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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
DOE OSTI2025

Experimental characterization and atomistic simulation of grain boundary segregation in Mg-Y alloys

As a rare earth solute element in Mg alloys, Y has the beneficial effects of increasing both the strength and the ductility as well as weakening the crystallographic texture. To achieve a more fundamental understanding on how Y addition affects the microstructural evolution and mechanical properties, the Y segregation behavior at grain boundaries was investigated in Mg-1wt.%Y and Mg-7wt.%Y alloys at different conditions. The segregation intensity and its dependence on the grain boundary misorientation angle were experimentally characterized and computationally predicted. Strong segregation at grain boundaries was observed in both low and high Y-containing alloys. Y segregation was found to remain in alloy Mg-7Y after high-temperature annealing heat treatment at 540 °C. No direct correlation between the Y segregation intensity and the grain boundary misorientation angle could be established based on either the experimental characterization or the atomistic simulation with a spectral model. We thus conclude that grain boundary segregation of Y is independent of grain boundary misorientation angle.

Grain boundary↗
DOE OSTI2019

LaserOrigami (LO) of three-dimensional (3D) components: Experimental analysis and numerical modeling-part II

The present work explores how the choice of the scanning patterns can affect the final shapes of 3D components manufactured by laser-origami with a High-Power Diode Laser (HPDL). The experimental approach allowed the achievement of high bending angles, also avoiding any distortion on the surface of AISI 304 stainless steel workpiece. Optimization of the operational parameters led to the best prototype of the 3D components, with the closest respect of the strictest dimensional and geometrical tolerances. In addition, a thermo-mechanical model to predict the final shape of the 3D components was developed. The numerical model, implemented by Finite Element Method (FEM), was discovered to be a reliable tool in predicting the final shape of the prototypes, matching with a great deal of accuracy the experimental results. Specifically, the model allowed the estimation of the temperature distribution and nodal displacements of the components varying both the setting of the laser parameters and the choice of the scanning patterns.

47 OTHER INSTRUMENTATION↗
DOE OSTI2019

An integrated analytical and experimental study of contact acoustic nonlinearity at rough interfaces of fatigue cracks

This paper presents an analytical model that describes the relationship between interface stiffness and separation of rough interfaces such as fatigue cracks. The contact acoustic nonlinearity at the interface is simulated by a quasi-static model based on Hertzian contact theory. The model is validated using the results of dynamic acoustoelastic testing (DAET) with a Rayleigh wave probe on fatigue cracks in two aluminum alloy samples. One novel aspect of this work is that all the required geometrical parameters for the model are acquired directly from the aperture profile of real cracks extracted from their scanning electron microscopy (SEM) images. Also, the separation of the crack faces during dynamic perturbation is independently measured using a 3D laser Doppler vibrometer (LDV). In addition, using DAET allows for an unprecedented direct comparison between experimental and analytical results. Overall, this is because unlike conventional nonlinear ultrasonic tests that are based on measuring the amplitude of higher harmonics, DAET outputs directly the strain-dependency of transmission and time delay of ultrasonic waves propagating across the interface. The model is found in good qualitative agreement with the experimental results, although the predictions tend to underestimate the variation of transmission coefficient and time delay. We conduct a sensitivity analysis to investigate the influence of different assumptions and simplifications on model predictions.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Low Activity Waste Glass Optimization with Property Models from Machine Learning, Part 2: Experimental Validation and Active Learning

The United States Department of Energy is responsible for managing legacy nuclear waste stored in underground tanks at the Hanford Site. To treat the waste, it is planned as the current baseline to separately vitrify low-activity waste (LAW) and high-level waste fractions. Previously, machine learning (ML) based glass property models (e.g., chemical durability, viscosity, electrical conductivity and SO3 solubility) were developed with prediction uncertainties. A waste glass optimization approach was then established to enable the capability of using these ML models in LAW glass formulation. In this study, the previous ML models were first experimentally validated, and the results were incorporated back into the database to update the ML models. The updated models and formulations showed increased waste loading while reducing the failure rate, demonstrating improved predictive accuracy, reduced uncertainties, and the effectiveness of active learning in guiding high-dimensional, nonlinear LAW glass design. This represents the first experimental validation of ML based LAW glass formulation, with practical benefits such as higher waste loading, shorter mission duration, and lower operational risk.

