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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

Representations and strategies for transferable machine learning improve model performance in chemical discovery

Strategies for machine-learning (ML)-accelerated discovery that are general across material composition spaces are essential, but demonstrations of ML have been primarily limited to narrow composition variations. By addressing the scarcity of data in promising regions of chemical space for challenging targets such as open-shell transition-metal complexes, general representations and transferable ML models that leverage known relationships in existing data will accelerate discovery. Over a large set (~1000) of isovalent transition-metal complexes, we quantify evident relationships for different properties (i.e., spin-splitting and ligand dissociation) between rows of the Periodic Table (i.e., 3d/4d metals and 2p/3p ligands). We demonstrate an extension to the graph-based revised autocorrelation (RAC) representation (i.e., eRAC) that incorporates the group number alongside the nuclear charge heuristic that otherwise overestimates dissimilarity of isovalent complexes. To address the common challenge of discovery in a new space where data are limited, we introduce a transfer learning approach in which we seed models trained on a large amount of data from one row of the Periodic Table with a small number of data points from the additional row. We demonstrate the synergistic value of the eRACs alongside this transfer learning strategy to consistently improve model performance. Analysis of these models highlights how the approach succeeds by reordering the distances between complexes to be more consistent with the Periodic Table, a property we expect to be broadly useful for other material domains.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Mechanical properties and microstructure of 316L stainless steel produced by hybrid manufacturing

Hybrid manufacturing is a combination of additive (deposition) and subtractive (machining) manufacturing in a single machine tool. Such a system can be used for near net shape manufacturing and component repair using either similar or dissimilar materials. Integrated into a single system, transition between additive and subtractive manufacturing can occur immediately and be leveraged to generate large components by alternating between the processes. In this investigation, we show how the interleaved capabilities can reduce overall cycle time by up to 68 %, improve average relative elongation to failure by 71 %, and reduce the average relative porosity fraction by 83 % when compared to traditional additive manufactured components. Results from this investigation builds the foundation needed for hybrid manufacturing to be applicable towards the manufacture of large complex components such as nosecones and marine propulsors.

36 MATERIALS SCIENCE↗

Magellan - Electrical and physical properties of Venus' surface

Magellan probes Venus'surface by 12.6-cm-wavelength vertical and oblique radar scattering and measures microwave thermal emission. Emissivity and root-mean-square slope maps between 330 deg and 30 deg E and 90 deg N and 80 deg S are dissimilar, although some local features are exceptions. Inferred surface emissivities typically are 0.85, but vary from 0.35 at Maxwell to 0.95 northeast of Gula Mons and other locations. Lowest emissivities appear in topographically high areas; this relation suggests that a phase change or differences in chemical weathering occur at about 6055-kilometer radius. Initial results indicate that there are significant variations in the surface scattering function.

Tyler, G. Leonard↗

Domain-Matching Epitaxy of Ferroelectric Hf 0.5 Zr 0.5 O 2 (111) on La 2/3 Sr 1/3 MnO 3 (001)

Epitaxial ferroelectric HfO2 films are the most suitable to investigate intrinsic properties of the material and for prototyping emerging devices. Ferroelectric Hf 0.5 Zr 0.5 O 2 (111) films were epitaxially stabilized on La 2/3 Sr 1/3 MnO 3 (001) electrodes. This epitaxy, considering the symmetry dissimilarity and the huge lattice mismatch, is not compatible with conventional mechanisms of epitaxy. In this work, to gain insight into the epitaxy mechanism, scanning transmission electron microscopy characterization of the interface was performed, revealing arrays of dislocations with short periodicities. Additionally, these observed periodicities agree with those expected for domain matching epitaxy, indicating that this unconventional mechanism could be the prevailing factor in the stabilization of ferroelectric Hf0.5Zr0.5O2 with (111) orientation in the epitaxial Hf 0.5 Zr 0.5 O 2 (111)/La 2/3 Sr 1/3 MnO 3 (001)heterostructure.

