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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,477 records · Page 82
All sourcesNASA NTRSDOE OSTI
NASA NTRS1977

Theoretic aspects of the identification of the parameters in the optimal control model

The identification of the parameters of the optimal control model from input-output data of the human operator is considered. Accepting the basic structure of the model as a cascade of a full-order observer and a feedback law, and suppressing the inherent optimality of the human controller, the parameters to be identified are the feedback matrix, the observer gain matrix, and the intensity matrices of the observation noise and the motor noise. The identification of the parameters is a statistical problem, because the system and output are corrupted by noise, and therefore the solution must be based on the statistics (probability density function) of the input and output data of the human operator. However, based on the statistics of the input-output data of the human operator, no distinction can be made between the observation and the motor noise, which shows that the model suffers from overparameterization.

Vanwijk, R. A.↗
NASA NTRS1985

Sol-Gel Glasses

Multicomponent homogeneous, ultrapure noncrystalline gels/gel derived glasses are promising batch materials for the containerless glass melting experiments in microgravity. Hence, ultrapure, homogeneous gel precursors could be used to: (1) investigate the effect of the container induced nucleation on the glass forming ability of marginally glass forming compositions; and (2) investigate the influence of gravity on the phase separation and coarsening behavior of gel derived glasses in the liquid-liquid immiscibility zone of the nonsilicate systems having a high density phase. The structure and crystallization behavior of gels in the SiO2-GeO2 as a function of gel chemistry and thermal treatment were investigated. As are the chemical principles involved in the distribution of a second network former in silica gel matrix being investigated. The procedures for synthesizing noncrystalline gels/gel-monoliths in the SiO2-GeO2, GeO2-PbO systems were developed. Preliminary investigations on the levitation and thermal treatment of germania silicate gel-monoliths in the Pressure Facility Acoustic Levitator were done.

Mukherjee, S. P.↗
NASA NTRS1993

Graphite fiber textile preform/copper matrix composites

This project has the objective of exploring the use of graphite fiber textile preform/copper matrix composites in spacecraft heat transmitting and radiating components. The preforms are to be fabricated by braiding of tows and when infiltrated with copper will result in a 3-D reinforced, near net shape composite with improved specific properties such as lower density and higher stiffness. It is anticipated that the use of textile technology will result in a more robust preform and consequently better final composite; it is hard to anticipate what performance tradeoffs will result, and these will be explored through testing and characterization.

Filatovs, G. J.↗
NASA NTRS2004

Fibrous-Ceramic/Aerogel Composite Insulating Tiles

Fibrous-ceramic/aerogel composite tiles have been invented to afford combinations of thermal-insulation and mechanical properties superior to those attainable by making tiles of fibrous ceramics alone or aerogels alone. These lightweight tiles can be tailored to a variety of applications that range from insulating cryogenic tanks to protecting spacecraft against re-entry heating. The advantages and disadvantages of fibrous ceramics and aerogels can be summarized as follows: Tiles made of ceramic fibers are known for mechanical strength, toughness, and machinability. Fibrous ceramic tiles are highly effective as thermal insulators in a vacuum. However, undesirably, the porosity of these materials makes them permeable by gases, so that in the presence of air or other gases, convection and gas-phase conduction contribute to the effective thermal conductivity of the tiles. Other disadvantages of the porosity and permeability of fibrous ceramic tiles arise because gases (e.g., water vapor or cryogenic gases) can condense in pores. This condensation contributes to weight, and in the case of cryogenic systems, the heat of condensation undesirably adds to the heat flowing to the objects that one seeks to keep cold. Moreover, there is a risk of explosion associated with vaporization of previously condensed gas upon reheating. Aerogels offer low permeability, low density, and low thermal conductivity, but are mechanically fragile. The basic idea of the present invention is to exploit the best features of fibrous ceramic tiles and aerogels. In a composite tile according to the invention, the fibrous ceramic serves as a matrix that mechanically supports the aerogel, while the aerogel serves as a low-conductivity, low-permeability filling that closes what would otherwise be the open pores of the fibrous ceramic. Because the aerogel eliminates or at least suppresses permeation by gas, gas-phase conduction, and convection, the thermal conductivity of such a composite even at normal atmospheric pressure is not much greater than that of the fibrous ceramic alone in a vacuum.

