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DOE OSTI2021

Cyclic bend over sheave performance of a steel tension member belt for wave energy conversion

Rotary power take-offs (PTOs) promise many benefits for commercial wave energy converters (WECs), including longer power strokes/reduced end-stop concerns, deployment advantages, and controllability. However, these winch-type PTOs can impose millions of bending cycles on the belt or rope element every year, which may lead to a failure mode known as Cyclic Bend Over Sheave, or “CBOS”. Synthetic rope, though attractive due to its high strength, low elongation, and durability, suffers from comparatively poor CBOS performance and struggles to reach a million load cycles without failing. Using belts instead of ropes for winching elements should improve CBOS performance due to having a smaller thickness that undergoes bending. Unfortunately, belts have their own host of problems. Maintaining even tension across the width of a belt subject to twist or fleet angles is a challenge, especially for WECs which can move in all 6 degrees of freedom in the ocean. This study sought to quantify the CBOS performance of a belt constructed of steel tension members in a polyurethane matrix containing longitudinal profiles. Belt samples were tested to failure or up to two million bend-unbend cycles and subject to a range of fleet angles. This paper summarizes the utilized testing methodology and the resulting belt performance.

16 TIDAL AND WAVE POWER↗

DOE OSTI2023

In-situ coating of silicon-rich films on tokamak plasma-facing components with real-time Si material injection

Abstract Experiments have been conducted in the DIII-D tokamak to explore the in-situ growth of silicon-rich layers as a potential technique for real-time replenishment of surface coatings on plasma-facing components (PFCs) during steady-state long-pulse reactor operation. Silicon (Si) pellets of 1 mm diameter were injected into low- and high-confinement (L-mode and H-mode) plasma discharges with densities ranging from 3.9– 7.5 × 10 19 m −3 and input powers ranging from 5.5 to 9 MW. The small Si pellets were delivered with the impurity granule injector at frequencies ranging from 4 to 16 Hz corresponding to mass flow rates of 5–19 mg s −1 (1– 4.2 × 10 20 Si s −1 ) at cumulative amounts of up to 34 mg of Si per five-second discharge. Graphite samples were exposed to the scrape-off layer and private flux region plasmas through the divertor material evaluation system to evaluate the Si deposition on the divertor targets. The Si II emission at the sample correlates with silicon injection and suggests net surface Si-deposition in measurable amounts. Post-mortem analysis showed Si-rich coatings containing silicon oxides, of which SiO 2 is the dominant component. No evidence of SiC was found, which is attributed to low divertor surface temperatures. The in-situ and ex-situ analysis found that Si-rich coatings of at least 0.4–1.2 nm thickness have been deposited at 0.4–0.7 nm s −1 . The technique is estimated to coat a surface area of at least 0.94 m 2 on the outer divertor. These results demonstrate the potential of using real-time material injection to form Si-enriched layers on divertor PFCs during reactor operation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1989

Exobiology site selection for future Mars missions: Martian paleolake sediments and terrestrial analogs

This research was conducted to establish the scientific framework for the exobiological study of sediments on Mars and to encourage the selection of these sedimentary deposits as sampling sites for future Mars missions. A study was completed on the Antarctic Dry Valley Lakes (terrestrial analogs of the purported Martian paleolakes) and their sediments that allowed the development of quantitative models relating environmental factors to the nature of the biological community and sediment forming processes. The publications presented include: (1) Diversity of micro-fungi isolated in an Antarctic dry valley; (2) Lake Hoare, Antarctica--sedimentation through a thick perennial ice cover; (3) The possibility of life on Mars during a water-rich past; (4) An Antarctic research outpost as a model for planetary exploration; (5) Early Martian environments--the Antarctic and other terrestrial analogs; (6) Lipophilic pigments from the benthos of a perennially ice-covered Antarctic lake; and (7) Perennially ice-covered Lake Hoare, Antarctica--physical environment, biology, and sedimentation.

