity of catastrophic failure in synchrotron X-ray tomography triaxial compression experiments on rocks using characteristics of evolving fracture networks. We then examine the characteristics that most strongly influence the model results, and thus may be considered the best predictors of the proximity of macroscopic failure. Finally, the resulting suite of predictive parameters underscores the importance of dilation in the precursory phase leading to catastrophic failure. The results indicate that the evolution of the strain energy density field may provide more robust predictions of the proximity of failure than other existing metrics of rock deformation.

58 GEOSCIENCES↗
DOE OSTI2020

Quantitative probing of the fast particle motion during the solidification of battery electrodes

Synchrotron x-ray tomography represents one of the most powerful imaging techniques that can visualize the three-dimensional microstructural complexity with a high spatial resolution. To date, however, the temporal resolution of this technique has been handicapped by the intrinsic limitations in the data acquisition speed and the lack of a suitable data processing method. The present study aims to fundamentally resolve this challenge by implementing a data analysis method that is based on differentiating discrete tomography reconstruction from a continuous scan reconstruction. With this methodological development, we capture and quantify the particle motion during the solidification of battery electrodes and reveal the statistics of the dynamically evolving motion in the drying process, which has been challenging to resolve. We discover that the particle motion exhibits a strong dependence on its geometric location within a drying electrode. Our results also imply that the final electrode quality can be controlled by balancing the solvent evaporation rate and the particle mobility in the region close to the drying surface.

25 ENERGY STORAGE↗
DOE OSTI2023

Assessing continuum plasticity postulates with grain stress and local strain measurements in triaxially compressed sand

Critical state and continuum plasticity theories have been used in research and engineering practice in soil and rock mechanics for decades. These theories rely on postulated relationships between material stresses and strains. Some classical postulates include coaxiality between stress and strain rates, stress–dilatancy relationships, and kinematic assumptions in shear bands. Although numerical and experimental data have quantified the strains and grain kinematics in such experiments, little data quantifying grain stresses are available. Here, we report the first-known grain stress and local strain measurements in triaxial compression tests on synthetic quartz sands using synchrotron X-ray tomography and 3D X-ray diffraction. We use these data to examine the micromechanics of shear banding, with a focus on coaxiality, stress-dilatancy, and kinematics within bands. Our results indicate the following: 1) elevated deviatoric stress, strain, and stress ratios in shear bands throughout experiments; 2) coaxial principal compressive stresses and strains throughout samples; 3) significant contraction along shear bands; 4) vanishing volumetric strain but nonvanishing stress fluctuations throughout samples at all stages of deformation. Our results provide some of the first-known in situ stress and strain measurements able to aid in critically evaluating postulates employed in continuum plasticity and strain localization theories for sands.

42 ENGINEERING↗
DOE OSTI2025

Defect-Free Growth of Decagonal Quasicrystals around Obstacles

Quasicrystals are aperiodic solids with exotic physical properties. The mechanisms driving their growth are far from understood, particularly in the presence of rigid obstacles. Here, using in situ synchrotron x-ray tomography and molecular dynamics simulations, we investigate the interaction between decagonal quasicrystals and obstacles (shrinkage pores) during solidification of an Al 79 ⁢Co 6 ⁢Ni 15 alloy. The results reveal defect-free quasicrystal growth around the pores, independent of pore size and geometry. Our findings point to a universal feature of aperiodic solids: their ability to accommodate structural disruptions due to additional (phasonic) degrees of freedom. This Letter opens new possibilities for synthesizing large-scale, single quasicrystals from a liquid metal precursor.

alloys↗
DOE OSTI2020

Computational Modeling of Heterogeneity of Stress, Charge, and Cyclic Damage in Composite Electrodes of Li-Ion Batteries

Charge heterogeneity is a prevalent feature in many electrochemical systems. In a commercial cathode of Li-ion batteries, the composite is hierarchically structured across multiple length scales including the sub-micron single-crystal primary-particle domains up to the macroscopic particle ensembles. The redox kinetics of charge transfer and mass transport strongly couples with mechanical stresses. This interplay catalyzes substantial heterogeneity in the charge (re)distribution, stresses, and mechanical damage in the composite electrode during charging and discharging. We assess the heterogeneous electrochemistry and mechanics in a LiNi x Mn y Co z O 2 (NMC) cathode using a fully coupled electro-chemo-mechanics model at the cell level. A microstructure-resolved model is constructed based on the synchrotron X-ray tomography data. We calculate the stress field in the composite and then quantitatively evaluate the kinetics of surface charge transfer and Li transport biased by mechanical stresses. We further model the cyclic behavior of the cell. The repetitive deformation of the active particles and the weakening of the interfacial strength cause gradual increase of the interfacial debonding. The mechanical damage impedes electron transfer, incurs more charge heterogeneity, and results in the capacity degradation in batteries over cycles.

