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DOE OSTI2025

Work Hardening Model of Structure in Hall-Petch Strengthening

The microstructural length scale of metals changes by orders of magnitude under extreme processing conditions producing a concurrent wide range of mechanical strength and plasticity behaviors. A unified stress-strain σε σ(ε) model is formulated that’s based on superposing the components of asymptotic-curvilinear work hardening Θσ Θ(σ) to qualify and quantify these mechanical behaviors. This approach accounts for the rapid strengthening of metals beyond the initial yield point, through extended steady-state deformation, to the structural instability. The relationship between the softening coefficients cbi c bi of the work hardening formulation Θσ Θ(σ) and strength are found to reveal the microstructural scale in the material. Specifically, the rapid decrease in the slope of the Θσ Θ(σ) curve provides a measure for microstructural size consistent with a functional Hall-Petch relationship of strength. A successful application is shown for the tensile behavior of pure aluminum microstructures that result from extreme plastic deformation by equal-channel angle pressing.

Hall-Petch strengthening↗

DOE OSTI2020

Anion Association Strength as a Unifying Descriptor for the Reversibility of Divalent Metal Deposition in Nonaqueous Electrolytes

Developing next-generation battery chemistries that move beyond traditional Li-ion systems is critical to enabling transformative advances in electrified transportation and grid-level energy storage. Here, we provide the first evidence for common descriptors for improved reversibility of metal plating/stripping in nonaqueous electrolytes for multivalent ion batteries. Focusing first on the specific role of chloride (Cl – ) in promoting electrochemical reversibility in multivalent systems, rotating disk (RDE) and ring-disk electrode (RRDE) investigations were performed utilizing a variety of divalent cations (Mg 2+ , Zn 2+ , and Cu 2+ ) and the bis-(trifluoromethane sulfonyl) imide (TFSI – ) anion. By introducing varying concentrations of Cl – , a cooperative effect is observed between TFSI – and Cl – that yields the more reversible behavior of mixed electrolytes relative to electrolytes containing only TFSI – . This effect is shown to be general for Mg, Zn, and Cu electrodeposition, and mechanistic understanding of the role of Cl – in improving reversibility of TFSI-based electrolytes is obtained through the combination of R(R)DE experimental results and density functional theory (DFT) evaluation of the redox activity and thermodynamic stability of various TFSI- and Cl-based solution complexes of metal ions. The cooperative anion effect is further generalized to other mixed-anion systems, where systematic variations in anion association strength predicted from DFT (i.e., Cl – > OTf – ≈ TFSI – > BF 4 – > PF 6 – ) yield corresponding trends in redox potentials and improvements of ≥200 mV in the reversibility of metal deposition/dissolution. These results identify anion association strength as a common descriptor for the reversibility of divalent metal anodes and suggest a set of general design principles for developing new electrolytes with improved activity and stability.

25 ENERGY STORAGE↗

DOE OSTI2026

Enhancing NO Reduction by CO Over NiO/CeO 2 Catalyst by Optimizing the Metal Oxide–Support Interaction

Noble metal catalysts are widely used in three-way catalysts (TWCs) due to their high efficiency, but their scarcity and high cost drive the need for effective, low-cost alternatives. Here, in this work, a series of NiO/CeO 2 catalysts were engineered by modulating the OH content and crystallite size of the CeO 2 support. This approach yielded Ni species ranging from isolated single atoms to small clusters and larger aggregates, with varied NiO/CeO 2 interaction strengths. Evaluation of their performance in NO reduction by CO, CO oxidation, and the water–gas shift reaction revealed that the NiO/CeO 2 -300 catalyst, featuring small CeO 2 crystallites and highly dispersed NiO clusters, delivered superior activity for NO reduction and CO oxidation. It was demonstrated that small NiO clusters, due to their efficient CO adsorption and activation, were more active than Ni single atoms. Furthermore, the presence of water was found to influence the catalyst stability, with NiO clusters less stable than single atoms likely due to the hydroxylation effect leading to the formation of Ni(OH) 2 . Oxygen storage capacity measurements revealed that performance was governed by a combination of CeO 2 crystallite size and the abundance of NiO/CeO 2 interfaces. These findings demonstrated that the catalytic performance of Ni/CeO 2 systems could be maximized by optimizing the Ni nanostructure and its interaction with CeO 2 support, positioning them as a promising, multifunctional nonprecious alternative for three-way catalysis application.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Characteristics of oxide-dispersion strengthened alloys produced by high-temperature severe deformation