Wharton, Robert A., Jr.↗

NASA NTRS1992

Hypervelocity impact effects on solar cells

One of the space hazards of concern is the problem of natural matter and space debris impacting spacecraft. In addition to mechanical damage, impact velocities greater than 5 km/sec can produce shock induced ionization effects with resultant surface charging and complex chemical interactions. The upper limit of the velocity distribution for these particles is on the order of 70 km/sec. The second source of particulate matter is due to the presence of man and the machinery needed to place satellites in orbit. This 'man made' component of the space debris consists of waste, rocket exhaust, and debris caused by satellite break-up. Most of the particles are small. However as the size increases, debris purposefully thrown overboard such as garbage and human waste, combined with paint chips, plastic, wire fragments, bolts, etc., become formidable hazards which completely dominate the distribution function for some orbits. These larger fragments can produce penetration and spalling of the thick metallic structures associated with spacecraft. The particles most often encountered are aluminum oxide, associated with fuel residue, and paint chips. These debris types can have a wide range of particle sizes. It has been stated that the design of spacecraft will have to take the debris evolution into account and provide additional suitable armor for key components in the near future. The purpose of this work was to subject samples from solar power arrays, one of the key components of any spacecraft, to a debris flux typical of what might be found in space, and measure the degradation of the power panels after impact.

Rose, M. Frank↗

NASA NTRS2007

Early Proterozoic (2.0 GA) Phosphorites from Pechenga Greenstone Belt and Their Origin

The period of 2500-2000 Ma is heralded by several other hallmark events, including onset and decline of the greatest positive excursion of Beta13Ccarb (Lomagundi-Jatuli Paradox), development of a significant seawater sulphate reservoir, abundant deposition of anomalously organic matter (OM)-rich sediments, the oldest known significant petroleum deposits (Shunga Event), and the appearance of first known marine phosphorites at 2000 Ma as reported here. They occur as numerous rounded, soft-deformed, clasts in fine-pebble intra-formational conglomerates, forming two separate c. 200 m-thick turbidite fans within the 1000 m-thick OM- and sulphide-rich turbiditic greywackes of the Pilgujaervi Formation in the Pechenga Greenstrone Belt, NW Russia. Carbonate-fluorapatite is the main mineral in the phosphorite clasts. OM, framboidal and micronodular pyrite as well as inclusions of quartz and chlorite are additional components. Many clasts show microlayering with a variable degree of soft-deformation, implying that they were derived from non-lithified, bedded phosphorites. Numerous samples revealed diverse microbial microstructures interpreted as cyanobacterial mats consisting of filamentous (1-3 micrometer in diameter, 20 micrometers in length), coccoidal (0.8-1.0 micrometers) and ellipsoidal or rod-shaped microfossils (0.8 micrometers in diameter, around 2 micrometers in length) which morphologically resemble modern Microcoleus and Syphonophycus, Thiocapsa, and Rhabdoderma, respectively, reported from alkaline or saline environments. No principle differences have been found between microfossils described from Cambrian and Phanerozoic and the 2000 Ma phosphorites. The sequence of the early Palaeoproterozoic events which point to a significant oxidation of the hydrosphere, now including formation of phosphorites and change in the phosphorous cycle, mimics the sequence which was repeated once again at the Neoproterozoic-Cambrian transition, implying that oxidation of the terrestrial atmosphere-hydrosphere system experienced an irregular cyclic development.

Rozanov, A. Yu.↗

NASA NTRSDate not supplied

Size Effects on Laser Powder Bed Fusion and Laser Powder Directed Energy Deposition GRCop-42 Alloy

Additive manufacturing (AM) plays a significant role in the fabrication of regeneratively cooled rocket engine combustion chambers, where internal channels are used to transport high pressure propellants to keep the engine from overheating. Cooling channels are designed with thin walls between the cooling and combustion sides, experiencing high thermal and mechanical stresses from large temperature gradients and internal pressures. Hence, selecting materials suited for this environment and maintaining a high-quality processing for this critical application is of utmost importance. GRCop-alloys (Cu-Cr-Nb) were developed as an ideal material for combustion chambers due to its high conductivity and high strength at temperature, being employed as a structural member for the hotwall with excellent heat transfer capabilities. GRCop-42 (Cu, 4 at% Cr, 2 at% Nb) has significantly matured using the Laser Powder Bed Fusion (L-PBF) process through microstructure, mechanical and thermophysical properties and evaluations using hot-fire testing. Additionally, Laser Powder Directed Energy Deposition (LP-DED) has demonstrated successful deposition and geometry samples using GRCop-42. While the maturation in properties has focused on bulk material properties from standard test specimens, these cannot be extrapolated to be used in thin walls, as different features (i.e., microstructure, porosity, and surface texture) have a greater effect on thin walls, especially on AM structures built using L-PBF and LP-DED. This presentation provides an overview of the effects introduced by reducing the thickness on the fabrication, microstructure, surface metrology and subsequent mechanical properties of GRCop-42 using L-PBF and LP-DED as well as future work planned for this research.

