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DOE OSTI2022

Experimental validation of the mechanistic scale-up methodology of gas–solid spouted beds using radioactive particle tracking (RPT)

The very high-temperature reactors (VHTRs) are highly ranked among candidates of Generation IV of nuclear reactors due to their high efficiency, safety, the resistance to proliferation, and reliability. The VHTRs are preferentially fueled by Tristructural-isometric (TRISO) coated fuel particles which has fuel kernels of fissile material coated by four coating layers: a porous buffer pyrolysis carbon layer (buffer PyC), an inner dense pyrolysis carbon layer (IPyC), a silicon carbide layer (SiC) and an outer dense pyrolysis carbon layer (OPyC). The heart of the operation and safety of the VHTRs significantly depends on the reliability of the coating layers of TRISO particles to retain metallic and gaseous fission products within the particles. The technique used for coating TRISO particles are gas-solids spouted beds via chemical vapor deposition (CVD). Fabrication of high-quality low-defect TRISO fuel particles fuel at larger scale spouted beds is required to support the commercialization of the VHTRs. In this work, our new developed mechanistic scale-up methodology of gas-solids spouted beds based on matching the radial profile of gas-holdup has been demonstrated and validated using radioactive particle tracking (RPT). Two spouted beds of small and larger scales were used in the study. Three sets of conditions were carried out which include the conditions of the reference case in the large scale, conditions that provide similar gas holdup radial profile to that of the reference case and conditions that provided dissimilar gas holdup radial in the small-scale spouted beds. The results confirm the validation of the scale-up methodology in terms of the dimensionless values of the spout diameter, cumulative probability distribution of the solids particles penetration into the spout, fraction of cycle time in each region of the bed, the radial profiles of the dimensionless values of the root-mean-square particle velocities and solids eddy diffusivity. Finally, the results further advance the knowledge and understanding of the gas-solids spouted beds provide deeper insight into their solids dynamics and presenting important benchmarking data for validating computational fluid dynamics codes and models. At last, procedures are established for the implementation of the new scale-up methodology.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

A continuum framework for coupled solid deformation–fluid flow through anisotropic elastoplastic porous media

We present a continuum framework for coupled solid deformation–fluid flow in anisotropic elastoplastic porous media. A thermodynamic formulation of the coupled processes gives rise to an anisotropic Biot tensor that is a function of drained elastic tangent moduli tensor of the solid skeleton and the intrinsic bulk modulus of the solid constituent. Two effective stress measures emerge from the formulation, namely, σ', which is energy-conjugate to the elastic strain, and σ'', which is energy-conjugate to the plastic strain. For the special case of transverse isotropy that is commonly encountered in natural rocks, the Biot tensor can be expressed in terms of its normal and tangential components to the bedding plane, along with a microstructure tensor. Apart from its thermodynamic consistency, an advantage of this new formulation is that standard mixed finite element formulation can be employed to discretize the domain and solve initial boundary-value problems. We conduct plane strain simulations of coupled solid deformation–fluid flow in a transversely isotropic porous medium to demonstrate the impacts of material anisotropy, stress history, and the Biot tensor on the system response.

42 ENGINEERING↗

DOE OSTI2022

Liquid lithium wetting and percolation in a porous tungsten/liquid Li plasma facing component (PFC)

This work explores the concept of a hybrid material system designed to protect the plasma from high-Z material emission while also protecting an underlying high-Z wall material from erosion by integrating a low-Z component in the liquid phase. Plasma-surface interaction properties of a porous tungsten (W)-liquid metal hybrid system, having the favorable bulk thermomechanical properties of W while serving as a scaffold for a liquid metal with self-healing and radiative vapor shielding characteristics, are examined. W-substrates with 70% density of bulk W and 1–5 μm sized pores have been fabricated with 50-nm W powders using spark plasma sintering. Enhanced lithium (Li) wettability, driven by percolation through the porous W architecture, is demonstrated with in-situ liquid Li drop measurements. Finally, results show complete wetting of liquid Li at 250 °C in the porous W, 100 °C lower temperature than what has been observed on traditional W surfaces. In operando ion beam analysis of Li films deposited on porous W substrates provides microscopic evidence of Li percolation into the substrate and a first look at D retention up to a depth of 100 nm after plasma exposure at a flux of 10 20 m –2 s –1 , 250 eV/amu D + plasma to a fluence of 1.16 × 10 23 m –2 at a temperature of 200 °C.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Assessment of Long-Term Degradation of Adsorbents for Direct Air Capture by Ozonolysis

