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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 1,189 records · Page 66
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Being Scientific: Saryu Fensin: Sparking innovations in both materials science and shock physics

As an enterprising materials scientist, Saryu Fensin leverages both experiments and simulations to improve understanding of how materials behave when subjected to extreme forces. Her aim is to use the complementary techniques to design and develop innovative materials for use in extreme conditions such as stockpile-focused applications. “To certify our stockpile with confidence, we need to understand the role a material’s microstructure plays in determining its dynamic properties,” Saryu says. “I’m hoping to solve this puzzle and improve our predictive capability to model material response in extreme conditions. Achieving this kind of specific controlled functionality of materials could have a big impact on the Laboratory’s national security science mission.” Her tools include molecular dynamics, Monte Carlo methods, gas gun experiments, metallography and various microscopy techniques. She looks forward to the prospect of new capabilities that could let her "see" inside materials.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Dendrite Growth Morphology Modeling in Liquid and Solid Electrolytes

The main goal of this project is to develop a multi-scale modeling approach that connects micron-scale phase-field models and atomic-scale density functional theory (DFT)-based simulations via parameter- and relationship-passing in order to predict Li-metal dendrite morphology evolution, in both liquid and solid electrolytes. The key hypothesis of the DFT-informed phase-field multiscale modeling approach is that it can capture the electrochemical-mechanical driving forces and incorporate the roles of nano-meter-thin solid electrolyte interphase (SEI) in liquid electrolytes as well as of the microstructures of micro-meter-thick solid electrolytes (SEs) for all-solid-state batteries. In this project, we have formulated and implemented phase-field models to incorporate the electrochemical driving forces in liquid electrolytes and then incorporate mechanical driving forces to simulate dendrite growth in solid electrolytes with resolved microstructures. We have implemented two treatments for the SEI: an explicit model to include the microstructure of the SE or SEI in the phase field model and an implicit model to simulate the impact of nano-meter thick SEI in liquid electrolytes by varying the electrode/electrolyte interfacial properties. The key interfacial properties, including the electronic and ionic transport properties, the charge transfer reaction kinetics, and mechanical properties, were computed by DFT-based calculations. At the DFT-based model, one key advancement is to directly predict the charge transfer reaction kinetics at a complex Li/SEI/electrolyte interface by linking DFT with density functional tight binding (DFTB) calculations. As the main accomplishments, we have demonstrated two successful predictions in both solid electrolyte and liquid electrolyte based on this multiscale approach. The predicted intergranular Li dendrite growth in LLZO revealed the importance of trapped electrons at internal interfaces in the microstructure of LLZO. The predicted electroplating morphology of mossy Li and faceted Mg agreed well with experiments. The insights provided by the multiscale model and the model enabled electrolyte and SEI design will accelerate the development of Li-metal electrode for high energy density batteries, that meet DOE’s target on cell density (>350 Wh/kg) and cost below $100/kWhuse for EV applications.

25 ENERGY STORAGE↗
NASA NTRSDate not supplied

Next Generation Durability and Damage Tolerance to Support Certification of Flight Hardware

Durability and Damage Tolerance (D&DT), as currently applied to flight hardware throughout the Agency, is based on continuum and similitude assumptions and does not consider local material properties, environments and responses. These limitations impact our ability to support certification of new component designs, material systems and manufacturing approaches. The primary concern in this Engineering R&A plan is related to the imminent proliferation of parts produced by additive manufacturing (AM). These parts are being advocated by NASA’s suppliers for use on a myriad of flight hardware because of their design flexibility and cost advantages. AM provides opportunities to reduce part counts through complex geometry and reduce manufacturing costs of low volume parts. However, AM materials have some notable metallurgical and microstructural differences compared to traditionally fabricated materials. One of the challenges for the acceptance of AM is the greater tendency for a deleterious defect state, most commonly in the form of porosity, to exist in AM parts. Though this defect state is typically reduced through a hot isostatic pressing (HIP) processing step, the structural performance risks associated with the remaining defects and HIP-healed features is not known. Potential fracture control issues that must be resolved stem from the real possibility that an unhealed defect or a closed defect with less than pristine strength remains at a fracture critical location after HIP. As a result, NASA and the entire aerospace community have been confronted with the need to develop a robust and relevant certification methodology to enable safe implementation of these components. The present work is an important step toward positioning NASA to credibly respond to vendors’ push to implement this new AM materials technology by improving our understanding of AM processing and performance and transitioning that research-based understanding to next-generation engineering capabilities.

