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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,117 records · Page 62
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Supply Chain Improvement & Process Modification Printing in Tantalum

Refractory metals and alloys are distinguished by their exceptional thermophysical properties, including high melting and recrystallization temperatures, remarkable strength, and superior corrosion resistance, all of which surpass those of conventional alloys. These unique characteristics position these materials as ideal candidates for applications in extreme environments. However, their potential has historically been underexploited due to limitations in processing capabilities. Recent advancements in melt-based additive manufacturing (AM) processes present opportunities to overcome these limitations. Previous Sandia studies have successfully characterized pure tantalum produced through laser powder bed fusion (LPBF) externally at Castheon, revealing that LPBF-fabricated tantalum exhibits properties exceeding those of wrought materials. This promising outcome sparked increased interest in the internal additive manufacturing of tantalum. This project aimed to establish the new SLM 280 machine at SNL-CA to successfully produce the first tantalum prints and characterize the material. Additionally, efforts were made to enhance the machine by incorporating Inert equipment to minimize oxygen content within the print volume. The results demonstrated that internally manufactured LPBF tantalum not only met but exceeded the standards of wrought materials, even prior to the integration of the additional equipment. The inert equipment is almost successfully integrated and ready for use. Future research should focus on understanding how this equipment influences the process-structure-property relationships, as well as further optimizing the printing parameters for tantalum.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Effects of Salt Concentration, Ionic Strength, and Water Activity on the Growth of a WIPP Archaeal Isolate, Halobacterium sp.

An extremely halophilic archaeon ( Halobacterium sp., WIPP strain), isolated from WIPP halite, was tested for its ability to grow in media containing various combinations of sodium and magnesium chloride that influenced overall ionic strength and water activity. Halobacterium sp. grew well in most tested salt combinations, and its growth appeared to depend more upon the relative contribution of sodium to overall ionic strength than on other parameters. Growth rates were highest when media consisted of at least 2 M NaCl and lowest when NaCl dropped below 20% of the ionic strength (usually less than 0.5 M). High magnesium concentrations ( 1 and 1.5 M MgCh 2 ) did not prevent Halobacterium sp. growth, as long as the sodium contribution was sufficient. Water activity was not a definitive factor in determining growth, because this value did not reach an extreme lower limit in the experimental media.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

The Role of Helium on Ejecta Production in Copper

The effect of helium (He) concentration on ejecta production in OFHC-Copper was investigated using Richtmyer–Meshkov Instability (RMI) experiments. The experiments involved complex samples with periodic surface perturbations machined onto the surface. Each of the four target was implanted with a unique helium concentration that varied from 0 to 4000 appm. The perturbation’s wavelengths were λ ≈ 65 μ m, and their amplitudes h 0 were varied to determine the wavenumber ( 2 π / λ ) amplitude product k h 0 at which ejecta production beganfor Cu with and without He. The velocity and mass of the ejecta produced was quantified using Photon Doppler Velocimetry (PDV) and Lithium-Niobate (LN) pins, respectively. Our results show that there was an increase of 30% in the velocity at which the ejecta cloud was traveling in Copper with 4000 appm as compared to its unimplanted counterpart. Our work also shows that there was a finer cloud of ejecta particles that was not detected by the PDV probes but was detected by the early arrival of a “signal” at the LN pins. While the LN pins were not able to successfully quantify the mass produced due to it being in the solid state, they did provide information on timing. Our results show that ejecta was produced for a longer time in the 4000 appm copper.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Predicting Electrical Conductivity in Bi-Metal Composites

Generating high magnetic fields requires materials with not only high electric conductivity but also good strength properties in order to withstand the necessarily strong Lorentz forces. A number of bi-metal composites, most notably Cu/Nb, are considered to be good candidates for this purpose. Here, we generalize our previous work on Cu/Nb in order to predict, from theory, the dependence of electric conductivity on the microstructure and volume fraction of the less conductive component for a number of other bi-metal composites. Together with information on strength properties (taken from previous literature), the conductivity information we provide in this work can help to identify new promising candidate materials (such as Cu/Nb, Cu/Ag, Cu/W, …) for magnet applications with the highest achievable field strengths.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Nanostructured Tube Wakefield Accelerator