Lu, Xiaonan (ORCID:0000000179708148)↗
DOE OSTI2021

Characterization of the molten salt FMgNaK through ab initio molecular dynamics and experimental density measurements

The selection of a salt species for use in a molten salt reactor MSR is a key part of any MSR design. However, many salts have sparse or no thermophysical property data sets, especially those with higher melting points. One such salt is the eutectic mixture of (NaF)0.345(KF)0.59(MgF 2 )0.065, or FMgNaK, and is explored here through ab initio molecular dynamics (AIMD) simulation (1023-1273K) as well as experimental measurement of the liquid density using the Archimedean method (973-1223K). Predicted densities from AIMD are similar to experimentally-measured densities, though with more noise, suggesting that the small scale necessitated by AIMD simulations may be problematic for simulating FMgNaK in particular. Here the coefficient of thermal expansion is predicted from simulation, and salt structure is characterized. Mg-F-Mg chaining is observed in the salt network, though the low concentration of Mg inhibits chaining on the scale that is observed in (LiF) 0.67 (BeF 2 ) 0.33 , or FLiBe.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Experimental validation of model predictive control for solid oxide fuel cells

Here, this paper presents implementation of a model predictive controller (MPC) for an experimental solid oxide fuel cell (SOFC) system. The MPC controller is based on a gain-scheduled predictor with block-oriented structure that can capture important non-linear effects while still keeping the computational complexity low enough to meet real time control requirements. Experimental results show the MPC is able to regulate the SOFC cathode outlet temperature in the face of startup transients and input perturbations.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Numerical and experimental analysis of mechanically induced failure in electric vehicle battery modules

Mitigating thermal runaway and cell-to-cell propagation is essential for improving the safety of electric and hybrid vehicles. Enhancing digital twin capabilities to predict battery mechanical abuse is particularly critical for automotive and aerospace applications, where crashworthiness is a key concern. Understanding failure conditions and propagation in battery modules during mechanical abuse is complex due to interactions between structural deformation, heat transfer, electrochemical processes, exothermic reactions and mechanical fracture. While prior studies have focused on modeling cell-level behavior, extending these models to module or pack level is necessary for a system level understating of electric vehicle safety. This study develops coupled large deformation finite element models that simultaneously solve for electrochemistry, material failure, internal short circuit and thermal runaway propagation. The models account for mechanical and thermal interactions between lithium-ion cells and other battery components while the contact interfaces are evolving with time. Model-predicted voltage, temperature and force responses are compared with experimental data for validation. The results demonstrate that the approach captures key failure mechanisms, including thermal propagation through heat transfer, electrical propagation from short circuits in parallel-connected cells, and mechanical propagation via penetration and crack formation. These findings show that computational models are valuable tools for understanding battery module failure and providing insight that can reduce the need for extensive experimental testing.

25 ENERGY STORAGE↗
DOE OSTI2014

Exploring the structural and magnetic properties of TiO{sub 2}/SnO{sub 2} core/shell nanocomposite: An experimental and density functional study