This study is to explore an economically attractive and technically feasible processing method for oxide-nanoparticle strengthened alloys for fusion reactor application. Despite many scientific merits of the advanced oxide-dispersion strengthened (ODS) alloys, such as the nanostructured ferritic alloy (NFA) 14YWT, the only viable production path for a high-quality NFA is the high-power mechanical alloying process. This process is often a multi-day high-speed ball milling of alloy powder with a small quantity of yttria (Y 2 O 3 ) powder, followed by the milled-powder consolidation using extrusion or other methods and additional thermomechanical processing (TMP) for property control. This complex production path, including the low-temperature mechanical alloying in particular, has limited technical advancement toward the cost-effective and scale-up production of ODS alloy components. To overcome such a practical limitation, we proposed to explore alternative low-cost processing routes using traditional thermomechanical processing (TMP) method only. Further, a series of continuous TMP cycles, which were designed to impose high-temperature severe plastic deformation (HT-SPD) conditions to the consolidated powder mixtures, were applied to achieve the effective distribution of oxide particles in nanograin structure and thus desirable mechanical properties. Since the reduced-activation ferritic-martensitic (RAFM) alloy powders (Fe-10Cr and Fe-14Cr alloys with various Y contents) are available in our inventory, we focused to utilize the new solid-state synthesis approach for controlling oxide (oxygen source) dissolution and nanoscale clustering in nanograin structure in those alloys. A combination of powder consolidation at 900 °C and continuous thermomechanical activation at 600 °C yielded two essential ODS alloy microstructure contents–nanograin structure and nanoparticle distribution–and thus demonstrated a good combination of strength and ductility.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Atomistic simulations for investigation of substrate effects on lipid in-source fragmentation in secondary ion mass spectrometry

In beam-based ionization methods, the substrate plays an important role on the desorption mechanism of molecules from surfaces. Both the specific orientation that a molecule adopts at a surface and the strength of the molecule-surface interaction can greatly influence desorption processes, which in turn will affect the ion yield and the degree of in-source fragmentation of a molecule. In the beam-based method of secondary ion mass spectrometry (SIMS), in-source fragmentation can be significant and molecule specific due to the hard ionization method of using a primary ion beam for molecule desorption. To investigate the role of the substrate on orientation and in-source fragmentation, we have used atomistic simulations—molecular dynamics in combination with density functional theory calculations—to explore the desorption of a sphingolipid (palmitoylsphingomyelin) from a model surface (gold). We then compare SIMS data from this model system to our modeling findings. Using this approach, we found that the combined adsorption and binding energy of certain bonds associated with the headgroup fragments (C3H8N+, C5H12N+, C5H14NO+, and C5H15PNO4+) was a good predictor for fragment intensities (as indicated by relative ion yields). This is the first example where atomistic simulations have been applied in beam-based ionization of lipids, and it presents a new approach to study biointerfacial lipid ordering effects on SIMS imaging.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

Chemically recyclable thermoplastics from reversible-deactivation polymerization of cyclic acetals

Identifying plastics capable of chemical recycling to monomer (CRM) is the foremost challenge in creating a sustainable circular plastic economy. Polyacetals are promising candidates for CRM but lack useful tensile strengths owing to the low molecular weights produced using current uncontrolled cationic ring-opening polymerization (CROP) methods. Here, we present reversible-deactivation CROP of cyclic acetals using a commercial halomethyl ether initiator and an indium(III) bromide catalyst. Using this method, we synthesize poly(1,3-dioxolane) (PDXL), which demonstrates tensile strength comparable to some commodity polyolefins. Depolymerization of PDXL using strong acid catalysts returns monomer in near-quantitative yield and even proceeds from a commodity plastic waste mixture. Our efficient polymerization method affords a tough thermoplastic that can undergo selective depolymerization to monomer.

