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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 1,495 records · Page 83
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

UV-Fluorescence Imaging of Silicon PV Modules After Outdoor Aging and Accelerated Stress Testing

Fast, non-destructive, outdoor-compatible methods for photovoltaic module characterization are essential for monitoring module quality without disrupting energy production. UV-fluorescence (UVF) imaging of the encapsulant layer can be used for crack detection in the field. We show that UVF patterns vary widely between modules and types of applied stress. We propose that combining accelerated stress testing (e.g. thermal cycling and damp heat) with field investigations can help build understanding of different types of UVF, which are formed and subsequently quenched at varying rates. Ultimately, such understanding could enable estimating when cracks were formed.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2019

Bond Wire Damage Detection and SOH Estimation of a Dual Pack IGBT Power Module using Active Power Cycling and Reflectometry

High thermal and electrical stress, over a period of time tends to cause deterioration of the health of power electronic switches. A huge fraction of research efforts involves the study of power electronic device reliability and development of novel techniques with higher accuracy in health estimation of such devices. Until today, no other existing techniques can determine the number of lifted bond wires and their locations in a live IGBT module. Through this paper, a new method for online condition monitoring of IGBTs and IGBT modules using SSTDR has been proposed. Unlike traditional methods, this research work concentrates at the gate terminals of the device instead of looking at the collector side. In addition, the RL-equivalent circuit to represent a bond wire has been developed for the DUT and simulated in CST Studio Suite to measure the reflection amplitudes. Both the experimental and simulation results have been compared. These results prove that a single measurement is sufficient to predict the failure of the device instead of looking at the traditional precursor parameter. With only two sets of measurements, it is possible to locate the aged device inside a module and detect the number of bond wire lift offs associated to that device.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

Vibrational spectroscopy analysis of silica and silicate glass networks

Vibrational spectroscopy has been widely used to investigate various structural aspects of the glass network, and there are a plethora of papers reporting subtle but consistent changes in infrared and Raman spectral features of glass upon alterations of glass compositions, thermal histories, mechanical stresses, or surface treatments. However, interpretations of such spectral features are still obscured due to the lack of well-established physical principles accurately describing vibrational modes of the non-crystalline glass network. Due to the non-equilibrium nature of the glass network, three-dimensionally connected without any long-range orders, vibrational spectral features of glass cannot be interpreted using the analogy with those of isolated molecular moieties or crystalline counterparts. Here, this feature article explains why such comparisons are outdated and describes the recent advances made from theoretical calculations of vibrational spectral features of amorphous networks or comparisons of computational results with experimental data. For the interpretation of vibrational spectral features of silica and silicate glasses, the following empirical relationships are suggested: (i) the intensity-weighted peak position of the Si-O-Si stretch mode negatively correlates with the weighted average of the Si-O bond length distribution, and (ii) the broad band of the Si-O-Si bending mode negatively correlates with the Si-O-Si bond angle distribution. Selected examples of vibrational spectroscopic imaging of surface defects are discussed to deliberate the implication of these findings in the structure-property relationship of silica and silicate glass materials. Unanswered questions and continuing research challenges are identified.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Evaluating the Influence of Rotor-Casing Eccentricity on Turbine Efficiency Including Time-Resolved Flow Field Measurements

Abstract The clearance that exists between the casing and turbine blade tips is one of the key drivers of efficiency in gas turbine engines. For this reason, engine manufacturers utilize precise manufacturing techniques and may use clearance control systems to minimize tip clearances to reduce associated losses. Despite these efforts, turbines typically exhibit some nominal casing ovality or rotor-casing eccentricity, and changes to blade tip clearance during operation commonly occur due to thermal and mechanical stresses. The present study investigates non-axisymmetric tip clearance effects by creating a rotor-casing eccentricity in a one-stage axial test turbine operating in a continuous-duration mode at engine-relevant conditions with engine representative hardware. A magnetic levitation bearing system was leveraged to move the turbine shaft to vary the rotor-casing eccentricity without test section disassembly. The results of this study indicate that rotor-casing eccentricity does not affect overall turbine efficiency over the range that was tested, but does locally influence efficiency and the rotor exit flow field. Comparisons of flow angle and secondary flow kinetic energy (SKE) agreed with previous studies and existing analytical methods, respectively. Collectively, these results indicate that tip clearance can be studied locally on an eccentric rotor.