Unprecedented $\rm TeVm^{-1}$ acceleration gradients are modeled to be realizable using a nonlinear surface crunch-in mode in nanostructured tubes. This mode is realizable using advances in nanofabrication and solid energy density attosecond bunch compression. Three dimensional computational and analytical modeling demonstrates GeV energy gain in sub-millimeter long tubes with effective wall densities $n_{\rm t}\sim10^{22-24}\rm cm^{-3}$ and hundreds of nanometer core radius when driven by submicron near solid electron beams, $n_{\rm b}\sim0.05n_{\rm t}$. Besides the many $\rm TVm^{-1}$ average gradients, strong self-focusing and nanomodulation of the beam which increases its peak density and the wakefield strength also opens up controlled high-energy photon production.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

DESIGN AND MEASUREMENT OF THE 1.4 GHZ CAVITY FOR LEReC LINAC

The Low Energy RHIC electron Cooler (LEReC) is the first electron cooler based on rf acceleration of electron bunches. To further improve RHIC luminosity for heavy ion beam energies below 10 GeV/nucleon, a normal conducting RF cavity at 1.4 GHz was designed and fabricated for the LINAC that will provide longer electron bunches for the LEReC. It is a single cell cavity with effective cavity length shorter than half of the 1.4 GHz wavelength. This cavity was fabricated and tested on site at BNL to verify RF properties, i.e. the resonance frequency, fundamental power coupler (FPC) coupling strength, tuner system performance, and high-power tests. In this paper, we report the RF test results for this cavity.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Analog B ( M 1 ) strengths in the T z = ± 3 2 mirror nuclei Mn 47 and Ti 47

The lifetimes of the first excited 7 2 − states in the T z = ± 3 2 mirror nuclei Mn 47 and Ti 47 have been extracted utilizing the γ -ray line shape method, giving τ = 687 ( 36 ) ps and τ = 331 ( 15 ) ps respectively. Since these transitions are essentially pure M 1 transitions, these results allow for a high-precision comparison of analog M 1 strengths in mirror nuclei. The two analog B ( M 1 ) s are observed to be identical to a precision of about 10 % . The expected dependence of the transition matrix element with T z has been used to extract the separate isoscalar and isovector components of the transition strength, and the results are discussed in the context of predictions, based on the isospin formalism, regarding analog B ( M 1 ) strengths. Published by the American Physical Society 2024

39 ≤ A ≤ 58↗
DOE OSTI2022

Gas Separations using Nanoporous Atomically Thin Membranes: Recent Theoretical, Simulation, and Experimental Advances

Abstract Porous graphene and other atomically thin 2D materials are regarded as highly promising membrane materials for high‐performance gas separations due to their atomic thickness, large‐scale synthesizability, excellent mechanical strength, and chemical stability. When these atomically thin materials contain a high areal density of gas‐sieving nanoscale pores, they can exhibit both high gas permeances and high selectivities, which is beneficial for reducing the cost of gas‐separation processes. Here, recent modeling and experimental advances in nanoporous atomically thin membranes for gas separations is discussed. The major challenges involved, including controlling pore size distributions, scaling up the membrane area, and matching theory with experimental results, are also highlighted. Finally, important future directions are proposed for real gas‐separation applications of nanoporous atomically thin membranes.