White, Susan M.↗
DOE OSTI2022

Synthesis and Characterization of Polymeric Pore Former Microspheres using Modified Polymer Resin

Porosity in polymer parts is often desired to improve mechanical properties. Individual pores must be small enough that bulk mechanical properties are retained but significant enough to reduce the density of the material. Filler materials can be incorporated into polymer matrices and subsequently removed to create voids. The materials used to create the voids are known as pore-formers. The present research aims to create spherical pores in a silicone matrix by inserting and removing core materials or fillers post-cure. A method was developed to incorporate pore formers into an uncured polymer resin and remove the materials from the matrix. Polyethylene Glycol (PEG) and Polylactic Acid (PLA) microspheres are created and incorporated into silicone matrices as pore formers. Microspheres with controllable size distributions are formed via ultrasonic spray pyrolysis and emulsion formation. Microspheres are removed from the matrix by solvent extraction and calcination. PLA microspheres were modified by hydroxyl addition to the surface to study their solubility in water. PEG-PLA block copolymers are also synthesized and investigated, comparing their physical and chemical properties to the monomers to identify whether the block copolymer microspheres will be more easily removable than their monomeric microspheres. Moreover, other properties including thermal stability, rheology, and mechanical response are studied. The present dissertation provides a comprehensive understanding of the synthesis and characterization of PEG and PLA-based pore formers, toward the future development of feedstock for additive manufacturing porous structures.

Damptey, Ransford↗
DOE OSTI2024

Scalable learning of potentials to predict time-dependent Hartree–Fock dynamics

We propose a framework to learn the time-dependent Hartree–Fock (TDHF) inter-electronic potential of a molecule from its electron density dynamics. Although the entire TDHF Hamiltonian, including the inter-electronic potential, can be computed from first principles, we use this problem as a testbed to develop strategies that can be applied to learn a priori unknown terms that arise in other methods/approaches to quantum dynamics, e.g., emerging problems such as learning exchange–correlation potentials for time-dependent density functional theory. We develop, train, and test three models of the TDHF inter-electronic potential, each parameterized by a four-index tensor of size up to 60 × 60 × 60 × 60. Two of the models preserve Hermitian symmetry, while one model preserves an eight-fold permutation symmetry that implies Hermitian symmetry. Across seven different molecular systems, we find that accounting for the deeper eight-fold symmetry leads to the best-performing model across three metrics: training efficiency, test set predictive power, and direct comparison of true and learned inter-electronic potentials. All three models, when trained on ensembles of field-free trajectories, generate accurate electron dynamics predictions even in a field-on regime that lies outside the training set. To enable our models to scale to large molecular systems, we derive expressions for Jacobian-vector products that enable iterative, matrix-free training.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Characterization of high thermal conductivity fuel surrogates before and after ion irradiation

High thermal conductivity nuclear fuels offer important potential advantages over traditional oxide-based fuels such as higher burnup, reduction in fission gas release, and better overall safety of the system. One proposed approach to high thermal conductivity fuels utilizes high thermal conductivity nonfissile additives with UO 2 fuel to lower the fuel operating temperature and thereby take advantage of the highly favorable radiation resistance of UO 2 at lower operating temperatures. However, differential swelling in the matrix and high conductivity additive phases during high dose irradiation could lead to internal cracking and poor performance. In the current study, ceria (CeO 2 ) and zirconia (ZrO 2 ) surrogate matrices were used to model UO2 behavior. Additives of 10 vol. % Al 2 O 3 or SiC in the form of short fibers or platelets were used for the high conductivity second phase. The nuclear fuel surrogates were sintered to achieve densities greater than 93% of the ideal values. Scanning electron microscopy (SEM) imaging and X-ray diffraction confirmed the uniform distribution of the second phase and that no intermetallic second phase was formed during sintering. The thermal conductivity of the sintered samples was measured from 50 °C to 900 °C and confirmed the desirable increase compared to pure CeO 2 /ZrO 2 pellets. Samples were irradiated with 20 MeV Ni 6+ ions at midrange doses ranging from 1 to 15 displacements per atom (dpa) and temperatures from 300 °C to 700 °C. Post irradiation characterization revealed a good stability of the samples at low to medium doses with matrix lattice parameter swelling of < 0.14 % but showed a significant microstructural deterioration and decrease of the mechanical properties at 15 dpa.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

A new perspective on the initial hydrogenation of $\mathrm{TiFe_{0.9}M_{0.1}}$ ($\mathrm{M = V, Cr, Fe, Co, Ni}$) gained from surface oxide analysis and nucleation thermodynamics