Edward H Glaessgen↗
NASA NTRSDate not supplied

GRX-810: NASA High Temperature Alloy Development for Additive Manufacturing

High-entropy alloys, and by extension, medium entropy alloys are an exciting new class of materials due to their impressive mechanical properties, especially at cryogenic and elevated temperatures. In this study, a novel oxide dispersion strengthened (ODS) NiCoCr-based alloy is presented which exhibits exceptional high temperature properties compared to conventional wrought superalloys. This new ODS alloy, GRX-810, leverages additive manufacturing to disperse nanoscale Y2O3 particles throughout the microstructure without the use of resource intensive processing steps, such as mechanical alloying. Microstructural and mechanical characterization confirms the successful incorporation and dispersion of nano-scale oxides throughout the build volume. As a result, this recently discovered processing route presents a new alloy design and production path that is synergistic between additive manufacturing and dispersion strengthening, possibly enabling a new generation of high-performance alloys.

Tim Smith↗
DOE OSTI2018

Effects of Controlled Cooling-Induced Ferrite–Pearlite Microstructure on the Cold Forgeability of XC45 Steel

The combination of hot/warm and cold forging with an intermediate controlled cooling process is a promising approach to saving costs in the manufacture of automobile parts. In this work, the effects of the ferrite–pearlite microstructure, which formed after controlled cooling, on the cold forgeability of a medium-carbon steel were investigated. Different specimens for both normal and notched tensile tests were directly heated to high temperature and then cooled down at different cooling rates, producing different ferrite volume fractions, ranging from 6.69 to 40.53%, in the ferrite–pearlite microstructure. The yield strength, ultimate tensile strength, elongation rate, percentage reduction of area, and fracture strain were measured by tensile testing. The yield strength, indicating deformation resistance, and fracture strain, indicating formability, were used to evaluate the cold forgeability. As the ferrite volume fraction increased, the cold forgeability of the dual-phase ferritic–pearlitic steel improved. A quantitatively relationship between the ferrite volume fraction and the evaluation indexes of cold forgeability for XC45 steel was obtained from the test data. To validate the mathematical relationship, different tensile specimens machined from real hot-forged workpieces were tested. There was good agreement between the predicted and measured values. Our predictions from the relationship for cold forgeability had an absolute error less than 5%, which is acceptable for industrial applications and will help to guide the design of combined forging processes.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Design and Development of a Custom Laser Powder Bed Fusion System

Additive manufacturing (AM) has gained great momentum both in industrial and research applications. Due to the ability to create custom and complex parts directly from a computer-aided design (CAD) file, AM is becoming a more reliable and efficient means to fabricate components. While being implemented throughout the aerospace, medical, automotive, and energy industries, the development of metal AM is still ongoing and presents many unique scientific challenges. For example, in laser powder bed fusion (PBF), intense localized heating of metal powder followed by rapid cooling leads to residual stresses and unique microstructures within a build. This may lead to cracking and a decrease in mechanical performance. In-situ diagnostics enable the laser-material interaction to be monitored as it occurs in order to optimize process parameters, and can be leveraged to develop tailored materials with specific microstructures that are more conducive for the complex thermal patterns encountered during laser PBF. Unfortunately, most commercial laser PBF machines are not suitable for research applications due to their large size, lack of diagnostics, and black box operation. A smaller system is better suited for using smaller quantities of powder to develop new tailored materials for AM, and a custom, modular design permits greater flexibility for incorporating in-situ diagnostics. Therefore, this project consisted of the design and construction of a custom, small scale, modular PBF system.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Ex-situ Heat Treatment of TEM Foils in a Custom Titanium Fixture: A Case Study on Ni-based Superalloy

The advancement of microstructural characterization at the nanoscale is critical to understanding the microstructural evolution and performance of engineering materials. Transmission electron microscopy (TEM) plays a vital role in such investigations, particularly when coupled with controlled ex- and in-situ experiments. In this study, we introduce a novel method for ex-situ heat treatment (HT) of TEM foils using a custom-designed fixture, made from pure titanium, and vacuum furnace to inhibit oxidation. This approach ensures precise temperature control and minimal sample contamination during HT, critical for substructural characterization and analysis of metallic materials. The fixture consists of a titanium base with three slits, for three sample foils, and a titanium cap for closure. The entire assembly is placed in a vacuum heat treatment furnace with high vacuum capability to prevent oxidation. To validate the effectiveness of the setup, precipitation behavior and microstructural changes were studied in an IN725 variant heat-treated at 500°C for 1 hour and 282 variant heat-treated at 700°C for 1 hour, as case studies.