TiO{sub 2}/SnO{sub 2} core/shell nanocomposite is prepared via a simple sol–gel method and the properties are compared with the individual TiO{sub 2} (core) and SnO{sub 2} (shell). The corresponding characterizations are carried out in terms of structural and magnetic properties of TiO{sub 2}/SnO{sub 2}, TiO{sub 2} and SnO{sub 2} nanosystems. Structural properties are studied via XRD, TEM, Raman spectroscopy, FTIR and XPS. Magnetic characterization is performed by measuring Moment vs. Applied Field for all the samples and Moment vs. Temperature for TiO{sub 2}/SnO{sub 2} core/shell nanocomposite. We also went for a better insight with the help of theoretical measures. First principle calculations have been executed using “Density Functional Theory” (DFT)-based MedeA VASP package to compare the results of TiO{sub 2}/SnO{sub 2} with TiO{sub 2} (1 1 0) and SnO{sub 2} (1 1 0) surface calculations and its effect on the magnetic nature of the specific nanoparticles. XRD, RAMAN and FTIR gave indirect evidence of formation of core shell nanostructure while TEM micrographs provide the direct evidence of formation of core shell nanostructure. The magnetic study shows a higher saturation magnetization for the core/shell nanostructure compared to pristine TiO{sub 2} and SnO{sub 2}. In this report, we have attempted to relate this experimental observation with the results of the first principle calculations. - Graphical abstract: Above pictorial presentation (from left) represents the model for TS, TiO{sub 2} and SnO{sub 2} used for DFT calculation and the obtained magnetic results for all the prepared systems. - Highlights: • Synthesis of TiO{sub 2}/SnO{sub 2} core/shell nanocomposites by a simple sol–gel technique. • The nanocomposites show better magnetic property than pristine nanoparticles. • DFT based calculations also support the experimental evidences.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

High pressure structural behavior of YGa{sub 2}: A combined experimental and theoretical study

High pressure structural stability studies were carried out on YGa{sub 2} (AlB{sub 2} type structure at NTP, space group P6/mmm) up to a pressure of ~35 GPa using both laboratory based rotating anode and synchrotron X-ray sources. An isostructural transition with reduced c/a ratio, was observed at ~6 GPa and above ~17.5 GPa, the compound transformed to orthorhombic structure. Bulk modulus B{sub 0} for the parent and high pressure phases were estimated using Birch–Murnaghan and modified Birch–Murnaghan equation of state. Electronic structure calculations based on projector augmented wave method confirms the experimentally observed two high pressure structural transitions. The calculations also reveal that the ‘Ga’ networks remains as two dimensional in the high pressure isostructural phase, whereas the orthorhombic phase involves three dimensional networks of ‘Ga’ atoms interconnected by strong covalent bonds. - Graphical abstract: High pressure X-ray diffraction patterns of YGa{sub 2} up to ~35 GPa shows an isostructural phase transition at ~5 GPa and transition to an orthorhombic structure ~14 GPa. - Highlights: • High pressure structural stability studies were carried out on YGa{sub 2} up to 35 GPa. • An isostructural transition with reduced c/a ratio was observed above 6 GPa. • Above 17.5 GPa, the compound transformed to orthorhombic structure. • PAW based electronic structure calculations have been carried out. • Calculations confirm the experimentally observed structural transitions.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Combined experimental and theoretical assessments of the lattice dynamics and optoelectronics of TaON and Ta{sub 3}N{sub 5}

Presented herein is a detailed discussion of the properties of the lattice dynamic and optoelectronic properties of tantalum(V) oxynitride (TaON) and tantalum(V) nitride (Ta{sub 3}N{sub 5}), from experimental and theoretical standpoint. The active Raman and infra red (IR) frequencies of TaON and Ta{sub 3}N{sub 5} were measured using confocal Raman and Fourier Transform Infrared spectroscopies (FTIR) and calculated using the linear response method within the density functional perturbation theory (DFPT). The detailed study leads to an exhaustive description of the spectra, including the symmetry of the vibrational modes. Electronic structures of these materials were computed using DFT within the range-separated hybrid HSE06 exchange–correlation formalism. Electronic and ionic contributions to the dielectric constant tensors of these materials were obtained from DFPT within the linear response method using the PBE functional. Furthermore, effective mass of photogenerated holes and electrons at the band edges of these compounds were computed from the electronic band structure obtained at the DFT/HSE06 level of theory. The results suggest that anisotropic nature in TaON and Ta{sub 3}N{sub 5} is present in terms of dielectric constant and effective masses. - Graphical abstract: Detailed investigation has been conducted from combined experimental and theoretical approaches on Raman and IR spectroscopies, electronic structures, dielectric constants and effective masses of TaON and Ta{sub 3}N{sub 5}. - Highlights: • Crystal structures of TaON and Ta{sub 3}N{sub 5} are discussed based on XRD and DFT calculation. • Raman and IR spectra of TaON and Ta{sub 3}N{sub 5} materials are measured and computed by DFPT method. • Optoelectronic properties of TaON and Ta{sub 3}N{sub 5} are discussed. • Dielectric constant and effective masses of TaON and Ta{sub 3}N{sub 5} are calculated.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2016