Abel, Brooks A.↗

NASA NTRS1973

Development of large diameter carbon monofilament

A process for preparing large diameter carbon-boron monofilament was developed. The process involves chemical vapor depositing a carbon-boron alloy monofilament from a BCl3, CH4, and H2 gas mixture onto a carbon substrate. Amorphous alloys were formed when gaseous mixtures containing greater than 20 percent methane (80 percent BCl3) were used. The longest uninterrupted lengths of carbon-boron monofilament were produced using a CH4/BCl3 gas ratio of 2.34. It was found that the properties of the carbon-boron alloy monofilament improved when the carbon substrate was precleaned in chlorine. The highest strength monofilament was attained when a CH4/BCl3 gas volume ratio of 0.44 was 28 million N/sq cm (40 million psi). While the highest strengths were attained in this run, the 0.44 gas ratio and other CH4/BCl3 ratios less than 2.34 would not yield long runs. Runs using these ratios were usually terminated because of a break in the monofilament within the reactor. It is felt better process control could probably be achieved by varying the amount of hydrogen; the BCl3/H2 ratio was kept constant in these studies.

Jacob, B.↗

NASA NTRS1975

Effect of temperature-dependent electrical conductivity on transport processes in magnetosolidmechanics

The effect of temperature-dependent electrical conductivity on transport processes for a solid block is analyzed on the basis of a one-dimensional steady-state model under specified thermal boundary conditions. Assumptions are that the solid has an infinitely segmented electrode configuration, the magnetic field (By) may be resolved into a constant applied field and an induced field, the gradient of the electrochemical potential is equal to the electrostatic potential, a constant potential difference is applied externally across each pair of opposite electrodes, and all material properties except electrical conductivity are constant. Conductivity is expressed in normalized form in terms of a baseline conductivity and a constant for the material. The application of the assumptions of the model to the general phenomenological relations yields the governing equations. Solution of these equations gives the distribution of temperature, electric current density, and magnetic field strength along the length of the solid. It is shown that significant differences exist between the case for constant electrical conductivity and the case where electrical conductivity is temperature dependent.

Craig, G. T.↗

NASA NTRS1976

Nonlinear dynamic theory for photorefractive phase hologram formation

A nonlinear dynamic theory is developed for the formation of photorefractive volume phase holograms. A feedback mechanism existing between the photogenerated field and free-electron density, treated explicitly, yields the growth and saturation of the space-charge field in a time scale characterized by the coupling strength between them. The expression for the field reduces in the short-time limit to previous theories and approaches in the long-time limit the internal or photovoltaic field. Additionally, the phase of the space charge field is shown to be time-dependent.

Kim, D. M.↗

NASA NTRS1984

A search for interstellar H2O(+) in diffuse clouds

Searches for H2O(+) toward HD 187982, Zeta Oph, O micron Per, and Zeta Per have yielded significant upper limits for H2O(+) when compared with existing models for similar lines of sight. Using available oscillator strength data, the column density for HD 187982, for example, cannot exceed 3 x 10 to the 12th per sq cm H2O(+) molecules. The most sensitive measurement for H2O(+) toward Zeta Oph is apparently limited by a blend with upper atmospheric H2O(+), which is also present in the HD 187982 spectrum.