Gabriel Demeneghi↗

NASA NTRSDate not supplied

Flash Thermal Diffusivity Measurements and Inspection of Additively Manufactured Ti-6Al-4V Specimens with Varying Process Parameters

Flash thermal diffusivity measurements were obtained on additively manufactured Ti-6Al-4V disk shaped specimens with various process parameters. For additively manufactured metal parts, processing parameters such as laser power and scanning speed are critical to ensure the desired microstructure. For this study, the laser powder bed fusion process parameters were changed at various angular sections on a 21 mm diameter and 3.0 mm thick disk. The measurement of thermal diffusivity was performed by fitting a 1-dimensional thermal model to the data pixel by pixel to produce an inspection image. The image revealed the detection of defects such as lack of fusion porosity and areas of aggregated porosity. The thermal diffusivity imagery was compared to immersion scan ultrasonic and X-ray computed tomography (CT) measurements for validation. Based on these results, additional samples were investigated using a single side thermal inspection technique to detect lack of fusion porosity and near surface voids.

thermal nondestructive evaluation↗

NASA NTRS2023

Flash Thermal Diffusivity Measurements and Inspection of Additively Manufactured Ti-6Al-4V Specimens with Varying Process Parameters

thermal nondestructive evaluation↗

NASA NTRS2024

Multiple Subscale Magnetic Reconnection Embedded inside a Heliospheric Current Sheet Reconnection Exhaust: Evidence for Flux Rope Merging

We report observations of multiple subscale reconnecting current sheets embedded inside a large-scale heliospheric current sheet (HCS) reconnection exhaust. The discovery was made possible by the unusual skimming trajectory of Parker Solar Probe through a sunward-directed HCS exhaust, sampling structures convecting with the exhaust outflows for more than 3 hr during Encounter 14, at a radial distance of ∼17 solar radii. A large number of subscale current sheets (SCSs) were detected inside the HCS exhaust. Remarkably, five SCSs showed direct evidence for reconnection, displaying near-Alfvénic outflow jets and bifurcated current sheets. The reconnecting SCSs all had small magnetic shears (27°–81°), i.e., strong guide fields. The thickness of the subscale reconnecting current sheets ranged from ∼60 km to ∼5000 km (∼20–2000 ion inertial lengths). The SCS exhausts were directed predominantly in the normal or out-of-plane direction of the HCS, i.e., nearly orthogonal to the HCS exhaust direction. The presence of multiple low-magnetic-shear reconnecting current sheets inside a large-scale exhaust could be associated with coalescence of multiple large flux ropes inside the HCS exhaust. The orientation of some SCS exhausts was partly in the ecliptic plane of the HCS, which may indicate that the coalescence process is highly three-dimensional. Since the coalescence process is likely short-lived, the detection of five such events inside a single HCS crossing could imply the common occurrence of flux rope coalescence in large-scale HCS reconnection exhausts.

T D Phan↗

DOE OSTI2020

Crushing behaviors of unidirectional carbon fiber reinforced plastic composites under dynamic bending and axial crushing loading

The dynamic crushing characteristics of unidirectional carbon fiber reinforced plastic composites under two loading types, dynamic three-point bending and axial crushing, are investigated by experiment and finite element simulation. Hat section samples with two different layup orientations are tested at various impact velocities to investigate its effects. The experiment results show that delamination plays a critical role in dynamic bending deformation. Different layup orientations lead to similar crushing bending behaviors, but remarkable variations in delamination pattern evolutions. In contrast, layup orientation exerts more significant effects on failure modes and energy absorption in axial crushing. A finite element model with multiple layers of thick shell element and cohesive element is established, and simulations are performed for both dynamic three-point bending and axial crushing. The model can capture the crushing behaviors in the two loading types reasonably well. The damage evolution and energy absorption through various mechanisms at different loading conditions are discussed.