2D materials↗
DOE OSTI2023

Nitrogen thermometry in an inductively coupled plasma torch using broadband nanosecond coherent anti-Stokes Raman scattering

The development of atmospheric hypersonic flight and re-entry capabilities requires the characterization of the thermo-chemical state of representative test environments. This study demonstrates the usage of multiplex nanosecond N 2 coherent anti-Stokes Raman scattering (CARS) to measure temperatures in an atmospheric, high-temperature (>6000K), air plasma plume, generated by an inductively coupled plasma torch. These are some of the highest temperatures ever accessed via gas-phase CARS, to our knowledge. Temperatures of N 2 in the equilibrium plasma plume are determined via theoretical fits to measured CARS spectra. We discuss the practical implementation of CARS at very high temperatures, including the scaling of the N 2 CARS signal strength from 300 to 6700 K, where the expected peak signal from the high-temperature plasma torch gases is two orders of magnitude less than commonly encountered in combustion environments. An intensified CCD camera enables single-laser-shot detection at temperatures as high as 6200 K, by increasing sensitivity and providing a time gate against intense background luminosity. We also discuss the impacts of unwanted two-beam CARS contributions from outside the nominal three-beam measurement volume. We present mean axial and radial temperature profiles, as well as time-series data derived from both single-laser-shot and accumulated CARS spectra. The single-laser-shot precision is 1.7%–2.6% at temperatures of 3500 to 6200 K. The presented results pave the way for the use of CARS at very high temperatures and the measurement of spatially resolved interface processes in high-enthalpy flows.

Fries, Dan (ORCID:0000000229513294)↗
DOE OSTI2022

Mechanical behavior of bimetallic stainless steel and gray cast iron repairs via directed energy deposition additive manufacturing

The utility of gray cast iron in engine components remains tied to the mechanical performance and cost. Repair and remanufacturing of castings offer economical and sustainable benefits; however, high thermal input from traditional fusion-based welding is unable to restore the original mechanical quality owing to brittle microstructures and porosity formed in situ. Directed energy deposition (DED) is an additive manufacturing method that has received considerable interest for repairs owing to the highly controllable nature of the process. Despite this, few works have connected the effect of DED parameters on actual interfacial strength. Consequently, distinct DED parameter combinations were identified to maximize the strength and fatigue life of the repaired cast iron. Further, high speed melt pool imaging and residual stress measurements are provided to aid in the understanding of the metallurgical quality and strength seen in these structures. In general, higher scanning speeds and lower thermal gradients promoted comparable tensile strength to that of the original gray cast iron. The results presented here provide a foundation to tune in the DED process to generate the required mechanical quality as a starting point for future process advancements.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Crystallographic Orientation Dependence of Mechanical Responses of FeCrAl Micropillars

Iron-chromium-aluminum (FeCrAl) alloys are used in automobile exhaust gas purifying systems and nuclear reactors due to its superior high-temperature oxidation and excellent corrosion resistance. Single-phase FeCrAl alloys with a body centered cubic structure plastically deform through dislocation slips at room temperature. Here, we investigated the orientation dependence of mechanical responses of FeCrAl alloy through testing single-crystal and bi-crystal micropillars in a scanning electron microscopy at room temperature. Single-crystal micropillars were fabricated with specific orientations which favor the activity of single slip system or two slip systems or multiple slip systems. The strain hardening rate and flow strength increase with increasing the number of activated slip system in micropillars. Bi-crystal micropillars with respect to the continuity of slip systems across grain boundary were fabricated to study the effect of grain boundary on slip transmission. The high geometrical compatibility factor corresponds to a high flow strength and strain hardening rate. Experimental results provide insight into understanding mechanical response of FeCrAl alloy and developing the mechanisms-based constitutive laws for FeCrAl polycrystalline aggregates.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Investigation of high field plasma dynamics in a laser-produced plasma expanding into a background gas

This paper presents an overview of experimental results of a laser-produced plasma expanding into a background gas, immersed within a large range of highly uniform magnetic fields (of up to 3 T), that are transverse to the expanding plasma. We used intensified gated imaging to capture the expansion of the plasma across and along the magnetic field lines to observe the spatiotemporal expansion dynamics for different magnetic field strengths. We observe changes in the perpendicular and parallel dynamics of the laser-produced plasmas expansion at high magnetic field. In addition, our results have also indicated the presence of electron-ion hybrid instabilities at relatively high pressures (100 mTorr) and relatively high magnetic field strengths (2 T), in accordance with theoretical calculations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Compressive strength improvements from noncircular carbon fibers: A numerical study