Doping effect on the structural properties of Cu{sub 1−x}(Ni, Zn, Al and Fe){sub x}O samples (0<x<0.10): An experimental and computational study

In this work, the effect of insertion of transition metal, TM (=Ni, Zn, Al and Fe), ions in Cu{sub 1−x}TM{sub x}O samples (0<x<0.10) prepared via co-precipitation method is studied through experimental and computational methods. The analyses of X-ray diffraction (XRD) patterns using Rietveld refinement show that i) at x=0, all samples present a monoclinic crystal system with space group C2/c and ii) for increasing the TM-doping, Ni and Zn-doped samples show a small amount of spurious phases for concentrations above x=0.05. Based on these results, a defect disorder study for using atomistic computational simulations which is based on the lattice energy minimization technique is employed to predict the location of the dopant ions in the structure. In agreement with XRD data, our computational results indicate that the trivalent (Al and Fe ions) are more favorable to be incorporated into CuO matrix than the divalent (Ni and Zn ions). - Graphical Abstract: The effect of insertion of transition metal, TM (=Ni, Zn, Al and Fe), ions in Cu{sub 1−x}TM{sub x}O samples (0<x<0.10) prepared via co-precipitation method is studied through experimental and computational methods. Display Omitted.

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

Impact of mixed grain size sediment input on braided river Morphodynamics: Insights from experimental and numerical modeling

The rate of sediment supply has significant impacts on river morphology, making it crucial to understand the geomorphic changes and grain size distribution dynamics in rivers. However, the effects of varying grain size sediment input on morphological changes in braided channels remain poorly understood. This study is the first to investigate the bar development and sediment sorting processes in braided channels with non-uniform sediment inputs using both numerical and experimental approaches. We applied a two-dimensional numerical model, Nays2DH to confirm and generalize experimental results. The model reproduced key experiment results, including 1) stream elevation changes, and 2) grain size distribution. Using this validated model, we explored the morphological changes and sorting process in a braided river with sediment inputs. The numerical experiments demonstrate that sediment input controls the elevation of the stream bed and the grain size distribution. Notably, both the elevation and grain-size distribution become relatively stable in downstream of the channel. Additionally, the simulation results suggest that an increased sediment supply leads to greater channel complexity, with bed surface armoring decreasing.

Nays2DH↗
DOE OSTI2023

Experimental and numerical study of the shielding effect of two tandem rough cylinders in flow-induce oscillation

The shielding effect of the downstream cylinder in flow induced oscillation (FIO) of two cylinders arranged in tandem is studied experimentally and numerically at Reynolds number 30,000 to 120,000. Both cylinders are in one degree-of-freedom, transverse-oscillations, and have turbulence stimulation in the form of selective surface roughness to expand FIO beyond vortex-induced vibration (VIV) into galloping. Shielding of the downstream cylinder has a negative effect on harnessing hydrokinetic energy. Further, to study its effect and mechanics, selective cases are studied both numerically and experimentally and discussed to demonstrate the shielding effect on the downstream cylinder and understand its cause. The main conclusions are: (1) The shielding effect for the downstream cylinder shows a strong relation to the damping ratio. As the damping ratio increases, the shielding effect is mitigated. Additionally, the oscillation of the rear cylinder becomes stable and shows stable frequency. (2) In the VIV region, as the stiffness and natural frequency increase, the shielding effect decreases substantially. (3) In the VIV region, the vorticity of the vortices shedding from both the upper and the lower sides of the downstream cylinder does not accumulate enough due to the attraction by the vortices shed from the upstream cylinder, thus resulting in partial suppression of the oscillation on the downstream cylinder. (4) In the galloping region, the shielding effect for the downstream cylinder depends on whether the vorticity near the downstream cylinder is strengthened by the vortices generated by the shear layers of the upstream cylinder or weakened.