electron microscopy↗
DOE OSTI2015

Elastodynamic metasurface: Depolarization of mechanical waves and time effects

We report the concept of microstructured surfaces with inner resonance in the field of elastodynamics, so-called elastodynamic metasurfaces. Such metasurfaces allow for wavefield manipulation of mechanical waves by tuning the boundary conditions at specific frequencies. In particular, they can be used to depolarize elastic waves without introducing heterogeneities in the medium itself; the physical means to do so in homogeneous elastic media used to remain, surprisingly, an open question while depolarization is commonplace in electromagnetism. The principle relies on the anisotropic behaviour of a subwavelength array of resonators: Their subwavelength configuration confines the Bragg interferences scattered by resonators into a boundary layer. The effective behaviour of the resonating array is expressed with homogenization as an unconventional impedance, the frequency-dependence, and anisotropy of which lead to depolarization and time effects. The concept of the elastodynamic metasurface is tested experimentally and results bear testament to its efficacy and robustness. Elastodynamic metasurfaces are easily realized and analytically predictable, opening new possibilities in tomography techniques, ultrasonics, geophysics, vibration control, materials and structure design.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2019

Strain Enhanced Functionality in a Bottom-Up Approach Enabled 3D Super-Nanocomposites

The ability to control nanoparticle size, concentration, and distribution in epitaxial nanocomposite films has been a formidable challenge in the synthesis of nanostructured composite materials. In this paper, a novel 3D super-nanocomposite (3D-sNC) architecture is successfully demonstrated by integrating superlattice and vertically aligned nanocomposite structures. In the 3D-sNC architecture, the feature size and distribution of the nanocylinders such as the height/lateral dimension and the vertical/lateral spacing of nanocylinders can be precisely controlled. The microstructure parameters such as nanocylinder height and spacing modulated interfacial area control the lattice strain, which further tunes the magnetotransport property. These results demonstrate that 3D-sNC is a simple and yet effective architecture to achieve controlled functionalities via the precise control of nanocylinder size, spacing, concentration, and distribution. Lastly, such a 3D-sNC structure can be used to design advanced nanostructures with desired physical properties for a variety of material systems.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Manufacturing of Fabric Electrodes using a High-Throughput Screening Platform for Redox Flow Batteries

The objective of this project is to establish a new manufacturing methodology with machine learning- based high-throughput screening for the design and development of hierarchical structured, high-performance fabric electrodes for redox flow batteries (RFBs). The end goal of the project is to design and manufacture fabric electrodes for RFB applications that can provide 250 mA/cm2 current density operation for 100-cycles with 80% average energy efficiency. This was accomplished by first examining the structure-performance-property linkages of the electrodes provided by our partner, AvCarb. The electrodes’ microstructure was characterized by determining their pore size distribution, tortuosity, specific surface area, and porosity. The ohmic, charge transfer and mass transfer resistances were then calculated using electrochemical impedance spectroscopy. Carbon cloth electrodes showed the greatest resistance, which was dominated by charge transfer resistance, which we believe is related to the surface functionalization. Full cell cycling was used in order to determine the area specific resistance and energy efficiency of the cells. All of this experimental data and the results of the mathematical model (to increase the amount of inputs with parametric sweeping) were used to develop a machine learning-based model for the design of high-performance fabric electrodes. Using the results from the machine learning tool, optimized electrodes were fabricated by AvCarb. The ohmic, charge transfer and mass transfer resistances for these new electrodes were measured, and both performed better than any of the initial samples which had been provided by AvCarb.

25 ENERGY STORAGE↗
DOE OSTI2016

Mesoscopic Framework Enables Facile Ionic Transport in Solid Electrolytes for Li Batteries

In Li-ion-conducting solid electrolytes can simultaneously overcome two grand challenges for Li-ion batteries: the severe safety concerns that limit the large-scale application and the poor electrolyte stability that forbids the use of high-voltage cathodes. Nevertheless, the ionic conductivity of solid electrolytes is typically low, compromising the battery performances. Precisely determining the ionic transport mechanism(s) is a prerequisite for the rational design of highly conductive solid electrolytes. For decades, the research on this subject has primarily focused on the atomic and microscopic scales, where the main features of interest are unit cells and microstructures, respectively. We show that the largely overlooked mesoscopic scale lying between these extremes could be the key to fast ionic conduction. In a prototype system, (Li 0.33 La 0.56 )TiO 3 , a mesoscopic framework is revealed for the first time by state-of-the-art scanning transmission electron microscopy. Corroborated by theoretical calculations and impedance measurements, it is demonstrated that such a unique configuration maximizes the number of percolation directions and thus most effectively improves the ionic conductivity. Finally, this discovery reconciles the long-standing structure–property inconsistency in (Li 0.33 La 0.56 )TiO 3 and also identifies mesoscopic ordering as a promising general strategy for optimizing Li+ conduction.