The benefits of high-performance unidirectional carbon fiber composites are limited in many cost-driven industries due to the high cost relative to alternative reinforcement fibers. Low-cost carbon fibers have been previously proposed, but the longitudinal compressive strength continues to be a limiting factor or studies are based on simplifications that warrant further analysis. A micromechanical model is used to (1) determine if the longitudinal compressive strength of composites can be improved with noncircular carbon fiber shapes and (2) characterize why some shapes are stronger than others in compression. In comparison to circular fibers, the results suggest that the strength can be increased by 10%–13% by using a specific six-lobe fiber shape and by 6%–9% for a three-lobe fiber shape. A slight increase is predicted in the compressive strength of the study two-lobe fiber but has the highest uncertainty and sensitivity to fiber orientation and misalignment direction. The underlying mechanism governing the compressive failure of the composites was linked to the unique stress fields created by the lobes, particularly the pressure stress in the matrix. Importantly, this work provides mechanics-based evidence of strength improvements from noncircular fiber shapes and insight on how matrix yielding is altered with alternative fiber shapes.

36 MATERIALS SCIENCE↗
DOE OSTI2025

High-resolution characterization of ceramic-metal interface of TiN coating on ferritic-steels for nuclear application

Advanced fuel cladding is critical for fast reactors, offering sufficient thermal conductivity, mechanical and dimensional stability and radiation tolerance of the cladding base material. Additionally, it must provide corrosion resistance and high temperature coolant compatibility on the cladding outer surface, as well as chemical stability on the cladding inner wall against fuel cladding chemical interaction (FCCI). TiN ceramic coating has been considered an effective diffusion barrier for inner and outer cladding-walls for enhanced performance. The TiN-metal interface microstructure and chemistry play a critical role in coating bond strength and integrity under harsh conditions. High-resolution transmission electron microscopy characterization of ceramic-metal interface at atomic resolution in unirradiated, irradiated and thermal cycled conditions were performed. The interface remained intact after irradiation up to 200 dpa or thermal cycling five times up to 550 °C. In conclusion, this work discusses the potential impact of these results on coating performance and design for advanced claddings.

36 - MATERIALS SCIENCE↗
DOE OSTI2023

Feasibility Evaluation of a Solid Phase Scalable HEA Cladding Manufacturing Route

First of a kind development result on two low-energy solid-phase processes applied on an irradiation-resistant alloy, NiCoFeCrCu 0.12 , are achieved and demonstrate moderate feasibility of successful tube fabrication using shear assisted processing and extrusion (ShAPE™) and friction stir layer deposition as a bulk manufacturing process. The scope of the work is performed in four phases: 1) direct tube manufacturing of the irradiation-resistant high-entropy alloy (HEA) composite with increased strength, 2) co-shear lining manufacturing process for the increased strength and corrosion-resistant, irradiation-tolerant HEAs, 3) ShAPE of the radially gradient corrosion resistance alloy, and 4) alloy development and fabrication enabled through friction stir additive manufacturing processes among others. This report describes the development activities from April to December 2023 to manufacture a direct customizable thin-walled tubular product from irradiation-tolerant composite high-entropy alloys (C-HEAs) while the overall project is continuing in 2024.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Anomalously high elastic modulus of a poly(ethylene oxide)-based composite electrolyte

