Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “materials development”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,297 records · Page 72

Computational Exploration of High Entropy Alloys as Promising Materials for Future Beam Windows

With the ever-increasing demand for high beam power, the currently used beam-intercepting devices (BIDs) such as targets, and beam windows may not be able to handle the high power required for future accelerator complexes or the lifetime may be reduced drastically. As beam power increases, the damage incurred by BIDs, including thermal shock, fatigue, and irradiation damage, also rises. Therefore, it is imperative to design materials that can withstand high beam power for longer lifetimes. High entropy alloys (HEAs) have emerged as potential alternative materials for designing next-generation BIDs. In this study, we primarily focus on materials for developing beam windows for next-generation accelerator complexes. We propose an integrated approach that combines various computational techniques to study and design new materials. Specifically, we use CALPHAD, density functional theory (DFT), and molecular dynamics (MD) to comprehensively investigate the defect properties of suitable HEAs, offering potential alternatives for future beam windows. We begin by scanning the extensive phase space provided by Cr-Mn-V-Ti-Al-Co HEAs, selecting 8 compositions after evaluating approximately 120,000 unique compositions using CALPHAD. We, then employ DFT-informed machine learning techniques to develop force-field parameters. Finally, MD simulations using these developed force-field parameters will be used to study the effects of radiation damage on the defect and mechanical properties of the selected alloys. This research explains the use of the CALPHAD approach and shows how critical modeling (DFT and MD) is in developing novel material such as HEAs. It also highlights the promising role of machine learning in this field. The results from this study will greatly improve the novel materials development to be used in next-generation accelerator components, leading to higher beam power and longer operational times of BIDs.

43 PARTICLE ACCELERATORS↗

Development of Lightweight Structural Materials with Improved Properties for Fission Batteries

The notion of a “fission battery” conveys a vision focused on realizing very simple “plug-and-play” nuclear systems that can be integrated into a variety of applications requiring affordable, reliable energy in the form of electricity and/or heat and function without operations and maintenance staff. Fission batteries require lightweight structural materials to increase their mobility, and the lightweight materials must demonstrate structural resilience under various conditions. The objective of this work is to develop lightweight structural material featuring a good combination of mechanical properties using advanced modeling and simulation together with an advanced additive manufacturing technique such as laser powder bed fusion. The preliminary results show that different lattice structures and types can be successfully meshed using nTopology software, and the lattice structure data can be successfully transformed to Multiphysics Object-Oriented Simulation Environment (MOOSE) input. Finite Element Analysis (FEA) displays that, at macro/engineering scale simulation, the weight saving design has an obvious effect on tensile behavior such as effective elastic modulus and yield stress. The novel approaches of this work are (1) development of optimized lattice structures for improved mechanical properties using advanced simulation and modeling techniques; and (2) model predictions of the mechanical properties (e.g., strength and stress distribution) of macroscopic materials in order to preliminarily select a lattice structure for additive manufacturing.

36 MATERIALS SCIENCE↗

The development of criticality response materials - 14282

The Sellafield nuclear facility in the UK comprises a highly complex suite of plants and processes. This in turn demands a consistent and high performance from Emergency Response teams and management in order to demonstrate readiness to respond and combat any nuclear emergency. In order to continue to improve such readiness, a comprehensive programme of development has been undertaken by the Licensee. The programme spans the totality of the emergency response cycle which is resolved into three broad areas: Preparedness; Response; Building Specific File. Within these broad categories the focus of the materials changes from broad and general materials in the preparedness section to actual scenario specific materials in the Building Specific Files Sellafield Ltd. provided the scope of work for the totality of the criticality response materials, known collectively as Criticality Accident Response Data (CARD). The UK National Nuclear Laboratory (NNL) was challenged to technically underpin, develop and present the information in a format and layout that would satisfy the requirements of consistency, brevity, simplicity and relevance. One of the key areas targeted for improvement, and the focus of this paper, was the criticality accident response information that sits within the Building Specific File. At this level of the emergency response cycle by necessity the information must be detailed and specific and enable the emergency responder to understand the problem and assist in formulating a recovery plan. One of the key challenges faced by NNL and discussed in this paper was how to provide the emergency responder with the greatest amount of relevant information in the simplest form. NNL solved this problem by presenting the information in a 'four-block' format which includes a common set of information in textual and diagrammatic form. This paper presents on overview of the criticality accident specific four-blocker, highlights the problems encountered and focuses on the new and innovative materials developed. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Spark-plasma-sintering magnetic field assisted compaction of Co{sub 80}Ni{sub 20} nanowires for anisotropic ferromagnetic bulk materials

