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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

Microtexture and Nanoindentation Study of Delamination Cracking in Al-Cu-Li-X Alloys

Commercial Al-Li alloys have strength and weight advantages over non-Li aluminum alloys. The fracture behavior of these alloys is unusual and has limited their use. The fracture mode, described as delamination, is intergranular, along the broad grain boundaries parallel to the rolling plane of the plate. Microtexture analyses have shown that delaminations occur along boundaries with greater than 30 misorientation. However, it was observed that relatively few of the high angle boundaries exhibited this behavior. Some grains of the retained deformation texture show high internal misorientation, which is a measure of stored strain energy. Delamination tends to occur between these grains and adjacent, recrystallized grains. Nanoindentation studies indicate a higher hardness for the high internal misorientation grains. These results suggest that the delamination could be reduced by processing the alloys to minimize grain-to-grain property disparities.

Crooks, R.↗
NASA NTRSDate not supplied

Boundary Layer Stability and Transition in a Chemically Reacting Martian Atmosphere using LASTRAC

The Thermal Protection System (TPS) is a significant portion of the mass of reentry vehicles, planetary probes, and Martian entry vehicles. Reducing this mass has benefits in terms of decreased fuel requirements and increased payload; however, due to the high risk and un-certainty, the TPS or heat shields are designed conservatively by assuming fully turbulent flow. Laminar flow results in reduced heat flux, and improved transition prediction has the potential to reduce TPS mass and uncertainty in aerothermodynamic predictions. Limited previous research exists examining the problem of transition prediction for Martian atmospheric entry, with studies available on transition on the Mars Science Laboratory TPS. Although transition was demonstrated in wind-tunnel tests, uncertainty in the transition location resulted in a TPS designed for fully turbulent flow, and therefore greater mass than required for a partially-laminar condition. In this work, we extend the boundary layer stability code LASTRAC, recently modified to include chemical and thermal nonequilibrium capabilities, to a model of the Martian atmosphere. LASTRAC provides Parabolized Stability Equations (PSE) as well as Linear Stability Theory (LST) to predict the stability of a boundary layer and transition with semi-empirical eN methods. Results included in this work compare disturbance growth characteristics between air and Martian atmosphere at similar nondimensional freestream conditions on a simple flat plate geometry. Both chemical nonequilibrium and thermochemical nonequilibrium, as well as both PSE and LST, are used.

Heather L Kline↗
NASA NTRS1998

Corrosion Studies of 2195 Al-Li Alloy and 2219 Al Alloy with Differing Surface Treatments

Corrosion studies of 2195 Al-Li and 2219 Al alloys have been conducted using the scanning reference electrode technique (SRET) and the polarization resistance (PR) technique. The SRET was used to study corrosion mechanisms, while corrosion rate measurements were studied with the PR technique. Plates of Al203 blasted, soda blasted and conversion coated 2219 Al were coated with Deft primer and the corrosion rates studied with the EIS technique. Results from all of these studies are presented.

Danford, M. D.↗
NASA NTRS1999

Mechanical Properties of Friction Stir Welds in A12195-T8

An extensive study of the mechanical properties of friction stir welded Al-Li 2195 has been conducted by Lockheed Martin Michoud Space Systems under contract to NASA. The study was part of a development program in which weld parameters were defined for using FSW to assemble large-scale aluminum cryogenic tanks. In excess of 300 feet of 0.320 in. gage plate material was welded and tested. The tests include room temperature and cryogenic temperature tensile tests and surface crack tension (SCT) tests, nondestructive evaluation, metallurgical studies, and photostress analysis. The results of the testing demonstrated improved mechanical properties with FSW as compared to typical fusion welding processes. Increases in ultimate tensile strength, cryogenic enhancement and elongation were observed with the tensile test results. Increased fracture toughness was observed with the SCT results. Nondestructive evaluations were conducted on all welded Joints. No volumetric defects were indicated. Surface indications on the root side of the welds did not significantly affect weld strength. The results of the nondestructive evaluations were confirmed via metallurgical studies. Photostress analysis revealed strain concentrations in multi-pass and heat-repaired FSW's. Details of the tests and results are presented.

Kinchen, David G.↗
DOE OSTI2025

Effects of shielding gas and spot reduction on humping suppression in high-speed laser welding

High-speed laser welding is a crucial process to enhance the production rate of fuel cell fabrication. However, exceeding a critical welding speed leads to defect formation such as humps and root concavities, which degrade weld quality and mechanical performance. This study employed shielding gas and spot reduction approaches to suppress these defects. The relationships between individual defect types and their influence on weld strength were systematically examined. Moreover, in situ high-speed synchrotron X-ray imaging was employed to comprehend the mechanisms of humping mitigation by shielding gas through analysis of instantaneous keyhole and melt pool dynamics. The observations reveal that shielding gas mitigates humping by shortening the molten pool through enhanced surface heat convection and by altering surface tension to prevent melt flow collisions. The effects of shielding gas and spot reduction were further incorporated into the dimensionless humping index (π h ) that describes the humping formation tendency. These findings provide mechanistic insights and quantitative guidance for defect control strategies in high-speed laser welding.