25 ENERGY STORAGE↗
DOE OSTI2024

Experimental investigation of the influence of drainage condition on change in saturation of sheared sand

Here, this paper investigates the validity of the interpretation of results from testing saturated axisymmetric triaxial compression (ATC) sand specimens utilising three-dimensional (3D) synchrotron micro-computed tomography (SMT) to probe localised events that are completely missed or misinterpreted when analysing ATC measurements based on global standard measurements. Drained and undrained experiments were conducted at low and high back-pressures (BPs) coupled with multiple in situ 3D SMT to acquire high-resolution scans of the specimens at different axial strains. Specimens tested under low BP exhibited a large pore air volume change, which was not detected by the pump system that represents standard volume measurement. The increase in air volume caused a significant reduction in the degree of saturation leading to a possible transition from saturated to partially saturated constitutive behaviour. Undrained experiments exhibited a significant volume change contrary to the assumption of negligible volumetric strain for saturated undrained experiments. Air bubbles within the shear band for drained and undrained low-BP specimens showed opposite capillary pressure responses, increased for drained and decreased for undrained cases, due to the variation in the mechanism by which each of the two experiments predominantly counters the volume expansion within the shear band.

capillary pressure↗
DOE OSTI2024

Spin Textures at Conformal Surfaces and Interfaces: CRADA Final Report

The scientific and technological exploration of artificially designed three-dimensional magnetic nanostructures opens the path to exciting novel physical phenomena, originating from the increased complexity in spin textures, topology, and frustration in three dimensions. Theory predicts that the equilibrium magnetic ground state of two-dimensional systems which reflects the competition between symmetric (Heisenberg) and antisymmetric (Dzyaloshinskii-Moriya interaction (DMI)) exchange interaction is significantly modified on curved surfaces when the radius of local curvature becomes comparable to fundamental magnetic length scales. In this CRADA we performed collaboratively an experimental study of the spin texture in an 8 nm thin magnetic multilayer with growth-induced in-plane anisotropy and DMI deposited onto the curved surface of a 1.8µm long non-magnetic carbon nanowire with a 67 nm radius. The sample was fabricated in Juelich and with collaborators at BESSY in Berlin. Using magnetic soft x-ray tomography at the ALBA synchrotron in Spain, the three-dimensional spin configuration in this nanotube was retrieved with about 30nm spatial resolution. The transition between two vortex configurations on the two ends of the nanotube with opposite circulation occurs through a domain wall that is aligned at an inclined angle relative to the wire axis. Three-dimensional micromagnetic simulations support the experimental observations and represent a visualization of the curvature-mediated DMI. They also allow a quantitative estimate of the DMI value for the magnetic multilayered nanotube.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2023

Convolutional Neural Network for Segmenting Micro-X-ray Computed Tomography Images of Wood Cellular Structures

To further enhance the performance of wood products, improved tools are needed to study in situ cellular scale phenomena like mechanical deformations and moisture swelling. Micro-X-ray computed tomography (μXCT) using brilliant synchrotron light sources now has the spatial and temporal resolution for real-time visualization of phenomena in three-dimensional cellular structures. However, the tradeoff for speed includes the loss of intensity contrast between different types of materials within the imaged structure, such as cell wall and air in wood. This loss of contrast prevents traditional histogram-based segmentation methods from being used effectively. A new convolutional neural network (CNN) approach was therefore developed to segment fast μXCT images of wood into cell wall and air volumes. The fast μXCT and segmentation were demonstrated in the study of moisture swelling in loblolly pine (Pinus taeda) earlywood and latewood cellular structures conditioned at 0%, 33%, 75%, and 95% relative humidity (RH). The CNN segmentation results had a mean intersection over union (IoU) metric accuracy of 96%. Initial analysis of the swelling in the latewood revealed cell walls swelled about 25% when conditioned from 0% to 95% RH. Additionally, the widths of ray cell lumina in the transverse plane of latewood could be observed to increase at higher RH. The segmentation method presented here will facilitate future quantitative analyses in in situ μXCT studies of wood and other similar cellular materials.

Arzola-Villegas, Xavier (ORCID:0000000305369766)↗
NASA NTRSDate not supplied

Direct Measurement of the Composition of Aqueous Fluids from the Parent Body of Asteroid 162173 Ryugu

Imaging using X-ray absorption contrast by synchrotron nano-computed tomography (47.4 nm/voxel, 7keV) of a Ryugu pyrrhotite crystal (C0002-FC012-from the second touch-down site) revealed probable fluid inclusions (Fig. 1A,B) [1]. The inclusions were completely encapsuled in pyrrhotite, suggesting the fluids were trapped in the early stages of crystal growth, and filled with low-Z material. We performed Time-of Flight-Secondary Ion Mass Spectrometry (TOF-SIMS) depth profiling and high-resolution map-ping at -120°C to exposure and measure the composition of the trapped fluids in a frozen state.

M Zolensky↗
NASA NTRSDate not supplied

Update on Measurement of the Composition of Ryugu Fluid Inclusions

Imaging using X-ray absorption contrast by synchrotron nano-computed tomography of a Ryugu pyrrhotite crystal (C0002-FC012 - from the second Hayabusa2 spacecraft touch-down site) revealed probable fluid inclusions in the center of a crystal of pyrrhotite, suggesting the parent fluids were trapped in the early stages of crystal growth on Ryugu’s parent asteroid. We previously described the performance of Time-of Flight-Secondary Ion Mass Spectrometry (TOF-SIMS) depth profiling and high-resolution mapping at -120°C to expose and measure the composition of the trapped fluids in a frozen state in two Ryugu inclusions [1,2]. Here we report results from follow-on measurements of additional inclusions in the same pyrrhotite crystal, and the initial results of measurement of standards. The ultimate goal is to reveal the quantitative composition of the fluids that caused aqueous alteration, in particular the H2O:CO2 ratio, which will also facilitate cosmochemical modeling of the alteration process.

M Zolensky↗