42 ENGINEERING↗
DOE OSTI2015

Effect of starting microstructure upon the nucleation sites and distribution of graphite particles during a graphitising anneal of an experimental medium-carbon machining steel

The potential for using graphite particles as an internal lubricant during machining is considered. Graphite particles were found to form during graphitisation of experimental medium-carbon steel alloyed with Si and Al. The graphite nucleation sites were strongly influenced by the starting microstructure, whether ferrite–pearlite, bainite or martensite, as revealed by light and electron microscopy. Favourable nucleation sites in the ferrite–pearlite starting microstructure were, not unexpectedly, found to be located within pearlite colonies, no doubt due to the presence of abundant cementite as a source of carbon. In consequence, the final distribution of graphite nodules in ferrite–pearlite microstructures was less uniform than for the bainite microstructure studied. In the case of martensite, this study found a predominance of nucleation at grain boundaries, again leading to less uniform graphite dispersions. - Highlights: • Metallography of formation of graphite particles in experimental carbon steel. • Potential for using graphite in steel as an internal lubricant during machining. • Microstructure features expected to influence improved machinability studied. • Influence of pre-anneal starting microstructure on graphite nucleation sites. • Influence of pre-anneal starting microstructure on graphite distribution. • Potential benefit is new free-cutting steel compositions without e.g. Pb alloying.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Multiscale mechanical behavior and microstructure evolution of extruded magnesium alloy sheets: Experimental and crystal plasticity analysis

Highlights: • Experimental stress-strain responses were reproduced by CPFE simulation based on Voronoi grains on three strain paths. • Textures predicted by simulation were in accordance with the ones measured by EBSD at the strain of 0.085. • Deformation heterogeneity in slip-dominated cases was found more significant than that in twin-favored case. • For slip-dominated cases, both high m′ value and high SFs in adjacent grains are responsible for strain localization. - Abstract: A phenomenological crystal plasticity finite element (CPFE) model based on Voronoi grains was applied to reproduce basic deformation features of a hot-extruded magnesium alloy sheet under various strain paths. Corresponding experimental investigations, including mechanical tests, electron back scattered diffraction (EBSD) measurements and optical observation, were also carried out as either a validation or a supplement of the numerical results. Predicted average stress-strain responses and texture evolution are in good accordance with measured ones. Furthermore, deformation heterogeneity at the mesoscopic and intergranular scale were investigated based on the proposed model. At the mesoscale, the heterogeneity in the slip-dominated cases tends to develop continuously, whereas the heterogeneity is retarded in twin-favored deformation. At the intergranular scale, it is concluded from the slip-dominated case that a high slip-transfer parameter and high Schmid factors (SFs) of principal slip systems in adjacent grains could accommodate higher local strain.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Experimental quantification of “hardenability” of 2195 and 2050 Al-Li alloys by using cold-rolled sheets