Porous adsorbents are a promising class of materials for the direct air capture of CO 2 (DAC). Practical implementation of adsorption-based DAC requires adsorbents that can be used for thousands of adsorption–desorption cycles without significant degradation. We examined the potential degradation of adsorbents by a mechanism that appears to have not been considered previously, namely, ozonolysis by trace levels of ozone from ambient air. We focused on amine-appended metal–organic frameworks, specifically amine-functionalized Mg 2 (dobpdc), as a representative DAC adsorbent. Estimates based on the number of amine sites in these adsorbents and the ozone concentration in air suggest that degradation by ozone may be relevant over thousands of adsorption–desorption cycles if reactions with adsorbed ozone are fast. We used density functional theory calculations to estimate reaction rates for amine groups and carbon–carbon double bonds in amine-functionalized Mg 2 (dobpdc).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Evolution of Electronic Properties of Graphene Nanoribbons with Progressive Carving: From Straight to Porous to Chevron Ribbons

Graphene nanoribbons (GNRs) are highly versatile materials due to their unique electronic, magnetic, and optical properties, which can be precisely tuned by controlling their width, edge structure, and topology. Here, we report the on-surface synthesis and characterization of a straight N = 15 armchair GNR with periodic annulene nanopores (15-pGNR). It serves as a structural link between two well-established GNRs: the pristine N = 15 armchair GNR without pores (15-AGNR) and the chevron GNR (cGNR). With the addition of the 15-pGNR reported in this study, these three GNRs form a rare experimentally accessible series of ribbons, in which the evolution of electronic properties can be tracked upon progressive carving of a basic 15-AGNR: first, by creating periodic nanopores to form 15-pGNR and then by extending the pore area and producing meandering cGNR. We have designed a molecular precursor for the 15-pGNR and grown the nanoribbons on single-crystal gold substrates by on-surface synthesis in ultra-high vacuum (UHV) conditions. The atomically precise structure of 15-pGNR was confirmed by scanning tunneling microscopy (STM) and non-contact atomic force microscopy (nc-AFM). The band gap of 15-pGNR was studied by scanning tunneling spectroscopy (STS) and dI/dV mapping, and the occupied electronic levels were investigated by angle-resolved photoemission spectroscopy (ARPES). A theoretical and experimental comparison of 15-pGNRs, 15-AGNRs, and cGNRs demonstrates that the introduction of periodic nanopores into 15-AGNR leads to a more than 2-fold increase in its band gap. In contrast, the band gaps of 15-pGNR and cGNR differ only by about 15%. Such band gap increase can be qualitatively understood to arise from two combined effects, the periodic perforation of the graphene lattice and the confinement effect induced by the GNR width.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2023

Synthesis and Characterization of Carbon Microbeads

We report a microfluidic-based droplet generation platform for synthesizing micron-sized porous carbon microspheres. The setup employs carbon materials such as graphite, carbon nanotubes, graphene, fullerenes, and carbon black as starting materials. Custom composition, structure, and function are achieved through combinations of carbon materials, cross-linkers, and additives along with variations in process parameters. Carbon materials can be assembled into spheres with a mean diameter of units to hundreds of μm with relatively tight size distribution (<25% RSD). Pore structure and size (tens to hundreds of angstrom) can be modulated by incorporating porogen/coporogen dilutants during synthesis. The microbeads have excellent mechanical stability with an elastic modulus of hundreds of MPa. They can sustain high dynamic fluid flow pressures of up to 9000 psi. This work lays the foundation for synthesizing novel tailorable and customizable carbon microbeads. It opens avenues for applying these novel materials for composite and additive manufacturing, energy, life science, and biomedical applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Characterization and Sampling of Ultralow Permeability Geomaterials using Electrokinetics (LDRD Final Report 209234)

This final report on Laboratory Directed Research and Development (LDRD) project 209234 presents background material for electrokinetics at the pore and porous media scales. We present some theoretical developments related to uncoupling electrokinetic flow solutions, from a manuscript recently accepted into Mathematical Geosciences for publication. We present a summary of two pore-scale modeling efforts undertaken as part of the academic alliance with University of Illinois, resulting in one already submitted journal publication to Transport in Porous Media and another in preparation for submission to a journal. We finally show the laboratory apparatus built in Laboratory B59 in Building 823 and discuss some of the issues that occurred with it.