Federman, S. R.↗

NASA NTRS1989

Improved silicon carbide for advanced heat engines

The development of high strength, high reliability silicon carbide parts with complex shapes suitable for use in advanced heat engines is studied. Injection molding was the forming method selected for the program because it is capable of forming complex parts adaptable for mass production on an economically sound basis. The goals were to reach a Weibull characteristic strength of 550 MPa (80 ksi) and a Weibull modulus of 16 for bars tested in four-point loading. Statistically designed experiments were performed throughout the program and a fluid mixing process employing an attritor mixer was developed. Compositional improvements in the amounts and sources of boron and carbon used and a pressureless sintering cycle were developed which provided samples of about 99 percent of theoretical density. Strengths were found to improve significantly by annealing in air. Strengths in excess of 550 MPa (80 ksi) with Weibull modulus of about 9 were obtained. Further improvements in Weibull modulus to about 16 were realized by proof testing. This is an increase of 86 percent in strength and 100 percent in Weibull modulus over the baseline data generated at the beginning of the program. Molding yields were improved and flaw distributions were observed to follow a Poisson process. Magic angle spinning nuclear magnetic resonance spectra were found to be useful in characterizing the SiC powder and the sintered samples. Turbocharger rotors were molded and examined as an indication of the moldability of the mixes which were developed in this program.

Whalen, Thomas J.↗

NASA NTRS1992

Viscous effects on a vortex wake in ground effect

Wake vortex trajectories and strengths are altered radically by interactions with the ground plane. Prediction of vortex strength and location is especially important in the vicinity of airports. Simple potential flow methods have been found to yield reasonable estimates of vortex descent rates in an otherwise quiescent ambient background, but those techniques cannot be adjusted for more realistic ambient conditions and they fail to provide satisfactory estimates of ground-coupled behavior. The authors have been involved in a systematic study concerned with including viscous effects in a wake-vortex system which is near the ground plane. The study has employed numerical solutions to the Navier-Stokes equations, as well as perturbation techniques to study ground coupling with a descending vortex pair. Results of a two-dimensional, unsteady numerical-theoretical study are presented in this paper. A time-based perturbation procedure has been developed which permits the use of analytical solutions to an inner and outer flow domain for the initial flow field. Predictions have been compared with previously reported laminar experimental results. In addition, the influence of stratification and turbulence on vortex behavior near the ground plane has been studied.

Zheng, Z.↗

NASA NTRS1989

Improving the low temperature ductility of NiAl

As part of a study aimed at developing a ductile NiAl-based alloy, ingots of Ni-Fe-Al alloys were cast and hot extruded to rods. The purpose of the iron additions was two-fold viz; to produce a change in the slip vector from 001 to 111 line and, in one alloy, to add a L1(2)-structured ductile second phase. Extruded Ni-20Al-30Fe was two-phase, containing a pro-eutectic B2 phase in a fine lamellar structure of B2+L1(2) phases. Room temperature tensile testing of both single extruded and double extruded alloys resulted in 8-percent and 22-percent plastic elongation and yield stresses of 850 and 760 MPa, respectively. Fracture in both cases occurred by ductile tearing of the eutectic and transgranular cleavage of the proeutectic phase at 1350 MPa. The ductility in double extruded condition is higher than that reported earlier in rapidly solidified wires by Inoue et al. (1984). By comparison, extruded single-phase B2-structured Ni-30Al-20Fe exhibited a fracture strength of 780 MPa, no plasticity, and a mixture of intergranular fracture and transgranular cleavage. This is contrast to earlier work by Inoue et al. where a yield stress of 400 MPa, 5 percent plastic strain, and a mixture of dimple and intergranular fracture was reported.

Guha, Sumit↗

DOE OSTI2022

Creep and Fatigue Characterization of High Strength Alloy Thin Sections in Advanced CO2 Heat Exchangers