08 HYDROGEN↗
NASA NTRS2003

An Update on C458 Al-Li

The 1.8 Li content and consequently the 0.0945 lb.cu in density of C458 along with its higher modulus and good strength and toughness at ambient and cryogenic temperatures made it an attractive alloy for single and multiple use cryogenic tankage and unpressurized structure for space launch and operational vehicles. A major effort during the past year was directed towards establishing a production capability for C458 plate. Alcoa established a production ingot casting capability under Air Force Research Laboratory and NASA's Space Launch Initiative (SLI) sponsorship. Three heat lots of material were rolled so that the criterion for S-basis allowables could be met for AMS specifications. Lot acceptance testing showed that the strength and toughness values equaled and exceeded those obtained under the earlier Air Force Program when the alloy was developed. The details of this effort and the results achieved will be described. During the testing of compact tension specimens, particularly at cryogenic temperatures, delaminations were noted on the fractured surface. An investigation was initiated to better understand this condition. The results of this investigation will be presented which includes some of the successful production application of alloys with and without Li that exhibit this type of behavior.

Babel, Hank↗
DOE OSTI2024

Evaluating Material Design Principles for Calcium-Ion Mobility in Intercalation Cathodes

Multivalent-ion batteries offer an alternative to Li-based technologies, with the potential for greater sustainability, improved safety, and higher energy density, primarily due to their rechargeable system featuring a passivating metal anode. Although a system based on the Ca 2+ /Ca couple is particularly attractive given the low electrochemical plating potential of Ca 2+ , the remaining challenge for a viable rechargeable Ca battery is to identify Ca cathodes with fast ion transport. In this work, a high-throughput computational pipeline is adapted to (1) discover novel Ca cathodes in a largely unexplored space of empty intercalation hosts and (2) develop material design rules for Ca-ion mobility. One candidate from the screening, W 2 O 3 (PO 4 ) 2 , is confirmed to have a low Nudged Elastic Band (NEB) barrier of 168 meV within a one-dimensional (1D) ion percolation topology. This candidate is subsequently synthesized and electrochemically tested, achieving reversible Ca cycling with a capacity of 25 mA h/g. To further accelerate the screening for promising Ca intercalation electrodes, machine learning (ML) Random Forest (RF) and Extreme Gradient Boosting (XGB) classification models are created with local environment descriptors based on a large, structurally and chemically diverse dataset of minimum energy pathways, spanning over 5,000 density functional theory (DFT) site energy calculations. Accuracies of 92% are achieved, material design metrics are quantified, ML force-fields are leveraged in an accelerated iteration of the screening, and a total of 27 novel Ca cathode materials are highlighted for further investigation.

25 ENERGY STORAGE↗
DOE OSTI2023

Composite Lithium Metal Structure to Mitigate Pulverization and Enable Long‐Life Batteries

In lithium metal batteries, non‐uniform stripping of lithium results in pit formation, which promotes subsequent non‐uniform, dendritic deposition. This viscous cycle leads to pulverization of lithium which promotes cell shorting or capacity degradation, symptoms further exaggerated by high electrode areal loading and lean electrolytes. Here, to address this challenge, a composite lithium metal anode is engineered that contains uniformly distributed, nanometer‐sized carbon particles. This composite lithium is shown to strip more uniformly since the growth of non‐uniform pits is intercepted by the carbon particles. This mechanism is corroborated by a continuum electrochemical model. Subsequent lithium deposition on carbon particles is also found to be more uniform than on the surface with irregular pits. Notably, the pulverization rate of composite lithium is 26 times slower than that of commercial lithium. Moreover, in a Li‐S battery with sulfurized polyacrylonitrile cathode, the use of the composite anode extends the cycle life by three times when the areal capacity is 8 mAh cm −2 . The approach of using an engineered lithium composite structure to address challenges during both stripping and plating can inform future designs of lithium metal anodes for high areal capacity operations.

high areal capacity↗
NASA NTRS1998

Buckling mode localization in elastic plates due to misplacement in the stiffener location

This paper deals with the buckling of the stiffened plate under uni-axial compression. The direct integration of the governing differential equation is performed and the exact solution to the problem is obtained. As examples, a square plate with single stiffener, and a stiffened three-span, continuous plate are investigated, with special attention given to the influence of stiffener misplacement on the buckling load and mode shape of the plate. It is found that a small misplacement of the stiffeners from the nominal configuration may change the buckling mode from a global one to a highly localized one.