42 ENGINEERING↗

DOE OSTI2025

Determining the nanostructure of polymer foams using 3D ptycho-tomography for inertial fusion energy applications

Polymer foams play a critical role in contemporary inertial fusion energy (IFE) target designs by enhancing energy yield and optimizing implosion dynamics. However, the lack of high-resolution characterization of the nanostructure of these foams restricts progress in fusion science. In this work, we demonstrate the first high-resolution three-dimensional (3D) reconstruction of a low-density, Si-doped polymer foam fabricated via two-photon polymerization, using ptychographic x-ray computed tomography (PXCT) at an x-ray free electron laser (XFEL). This imaging method reconstructs two-dimensional (2D) attenuation and phase information at multiple sample angles that are combined into a 3D density map used to extract local mass density and determine structural dimensions. We achieve a 2D spatial resolution of 19 ± 3 nm on a high-contrast Ronchi pattern target and 78.7 ± 3 nm for low-contrast polymer foams, marking a significant advancement for XFEL-based ptychography of low-density materials. Furthermore, our experimental results reveal an average foam strut thickness of 1.17 ± 0.4 μm, consistent with fabrication expectations, and a reconstructed average mass density of 0.35 g/cc, aligning closely with the predicted density of 0.29 g/cc. These findings provide important insights for improving foam design and refining radiation hydrodynamics modeling in future IFE experiments. Our study establishes PXCT at an XFEL as a powerful tool for high-resolution characterization of fusion-relevant materials, paving the way for enhanced target performance in IFE research.

Hancock, Levi [Colorado State Univ., Fort Collins,↗

DOE OSTI2021

Photoelectrochemically Self Improving Si/GaN Photocathode: Figure 4a Raw Data

Calculated formation energy of (0001 ̅) c-plane GaN surfaces. The density-functional theory (DFT) calculations were performed with the generalized gradient approximation, using the plane-wave pseudopotential quantum-ESPRESSO package. Ultrasoft pseudopotentials were used to describe the interaction between valence electrons and ionic cores, where Ga 3d electrons were explicitly treated as valence electrons. The wave functions and electronic density were expanded in a plane-wave basis set truncated at a cutoff energy of 30 Ry and 240 Ry, respectively. The surface was modeled using a repeated slab geometry using a (2×2) unit cell with a thickness of seven GaN bilayers, where the Ga-terminated bottom side was passivated by pseudo-hydrogen with charge of 1.25e. In addition, the (1010) surface was modeled using 8 GaN atomic layers with a lateral dimension of 9.57 Å x 10.38 Å. A vacuum width of at least 15.0 Å was introduced between consecutive slabs, and a k-point mesh of 5x5x1 and 2x2x1 was used to sample the surface Brillouin zone for the polar and non-polar surfaces, respectively. Calculated formation energy of (0001 ̅) c-plane GaN surfaces with different oxygen configuration within the anion and cation-rich limits: ideal GaN surfaces of c-plane and m-plane; configurations with 100% replacement of nitrogen by oxygen on the surface c-plane and m-plane; 100% replacement of nitrogen by oxygen in the subsurface bilayer c-plane and m-plane; and configurations with 50% replacement of nitrogen of the surface and subsurface bilayers by oxygens c-plane and m-plane. In both cases, the ideal surface is chosen as the reference.