Highlights: • An experimental simulation method for intuitive “hardenability” evaluation. • With increasing the distance from the quenching end, the strength of 2050 alloy lowers more slowly than that of 2195 alloy, indicating its better “hardenability”. • At the location far away from the quenching end, lenticular-shaped phases form within grains, which impede T1 precipitation at the same local location during the following aging process. • More intra-granular lenticular-shaped phases in 2195 Al-Li alloy corresponds to its lower “hardenability”. - Abstract: To effectively and intuitively evaluate the “hardenability” during the design of new heat-treatable Al alloys, an experimental evaluation method by using cold-rolled thin sheets was proposed, which combined end-quenching with tensile test after aging, and eliminated the effect of different original structure of thick plate through-thickness. The “hardenability” of 2050 and 2195 Al-Li alloys was then intuitively characterized by their strength lowering as a function of distance away from the quenching end after T8-aging following end-quenching. As the distance is increased, the strength of the 2050 Al-Li alloy lowers more slowly than that of the 2195 Al-Li alloy, indicating a better “hardenability” of the 2050 Al-Li alloy. At the location with a certain distance away from the quenching end, in addition to the Cu-rich secondary phases at the grain boundary, lenticular-shaped Cu-containing secondary phases also form within grains during the end quenching process, which impede the precipitation of T1 (Al{sub 2}CuLi) phase at the same local location during the following aging process. More importantly, the number of the intra-granular lenticular-shaped phases in the 2195 Al-Li alloy is much more than that in the 2050 Al-Li alloy, which contributes to a less “hardenability” of the 2195 Al-Li alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Austenite stability and M2C carbide decomposition in experimental secondary hardening ultra-high strength steels during high temperature austenitizing treatments

The present study deals with the austenite stability and M{sub 2}C carbide decomposition in three secondary hardening ultra-high strength (SHUHS) steels with varying levels of Cr and Mo (2Cr-1Mo, 2Cr-3Mo and 5Cr-5Mo) investigated using Vicker's hardness, optical and electron microscopy. These steels were subjected to high temperature austenitizing treatments at 1000, 1050, 1100 and 1150 °C. It has been established that increasing both Cr and Mo to 5 wt% as well as increasing the austenitizing temperature in this class of SHUHS steels is stabilizing the austenite such that almost 100% austenite is produced upon oil quenching. Further, higher Cr and Mo is also found to influence the stability of metastable M{sub 2}C carbide formed during processing of the steels. While the M{sub 2}C carbide in 2Cr-3Mo steel remained untransformed, it was found to transform partially to M{sub 6}C during austenitization of 5Cr-5Mo steel. Hardness measurements on these steels revealed that hardness is relatively insensitive to austenitizing temperature in 2Cr-1Mo steel, decreased in 2Cr-3Mo and decreased more drastically in 5Cr-5Mo steel with austenitizing temperature. This dependence has been correlated to the influence of composition on M{sub s} temperature and hence on retention of austenite as well as primary carbides. The experimental results were compared against theoretical calculations using ThermoCalc, which predict the presence of only M{sub 6}C in both 2Cr-3Mo and 5Cr-5Mo steels. The apparent discrepancy between theoretical and experimental observations has been correlated to kinetic factors.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A numerical and experimental approach to compare the effect of sample thickness in small in-situ SEM and large ex-situ tensile testing in Alloy 709

ASTM standards for tensile tests define specific sample size requirements regardless of grain size of the material. However, sample size requirements for testing should be considered in conjunction with the number of grains within its reduced cross-sectional area. This is particularly important for in-situ Scanning Electron Microscope (SEM) tensile tests, as they have to be conducted on smaller samples. In this study, a comprehensive experimental and numerical evaluation of the effect of specimen thickness (and the resulting number of grains within the cross-section) were conducted using in-situ SEM tensile test (on submillimeter thick samples) and ex-situ tensile tests (on samples of 0.68–5.9 mm thickness) and the results are compared with FEM simulations outcome. All tests were conducted at room temperature and the results are correlated to the number of grains within the thickness of specimens. The tensile test results indicated that even though the 0.2% proof stress and the tensile strength do not vary for the current range of thicknesses (with number of grains in the cross-section varying from 13 to 118), a difference in necking mechanism exists. Post tensile strength, thinner samples undergo more shear failure and diagonal localized necking whereas thicker samples experience more diffuse necking indicated by decreased area of shear failure at the edges and increased area of dimpled tensile failure at the center of the sample. Further, FEM results complement the experimental findings by showing the formation of conjugated localized shear bands on the upper and lower surface in the 0.68 mm thick sample and shear bands combining to form singular shear bands in thicker samples. These results also confirm the validity of the in-situ SEM tensile tests conducted on thinner samples as long as the required minimum number of grains exist within the cross-section.

36 MATERIALS SCIENCE↗