Elishakoff, I.↗
DOE OSTI2026

Molten pool dynamics and humping suppression in high-speed laser welding via tailored beam configurations

High-speed laser welding is essential for increasing the production rate of fuel cell fabrication. However, when the welding speed exceeds a critical limit, humping occurs and reduces the weld quality. In this study, two tailored beam configurations, including an adjustable ring mode and a dual-beam configuration, were employed to suppress humping. Computational fluid dynamics simulations were performed to elucidate the underlying suppression mechanisms. Here, the results show that, in the adjustable ring mode, humping mitigation arises from a reduced backward cross-sectional melt flow rate and a more stable molten pool. In the dual-beam configuration, humping suppression is attributed to the deceleration of melt flow, the conduction-mode behavior of the trailing beam, and the widening of the molten pool induced by the trailing laser. Furthermore, because the dual-beam configuration directly modifies the trailing molten pool dynamics, it achieves more effective humping suppression, extending the welding speed limit to 1.50 m/s, compared with 1.00 m/s for the adjustable ring mode.

08 HYDROGEN↗
DOE OSTI2025

Unveiling the Role of Lithium Iodide in Stabilizing Solid Interfaces in All-Solid-State Li Metal Batteries

A critical challenge in all-solid-state lithium metal batteries (ASSLMBs) is achieving a stable interface between the lithium metal anode and the solid electrolyte. Leveraging its success in Li/I 2 batteries, lithium iodide has garnered significant attentions for its potential to enhance interfacial stability and overall cell performance in ASSLMBs. Here, we elucidate the role of lithium iodide in stabilizing the solid interface in all-solid-state Li metal batteries with a Li argyrodite electrolyte, particularly focusing on its influence on lithium deposition behavior and interfacial evolution. Through in situ optical imaging, we demonstrate more uniform lithium deposition on an iodide-contained argyrodite electrolyte compared to a chloride-based counterpart. Complementary density functional theory calculations attribute improved lithium plating behavior to the enhanced lithiophilicity and better ionic conductivity of lithium iodide at the solid interface, effectively reducing localized current density. In conclusion, these findings provide useful insights into the mechanisms through which lithium iodide enhances the interfacial stability in ASSLMBs.

Anions↗
NASA NTRS1988

Boundary element method for 3-D cracks in a plate

Fundamental solutions which automatically satisfy boundary conditions at the interfaces of an elastic plate perfectly bonded to two elastic halfspaces are implemented in a three-dimensional BEM for crack problems. The BEM features a new integration scheme for highly singular kernels. The capability is achieved through a part analytic and part numerical integration procedure, such that the analytic part of the integration is similar for all slip/opening variations. Part-through elliptic cracks in an elastic plate with traction-free surfaces are analyzed and the SIF values along the crack front are found to compare favorably with the numerical SIF results of Raju and Newman (1979).

Fares, N.↗
DOE OSTI2024

Dynamical Janus Interface Design for Reversible and Fast-Charging Zinc–Iodine Battery under Extreme Operating Conditions

Aqueous zinc (Zn) iodine (I 2 ) batteries have emerged as viable alternatives to conventional metal-ion batteries. However, undesirable Zn deposition and irreversible iodine conversion during cycling have impeded their progress. Here, to overcome these concerns, we report a dynamical interface design by cation chemistry that improves the reversibility of Zn deposition and four-electron iodine conversion. Due to this design, we demonstrate an excellent Zn-plating/-stripping behavior in Zn||Cu asymmetric cells over 1000 cycles with an average Coulombic efficiency (CE) of 99.95%. Moreover, the Zn||I 2 full cells achieve a high-rate capability (217.1 mA h g –1 at 40 A g –1 ; C rate of 189.5C) at room temperature and enable stable cycling with a CE of more than 99% at -50 °C at a current density of 0.05 A g –1 . In situ spectroscopic investigations and simulations reveal that introducing tetraethylammonium cations as ion sieves can dynamically modulate the electrode–electrolyte interface environment, forming the unique water-deficient and chloride ion (Cl – )-rich interface. Such Janus interface accounts for the suppression of side reactions, the prevention of ICl decomposition, and the enrichment of reactants, enhancing the reversibility of Zn-stripping/-plating and four-electron iodine chemistry. This fundamental understanding of the intrinsic interplay between the electrode–electrolyte interface and cations offers a rational standpoint for tuning the reversibility of iodine conversion.