photocathode↗

DOE OSTI2021

Photoelectrochemically Self Improving Si/GaN Photocathode: Figure 4b Raw Data

Calculated formation energy of (1010 ̅) m-plane GaN surfaces. The density-functional theory (DFT) calculations were performed with the generalized gradient approximation, using the plane-wave pseudopotential quantum-ESPRESSO package. Ultrasoft pseudopotentials were used to describe the interaction between valence electrons and ionic cores, where Ga 3d electrons were explicitly treated as valence electrons. The wave functions and electronic density were expanded in a plane-wave basis set truncated at a cutoff energy of 30 Ry and 240 Ry, respectively. The surface was modeled using a repeated slab geometry using a (2×2) unit cell with a thickness of seven GaN bilayers, where the Ga-terminated bottom side was passivated by pseudo-hydrogen with charge of 1.25e. In addition, the (1010) surface was modeled using 8 GaN atomic layers with a lateral dimension of 9.57 Å x 10.38 Å. A vacuum width of at least 15.0 Å was introduced between consecutive slabs, and a k-point mesh of 5x5x1 and 2x2x1 was used to sample the surface Brillouin zone for the polar and non-polar surfaces, respectively. Calculated formation energy of (1010 ̅) m-plane GaN surfaces with different oxygen configuration within the anion and cation-rich limits: ideal GaN surfaces of c-plane and m-plane; configurations with 100% replacement of nitrogen by oxygen on the surface c-plane and m-plane; 100% replacement of nitrogen by oxygen in the subsurface bilayer c-plane and m-plane; and configurations with 50% replacement of nitrogen of the surface and subsurface bilayers by oxygens c-plane and m-plane. In both cases, the ideal surface is chosen as the reference.

photocathode↗

NASA NTRS1985

Orbital atomic oxygen effects on thermal control and optical materials - STS-8 results

The effects of exposing 23 specimens of optical and thermal control materials to space at 120 km altitude for over 40 hrs during the STS-8 mission are discussed. Ten samples of paint targeted for the Space Telescope (ST) and the Tethered Satellite were exposed, and included polyurethane, oxide, silicone, and glossy black and white samples which were scanned for alterations in the optical properties after being retrieved. Nine mirror-type materials were also investigated, along with silver specimens typical of solar cell interconnects. The oxygen flow at the orbital altitude was 3.5 x 10 to the 20th atoms/cu cm. The exposures caused no degradation of the magnesium fluoride mirror coatings, while the Kapton coating for the ST solar cell panels showed evidence of losing thickness. The Ag solar cell contacts will require coatings to extend their lifetimes. Overcoatings were also proven necessary for inhibiting degradation of painted surfaces.

Whitaker, A. F.↗

NASA NTRS1993

Quantitative Mapping of Pore Fraction Variations in Silicon Nitride Using an Ultrasonic Contact Scan Technique

An ultrasonic scan procedure using the pulse-echo contact configuration was employed to obtain maps of pore fraction variations in sintered silicon nitride samples in terms of ultrasonic material properties. Ultrasonic velocity, attenuation coefficient, and reflection coefficient images were obtained simultaneously over a broad band of frequencies (e.g., 30 to 110 MHz) by using spectroscopic analysis. Liquid and membrane (dry) coupling techniques and longitudinal and shear-wave energies were used. The major results include the following: Ultrasonic velocity (longitudinal and shear wave) images revealed and correlated with the extent of average through-thickness pore fraction variations in the silicon nitride disks. Attenuation coefficient images revealed pore fraction nonuniformity due to the scattering that occurred at boundaries between regions of high and low pore fraction. Velocity and attenuation coefficient images were each nearly identical for machined and polished disks, making the method readily applicable to machined materials. Velocity images were similar for wet and membrane coupling. Maps of apparent Poisson's ratio constructed from longitudinal and shear-wave velocities quantified Poisson's ratio variations across a silicon nitride disk. Thermal wave images of a disk indicated transient thermal behavior variations that correlated with observed variations in pore fraction and velocity and attenuation coefficients.