58 GEOSCIENCES↗

NASA NTRS1973

Surface brightness temperatures at the Apollo 17 heat flow site - Thermal conductivity of the upper 15 cm of regolith

Lunar surface brightness temperatures derived as part of the Apollo 17 heat flow experiment are reported. Nighttime surface temperatures, calculated from the data provided by two thermocouples suspended about 15 cm above the lunar surface, are used to determine the conductivity profile of the upper 15 cm of regolith at the ALSEP site. The surface reaches a maximum temperature of 384 (plus or minus 6) K at lunar noon and cools to a minimum temperature of 102 (plus or minus 1.5 K) at the end of the lunar night. Conductivities of the order of .000015 W/cm-deg K are postulated for a 2-cm porous surface layer overlying more compact regolith material with conductivities in the range of .0001 to .00015 W/cm-deg K between 2 and 15 cm. A mean surface temperature of 216 (plus or minus 5) K is deduced from the thermocouple data. The 256 K temperature measured by the probe sensors at 130 cm thus indicates that a large mean temperature gradient exists at the Apollo 17 site.

Keihm, S. J.↗

NASA NTRS1984

Design and performance analysis of a conical-aerobrake, orbital-transfer vehicle concept

A Shuttle-compatible systems design based on the core concept of attachable modules for the major vehicle components is proposed. The principal features include a disposable cargo/extra-propellant tank module; a porous, radiative, backscattering drag-brake surface material of thin silica cloth; and a lightweight carbon-composite support structure. The mission payload capability for delivery, retrieval, and combined operations is determined for a broad range of missions including NASA/DOD requirements and extending through cis-lunar space. The effects of finite-rate surface catalysis, negative lift, and multiple atmospheric passes in reducing the aerothermal heating rates are also investigated. In addition, the structural and thermal-protection problems of the drag-brake support apparatus are analyzed and recommendations are proposed for future design refinements.

Menees, G. P.↗

NASA NTRS1985

Capsulation of moldings made from silicon ceramic material

Ceramic articles are potted for hot isostatic pressing by porous glass and/or ceramic coating which is sintered to a pressure-tight coating in vacuo. Thus, a powdered SiO2 glass mixture with saturated alcohol sterin is sprayed on a SI3N4 ceramic, dried, introduced into the press which is evacuated to less than 0.013 mbar and heated to approximately 1200 C to drive off the organic binder and leave a powdered glass coating on the ceramic. The coating is sintered by heating to approximately 1200 C for 0.5 to 2 hours and forms a tight gass-impermeable layer. The press is heated to approximately 1700 C at 1000-300 bar and isostatic pressing is performed in the conventional manner.

Rossmann, A.↗

NASA NTRS1993

Preliminary experimental results for a cryogenic brush seal configuration

Preliminary fluid nitrogen flow data are reported for a five-brush, ceramic-coated-rub-runner brush seal system, where the brushes and the rub runner were placed at each end of a centrally pressurized multifunction tester ('back-to-back' set of brushes) and tested at rotor speeds of 0, 10, 18, and 22.5 krpm. After testing, both the brushes and the ceramic-coated rub runner appeared pristine. The coating withstood both the thermomechanical and dynamic loadings with minor wear track scarring. The bristle tips showed some indication of material shearing (smearing) wear. The Ergun (1952) porous flow equation was applied to the brush seal data. The Ergun relation fit the gaseous data but was in poor agreement with the fluid results. The brush seal exit conditions were two phase. Two-phase, choked-flow design charts were applied but required one data point at each rotor speed to define the flow and area coefficients. Reasonable agreement between prediction and data was found, but such methods are not to be construed as two-phase-flow brush seal analyses.

Carlile, J. A.↗

DOE OSTI2020

Porous architecture and thermal properties of thermal barrier coatings deposited by suspension plasma spray

Besides the intrinsic low heat transfer capability of material, the thermal insulation property of thermal barrier coatings (TBCs) also relies on their microstructures. For better understanding the relationship between process parameters, porous architecture, and thermal properties of coatings, YSZ coatings were firstly manufactured by suspension plasma spray (SPS). Afterwards their total porosities were characterized by using the technique of X-ray transmission, the nano/submicro pores in those coatings were detected with Ultra-Small Angle X-ray Scattering (USAXS), and the thermal properties of coatings were measured using the laser flash method. The results indicated that: i) the porous architecture of SPS coatings can be tailored by adapting process parameters. ii) increasing total porosity is an effective means for reducing the heat transfer capability of SPS coatings. iii) nano/submicro pores have higher influence sensitivity on thermal properties than that of larger pores. Increasing the content of nano-submicro pores is therefore more effective for improving the thermal insulation property of SPS coatings. The potential of SPS technique for fabricating TBCs was discussed as well.