Despite the promise of TiFe-based alloys as low-cost solid-state hydrogen storage materials with mild operating conditions and reasonable hydrogen capacity, their initial hydrogenation process is difficult, hindering broad utilization. The effect of alloying element on the initial hydrogenation kinetics of TiFe alloys, TiFe 0.9 M 0.1 (M = V, Cr, Fe, Co and Ni), was evaluated by analyzing changes to the passivating surface oxide layer that inhibits hydrogen permeation, as well as the ease of initial-stage hydrogen absorption into the underlying matrix. X-ray photoelectron spectroscopy and atom probe tomography revealed key variations in surface oxide compositions and thinning of the passivating oxide layer compared to pure TiFe, which suggests suppressed oxide growth by alloying-induced elemental redistribution. At the same time, density functional theory calculations predicted exothermic formation of hydride nuclei when alloying with V or Cr, as well as a reduced nucleation barrier when alloying with Co or Ni. Overall, these results are consistent with the observed experimental trend of the activation kinetics. We propose that improvements in activation kinetics of TiFe with alloying arises from the combined effect of reduced passivating oxide thickness and easier hydride nucleation, offering a starting point for alloy design strategies towards further improvement.

25 ENERGY STORAGE↗
DOE OSTI2022

Chrome-free qandilite (Mg 2 TiO 4 ) refractory aggregates: Role of titania source and evaluation of thermal expansion coefficient

As used chrome-based refractories may contain toxic Cr 6+ , the chrome-free Mg 2 TiO 4 phase is being considered which is known to improve hot strength and resistance to thermal shock and slag corrosion. As in situ Mg 2 TiO 4 formation generates porosity, preformed aggregates are desirable. Dilatometric studies revealed that when dead burned magnesia is combined with industrial anatase instead of rutile, it expanded less (1% versus 7.2%) and the reaction occurred earlier (965°C compared to 1120°C). After sintering at 1,600°C, rutile produced an aggregate with 3.8% open porosity, whereas anatase led to 0 % porosity and a bulk density of 3.24g/cm 3 with a thermal expansion coefficient (70–1,600°C) of 13.5×10 -6 K -1 . Moreover, replacing rutile by anatase eliminates the undesirable MgTiO 3 phase. The anatase-based aggregate consisted of a Mg 2 TiO 4 matrix with residual unreacted MgO and an intergranular, refractory CaTiO 3 phase. In conclusion, the rutile-based aggregate was deemed unsuitable due to a low-melting microstructure of forsterite contiguous with CaTiO 3 .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

A single-ion-conducting polymer and high-entropy Li-garnet composite electrolyte with simultaneous enhancement in ion transport and mechanical properties

Enabling the lithium metal anode has been the holy grail for improving the energy density for the next generation advanced batteries. Developing electrolytes that will suppress Li dendrite growth and provide sufficient ionic conductivity remains a major challenge in this field. In this study, we develop a polymer–ceramic composite electrolyte for lithium metal batteries. The polymer matrix is a vinyl ethylene carbonate (VEC) based single-ion-conducting polymer electrolyte. The ceramic filler is a Li 7 La 3 Zr 0.5 Nb 0.5 Ta 0.5 Hf 0.5 O 12 high-entropy Li-garnet (HE Li-garnet) ceramic, which is less prone to surface Li 2 CO 3 formation compared to Al-doped Li garnets. The addition of HE Li-garnet leads to a 7-fold increase in the ionic conductivity (8.6 × 10 −5 S cm −1 at 30 °C) compared to the pure polymer, while maintaining a high Li + transference of 0.73. Proton nuclear magnetic resonance and thermogravimetric analysis results suggest that the addition of HE Li-garnet results in a lower degree of polymerization of VEC, leaving more unpolymerized VEC monomers in the matrix, serving as the governing mechanism for conductivity enhancement. The favorable interactions between HE Li-garnet particles and the polymer matrix lead to a stable and well-mixed composite with 2-fold enhancement of storage modulus at 40 °C. The simultaneous ion transport and mechanical property enhancement significantly improves the composite electrolyte's dendrite resistance and cycle life in Li symmetric cells. This work highlights the positive role HE Li-garnet can play in improving polymer electrolytes to enable lithium metal anodes.