The objective of this work was to characterize and model elevated temperature creep and fatigue behavior for thin sheet and foil forms of gamma-prime strengthened alloys in wrought form and as-processed folded and brazed constructions. This work was motivated by the demanding temperature and pressure service conditions of the GEN3 Concentrated Solar Power (CSP) and supercritical CO2 (sCO2) power cycle working fluid. More specifically, the possibility of leveraging the superior creep strength of gamma-prime alloys in folded-fin and brazed-plate heat exchanger constructions. Gamma-prime alloys represent a step-change in raw-material strength over solid-solution strengthened alloys. And the folded-fin and brazed-plate heat exchanger architecture is lightweight and leverages cost-effective material stock forms. The investigation contained two parallel paths. (1) The first is referred to as a fundamental investigation where Oak Ridge National Laboratory conducts uniaxial creep testing on thin sheet and foil in wrought form. This effort aimed to serve as a benchmark against a relatively sparse existing database and a baseline comparison for path number 2. (2) The second path is referred to as the practical investigation where Brayton Energy manufactures plate-fin heat exchangers and performs pressurized creep and fatigue testing. This effort aimed to de-risk heat exchanger manufacturing process for service under sCO2 CSP conditions. A total of 14 uniaxial creep tests were completed using Haynes 282 thin sheet and foil. A variety of heat treatments were specified to coincide with path number 2. Baseline metallography of test samples and creep strength performance are contained. Benchmarks relatively to existing thick-form Haynes 282 are made, as well as to other thin-form Nickel-based superalloys. Description of a wrought-form modeling approach for thin gamma-prime alloys is also discussed. A total of 11 pressurized creep and fatigue tests were completed successfully with Haynes 282 heat exchanger prototypes. Manufacturing processing details, testing details, testing results, and failure analysis are discussed. Additionally, creep modeling techniques to predict failure are discussed, and modeling to support technological-to-market. In conclusion, Haynes 282 foils were demonstrated to yield rupture two-to-three orders of magnitude higher than Haynes 230 foils under similar conditions. And the manufactured heat exchanger prototypes demonstrated strength similar to the wrought constituents. Both of which contribute to elevated performance potential or cost savings in practice. Discussion is included.

14 SOLAR ENERGY↗

DOE OSTI2025

Compositing and Characterization of SE Quadrant Waste Exemplars

This report outlines the experimental investigation and characterization of transport properties in Hanford SE quadrant High-Level Waste (HLW). The goal of the study was to establish baseline behaviors of bulk composite rheology and settling characteristics to facilitate waste treatment process design for the Waste Treatment and Immobilization Plant (WTP) and avoid waste conditions and properties favorable to bubble cascade gas release events. The study focused on two major objectives: 1) identifying, obtaining, and preparing relevant Hanford tank waste samples for evaluation and 2) quantifying the “as-received” rheology and transport properties of the samples. Twenty-three centrifuged core segments originating from tanks AN-101, AN-106, and AW-105 were selected based on compositional relevance to SE quadrant PUREX cladding waste. These materials were composited into five waste composites enriched with target analytes: aluminum (Al), iron (Fe), phosphate (PO 4 ), uranium (U), and zirconium (Zr). Physical property and transport testing examined particle size distributions, bulk densities, settling behaviors, rheological properties, shear strengths, and just-suspended mixing speeds (NJS). Testing revealed two distinct composite classifications based on rheological characteristics: non-Newtonian composites (Fe and PO 4 ) and Newtonian composites (Al, U, and Zr). The Fe and PO 4 composites exhibited slow settling rates and reduced mobilization proclivity, attributable to strong particle-particle interactions and the formation of yield structures within non-Newtonian slurries. In contrast, the Al, U, and Zr composites displayed rapid settling and dense compaction behaviors, indicative of minimal structuring and interactions. Shear strengths for all composites were generally low relative to prior studies of SE quadrant waste, with only the U composite showing elevated strength approaching values reported in previous literature. Repeat shear strength measurements revealed contributions from dense granular material in the U composite and stronger cohesive properties in the Al composite. Settling data highlighted hindered settling behavior, with rates falling more than one order of magnitude below estimates based on Stokes’ law and rate decreasing as composite UDS content increased. NJS testing demonstrated different mobilization behaviors between cohesive and granular composites. The Fe composite required the highest mixing rate for resuspension, while the Al composite was the easiest to resuspend. Comparison of measured NJS against predictions made using the Zwietering correlation suggests non-Newtonian behavior alters resuspension mechanics, rendering non-Newtonian systems more stable against resuspension lift forces relative to their granular counterparts.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Dispersing nano- and micro-sized portlandite particulates via electrosteric exclusion at short screening lengths