36 MATERIALS SCIENCE↗

Integrated Computational Materials and Mechanical Modeling for Additive Manufacturing of Alloys with Graded Structure Used in Fossil Fuel Power Plants

Wire-arc additive manufacturing (WAAM) has demonstrated its unique capability of producing large-size alloy components with a significantly reduced fabrication time and enhanced geometry design freedom. In this project, the team has developed an ICME (Integrated Computational Materials Engineering) modeling framework, which supports the WAAM of the AUSC (Advanced Ultra-Supercritical) power plant components. The manufacturing design has been applied to Inconel 740H, steel P91, as well as the dissimilar alloy components between steel P91 and Inconel 740H. The ICME model framework is developed by considering two types of modeling. First, mechanistic modeling has been applied to control the printing quality and understand the sequence of the dissimilar printing of the wall structure. The following models have been included in the developed ICME framework: finite element thermal model, grain structure model, residual stress simulation, crystal plasticity model, CALPHAD-based precipitation kinetic model, phase stability prediction, thermal expansion predictive model, and heuristic creep model. Secondary, a physics-based machine learning model has also been developed based on the ICME model structure. The machine learning model development is based on the ICME model prediction with calibration of the experiments. In addition, the WAAM has been utilized as a high-throughput experimental tool rapidly generating a gradient of alloy composition to facilitate experimental database generation for process-structure-property relationships. Such a database directly supported the ICME-enhanced machine learning, which further assisted in intermediate composition block design between P91 and 740H. A high-throughput screening study of the oxidation resistance has been performed based on such high-throughput experimentation. Based on the computational design, several dissimilar alloy manufacturing with post-heat treatment have been performed with a comprehensive evaluation of mechanical performance, including hardness mapping, yield strength, creep resistance. In this project, the single component of P91 and 740H processed by WAAM after heat treatment designed by ICME has demonstrated higher performance in yield strength and creep resistance than the wrought materials. The P91 sample prepared by WAAM with ICME-designed heat treatment performs better than P92 in creep resistance. The designed graded alloy printing with intermediate block shows a promising performance that exceeds the traditional welding. Moreover, the current research indicates the high need for location-specific design analysis with uncertainty quantification, an important topic that deserves more dedicated research. The achievement of this project demonstrated the promising future of WAAM in structural alloy manufacturing for energy power plant development. Successful printing requires synergetic efforts made by manufacturing, mechanical, and materials sciences.

20 FOSSIL-FUELED POWER PLANTS↗

Electron Linear Accelerator Additive Manufacturing

Superconducting electron linear accelerators open up new opportunities for advanced materials processing. High energy electrons penetrate deeper within materials, increase the processing depth and rate and enables production of far-from-equilibrium materials and selective processing within a material surface and subsurface. With support from the Office of Naval Research, NASA, and DoE, Mainstream Engineering commissioned a superconducting linear electron accelerator to investigate advanced materials processing and additive manufacturing. The goal of Mainstream's Electron Beam Enabled Advanced Manufacturing (EBEAM) center is to develop unique, far-from-equilibrium materials and alleviate significant technological deficiencies. We will present results of irradiating various metals and their unique material properties. Monte Carlo simulations electron beam and sample interaction were used to optimize the processing parameters and study far-from-equilibrium processing conditions. Applications include stainless steel additive manufacturing for small modular nuclear reactors and dissimilar metal bonding of corrosion-resistant cladding for next-generation molten salt reactors.

36 MATERIALS SCIENCE↗

Interpretation of Spectral LiDAR Backscattering off the Florida Coast

A multispectral backscattering LiDAR (Light detection and range) system (hereafter Oculus) was integrated into a wave glider and used to estimate the scattering order (i.e., single vs multiple collisions), inherent optical properties (IOPs) and characteristics of particulate scatterers (i.e., relative size, composition and motion) on shelf waters of South East Florida. Oculus has a dual-wavelength configuration (473 and 532 nm) and two detection geometries (off- and on-axis). Characteristics of scatterers were investigated based on two complementary LiDAR-derived proxies (the Structural Dissimilarity Index and the spectral slope of LiDAR backscattering). In March 2017, field measurements showed a covariation between direct and diffuse backscattering contributions during morning hours and away from shore. LiDAR attenuation coefficients explained up to 57% of IOPs variability. The analysis of LiDAR-derived proxies suggested higher turbidity and larger particulates near the coast.

LiDAR↗

Fullerene Derived Molecular Electronic Devices

The carbon Nanotube junctions have recently emerged as excellent candidates for use as the building blocks in the formation of nanoscale electronic devices. While the simple joint of two dissimilar tubes can be generated by the introduction of a pair of heptagon-pentagon defects in an otherwise perfect hexagonal grapheme sheet, more complex joints require other mechanisms. In this work we explore structural and electronic properties of complex 3-point junctions of carbon nanotubes using a generalized tight-binding molecular-dynamics scheme.