We developed a two-step process showing the way for sintering anisotropic nanostructured bulk ferromagnetic materials. A new reactor has been optimized allowing the synthesis of several grams per batch of nanopowders via a polyol soft chemistry route. The feasibility of the scale-up has been successfully demonstrated for Co{sub 80}Ni{sub 20} nanowires and a massic yield of ∼97% was obtained. The thus obtained nanowires show an average diameter of ∼6 nm and a length of ∼270 nm. A new bottom-up strategy allowed us to compact the powder into a bulk nanostructured system. We used a spark-plasma-sintering technique under uniaxial compression and low temperature assisted by a permanent magnetic field of 1 T. A macroscopic pellet of partially aligned nanowire arrays has been easily obtained. This showed optimized coercive properties along the direction of the magnetic field applied during compaction (i.e., the nanowires' direction)

36 MATERIALS SCIENCE↗

Exploitation of Defects in High Entropy Ceramic Barrier Materials

A critical mission need exists to develop new materials that can withstand extreme environments and multiple sequential threats. High entropy materials, those containing 5 or more metals, exhibit many exciting properties which would potentially be useful in such situations. However, a particularly hard challenge in developing new high entropy materials is determining a priori which compositions will form the desired single phase material. The project outlined here combined several modeling and experimental techniques to explore several structure-property-relationships of high entropy ceramics in an effort to better understand the connection between their compositional components, their observed properties, and stability. We have developed novel machine learning algorithms which rapidly predict stable high entropy ceramic compositions, identified the stability interplay between configurational entropy and cation defects, and tested the mechanical stability of high entropy oxides using the unique capabilities at the Dynamic Compression Sector facility and the Saturn accelerator.

36 MATERIALS SCIENCE↗

Technique for Evaluating the Erosive Properties of Ablative Internal Insulation Materials

A technique for determining the average erosion rate versus Mach number of candidate internal insulation materials was developed for flight motor applications in 12 inch I.D. test firing hardware. The method involved the precision mounting of a mechanical measuring tool within a conical test cartridge fabricated from either a single insulation material or two non-identical materials each of which constituted one half of the test cartridge cone. Comparison of the internal radii measured at nine longitudinal locations and between eight to thirty two azimuths, depending on the regularity of the erosion pattern before and after test firing, permitted calculation of the average erosion rate and Mach number. Systematic criteria were established for identifying erosion anomalies such as the formation of localized ridges and for excluding such anomalies from the calculations. The method is discussed and results presented for several asbestos-free materials developed in-house for the internal motor case insulation in solid propellant rocket motors.

McComb, J. C.↗

Magnetic susceptibility and magnetic resonance measurements of the moisture content and hydration condition of a magnetic mixture material

We developed a magnetic measurement method to measure the moisture content and hydration condition of mortar as a magnetic mixture material. Mortar is a mixture of Portland cement, sand, and water, and these materials exhibit different magnetic properties. The magnetization–magnetic field curves of these components and of mortars with different moisture contents were measured, using a specially developed high-temperature-superconductor superconducting quantum interference device. Using the differences in magnetic characteristics, the moisture content of mortar was measured at the ferromagnetic saturation region over 250 mT. A correlation between magnetic susceptibility and moisture content was successfully established. After Portland cement and water are mixed, hydration begins. At the early stage of the hydration/gel, magnetization strength increased over time. To investigate the magnetization change, we measured the distribution between bound and free water in the mortar in the early stage by magnetic resonance imaging (MRI). The MRI results suggest that the amount of free water in mortar correlates with the change in magnetic susceptibility.