36 MATERIALS SCIENCE↗

NASA NTRS2026

PROTECT: Production and Reuse of Thermally Efficient Ceramic Thermal Protection Systems

PROTECT (Production and Reuse Of Thermally Efficient Ceramic TPS) is a NASA Early Career Initiative focused on developing the next generation of reusable ceramic thermal protection systems (TPS). This project addresses key challenges in TPS design, including temperature capability, thermal stability, and refurbishment time, by integrating novel material development with predictive modeling. Leveraging enhanced capabilities in NASA’s Porous Microstructure Analysis (PuMA) software, PROTECT introduces new modeling tools to predict the thermal and mechanical behavior of fibrous ceramic materials. These tools enable accurate prediction of performance metrics such as thermal conductivity and structural integrity, reducing reliance on costly physical testing. Preliminary advances in these areas will be presented. To support model validation, PROTECT is building a comprehensive database of raw material properties using advanced characterization techniques, including micro computed tomography (CT) scanning in collaboration with the University of Illinois Urbana-Champaign (UIUC). The presentation will detail the sampling workflows and analysis methods used to generate this detailed microstructural data and how it is used to develop improved models in PuMA. This multi-center collaboration, spanning NASA (JSC, ARC, KSC, GRC), Oak Ridge National Laboratory, UIUC, and SpaceX, is developing tailored TPS solutions for LEO, lunar, and Martian missions. By bridging heritage systems with the demands of modern spaceflight, PROTECT contributes to the advancement of reusable TPS technologies for future exploration missions.

Propulsion, Refractory, and Coating Materials↗

NASA NTRS2026

PROTECT: Production and Reuse of Thermally Efficient Ceramic Thermal Protection Systems

Propulsion, Refractory, and Coating Materials↗

NASA NTRS2005

Surface Collisions Involving Particles and Moisture (SCIP'M)

Experiments were performed on the collision of a solid sphere with a nearly horizontal flat surface covered with a thin layer of viscous liquid. High-speed collisions were obtained by dropping the ball onto the surface from various heights, using gravitational acceleration. Low-speed collisions were obtained using pendulums with long strings or by launching the balls at low velocities in the reduced-gravity environment of parabolic flight. The sphere bounces only when the impact velocity exceeds a critical value. The coefficient of restitution (ratio of rebound velocity to impact velocity) increases with increasing impact velocity above the critical value, indicating the increasing relative importance of elastic deformation to viscous dissipation. The critical impact velocity increases, and the coefficient of restitution decreases, with increasing viscosity or thickness of the liquid layer and with decreasing density or size of the sphere. The ratio of the wet and dry coefficients is expressed as a function of the Stokes number (ratio of particle inertia and viscous forces), showing good agreement between theory and experiment. Similar experiments were performed with the flat surface inclined at various angles to the approaching sphere. A modified Stokes number, which is a measure of the ratio of inertia of the sphere in the normal direction to the viscous forces exerted by the fluid layer, was used for the analysis of oblique collisions. Even for these oblique collisions, it was found that no rebound of the ball was observed below a certain critical Stokes number. The coefficient of normal restitution, defined as a ratio of normal rebound velocity to normal approach velocity, was found to increase beyond the critical Stokes number and even out as it approaches the value for dry restitution at high Stokes numbers. It was also found that, for smooth spheres like steel, the normal restitution at the same modified Stokes number is independent of the angle of impact. The tangential coefficient of restitution, defined as the ratio of tangential rebound velocity to tangential approach velocity, is found to be nearly unity, except for very low approach velocities. Thus, as a first approximation, the theories that predict the coefficient of restitution for head-on wet collisions can be extended to predict the coefficient of normal restitution for oblique wet collisions. Additional experiments were performed with soft surfaces in which a porous cloth or sponge layer was placed over the hard, flat surface. In these experiments, the coefficient of restitution was found to decrease with increasing impact velocity, due to inelastic losses in the soft material. A model combining inelastic deformation and flow through porous media was developed to describe these findings.

Davis, Robert H.↗

DOE OSTI2021

Center for Gas Separations (CGS)