25 ENERGY STORAGE↗
NASA NTRS1991

Weldability of Weldalite (tm) 049 with and without TiB2 reinforcement

The effects are assessed of TiB2 reinforcement and parent alloy Li content on the weldability of Weldalite (tm) 049 type alloys. Welding trials were performed using either AC or DC polarity gas tungsten arc (GTA) welding according to described procedures. The welding was performed under conditions of high restraint on 5 cm (2 in) wide x 25.4 cm (10 in) long plates machined from the 0.952 cm (0.375 in) extruded bar parallel to the extrusion direction. A 37.5 deg bevel was machined on the center edge of the extruded bar. Cut rod filler wire was machined from three alloys, and one commercially available 2319 filler wire was also used. The preliminary assessment of the weldability revealed no propensity for hot cracking under conditions of high restraint. This result is significant, because hot cracking has been reported for all other leading aluminum lithium alloys welded with certain conventional filler alloys. The strengths for Weldalite parent welded with parent filler obtained were higher than those for alloys used in launch systems, such as 2219 and 2014 welded with 2319 and 4043 fillers, respectively. Even higher values were obtained by variable polarity plasma arc welding (e.g., 54 ksi (372 MPa) mean tensile strength).

Source record↗
NASA NTRS1998

Friction Stir Weld Tooling Development for Application on the 2195 Al-Cu-Li Space Transportation System External Tank

Friction Stir Welding (FSW) is a new and innovative solid-state joining process which can be applied to difficult-to- weld aluminum alloys. However, the large forces involved with the process have posed a production tooling challenge. Lockheed Martin Michoud Space Systems has overcome many of these challenges on the Super Lightweight External Tank (ET) program. Utilizing Aluminum-Copper-Lithium alloy 2195 in the form of plate and extrusions, investigations of FSW process parameters have been completed. Major loading mechanisms are discussed in conjunction with deflection measurements. Since the ET program is a cryogenic application, a brief comparison of cryogenic material properties with room temperature material properties is offered for both FSW and fusion welds. Finally, a new approach to controlling the FSW process from a load perspective is introduced. Emphasis will be put on tooling development, as well as the impact of tooling design and philosophy on Friction Stir Weld success probability.

Loftus, Zachary↗
NASA NTRS1992

A numerical study of Li-SF6 wick combustion - Forced and mixed convective burning

A numerical study is conducted to study Li-SF6 wick diffusion flames under mixed convective burning conditions at a pressure of 0.01 MPa. Both planar and cylindrical wicks are considered. The model is based on a conserved scalar approach. The objective of this study is to assess the effects of particular parameters on the burning rate and heat transfer. The flat-plate solution yields a fuel mass burning rate per unit surface area following the x exp -1/2 dependence of the classical similarity solution, where x is the streamwise distance. Cylindrical wick geometries yield enhanced burning rates over planar wicks. For the case of mixed convective burning, the burning rate results approach either the forced or natural convective burning limits as ambient streamwise velocity is changed. Critical Richardson numbers specifying these burning limits are determined for a given condition. Reducing gravity results in a lower burning rate because the influence of natural convection is diminished. Under reduced gravity of 1/1000 of the sea-level value, mixed convective burning nearly resembles forced convection.

Damaso, R. C.↗
DOE OSTI2025

Derivation of physical equations for high-speed laser welding using large language models

It is challenging to formulate complex physical phenomena that occur in a manufacturing process, particularly when the available data are limited, rendering conventional data-driven approaches ineffective. This study aims to predict humping onset in high-speed laser welding by introducing a novel framework, namely text-to-equations generative pre-trained transformer (T2EGPT). This method leverages the capabilities of large language models (LLMs), in combination with sparse experimental data and enriched literature data, to derive an interpretable and generalizable equation for predicting humping initiation. By capturing key correlations among physical parameters, T2EGPT generates a compact and dimensionless expression that accurately predicts hump formation. The equation reveals that humping arises from the interplay between inertia-driven backward melt flow and capillary-driven surface stabilization, where inertial forces drive molten metal backward and capillary forces resist surface deformation. Furthermore, compared to traditional data-driven models, T2EGPT demonstrates enhanced predictive accuracy and cross-material transferability. More broadly, this study highlights the potential of LLMs to integrate textual information with data-driven discovery, enabling the extraction of physical laws in data-scarce scientific domains.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Stress engineering for crack and dendrite prevention in solid electrolytes via ion implantation

Solid-state batteries represent a promising technology that offers safer and more densely packed energy storage. A primary cause of failure in solid-state cells is the penetration of metal dendrites through the solid electrolyte. Here, we report that fluorine-ion implantation can enhance the mechanical resistance of solid electrolyte Li 6.5 La 3 Zr 1.5 Ta 0.5 O 12 to dendrite propagation by inducing residual compressive stress in the subsurface of the electrolyte. Ion implantation modifies subsurface residual stress and also alters the electrolyte’s surface, resulting in multifunctional enhancement. The combined chemical and mechanical effects of ion implantation enable reversible lithium metal stripping and plating at elevated current densities while enhancing air stability and mitigating the formation of a harmful carbonate layer at the surface. This study provides new insights into a scalable dendrite-suppression strategy for designing solid-state batteries suitable for cycling at room temperature and low stack pressures.

25 ENERGY STORAGE↗