Engineering↗
DOE OSTI2021

Seismic fault weakening via CO 2 pressurization enhanced by mechanical deformation of dolomite fault gouges

Carbon dioxide emissions from dolomite decarbonation play an essential role in the weakening of carbonate faults by lowering the effective normal stress, which is thermally activated at temperatures above 600–700 °C. However, the mechanochemical effect of low-crystalline ultrafine fault gouge on the decarbonation and slip behavior of dolomite-bearing faults remains unclear. In this study, we obtained a series of artificial dolomite fault gouges with systematically varying particle sizes and dolomite crystallinities using a high-energy ball mill. The laboratory-scale pulverization of dolomite yielded MgO at temperatures below 50 °C, indicating that mechanical decarbonation without significant heating occurred due to the collapse of the crystalline structure, as revealed by X-ray diffraction and solid-state nuclear magnetic resonance results. Furthermore, the onset temperature of thermal decarbonation decreased to ~400 °C. Numerical modeling reproduced this two-stage decarbonation, where the pore pressure increased due to low-temperature thermal decarbonation, leading to slip weakening on the fault plane even at 400–500 °C; i.e., 200–300 °C lower than previously reported temperatures. Thus, the presence of small amounts of low-crystalline dolomite in a fault plane may lead to a severely reduced shear strength due to thermal decomposition at ~400 °C with a small slip weakening distance.

58 GEOSCIENCES↗
DOE OSTI2025

Improving high temperature resilience of fiber sensor embedded smart components through laser shock peening

This study explores the use of laser shock peening (LSP) to enhance material properties and high-temperature performance of fiber-sensor-fused smart parts fabricated by additive manufacturing (AM) methods. Using embedded fiber sensors as distributed strain gauges, the study demonstrates that LSP can induce compressive strains of up to 130 µε on fiber embedded 1-mm below metal surfaces. The electron backscatter diffraction (EBSD) analysis shows that, with optimized LSP parameters, the metallic matrix undergoes substantial microstructural refinement, resulting in denser structures. Thermal cycling tests showed that the LSP process can increase fiber slippage temperatures by more than 50 °C. This work shows that the LSP process is an effective room-temperature process for enhancing both surface quality and increasing fiber slippage threshold under both thermal and mechanical stress.

Zhong, Shuda [University of Pittsburgh, PA (United↗
DOE OSTI2018

Probability Distributions for Effective Permeability of Potentially Leaking Wells at CO 2 Sequestration Sites

Wells with defects originating from either poor completions or subsequent damage arising from chemical, thermal and/or mechanical stresses provide potential pathways for leakage of carbon dioxide (CO 2 ) and brine from a CO 2 sequestration site. This report provides a methodology for analyzing data on the frequency of occurrence of defective wells and the effective permeability of the damaged wells. The results include bimodal, log-normal distributions of the effective permeability of wells in addition to other distributions designed to provide a measure of the likelihood of encountering a leaking well in a CO 2 storage project.

58 GEOSCIENCES↗
DOE OSTI2018

Precursor-Derived Nanostructured Silicon Carbide Based Materials for Magnetohydrodynamic Electrode Applications

Development of suitable materials for use in the MHD generator is one of the most challenging tasks. Extremely high temperatures coupled with highly corrosive seed-laden atmosphere limit choice of the materials in contact with the high temperature plasma to just a few materials. These materials are simultaneously subjected to stresses of mechanical, thermal, chemical, electrical and high temperature-electicalmagnetic nature. In this work, novel class of SiC based ceramic composite materials with tailored compositions through a polymer precursor derived synthesis route was developed. SiC has a strong covalent bonding character, resulting in high values of mechanical strength, high hardness and chemical stability while retaining good electrical properties at elevated temperatures. A unique feature of the precursor-derived materials was the presence of nanostructured crystalline SiC domains separated by nanoscale carbon which made these materials excellent candidates for the electrodes that withstands at extremely high temperatures while maintaining good mechanical and electrical properties.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

Precursor-Derived Nanostructured Silicon Carbide Based Materials for Magnetohydrodynamic Electrode Applications

Development of suitable materials for use in a magneto-hydro-dynamic (MHD) generator is a challenging task. Extremely high temperatures coupled with highly corrosive seed-laden atmosphere limit the choice of materials in contact with the high temperature plasma to just a few materials. These materials are simultaneously subjected to stresses of mechanical, thermal, chemical, electrical and high temperature-electromagnetic nature. In this work, a novel class of silicon carbide (SiC) based ceramic composite materials with compositions tailored through a polymer precursor derived synthesis route was developed. SiC has a strong covalent bonding character, resulting in high values of mechanical strength, high hardness and chemical stability while retaining good electrical properties at elevated temperatures. Since a unique feature of the precursor-derived materials was the presence of crystalline SiC domains separated by nanoscale carbon, feasibility of materials for electrodes that need to withstand at extremely high temperatures while maintaining good mechanical and electrical properties was investigated.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2019