Menon, Madhu↗

Reducing leakage current and enhancing polarization in multiferroic 3D super-nanocomposites by microstructure engineering

Abstract Multiferroic materials have generated great interest due to their potential as functional device materials. Nanocomposites have been increasingly used to design and generate new functionalities by pairing dissimilar ferroic materials, though the combination often introduces new complexity and challenges unforeseeable in single-phase counterparts. The recently developed approaches to fabricate 3D super-nanocomposites (3D‐sNC) open new avenues to control and enhance functional properties. In this work, we develop a new 3D‐sNC with CoFe 2 O 4 (CFO) short nanopillar arrays embedded in BaTiO 3 (BTO) film matrix via microstructure engineering by alternatively depositing BTO:CFO vertically-aligned nanocomposite layers and single-phase BTO layers. This microstructure engineering method allows encapsulating the relative conducting CFO phase by the insulating BTO phase, which suppress the leakage current and enhance the polarization. Our results demonstrate that microstructure engineering in 3D‐sNC offers a new bottom–up method of fabricating advanced nanostructures with a wide range of possible configurations for applications where the functional properties need to be systematically modified.

36 MATERIALS SCIENCE↗

Joining Dissimilar Materials via Rotational Hammer Riveting Technique

A mechanically robust joining method for Mg/Al and Mg/CFRP could enable multi-material assemblies that decrease vehicle weight while offering more flexibility for designers. However, certain challenges exist for joining Mg/Al and Mg/CFRP. Mechanical joining, such as conventional riveting, clinching and bolting do not form a metallurgical bond between the fastener and metal sheet being fastened. Large differences in physical and mechanical properties of metals and polymers make joining Al or Mg to CFRP challenging via various welding techniques. With solid-state and fusion based welding, rapid formation of brittle intermetallic compounds at the Mg/Al interface lead to interfacial fracture under mechanical loading. In this study, a Rotational Hammer Rivet (RHR) technique was developed to fabricate Mg/CFRP and Mg/Al joints. With RHR technique, direct joining between Mg/Al and Mg/CFRP were replaced by joining Mg rivet head and top Mg sheet. Through heat generated by plastic deformation of an Mg rivet, RHR creates a metallurgical bond between rivet head and Mg sheet which seals corrosive electrolyte from penetrating around the rivet head.

riveting, magnesium alloys, CFRP, Dissimilar Joini↗

Topological materials by molecular beam epitaxy

Topology appears across condensed matter physics to describe a wide array of phenomena which could alter, augment, or fundamentally change the functionality of many technologies. Linking the basic science of topological materials to applications requires producing high-quality thin films. This will enable combining dissimilar materials while utilizing dimensionality, symmetry, and strain to create or control the electronic phase, as well as platforms to fabricate novel devices. Yet, one of the longstanding challenges in the field remains understanding and controlling the basic material properties of epitaxial thin films. Here, we discuss how understanding the fundamental properties of topological materials grown by molecular beam epitaxy (MBE) is key to deepening the knowledge of the basic physics, while developing a new generation of topological devices. A focus will be on the MBE growth of intrinsic materials, creation, and control of superconducting and magnetic topological phases. Addressing these questions in the coming decade will undoubtedly uncover many surprises as new materials are discovered and their growth as high-quality thin films is refined.

2d quantum materials↗

Modeling-Based Design and Optimization of a Gradient Composite Transition Joint

An innovative additively manufactured gradient composite transition joint (AM-GCTJ) has been designed to join dissimilar metals, to address the pressing issue of premature failure observed in conventional dissimilar metal welds (DMWs) when subjected to increased cyclic operating conditions of fossil fuel power plants. The transition design, guided by computational modeling, developed a gradient composite material distribution, facilitating a smooth transition in material volume fraction and physical properties between different alloys. This innovative design seeks to alleviate structural challenges arising from distinct material properties, including high thermal stress and potential cracking issues resulting from the thermal expansion mismatch typically observed in conventional DMWs. In this study, we investigated the creep properties of transition joints comprising Grade 91 steel and 304 stainless steel through a combination of simulations and creep testing experiments. The implementation of a gradient composite design in the plate transition joint resulted in a significant enhancement of creep resistance when compared to the baseline conventional DMW. For instance, the creep rupture life of the transition joint was improved by > 400% in a wide range of temperature and stress testing conditions. Meanwhile, the failure location shifted to the base material of Grade 91 steel. Such enhancement can be primarily attributed to the strong mechanical constraint facilitated by the gradient composite design, which effectively reduced the stresses on the less creep-resistant alloy in the transition zone. Beyond examining plate joints, it is crucial to assess the deformation response of tubular transition joints under pressure loading and transient temperature conditions to substantiate and demonstrate the effectiveness of the design. The simulation results affirm that the tubular transition joint demonstrates superior resistance compared to its counterpart DMW when subjected to multiaxial stresses in tubular structures. In addition, optimization of the transition joint’s geometry dimensions has been conducted to diminish the accumulated deformation and enhance the service life. Lastly, the scalability and potential of the innovative transition joints for large-diameter pipe applications are addressed.