25 ENERGY STORAGE↗
DOE OSTI2023

Perspectives on novel refractory amorphous high-entropy alloys in extreme environments

Two new refractory amorphous high-entropy alloys (RAHEAs) within the W–Ta–Cr–V and W–Ta–Cr–V–Hf systems were herein synthesized using magnetron-sputtering and tested under high-temperature annealing and displacing irradiation using in situ Transmission Electron Microscopy. While the 14W-41Ta-26Cr-19V in at.% RAHEA (defined as WTaCrV RAHEA) was found to be unstable under such tests, additions of Hf in this system composing a new quinary 24W-40Ta-18Cr-5V-13Hf in at.% RAHEA (defined as WTaCrVHf RAHEA) was found to be a route to achieve stability both under annealing and irradiation. A new effect of nanoprecipitate reassembling observed to take place within the WTaCrVHf RAHEA under irradiation indicates that a duplex microstructure composed of an amorphous matrix with crystalline nanometer-sized precipitates enhances the radiation response of the system. Further, it is demonstrated that tunable chemical complexity arises as a new alloy design strategy to foster the use of novel RAHEAs within extreme environments. New perspectives for the alloy design and application of chemically-complex amorphous metallic alloys in extreme environments are presented with focus on their thermodynamic phase stability when subjected to high-temperature annealing and displacing irradiation.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Influence of electronic transport on electrochemical performance of (Cu,Mn) 3 O 4 solid oxide fuel cell cathodes

Alkaline Earth free spinel oxides provide a potential benefit over Sr-doped perovskite-based materials commonly used as electrodes in high-temperature electrochemical energy conversion devices, e.g., solid oxide fuel cells (SOFCs). Sr-segregation is a known issue leading to performance degradation. In this study, Cu x Mn 3-x O 4 (x = 1, 1.2, and 1.5) porous electrodes were examined as SOFC cathodes using electrochemical impedance spectroscopy to investigate the oxygen reduction reaction (ORR) kinetics in relation to the material's intrinsic conductivity, the extrinsic electrode structure, and the cell test design. Similar to the electronic conducting (La,Sr)MnO 3 SOFC cathodes, the ORR kinetics of Cu x Mn 3-x O 4 spinel electrodes was governed by the oxygen adsorption and diffusion at the particle surface as well as the charge transfer at the triple phase boundaries. The overall electrode polarization resistance was highly dependent on contact density with the metallic current collector, active material particle connectivity, electrode thickness, and the intrinsic electronic materials conductivity. Here, we describe the importance of effective electronic charge transport parallel to the electrode surface in maximizing the electrochemically active electrode volume and enhancing electrode performance. We discuss an approach to optimize cell and electrode design with respect to active materials properties. This aspect is critical to ensure reliable evaluation of new materials, since laboratory-scale button-cells typically exhibit a high degree of electrode microstructure (e.g. porosity, thickness) and electrical contact density variation from sample to sample.

(Cu,Mn)3O4↗
DOE OSTI2020

The Effect of η Phase Precipitates on the Creep Behavior of Alloy 263 and Variants

Phase stability is an important design parameter for Ni-based superalloys to be used in future advanced ultra-supercritical (AUSC) power plants as exposure times in this type of environment are considerable. In this investigation, microstructures based on candidate alloy 263 were obtained with varying amounts of η precipitates using isothermal exposure at 800°C for times ranging from 1,000 h to 10,000 h. The effect of η phase stability on the creep properties was determined using creep specimens isothermally aged at 800°C for 8 h, 3,000 h, 5,000 h and 10,000 h prior to creep screening. The creep life was found to exponentially decrease with increasing density of η phase while the elongation to failure was found to increase. Furthermore, the minimum creep rate was related to the density of η phase; a relationship that did not depend on the alloy formulation. Modification to the Ti and Al concentrations slowed down the γ' to η transformation while doubling the γ' fraction after standard heat treatment. By modifying the Ti and Al content, and thereby improving γ' stability over η, the creep lives of specimens isothermally aged for up to 5,000 h were greater than that of the nominal alloy in its standard aged condition.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Multifunctional ferrofluid-infused surfaces with reconfigurable multiscale topography