Assembly of Capsules for Irradiation of Silicon Carbide Joint Specimens in the High Flux Isotope Reactor

This report provides a summary of the test matrix and assembly of thirteen capsules containing silicon carbide joint specimens, where the goal of this experiment is to investigate the effects of irradiation on such joints. Two capsule designs are used to accommodate two different specimen geometries: a small torsion specimen to measure basic thermomechanical properties, and a cladding-style “end plug” specimen to demonstrate the strength and integrity of such cladding under typical thermal gradients and stresses. The assembled capsules are scheduled for two cycles of irradiation in the flux trap of the High Flux Isotope Reactor with two different target temperatures: 350 and 750°C.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Development of Electro-chemical Battery Model for Plug-and-Play Eco-system Library

Energy storage components are fundamental to the concept of an Integrated Energy System (IES). They serve to store surplus energy during low-demand periods for later release when other IES components (i.e., Secondary Energy Source, Balance of Plant, etc.) would otherwise have to operate flexibly. This provision for storage avoids high-amplitude power ramps in these components thereby limiting thermal and mechanical stresses to their internals and providing for extended service life. This report describes a dynamic model that has been developed for an electrochemical battery. The lithium-ion (Li-ion) cell was selected as representative technology. The battery model was developed in the Dymola simulation environment and meets the requirements of the ecosystem plug-and-play library. The model accurately describes the electric dynamic response of a Li-ion battery for an imposed charging/discharging power profile. The corresponding physical limitations related to over-power scenarios, and the impact of the residual state of charge are accounted for in the model. A literature review of the major degradation processes affecting Li-ion batteries was performed. Given the purposes of the CTD-IES project, the progressive fade of the installed capacity, the reduction of the round-trip efficiency, and the limits on the number of charging/discharging cycles are aspects that need to be taken into account in techno-economic analyses. The modeling of these degradation phenomena becomes crucial when predictions over long time horizons (capacity expansion) are made. For each one of these phenomena, a brief description is given, and some figures to be implemented in the HERON optimization algorithm are presented.

25 ENERGY STORAGE↗
DOE OSTI2023

Machine-Learned Structure-Property Relationship in Metallic Glasses (Final Report)

The goal of the proposed work was to gain the ability to predict properties from the known coordinates (relative positions) of atoms in a metallic glass, presuming that information about which regions of the glass are fertile for rearrangment (defects) are encoded in this structural information. This goal is important to the science of metallic glasses. This research of applied machine learning methods to automate the development of a relationship between structural measures and thermally and stress-activated events in the metallic glass. In this way, the work aimed to building a bridge between structure and properties for this class of materials. The work is expected to have timely impact on guiding the tuning of internal structures of metallic glasses for desired properties. It also represents an advance in applying machine learning techniques to discerning the properties of materials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Salt Tank Testbed: a Test Site Designed to Replicate Floor Buckles Observed in Commercial TES Tanks

A test site has been designed and is under construction to replicate the buckling failure ob-served in several in-service storage tanks for nitrate salts operating up to 565°C. In commercial tanks multiple factors have been identified that influence the floors susceptibility to buck-ling, including: the as-manufactured shape of the floor, high compressive stresses due to thermal gradients and/or friction, fluid inventory and absolute temperature. Based on exten-sive modeling analysis it was determined that similar buckles can be reproduced in a scaled test tank (approximately 9x smaller than a representative commercial tank design). To buckle the scaled tank a radial thermal gradient is generated in the tank with a low fluid level, the fluid level is then increased while maintaining the thermal gradient; based on the modeling results just one of these cycles can plastically deform the tank floor. The test site which is under construction is designed to replicate this damaging cycle at lower temperatures. The goal of testing will be to reproduce this damaging cycle and buckle the scaled test tank floor, allowing proper model validation and a methodology for comparing different tank designs at a smaller (and less costly) scale.

25 ENERGY STORAGE↗
DOE OSTI2023

Repairing High γ’ Hot Section Gas Turbine Components Using Advanced Manufacturing

This article describes the ability to use laser-blown powder deposition to repair high γ' IN-100 superalloy gas turbine components. The influence of various process conditions on the ability to make crack-free IN-100 deposits over surrogate high γ' alloys was investigated to identify cracking mechanisms in the deposit and heat-affected zones (HAZs). The various crack formation mechanisms, such as solidification cracking and liquation cracking, were evaluated using multiscale characterization and numerical simulation. The cracking in the deposit region was predominantly solidification cracking, while those observed in the HAZ were liquation cracking. The results showed that controlling thermally induced residual stresses is the key to eliminating cracking, and the optimum preheat temperature was determined. In conclusion, the results were then contrasted with those in published literature and an approach to effectively repair hot section parts was presented.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A Review of the Research and Development of Brayton Cycle Technology in Nuclear Power Applications with a Focus on Compressor Technology