Zhang, Wei↗

Assessing the Time Variability of Jupiter's Tropospheric Properties from 1996 to 2011

We acquired and analyzed mid-infrared images of Jupiter's disk at selected wavelengths from NASA's Infrared Telescope Facility (IRTF) from 1996 to 2011, including a period of large-scale changes of cloud color and albedo. We derived the 100-300 mbar temperature structure, together with tracers of vertical motion: the thickness of a 600- mbar cloud layer, the 300-mbar abundance of the condensable gas NH3, and the 400- mbar para- vs. ortho-H2 ratio. The biggest visual change was detected in the normally dark South Equatorial Belt (SEB) that 'faded' to a light color in 2010, during which both cloud thickness and NH3 abundance rose; both returned to their pre-fade levels in 2011, as the SEB regained its normal dark color. The cloud thickness in Jupiter's North Temperate Belt (NTB) increased in 2002, coincident with its visible brightening, and its NH3 abundance spiked in 2002-2003. Jupiter's Equatorial Zone (EZ), a region marked by more subtle but widespread color and albedo change, showed high cloud thickness variability between 2007 and 2009. In Jupiter's North Equatorial Belt (NEB), the cloud thickened in 2005, then slowly decreased to a minimum value in 2010-2011. No temperature variations were associated with any of these changes, but we discovered temperature oscillations of approx.2-4 K in all regions, with 4- or 8-year periods and phasing that was dissimilar in the different regions. There was also no detectable change in the para- vs. ortho-H2 ratio over time, leading to the possibility that it is driven from much deeper atmospheric levels and may be time-invariant. Our future work will continue to survey the variability of these properties through the Juno mission, which arrives at Jupiter in 2016, and to connect these observations with those made using raster-scanned images from 1980 to 1993 (Orton et al. 1996 Science 265, 625).

Orton, G. S.↗

SA508 low alloy steel to 316L stainless steel dissimilar metal joint made by powder metallurgy hot isostatic pressing

Joining ferritic SA508 low alloy steel (LAS) and austenitic 316 L stainless steel (SS) via powder metallurgy hot isostatic pressing (PM-HIP) was evaluated as an alternative method to welding. This study investigated the mechanical and microstructural evolutions of the bimetallic interface under different joint designs and heat treatments. Here, the direct joining of dissimilar metal alloys by PM-HIP method resulted in two designs: 1) powder SA508 to solid bar 316 L (P508–B316L) and 2) powder 316 L solid bar SA508 (P316L-B508). In both cases, P508–B316L and P316L-demonstrated satisfactory tensile strength, however, high hardness and severe depreciation in toughness were located on the bimetallic interface. The mechanisms responsible for the detrimental mechanical properties were verified. Large oxides were observed in P508–B316L due to the prior powder boundary (PPB) oxides present in SA508 powder. The intense sensitization occurred from the formation of M 23 C 6 carbides, consequently from the slow cooling after PM-HIP in P316L-B508. Post-HIP heat treatments were explored to reduce the distance of carbide formation; however, the heat treatment could not eliminate the carbides. The experimental results were compared to the diffusion couple simulation as a function of carbide formation with distance. The analysis also showed the high hardness at the bimetallic interface was primarily contributed by solid solution strengthening. In conclusion, the direct joining of P316L-B508 and P508–B316L via PM-HIP was deemed to be unfeasible, and a transitional material is necessary to impede the diffusion of carbon.