Ock, Ji-young [Oak Ridge National Laboratory (ORNL↗
DOE OSTI2025

Quadrupole strength in isobaric triplets

The dependence of the 𝐸⁢2 matrix elements on isospin projection 𝑇 𝑧 is linked to the conservation of the isospin symmetry. To study this conjecture, we calculated the 𝐵⁡(𝐸⁢2 : 2 + →0 + ) rates for the even-even 𝑇=1 mirror nuclei with 42 ≤ 𝐴 ≤ 98 within nuclear density functional theory, employing the generalized Bohr Hamiltonian, and carrying out angular momentum projection. We demonstrated that collective effects are crucial for describing experimental data near the 𝑁=𝑍 line without invoking explicit beyond-Coulomb isospin symmetry-breaking corrections. We also determined the 𝐵⁡(𝐸⁢2↓) values for odd-odd 𝑇 𝑧 =0 nuclei 70 Br and 78 Y in doubly blocked configurations. We discussed the requirements for accurately describing isobaric analog states and emphasized how current theoretical results should be interpreted within the study of isospin symmetry across isospin triplets.

collective levels↗
NASA NTRS2014

Supersonic Retropropulsion Test 1853 in NASA LaRC Unitary Plan Wind Tunnel Test Section 2

A supersonic retropropulsion experiment was conducted in the Langley Research Center Unitary Plan Wind Tunnel Test Section 2 at Mach numbers of 2.4, 3.5, and 4.6. Intended as a code validation effort, this study used pretest computations to size and refine the model such that tunnel blockage and internal flow separations were minimized. A 5-in diameter 70 degree sphere-cone forebody, which can accommodate up to four 4:1 area ratio nozzles, followed by a 9.55 inches long cylindrical aft body was selected for this test after computational maturation. The primary measurements for this experiment were high spatial-density surface pressures. In addition, high speed schlieren video and internal pressures and temperatures were acquired. The test included parametric variations in the number of nozzles utilized, thrust coefficients (roughly 0 to 4), and angles of attack (-8 to 20 degrees). The run matrix was developed to also allow quantification of various sources of experimental uncertainty, such as random errors due to run-to-run variations and systematic errors due to flowfield or model misalignments. To accommodate the uncertainty assessment, many runs and replicates were conducted with the model at various locations within the tunnel and with model roll angles of 0, 60, 120, and 180 degrees. This test report provides operational details of the experiment, contains a review of trends, and provides all schlieren and pressure results within appendices.

Berry, Scott A.↗
DOE OSTI2024

Effects of carbon concentration on the local atomic structure of amorphous GST

Ge-Sb-Te (GST) alloys are leading phase-change materials for data storage due to the fast phase transition between amorphous and crystalline states. Ongoing research aims at improving the stability of the amorphous phase to improve retention. This can be accomplished by the introduction of carbon as a dopant to Ge 2 Sb 2 Te 5 , which is known to alter the short- and mid-range structure of the amorphous phase and form covalently bonded C clusters, both of which hinder crystallization. The relative importance of these processes as a function of C concentration is not known. Here we used molecular dynamics simulation based on density functional theory to study how carbon doping affects the atomic structure of GST-C. Carbon doping results in an increase in tetrahedral coordination, especially of Ge atoms, and this is known to stabilize the amorphous phase. We observe an unexpected, non-monotonous trend in the number of tetrahedral bonded Ge with the amount of carbon doping. Our simulations show an increase in the number of tetrahedral bonded Ge up to 5 at.% C, after which the number saturates and begins to decrease above 14 at.% C. The carbon atoms aggregate into clusters, mostly in the form of chains and graphene flakes, leaving less carbon to disrupt the GST matrix at higher carbon concentrations. Different degrees of carbon clustering can explain divergent experimental results for recrystallization temperature for carbon doped GST.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

A review of the fabrication methods and mechanical behavior of continuous thermoplastic polymer fiber–thermoplastic polymer matrix composites