This study reviews the integration of Brayton Cycle (BC) systems in nuclear power generation, emphasizing their potential to enhance thermal efficiency and operational flexibility over traditional Rankine Cycle (RC) systems. Key working fluids, such as helium (He), supercritical carbon dioxide (sCO 2 ), nitrogen (N 2 ), and air, are evaluated for their performance, efficiency, and compatibility with nuclear systems. He is recognized for its high thermal conductivity and inertness at elevated temperatures, while sCO 2 demonstrates advantages in compactness and efficiency in midrange temperatures. This article also highlights the importance of compressor designs in optimizing BC performance and reviews, available compressor technologies. Axial and centrifugal compressor designs enable efficient gas compression while managing the thermal and mechanical stresses associated with high-pressure operations in nuclear systems. Combined with variable geometry components and advanced materials, these technologies address the challenges posed by varying load conditions. Despite the promising features of BC systems, several challenges persist, including high leakage rates and material degradation under extreme conditions, which necessitate robust sealing technologies and thorough testing. The insights gained from operational experiences at facilities, such as the Oberhausen II plant and the High-Temperature He Test Facility (HHV), underscore the complexities involved in designing high-temperature gas turbines for nuclear applications. This review concludes that as the nuclear industry evolves, BC systems hold significant promise for contributing to a sustainable energy future, particularly in the context of small modular reactors (SMRs) and microreactors. Further exploration of combined cycle configurations that combine BCs with RCs may enhance overall efficiency and flexibility in power generation.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Accessibility and Mechanical Stability of Nanoporous Zinc Oxide and Aluminum Oxide Coatings Synthesized via Infiltration of Polymer Templates

The conformal nanoporous inorganic coatings with accessible pores that are stable under applied thermal and mechanical stresses represent an important class of materials used in the design of sensors, optical coatings, and biomedical systems. Here, we synthesize porous AlO x and ZnO coatings by the sequential infiltration synthesis (SIS) of two types of polymers that enable the design of porous conformal coatings—polymers of intrinsic microporosity (PIM) and block co-polymer (BCP) templates. Using quartz crystal microbalance (QCM), we show that alumina precursors infiltrate both polymer templates four times more efficiently than zinc oxide precursors. Using the quartz crystal microbalance (QCM) technique, we provide a comprehensive study on the room temperature accessibility to water and ethanol of pores in block copolymers (BCPs) and porous polymer templates using polystyrene-block-poly-4-vinyl pyridine (PS75-b-P4VP25) and polymers of intrinsic microporosity (PIM-1), polymer templates modified by swelling, and porous inorganic coatings such as AlO x and ZnO synthesized by SIS using such templates. Importantly, we demonstrate that no structural damage occurs in inorganic nanoporous AlO x and ZnO coatings synthesized via infiltration of the polymer templates during the water freezing/melting cycling tests, suggesting excellent mechanical stability of the coatings, even though the hardness of the inorganic nanoporous coating is affected by the polymer and precursor selections. We show that the hardness of the coatings is further improved by their annealing at 900 °C for 1 h, though for all the cases except ZnO obtained using the BCP template, this annealing has a negligible effect on the porosity of the material, as is confirmed by the consistency in the optical characteristics. These findings unravel new potential for the materials being used across various environment and temperature conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Smart Adhesive Joint with High-Definition Fiber-Optic Sensing for Automotive Applications

Structural health monitoring of fiber-reinforced composite-based joints for automotive applications during their manufacturing and on-demand assessment for its durability in working environments is critically needed. High-definition fiber-optic sensing is an effective method to measure internal strain/stress development using minimally invasive continuous sensors. The sensing fiber diameters are in the same order of magnitude when compared to reinforcement (glass, basalt, or carbon fibers) used in polymer composites. They also offer a unique ability to monitor the evolution of residual stresses after repeated thermal exposure with varying temperatures for automotive components/joints during painting using an electrophoretic painting process. In this paper, a high-definition fiber-optic sensor utilizing Rayleigh scattering is embedded within an adhesive joint between a carbon fiber-reinforced thermoset composite panel and an aluminum panel to measure spatially resolved strain development, residual strain, and thermal expansion properties during the electrophoretic paint process-simulated conditions. The strain measured by the continuous fiber-optic sensor was compared with an alternate technique using thermal digital image correlation. The fiber-optic sensor was able to identify the spatial variation of residual strains for a discontinuous carbon fiber-reinforced composite with varying local fiber orientations and resin content.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