316L stainless Steel↗

Printing polymer blends through in situ active mixing during fused filament fabrication

Fused filament fabrication (FFF) enables production of 3D objects over a range of material compositions at low-cost relative to traditional manufacturing approaches. To date, a limited but growing number of materials are able to be used with FFF, however many applications exist where specific mechanical, thermal, or chemical properties are needed that cannot currently be met with the available feedstock selection. Therefore, a need exists to tune these materials for specific chemical or mechanical properties. One common formulation strategy to address these demanding design parameters is to develop composites or polymer blend filaments. Typically, this is a time-consuming and costly optimization process. Here, we have developed hardware for reproducibly mixing two filaments of similar or dissimilar compositions at the time of printing within individual printed layers. This mixing occurs via software-controlled rotating hardware in the chamber of an extruder’s hot-end. The efficiency of mixing within the printed layers has been characterized in detail as a function of the rotational speed and geometry of the blending hardware. These parameters were exploited to program the ratio and distribution of thermoplastic-based filaments blended within printed extrudate. Example printed specimens were produced with thermoplastic polyurethane (TPU) elastomer blended with rigid polylactic acid (PLA) and Nylon blended with PLA. In addition, a conductive carbon nanotube (CNT)-PLA composite was blended as a function of mixer geometry and input feed ratios with non-conductive PLA and resistance values were measured across the resulting printed specimens.

36 MATERIALS SCIENCE↗

Thermal Stir Welding: A New Solid State Welding Process

Thermal Stir Shielding is a revolutionary new welding process developed at NASA's Marshall Space Flight Center in Huntsville, AL. Thermal stir welding is similar to friction stir welding in that it joins similar or dissimilar materials without melting the parent material. However, unlike friction stir welding, the heating and stirring functions are independent allowing more degrees of freedom for greater process control. This paper introduces the mechanics of the thermal stir welding process. In addition, weld mechanical property data is presented for selected alloys as well as metallurgical analysis.

Ding, R. Jeffery↗

Safety Expertise and the Perils of Novelty

Emerging aviation markets such as urban air mobility are giving rise to new technologies and means of operation. However, novelty may hide ‘unknown unknowns,’ raising new hazards. This paper examines how expertise and safety techniques enable transformative technologies such as reduced crew operations, hybrid wing-borne and rotor-born flight, federated air traffic services, and urban operations. We explore how analysts use expertise to address common-cause failures, collect and interpret safety data, and perform exacting tradeoffs between dissimilarity, redundancy, independence, and diversity (human, process lifecycle, or otherwise) to ensure safety. When novelty is present, analysts might not possess the expertise needed to fully understand the implications of design decisions and tradeoffs being made, especially in early lifecycle phases, on emergent properties such as safety. Safety expertise must be carefully cultivated. The conflicting views of safety experts must be unpacked to identify the divergence in fundamental assumptions, models, means, and methods that may be causing them. Once systems venture beyond the basis of what safety expertise can reliably guarantee, projects take on risk that must be managed. The paper contains key takeaways and actionable recommendations for novel OEMs and regulators touching on topics such as robust monitoring; clear and transparent reporting; incremental approaches to fielding novel systems in hazard-rich, risk-tolerant environments; the cultivation of safety culture and expertise in an organization; and the use of scientific study to reduce epistemic uncertainty in novel operations with new technologies. Since excessive novelty in aviation can undermine the current foundation of safety, humility and incrementalism are necessary to enable emerging aviation markets safely.

safety expertise↗

Safety Expertise and the Perils of Novelty

Emerging aviation markets such as urban air mobility are giving rise to new technologies and means of operation. However, novelty may hide ‘unknown unknowns,’ raising new hazards. This paper examines how expertise and safety techniques enable transformative technologies such as reduced crew operations, hybrid wing-borne and rotor-born flight, federated air traffic services, and urban operations. We explore how analysts use expertise to address common-cause failures, collect and interpret safety data, and perform exacting tradeoffs between dissimilarity, redundancy, independence, and diversity (human, process lifecycle, or otherwise) to ensure safety. When novelty is present, analysts might not possess the expertise needed to fully understand the implications of design decisions and tradeoffs being made, especially in early lifecycle phases, on emergent properties such as safety. Safety expertise must be carefully cultivated. The conflicting views of safety experts must be unpacked to identify the divergence in fundamental assumptions, models, means, and methods that may be causing them. Once systems venture beyond the basis of what safety expertise can reliably guarantee, projects take on risk that must be managed. The paper contains key takeaways and actionable recommendations for novel OEMs and regulators touching on topics such as robust monitoring; clear and transparent reporting; incremental approaches to fielding novel systems in hazard-rich, risk-tolerant environments; the cultivation of safety culture and expertise in an organization; and the use of scientific study to reduce epistemic uncertainty in novel operations with new technologies. Since excessive novelty in aviation can undermine the current foundation of safety, humility and incrementalism are necessary to enable emerging aviation markets safely.

safety expertise↗