36 MATERIALS SCIENCE↗

Requirements and Techniques for Developing and Measuring Simulant Materials

The 1989 workshop report entitled Workshop on Production and Uses of Simulated Lunar Materials and the Lunar Regolith Simulant Materials: Recommendations for Standardization, Production, and Usage, NASA Technical Publication identify and reinforced a need for a set of standards and requirements for the production and usage of the lunar simulant materials. As NASA need prepares to return to the moon, a set of requirements have been developed for simulant materials and methods to produce and measure those simulants have been defined. Addressed in the requirements document are: 1) a method for evaluating the quality of any simulant of a regolith, 2) the minimum Characteristics for simulants of lunar regolith, and 3) a method to produce lunar regolith simulants needed for NASA's exploration mission. A method to evaluate new and current simulants has also been rigorously defined through the mathematics of Figures of Merit (FoM), a concept new to simulant development. A single FoM is conceptually an algorithm defining a single characteristic of a simulant and provides a clear comparison of that characteristic for both the simulant and a reference material. Included as an intrinsic part of the algorithm is a minimum acceptable performance for the characteristic of interest. The algorithms for the FoM for Standard Lunar Regolith Simulants are also explicitly keyed to a recommended method to make lunar simulants.

Rickman, Doug↗

Coupled cluster and dislocation dynamics modeling of microstructure evolution in irradiated materials

We develop here a coupled cluster and dislocation dynamics framework to study the microstructure evolution of irradiated materials. The framework not only accounts for the three dimensional diffusion of radiation-generated clusters, but also their interaction with dislocation networks and the resultant climb motion of discrete dislocations within finite crystals. The framework is solved with a superposition solution scheme, and is applied to investigate the evolution of the irradiation-induced dislocation loops in zirconium (Zr), considering the effects of various bias factors including the diffusion anisotropy difference (DAD) of interstitials and interstitial clusters, the dislocation bias of defects to discrete dislocation segments, and the production bias of defects from the radiation cascade. We find that the DAD is the most critical factor influencing the kinetics of the loop evolution in Zr, while the recombination/interaction of mobile defects can induce a strong spatial dependence of the loop evolution together with the DAD. Here, the method is also adopted to study the evolution of interstitial $\langle$a$\rangle$ and vacancy $\langle$c$\rangle$ dislocation loop ensembles consistent with the microstructure observed during irradiation-induced growth of Zr. Our findings not only reveal the spatial dependence of the size and ellipticity of the dislocation loops, but also suggest a limit on the anisotropy factor of interstitials to reproduce the co-growth of $\langle$a$\rangle$ and $\langle$c$\rangle$ loops in zirconium, in good agreement with experimental observations and other simulation results.

Bias factors↗

Infrared fiber optic materials

The development of IR fiber optics for use in astronomical and other space applications is summarized. Candidate materials were sought for use in the 1 to 200 micron and the 200 to 1000 micron wavelength range. Synthesis and optical characterization were carried out on several of these materials in bulk form. And the fabrication of a few materials in single crystal fiber optic form were studied.

Feigelson, Robert S.↗

Materials, Manufacturing, and Test Development of a Composite Fan Blade Leading Edge Subcomponent for Improved Impact Resistance

Application of polymer matrix composite materials for jet engine fan blades is becoming attractive as an alternative to metallic blades; particularly for large engines where significant weight savings are recognized on moving to a composite structure. However, the weight benefit of the composite is offset by a reduction of aerodynamic efficiency resulting from a necessary increase in blade thickness; relative to the titanium blades. Blade dimensions are largely driven by resistance to damage on bird strike. Further development of the composite material is necessary to allow composite blade designs to approximate the dimensions of a metallic fan blade. The reduction in thickness over the state of the art composite blades is expected to translate into structural weight reduction, improved aerodynamic efficiency, and therefore reduced fuel consumption. This paper presents test article design, subcomponent blade leading edge fabrication, test method development, and initial results from ballistic impact of a gelatin projectile on the leading edge of composite fan blades. The simplified test article geometry was developed to realistically simulate a blade leading edge while decreasing fabrication complexity. Impact data is presented on baseline composite blades and toughened blades; where a considerable improvement to impact resistance was recorded.

Materials↗

Materials, Manufacturing and Test Development of a Composite Fan Blade Leading Edge Subcomponent for Improved Impact Resistance

Application of polymer matrix composite materials for jet engine fan blades is becoming attractive as an alternative to metallic blades; particularly for large engines where significant weight savings are recognized on moving to a composite structure. However, the weight benefit of the composite of is offset by a reduction of aerodynamic efficiency resulting from a necessary increase in blade thickness; relative to the titanium blades. Blade dimensions are largely driven by resistance to damage on bird strike. Further development of the composite material is necessary to allow composite blade designs to approximate the dimensions of a metallic fan blade. The reduction in thickness over the state of the art composite blades is expected to translate into structural weight reduction, improved aerodynamic efficiency, and therefore reduced fuel consumption. This paper presents test article design, subcomponent blade leading edge fabrication, test method development, and initial results from ballistic impact of a gelatin projectile on the leading edge of composite fan blades. The simplified test article geometry was developed to realistically simulate a blade leading edge while decreasing fabrication complexity. Impact data is presented on baseline composite blades and toughened blades; where a considerable improvement to impact resistance was recorded.