The total energy consumption in the U.S. has been rising steadily for decades, and it currently amounts to ~98,000 TBtu/yr, with approximately 30% of this total attributable to the industrial sector. Reasonable estimates indicate that 45–55% of total industry energy consumption derives from chemical separations, and for example, over 120 TBtu/yr alone is used in carrying out olefin/paraffin separations via energy-intensive cryogenic distillation. Therefore, the pursuit of new, even radically different approaches to some of the most energy-intensive industrial separations processes is an imperative scientific pursuit for reducing energy consumption toward a more sustainable future. Adsorbent and membrane-based separations can require a fraction of the energy needed for distillation methods, and as such are considered promising solutions for balancing increasing energy demand in the U.S. with the need for a massive reduction in energy consumption. Although considerable research effort has been devoted to the design of materials capable of carrying out various gas separations, usually operating through size-selective, chemisorptive, or physisorptive mechanisms, it remains a great challenge to design materials that function adequately for real-world applications. Indeed, the chemical and physical differences between molecules in gas mixtures of interest are often small, and therefore it is necessary, through the use of nanoscience and synthetic chemistry, to engineer unprecedented molecular-level control in adsorbate–adsorbent interactions. The overarching mission of the Center for Gas Separations (CGS) was to discover fundamental innovations that have the potential to dramatically reduce the energy associated with critical gas separations. In particular, the CGS developed novel synthetic routes, guided by molecular chemistry principles, as well as advanced characterization and computational methods, that have enabled the discovery of new materials and membranes tailor-made to exhibit exceptional performance for a range of gas separations processes, as required in the clean use of fossil fuels and in reducing CO 2 emissions from industry. A challenge of this magnitude required the collaboration and synergy of a large team of researchers with expertise in materials synthesis, characterization, and computations. During the 11-year project period, the CGS created a range of new materials within the family of highly-tunable, porous solids known as metal–organic frameworks (MOFs). These new frameworks demonstrate novel mechanisms for key industrial gas separations, including revolutionary new cooperative adsorption processes that enable low-energy CO 2 and CO capture, and are capable of efficiently separating olefins from paraffins, O 2 from air, and the shape-selective separation of alkane isomers. In addition, the CGS developed new strategies for incorporating these materials into composite membranes toward highly efficient and selective membrane-based separations. As a testament to the success of the CGS, two start-up companies, Mosaic Materials,4 Inc. and Flux Technology, Inc., grew out of these research efforts, and these companies are seeking to commercialize MOF and composite membranes materials for key separations in industry, including large-scale CO 2 capture and hydrocarbon separations, respectively. Another company, framergy, Inc., licensed IP resulting from CGS research toward the commercialization of adsorbents for various energy-relevant applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2014

Development of a Batch Fabrication Process for Chemical Nanosensors: Recent Advancements at NASA Glenn Research Center

A major objective in aerospace sensor development is to produce sensors that are small in size, easy to batch fabricate and low in cost, and have low power consumption. Chemical sensors involving nanostructured materials can provide these characteristics as well as the potential for the development of sensor systems with unique properties and improved performance. However, the fabrication and processing of nanostructures for sensor applications currently is limited by the ability to control their location on the sensor platform, which in turn hinders the progress for batch fabrication. This presentation will discuss the following: the development of a novel room temperature methane (CH4) sensor fabricated using porous tin oxide (SnO2) nanorods as the sensing material, the advantages of using nanomaterials in sensor designs, the challenges encountered with the integration of nanostructures into microsensordevices, and the different methods that have been attempted to address these challenges. An approach for the mass production of sensors with nanostructures using a method developed by our group at the NASA Glenn Research Center to control the alignment of nanostructures onto a sensor platform will also be described.

Nanotechnology↗

DOE OSTI2024

Operando visualization of porous metal additive manufacturing with foaming agents through high-speed x-ray imaging

Porous metals find extensive applications in soundproofing, filtration, catalysis, and energy-absorbing structures, thanks to their unique internal pore structure and high specific strength. In recent years, there has been an increasing interest in fabricating porous metals using additive manufacturing (AM), leveraging its unique advantages, including improved design freedom, spatial material control, and cost-effective small-batch production. In this study, we conducted pioneering operando visualization of AM porous metal using a laser powder bed fusion (L-PBF) setup combined with a high-speed synchrotron x-ray imaging system. Single track printing experiments using Ti6Al4V (Ti64) combined with titanium hydride (TiH 2 ) and sodium carbonate (Na 2 CO 3 ) as foaming agents, with varying mixing ratios were performed under different processing conditions. Here. the results elucidate the dynamic development of porosity formation. The average pore size is significantly influenced by the particle size of foaming agents when pore coalescence is absent. For all foaming agent content tested in the current study, the number of pores is found to be more sensitive to changes in laser power than in laser scanning speed. Increasing linear energy density (increasing laser power or reducing laser scanning speed) promotes the foaming agent activation thereby porosity formation. However, high linear energy density skews pore distribution towards the surface despite forming deeper melt pools. In addition, the impact of additional factors including foaming agent's laser absorptivity and decomposition kinetics with respect to AM time scales should be carefully considered to avoid ineffective activation of foaming agents during the AM of porous metals.

36 MATERIALS SCIENCE↗