In spite of their high surface charge (zeta potential ζ = +34 mV), aqueous suspensions of portlandite (calcium hydroxide: Ca(OH) 2 ) exhibit a strong tendency to aggregate, and thereby present unstable suspensions. While a variety of commercial dispersants seek to modify the suspension stability and rheology (e.g., yield stress, viscosity), it remains unclear how the performance of electrostatically and/or electrosterically based additives is affected in aqueous environments having either a high ionic strength and/or a pH close to the particle's isoelectric point (IEP). We show that the high native ionic strength (pH ≈ 12.6, IEP: pH ≈ 13) of saturated portlandite suspensions strongly screens electrostatic forces (Debye length: κ -1 = 1.2 nm). As a result, coulombic repulsion alone is insufficient to mitigate particle aggregation and affect rheology. However, a longer-range geometrical particle–particle exclusion that arises from electrosteric hindrance caused by the introduction of comb polyelectrolyte dispersants is very effective at altering the rheological properties and fractal structuring of suspensions. As a result, comb-like dispersants that stretch into the solvent reduce the suspension's yield stress by 5× at similar levels of adsorption as compared to linear dispersants, thus enhancing the critical solid loading (i.e., at which jamming occurs) by 1.4×. Significantly, the behavior of diverse dispersants is found to be inherently related to the thickness of the adsorbed polymer layer on particle surfaces. These outcomes inform the design of dispersants for concentrated suspensions that present strong charge screening behavior.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Block Polyelectrolyte Additives That Modulate the Viscoelasticity and Enhance the Printability of Gelatin Inks at Physiological Temperatures

We demonstrate the utility of block polyelectrolyte (bPE) additives to enhance viscosity and resolve challenges with the three-dimensional (3D) printability of extrusion-based biopolymer inks. The addition of oppositely charged bPEs to solutions of photocurable gelatin methacryloyl (GelMA) results in complexation-driven self-assembly of the bPEs, leading to GelMA/bPE inks that are printable at physiological temperatures, representing stark improvements over GelMA inks that suffer from low viscosity at 37 °C, leading to low printability and poor structural stability. The hierarchical microstructure of the self-assemblies (either jammed micelles or 3D networks) formed by the oppositely charged bPEs, confirmed by small-angle X-ray scattering, is attributed to the enhancements in the shear strength and printability of the GelMA/bPE inks. Varying bPE concentration in the inks is shown to enable tunability of the rheological properties to meet the criteria of pre- and postextrusion flow characteristics for 3D printing, including prominent yielding behavior, strong shear thinning, and rapid recovery upon flow cessation. Moreover, the bPE self-assemblies also contribute to the robustness of the photo-cross-linked hydrogels; photo-cross-linked GelMA/bPE hydrogels are shown to exhibit higher shear strength than photo-cross-linked GelMA hydrogels. Last, the assessment of the printability of GelMA/bPE inks indicates excellent printing performance, including minimal swelling postextrusion, satisfactory retention of the filament shape upon deposition, and satisfactory shape fidelity of the various printed constructs. We envision this study to serve as a practical guide for the printing of bespoke extrusion inks where bPEs are used as scaffolds and viscosity enhancers that can be emulated in a range of photocurable precursors.

36 MATERIALS SCIENCE↗

NASA NTRS1988

The V3, V4 and V6 bands of formaldehyde: A spectral catalog from 900 cm(-1) to 1580 cm(-1)

The results of a complete high resolution study of the three vibration-rotation bands v sub 3, v sub 4, and V sub 6 using both TDLs and FT-IR spectroscopy are presented. The reults are given in terms of a table of over 8000 predicted transition frequencies and strengths. A plot of the predicted and calculated spectra is shown. Over 3000 transitions were assigned and used in the simultaneous analysis of the three bands. The simultaneous fit permitted a rigorous study of Coriolis and other type iterations among bands yielding improved molecular constants. Line intensities of 28 transitions measured by a TDL and 20 transitions from FTS data were used, along with the eigenvectors from the frequency fitting, in a least squares analysis to evaluate the band strengths.

Nadler, Shachar↗