Ballistic Impact↗

Near-field transport imaging applied to photovoltaic materials

We developed and applied a new analytical technique - near-field transport imaging (NF-TI or simply TI) - to photovoltaic materials. Charge-carrier transport is an important factor in solar cell performance, and TI is an innovative approach that integrates a scanning electron microscope with a near-field scanning optical microscope, providing the possibility to study luminescence associated with recombination and transport with high spatial resolution. In this paper, we describe in detail the technical barriers we had to overcome to develop the technique for routine application and the data-fitting procedure used to calculate minority-carrier diffusion length values. The diffusion length measured by TI agrees well with the results calculated by time-resolved photoluminescence on well-controlled gallium arsenide (GaAs) thin-film samples. We report for the first time on measurements on thin-film cadmium telluride using this technique, including the determination of effective carrier diffusion length, as well as the first near-field imaging of the effect of a single localized defect on carrier transport and recombination in a GaAs heterostructure. Furthermore, by changing the scanning setup, we were able to demonstrate near-field cathodoluminescence (CL), and correlated the results with standard CL measurements. In conclusion, the TI technique shows great potential for mapping transport properties in solar cell materials with high spatial resolution.

14 SOLAR ENERGY↗

Heat's on to develop high-temperature materials

An evaluation is made of the state-of-the-art and foreseeable development prospects in high temperature engineering materials applicable to advanced heat engines and other aerothermodynamically affected structures. Attention is given to monocrystal- and microcrystal-producing metal solidification processes, soft oxide and chemically stable fluoride high temperature solid lubricants, polyimide and other high temperature polymers for propulsion system applications, high strength/toughness ceramics for heat engine structural components, thermal barrier coatings, and metal-matrix composites employing refractory matrices as well as reinforcing fibers.

Gray, Hugh R.↗

Impact damage development in damaged composite materials

A procedure for predicting the nature of impact damage development based on the measured acousto-ultrasonic (AU) response of fiber reinforced crossply laminates with or without damage is described. Results of AU evaluation as well as penetrant enhanced radiographs of damaged laminates are presented.

Duke, J. C., Jr.↗

Scale up production of carbon fibers from petroleum mesophase pitch

This work investigates the scale-up of pitch precursors for the carbon fiber market using mesophase pitch formulated and produced by Advanced Carbon Products Technologies’ (ACPT’s) patented mesophase pitch processing technology. Through use of its patented process, ACPT developed strategic materials by converting petroleum-based pitch into a high-value, low-cost, carbon-rich feedstock for carbon fiber and other materials critical to our national security. The team successfully developed processing criteria for the tailored mesophase pitch material that can be processed further into precursor and carbon fiber. Processability of the mesophase pitch into precursor and carbon fiber was demonstrated at scale. The resulting materials sequester the carbon that would otherwise be burned and released into the atmosphere, making this an environmentally friendly way to produce these materials in the United States.Pitch-based carbon fibers offer a promising pathway toward cost-effective, high-performance materials for structural and high-modulus composite applications; however, adoption has been limited by challenges in precursor processability and scale-up. In this work, tailored isotropic and mesophase petroleum-derived pitch materials were developed and evaluated for precursor and carbon fiber production through a collaborative effort between Oak Ridge National Laboratory (ORNL) and ACPT. Processing conditions were established at ORNL’s Carbon Fiber Technology Facility to enable stable melt-blowing of pitch-based precursors under continuous operation. Mesophase pitch precursor fibers were produced following oxidation and carbonization, corresponding to a diameter shrinkage of approximately 12%–13% and an estimated mass yield of about 75%–80%. Continuous melt-blowing steady-state operation was demonstrated over time, indicating robust process stability. Melt-blowing was achieved at throughput rates of approximately 20 lb/h⁻¹, validating the commercial viability of petroleum-derived pitch feedstocks for fiber production. Further studies are required to tailor carbon fiber microstructure and properties for specific composite applications.

99 GENERAL AND MISCELLANEOUS↗