The practical use of lithium metal anodes in solid-state batteries requires a polymer membrane with high lithium-ion conductivity, thermal/electrochemical stability, and mechanical strength. The primary challenge is to effectively decouple the ionic conductivity and mechanical strength of the polymer electrolytes. We report a remarkably facile single step synthetic strategy based on in-situ crosslinking of poly(ethylene oxide) (xPEO) in the presence of a woven glass fiber (GF). Such a simple method yields composite polymer electrolytes (CPE) of anomalously high elastic modulus up to 2.5 GPa over a broad temperature range (20 °C – 245 °C) that has never been previously documented. An unsupervised machine learning algorithm, K-mean clustering analysis, was implemented on the hyperspectral Raman mapping at the xPEO/GF interface. Using such a unique means, we show for the first time that the promoted mechanical strength originates from xPEO and GF interactions through dynamic hydrogen and ionic bonding. High ionic conductivity is achieved by the addition plasticizer (e.g. tetraglyme), where trifluoromethanesulfonate anions are tethered to the xPEO matrix and Li + cations are favorably transported through coordination with the plasticizer. Further, stringent galvanostatic cycling tests indicates the CPE can be stably cycled for >3000 h in a Li-metal symmetric cell at a moderate temperature (nearly 1500 Coulombs/cm 2 Li equivalents), outperforming most of the PEO-based electrolytes. The GF reinforced CPE reported here has multifunctional uses, such as solid electrolytes for all solid-state batteries and membranes for redox-flow batteries. Although the focus of this study is on lithium-based batteries, the results are equally promising for other alkali metal based batteries such as sodium and potassium.

25 ENERGY STORAGE↗
DOE OSTI2021

Modeling and Measuring the Stress Distribution in Soft Magnetic Cores due to Epoxy Impregnation and Curing

Understanding the effects of viscoelastic relaxation of stresses is critical in electric motor and inductor applications, where the magnetic material is fully or partially comprised of an amorphous phase and impregnated in an epoxy. Magnetic Amorphous Nanocomposites (MANCs) are a class of recently developed high-frequency magnetic materials that exhibit low magnetic hysteresis, high saturation flux density and very low AC magnetic losses. MANCs are formed as long, thin ribbons, a shape factor that minimizes eddy current-induced self-heating. This feature, in addition to their 1 GPa strength, and makes them attractive candidates for high-speed, high-power density, electric motors. MANCs are used in the form of tape-wound cores (TWCs). During the manufacturing process, the cores are impregnated with liquid epoxy between each layer of ribbon. Validated knowledge of the stresses imposed by the manufacturing process and during operation is necessary to understand motor performance limitations with respect to strength. Magnetostriction, the strain imposed by reversal of the magnetic field, also affects performance. When the epoxy cures, it contracts volumetrically by 8%, imposing radial and circumferential stresses that vary along the radial direction. To date, these stresses have received little attention in the literature. Here, we model the stress distribution throughout a TWC due to epoxy curing. Strain gauge measurements reported here indicate substantially lower tangential strain than model values, which is beneficial and which we attribute to viscoelastic relaxation of the epoxy layers. We will incorporate a constitutive model of this viscoelastic relaxation, and conduct more detailed strain measurements to understand how this takes

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Prediction of superconductivity in metallic boron–carbon compounds from 0 to 100 GPa by high-throughput screening

Boron–carbon compounds have been shown to have feasible superconductivity. In our earlier paper [Zheng et al., Phys. Rev. B, 2023, 107, 014508], we identified a new conventional superconductor of LiB 3 C at 100 GPa. Here, we aim to extend the investigation of possible superconductivity in this structural framework by replacing Li atoms with 27 different cations from periods 3, 4, and 5 under pressures ranging from 0 to 100 GPa. Using the high-throughput screening method of zone-center electron–phonon interaction, we found that ternary compounds like CaB 3 C, SrB 3 C, TiB 3 C, and VB 3 C are promising candidates for superconductivity. The consecutive calculations using the full Brillouin zone confirm that they have a T c of <31 K at moderate pressures. In conclusion, our study demonstrates that fast screening of superconductivity by calculating zone-center electron–phonon coupling strength is an effective strategy for high-throughput identification of new superconductors.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