Developing adaptive materials with geometries that change in response to external stimuli provides fundamental insights into the links between the physical forces involved and the resultant morphologies and creates a foundation for technologically relevant dynamic systems. In particular, reconfigurable surface topography as a means to control interfacial properties has recently been explored using responsive gels, shape-memory polymers, liquid crystals and hybrid composites, including magnetically active slippery surfaces. However, these designs exhibit a limited range of topographical changes and thus a restricted scope of function. Here we introduce a hierarchical magneto-responsive composite surface, made by infiltrating a ferrofluid into a microstructured matrix (termed ferrofluid-containing liquid-infused porous surfaces, or FLIPS). We demonstrate various topographical reconfigurations at multiple length scales and a broad range of associated emergent behaviours. An applied magnetic-field gradient induces the movement of magnetic nanoparticles suspended in a viscous fluid, which leads to microscale flow of this ferrofluid first above and then within the microstructured surface. This redistribution changes the initially smooth surface of the ferrofluid (which is immobilized by the porous matrix through capillary forces) into various multiscale hierarchical topographies shaped by the size, arrangement and orientation of the confining microstructures in the magnetic field. We analyse the spatial and temporal dynamics of these reconfigurations theoretically and experimentally as a function of the balance between capillary and magnetic pressures and of the geometric anisotropy of the FLIPS system. Several interesting functions at three different length scales are demonstrated: self-assembly of colloidal particles at the micrometre scale; regulated flow of liquid droplets at the millimetre scale; and switchable adhesion and friction, liquid pumping and removal of biofilms at the centimetre scale. We envision that FLIPS could be used as part of integrated control systems for the manipulation and transport of matter, thermal management, microfluidics and fouling-release materials.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Softening due to Grain Boundary Cavity Formation and its Competition with Hardening in Helium Implanted Nanocrystalline Tungsten

The unique ability of grain boundaries to act as effective sinks for radiation damage plays a significant role in nanocrystalline materials due to their large interfacial area per unit volume. Leveraging this mechanism in the design of tungsten as a plasma-facing material provides a potential pathway for enhancing its radiation tolerance under fusion-relevant conditions. In this study, we explore the impact of defect microstructures on the mechanical behavior of helium ion implanted nanocrystalline tungsten through nanoindentation. Softening was apparent across all implantation temperatures and attributed to bubble/cavity loaded grain boundaries suppressing the activation barrier for the onset of plasticity via grain boundary mediated dislocation nucleation. An increase in fluence placed cavity induced grain boundary softening in competition with hardening from intragranular defect loop damage, thus signaling a new transition in the mechanical behavior of helium implanted nanocrystalline tungsten.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Evolution of dislocation substructures in metals via high-strain-rate nanoindentation

Deformation at high strain rates often results in high stresses on many engineering materials, potentially leading to catastrophic failure without proper design. High-strain-rate mechanical testing is thus needed to improve the design of future structural materials for a wide range of applications. Although several high-strain-rate mechanical testing techniques have been developed to provide a fundamental understanding of material responses and microstructural evolution under high-strain-rate deformation conditions, these tests are often very time consuming and costly. In this work, we utilize a high-strain-rate nanoindentation testing technique and system in combination with transmission electron microscopy to reveal the deformation mechanisms and dislocation substructures that evolve in pure metals from low (10 –2 s –1 ) to very high indentation strain rates (10 4 s –1 ), using face-centered cubic aluminum and body-centered cubic molybdenum as model materials. The results help to establish the conditions under which micro- and macro-scale tests can be compared with validity and also provide a promising pathway that could lead to accelerated high-strain-rate testing at substantially reduced costs.

36 MATERIALS SCIENCE↗
DOE OSTI2024

High Strength Aluminum Additive Manufacturing

High-strength aluminum alloys for elevated temperature applications are desirable to replace heavier and more expensive titanium alloys. However, most aluminum alloys lose a large fraction of their strength at temperatures above approximately 200°C. ORNL has designed DuAlumin-3D, an alloy with nominal composition Al-9Ce-4Ni-0.5Mn-1Zr (wt.%), which utilizes the high cooling rates in additive manufacturing (AM) to achieve a refined microstructure, and thermally stable mechanical properties. DuAlumin-3D was fabricated by laser powder bed fusion and tested for its tensile mechanical properties across a range of temperature, and for its room temperature high-cycle fatigue resistance. The alloy was tested in both the as-printed and heat treated conditions, and both parallel and perpendicular to the AM build direction. The alloy was found to have anisotropic mechanical behavior in the as-printed state, but the anisotropy significantly decreased (both for tensile and fatigue properties) following heat treatment. The tensile properties significantly out-performed benchmark wrought 2219-T61 across a wide temperature range. The room temperature fatigue performance was approximately similar to 2219-T61.

36 MATERIALS SCIENCE↗