Abstract Thermoplastic polymer fiber–thermoplastic polymer matrix composites (PPCs or PRFPs), often recognized as self‐reinforced or single polymer composites, are potential candidates for future advanced polymer composites because of various advantages ( e.g., recyclability, formability, low‐cost, ultra‐lightweight, environmental friendliness, etc.). The manufacturability and mechanical behavior of these composites compared to conventional carbon‐/glass‐/aramid‐fiber‐reinforced polymers is of great interest to the composites community, but there are a limited number of studies in this area. To this end, this paper reviewed fabrication methods with different processing parameters and mechanical behavior of uni‐/multi‐directional thermoplastic PPCs featuring continuous thermoplastic polymer fibers from limited data in the literature. It was shown that most specific behaviors (normalized by density) of these materials in various loading conditions (e.g., quasi‐static tension/shear/flexure, tension‐tension fatigue, and out‐of‐plane impacting, etc.) are comparable to or better than glass‐/aramid‐fiber‐reinforced polymers. Particularly, the specific ductility in the foregoing conditions outperforms all the carbon‐/glass‐/aramid‐fiber‐reinforced polymers. Thermoplastic PPCs with remarkable performance can be achieved through several uncomplicated methods (e.g., film stacking, hot compaction, powder and solution impregnations, matrix infusion and injection molding, additive manufacturing, etc.), which have some similarities to the methods used for carbon‐/glass‐/aramid‐fiber‐reinforced polymers. Moreover, several opportunities and challenging problems of thermoplastic PPCs were summarized at the end of this review paper. Efficient solutions may require countless efforts in the composites community to further strengthen the performance and understanding of thermoplastic PPCs for wide applications in various engineering fields in the future.

36 MATERIALS SCIENCE↗
NASA NTRS2007

Sequestration of Single-Walled Carbon Nanotubes in a Polymer

Sequestration of single-walled carbon nanotubes (SWCNs) in a suitably chosen polymer is under investigation as a means of promoting the dissolution of the nanotubes into epoxies. The purpose of this investigation is to make it possible to utilize SWCNs as the reinforcing fibers in strong, lightweight epoxy-matrix/carbon-fiber composite materials. SWCNs are especially attractive for use as reinforcing fibers because of their stiffness and strength-to-weight ratio: Their Young s modulus has been calculated to be 1.2 TPa, their strength has been calculated to be as much as 100 times that of steel, and their mass density is only one-sixth that of steel. Bare SWCNs cannot be incorporated directly into composite materials of the types envisioned because they are not soluble in epoxies. Heretofore, SWCNS have been rendered soluble by chemically attaching various molecular chains to them, but such chemical attachments compromise their structural integrity. In the method now under investigation, carbon nanotubes are sequestered in molecules of poly(m-phenylenevinylene-co-2,5-dioctyloxy-p-phenylenevinylene) [PmPV]. The strength of the carbon nanotubes is preserved because they are not chemically bonded to the PmPV. This method exploits the tendency of PmPV molecules to wrap themselves around carbon nanotubes: the wrapping occurs partly because there exists a favorable interface between the conjugated face of a nanotube and the conjugated backbone of the polymer and partly because of the helical molecular structure of PmPV. The constituents attached to the polymer backbones (the side chains) render the PmPV-wrapped carbon nanotubes PmPV soluble in organic materials that, in turn, could be used to suspend the carbon nanotubes in epoxy precursors. At present, this method is being optimized: The side chains on the currently available form of PmPV are very nonpolar and unable to react with the epoxy resins and/or hardeners; as a consequence, SWCN/PmPV composites have been observed to precipitate out of epoxies while the epoxies were being cured. If the side chains of the PmPV molecules were functionalized to make them capable of reacting with the epoxy matrices, it might be possible to make progress toward practical applications. By bonding the side chains of the PmPV molecules to an epoxy matrix, one would form an PmPV conduit between the epoxy matrix and the carbon nanotubes sequestered in the PmPV. This conduit would transfer stresses from the epoxy matrix to the nanotubes. This proposed load-transfer mode is similar to that of the current practice in which silane groups are chemically bonded to both the epoxy matrices and the fibers (often glass fibers) in epoxymatrix/fiber composites.

Bley, Richard A.↗
DOE OSTI2021

Dual-atom active sites embedded in two-dimensional C 2 N for efficient CO 2 electroreduction: A computational study

Double-atom catalysts (DACs) have emerged as an enhanced platform of single-atom catalyst for promoting electrocatalytic CO 2 reduction reaction (CO 2 RR). Herein, we present a density-functional theory study on CO 2 RR performance of seven C 2 N-supported homo- and heteronuclear DACs, denoted as M 2 @C 2 N. Our results demonstrate that there exists substantial synergistic effect of dual-metal-atom N 2 M 2 N 2 active site and C 2 N matrix on O&#x2550 C &#x2550O bond activation. The dual-atom M 2 sites are able to drive CO 2 RR beyond C 1 products with low limiting potential (U L ). Specifically, C 2 H 4 formation is preferred on FeM@C 2 N (M = Fe, Co, Ni, Cu) versus CH 4 formation on CuM@C 2 N (M = Co, Ni, Cu). Furthermore, *CO+*CO co-binding strength can serve as a descriptor for CO 2 RR activity for making C 2 products such that the moderate binding results in the lowest U L . Remarkably, C-affinity matters most to C—C bond coupling and C 2 H 4 formation while both C- and O-affinity control CH 4 formation. Furthermore, our results provide theoretical insight into rational design of DACs for efficient CO 2 RR.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2015