Roth, Don J.↗

NASA NTRS2007

Fabrication and Characterization of Diffusion Bonds for Silicon Carbide

Diffusion bonds of silicon carbide (SiC) were fabricated using several different types of titanium (Ti) based interlayers between the SiC substrates. The interlayers were an alloyed Ti foil, a pure Ti foil, and a physically vapor deposited (PVD) Ti coating. Microscopy was conducted to evaluate the cross-sections of the resulting bonds. Microprobe analysis identified reaction formed phases in the diffusion bonded region. Uniform and well adhered bonds were formed between the SiC substrates. In the case where the alloyed Ti foil or a thick Ti coating (i.e. 20 micron) was used as the interlayer, microcracks and several phases were present in the diffusion bonds. When a thinner interlayer was used (i.e. 10 micron PVD Ti), no microcracks were observed and only two reaction formed phases were present. The two phases were preferred and fully reacted phases that did not introduce thermal stresses or microcracks during the cool-down stage after processing. Diffusion bonded samples were evaluated with the non-destructive evaluation (NDE) methods of pulsed thermography and immersion ultrasonic testing. Joined SiC substrates that were fully bonded and that had simulated bond flaws in the interlayer were also evaluated using immersion ultrasound. Pull testing was conducted on the bonds to determine the tensile strength. To demonstrate the joining approach for a complex multilayered component for a low NOx injector application, the diffusion bonding approach was used to join three 4" diameter SiC discs that contained complex fuel and air flow channels.

Halbig, Michael↗

DOE OSTI2024

Magnetic anisotropy and GGG substrate stray field in YIG films down to millikelvin temperatures

Abstract Quantum magnonics investigates the quantum-mechanical properties of magnons, such as quantum coherence or entanglement for solid-state quantum information technologies at the nanoscale. The most promising material for quantum magnonics is the ferrimagnetic yttrium iron garnet (YIG), which hosts magnons with the longest lifetimes. YIG films of the highest quality are grown on a paramagnetic gadolinium gallium garnet (GGG) substrate. The literature has reported that ferromagnetic resonance (FMR) frequencies of YIG/GGG decrease at temperatures below 50 K despite the increase in YIG magnetization. We investigated a 97 nm-thick YIG film grown on 500 μm-thick GGG substrate through a series of experiments conducted at temperatures as low as 30 mK, and using both analytical and numerical methods. Our findings suggest that the primary factor contributing to the FMR frequency shift is the stray magnetic field created by the partially magnetized GGG substrate. This stray field is antiparallel to the applied external field and is highly inhomogeneous, reaching up to 40 mT in the center of the sample. At temperatures below 500 mK, the GGG field exhibits a saturation that cannot be described by the standard Brillouin function for a paramagnet. Including the calculated GGG field in the analysis of the FMR frequency versus temperature dependence allowed the determination of the cubic and uniaxial anisotropies. We find that the total crystallographic anisotropy increases more than three times with the decrease in temperature down to 2 K. Our findings enable accurate predictions of the YIG/GGG magnetic systems behavior at low and ultralow millikelvin temperatures, crucial for developing quantum magnonic devices.

Serha, Rostyslav O.↗

DOE OSTI2022

Effect of proton irradiation temperature on persistent photoconductivity in zinc oxide metal-semiconductor-metal ultraviolet photodetectors

The electrical and structural characteristics of 50-nm-thick zinc oxide (ZnO) metal-semiconductor-metal ultraviolet (UV) photodetectors subjected to proton irradiation at different temperatures are reported and compared. The devices were irradiated with 200 keV protons to a fluence of 1016 cm−2. Examination of the x-ray diffraction (XRD) rocking curves indicates a preferred (100) orientation prior to irradiation, with decrease in crystal quality afterward. Additionally, peak shifts in XRD and Raman spectra of the control sample relative to well-known theoretical positions are indicative of tensile strain in the as-deposited ZnO films. Shifts toward theoretical unstrained positions are observed in the irradiated films, which indicates partial relaxation. Raman spectra also indicate increase in oxygen vacancies (VO) and zinc interstitial defects (Zni) compared to the control sample. Additionally, transient photocurrent measurements performed on each sample at different temperatures showed up to 2× increase in photocurrent decay time constants for irradiated samples vs the control. This persistent photoconductive behavior is linked to the activation of electron and hole traps near the surface, and to the desorption and reabsorption of O2 molecules on the ZnO surface under the influence of UV light. Using an Arrhenius model, trap activation energies were extracted and, by comparing with known energies from the literature, the dominant defects contributing to persistent photoconductivity for each irradiation condition were identified. The persistence of differences in photocurrent transients between different samples months after irradiation indicates that the defects introduced by the suppression of thermally activated dynamic annealing processes have a long-term deleterious effect on device performance.

Heuser, Thomas A. (ORCID:0000000225642400)↗