A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing of Ceramic Composites: Additive Manufacturing and Characterization of Ceramic Composites - Part III

This publication is the third part of a three part report of the project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing" funded by NASA Aeronautics Research Institute (NARI). The objective of this project was to conduct additive manufacturing to produce ceramic matrix composite materials and aircraft engine components by the binder jet process. Different SiC powders with median sizes ranging from 9.3 to 53.0 microns were investigated solely and in powder blends in order to maximize powder packing. Various infiltration approaches were investigated to include polycarbosilane (SMP-10), phenolic, and liquid silicon. Single infiltrations of SMP-10 and phenolic only slightly filled in the interior. When the SMP-10 was loaded with sub-micron sized SiC powders, the infiltrant gave a much better result of filling in the interior. Silicon carbide fibers were added to the powder bed to make ceramic matrix composite materials. Microscopy showed that the fibers were well distributed with no preferred orientation on the horizontal plane and fibers in the vertical plane were at angles as much as 45deg. Secondary infiltration steps were necessary to further densify the material. Two to three extra infiltration steps of SMP-10 increased the density by 0.20 to 0.55 g/cc. However, the highest densities achieved were 2.10 to 2.15 g/cc. Mechanical tests consisting of 4 point bend tests were conducted. Samples from the two CMC panels had higher strengths and strains to failure than the samples from the two nonfiber reinforced panels. The highest strengths were from Set N with 65 vol% fiber loading which had an average strength of 66 MPa. Analysis of the fracture surfaces did not reveal pullout of the reinforcing fibers. Blunt fiber failure suggested that there was not composite behavior. The binder jet additive manufacturing method was used to also demonstrate the fabrication of turbine engine vane components of two different designs and sizes. The binder jet method has benefits over the conventional manufacturing of CMCs in that prototype and production parts can be fabricated quickly and economically with no tooling and extensive hand layup.

Additive Manufacturing↗
DOE OSTI2022

Cold spray manufacturing of oxide-dispersion strengthened (ODS) steels using gas-atomized and ball-milled 14YWT powders

The cold spray deposition process has been investigated for the manufacture of 14YWT oxide-dispersion strengthened (ODS) steel, a nanostructured ferritic alloy (NFA), using gas-atomized and ball-milled feedstock powders. Cold spraying of the gas-atomized powder resulted in a thick dense deposit, but annealing them above 900 °C induced grain growth and heterogeneous precipitation of nanoparticles, thus resulting in lower hardness (~ 170 HV) compared to 14YWT ODS steel manufactured by the conventional method. The ball-milled powder (Fe-14Cr-3W-0.4Ti-0.2Y-0.125O) was cryomilled in liquid N 2 to achieve small particle sizes followed by annealing in a H 2 /Ar environment at 1000 °C and 1100 °C to reduce the hardness from ~ 8 GPa to ~ 5 GPa. Both smaller particle sizes and lower hardness of annealed powders made them amenable to the cold spray deposition process, resulting in thick and dense deposits, while retaining the favorable fully solutionized microstructure of the ball-milled powders. The microstructure of the as-deposited ODS exhibited very fine grain sizes (50–250 nm) with a uniform dispersion of Y-Ti-O nanoprecipitates in the ferritic steel matrix. The hardness values of the cold spray deposits using the powders annealed at 1000 °C and 1100 °C was 770 HV and 496 HV, respectively. Post-heat treatment of the as-deposited material up to 1100 °C showed a high-density microstructure with uniformly dispersed nanoscale oxide particles. The hardness of the annealed deposits up to 1000 °C had a notably higher hardness than bulk 14YWT ODS steel manufactured by conventional methods. The study demonstrates that cold spray deposition of the microstructurally-tailored feedstock powders can be used to successfully manufacture ODS steel with microstructure and properties comparable to those produced by the conventional methods, while providing for an attractive option for the more rapid and cost-effective manufacturing of ODS steel cladding tubes.

14YWT↗