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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

The effect of carbon on surface quality of solid-state-sintered silicon carbide as optical materials

The microstructure and the distribution of carbon (C) in silicon carbide (SiC) ceramics were investigated by scanning electron microscopy and transmission electron microscopy. The results show that C can restrain the growth of SiC grains and densify SiC ceramics with the increase of the C content, but residual C introduces a new phase-C to SiC ceramics. The hardness of C is less than that of SiC, so it's difficult to be polished as optical materials. The existence of C phase doesn't lead to the increase of surface roughness on SiC optical materials, but it leads to the decrease of the reflectance of SiC as the optical materials because the optical absorption of C in visible light is stronger than that of SiC. It indicates that C content is very important to the surface properties of SiC, which will affect the coating of chemical vapor deposition SiC or Si on the surface of SiC ceramics because of the different physical and chemical properties between C and SiC. - Highlights: • The microstructure and the distribution of carbon were investigated. • A new phase in the optical materials is introduced. • It is difficult to be polished as the optical materials because of different phases. • Carbon leads to the decrease of reflectance because of its absorption to light wave. • The different properties may affect the coating of chemical vapor deposition on SiC.

36 MATERIALS SCIENCE↗
DOE OSTI2018

High temperature deformability of ductile flash-sintered ceramics via in-situ compression

Flash sintering has attracted significant attention as its remarkably rapid densification process at low sintering furnace temperature leads to the retention of fine grains and enhanced dielectric properties. However, high-temperature mechanical behaviors of flash-sintered ceramics remain poorly understood. Here, we present high-temperature (up to 600 °C) in situ compression studies on flash-sintered yttria-stabilized zirconia (YSZ). Below 400 °C, the YSZ exhibits high ultimate compressive strength exceeding 3.5 GPa and high inelastic strain (~8%) due primarily to phase transformation toughening. At higher temperatures, crack nucleation and propagation are significantly retarded, and prominent plasticity arises mainly from dislocation activity. The high dislocation density induced in flash-sintered ceramics may have general implications for improving the plasticity of sintered ceramic materials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Extended Kohler's rule of magnetoresistance in TaCo 2 Te 2

TaCo 2 Te 2 is recently reported to be an air-stable, high mobility van der Waals material with probable magnetic order. Here we investigate the scaling behavior of its magnetoresistance. Here we measured both the longitudinal (p xx ) and Hall (p xy ) magnetoresistivities of TaCo 2 Te 2 crystals in magnetic fields parallel to the c axis and found that the magnetoresistance violates the Kohler's rule MR similar to f [H/p 0 ] while obeying the extended Kohler's rule MR ~ f [H/(n T p 0 )], where MR ~ [p xx (H) - p 0 ]/p 0 , H is the magnetic field, n T is a thermal factor, and p xx (H) and p 0 are the resistivities at H and zero field, respectively. Further, while deviating from those of the densities of electrons (n e ) and holes (n h ) obtained from the two-band model analysis of the magnetoconductivities, the temperature dependence of n T is close to that of the Hall carrier densities n H calculated from the slopes of p xy (H) curves at low magnetic fields, providing a different way to obtain the thermal factor in the extended Kohler's rule.

36 MATERIALS SCIENCE↗
NASA NTRS1976

High temperature reflectance of hyperpure slip cast silica

An experimental program to optically characterize hyperpure slip cast silica at elevated temperatures is described. This sintered ceramic material is being used in the development of a reflective heat shield for the Outer Planet Entry Probe. A unique high temperature integrating sphere reflectometer is described and reflectance data in the spectral range 0.23-2.3 micron are presented at temperatures up to 1427 C in air and helium environments. Kubelka-Munk (K-M) scattering and absorptance coefficients (K and S), using the Reichman extension of the K-M theory, are presented as is a unique method of obtaining K and S from the Reichman equations using only reflectance data. The hyperpure slip cast silica material was found to retain its high diffuse reflectance at temperatures up to 1204 C, with slight degradation occurring at higher temperatures.

Dillow, C. F.↗
NASA NTRS1992

Toughened uni-piece fibrous insulation

A porous body of fibrous, low density silica-based insulation material is at least in part impregnated with a reactive boron oxide containing borosilicate glass frit, a silicon tetraboride fluxing agent and a molybdenum silicide emittance agent. The glass frit, fluxing agent and emittance agent are separately milled to reduce their particle size, then mixed together to produce a slurry in ethanol. The slurry is then applied to the insulation material and sintered to produce the porous body.

Leiser, Daniel B↗
NASA NTRS2003

Enhancement and Extension of Porosity Model in the FDNS-500 Code to Provide Enhanced Simulations of Rocket Engine Components

In the past, the design of rocket engines has primarily relied on the cold flow/hot fire test, and the empirical correlations developed based on the database from previous designs. However, it is very costly to fabricate and test various hardware designs during the design cycle, whereas the empirical model becomes unreliable in designing the advanced rocket engine where its operating conditions exceed the range of the database. The main goal of the 2nd Generation Reusable Launching Vehicle (GEN-II RLV) is to reduce the cost per payload and to extend the life of the hardware, which poses a great challenge to the rocket engine design. Hence, understanding the flow characteristics in each engine components is thus critical to the engine design. In the last few decades, the methodology of computational fluid dynamics (CFD) has been advanced to be a mature tool of analyzing various engine components. Therefore, it is important for the CFD design tool to be able to properly simulate the hot flow environment near the liquid injector, and thus to accurately predict the heat load to the injector faceplate. However, to date it is still not feasible to conduct CFD simulations of the detailed flowfield with very complicated geometries such as fluid flow and heat transfer in an injector assembly and through a porous plate, which requires gigantic computer memories and power to resolve the detailed geometry. The rigimesh (a sintered metal material), utilized to reduce the heat load to the faceplate, is one of the design concepts for the injector faceplate of the GEN-II RLV. In addition, the injector assembly is designed to distribute propellants into the combustion chamber of the liquid rocket engine. A porosity mode thus becomes a necessity for the CFD code in order to efficiently simulate the flow and heat transfer in these porous media, and maintain good accuracy in describing the flow fields. Currently, the FDNS (Finite Difference Navier-Stakes) code is one of the CFD codes which are most widely used by research engineers at NASA Marshall Space Flight Center (MSFC) to simulate various flow problems related to rocket engines. The objective of this research work during the 10-week summer faculty fellowship program was to 1) debug the framework of the porosity model in the current FDNS code, and 2) validate the porosity model by simulating flows through various porous media such as tube banks and porous plate.

Cheng, Gary↗
NASA NTRS2009

Heat rejection sublimator

A sublimator includes a sublimation plate having a thermal element disposed adjacent to a feed water channel and a control point disposed between at least a portion of the thermal element and a large pore substrate. The control point includes a sintered metal material. A method of dissipating heat using a sublimator includes a sublimation plate having a thermal element and a control point. The thermal element is disposed adjacent to a feed water channel and the control point is disposed between at least a portion of the thermal element and a large pore substrate. The method includes controlling a flow rate of feed water to the large pore substrate at the control point and supplying heated coolant to the thermal element. Sublimation occurs in the large pore substrate and the controlling of the flow rate of feed water is independent of time. A sublimator includes a sublimation plate having a thermal element disposed adjacent to a feed water channel and a control point disposed between at least a portion of the thermal element and a large pore substrate. The control point restricts a flow rate of feed water from the feed water channel to the large pore substrate independent of time.

Dingell, Charles W.↗
DOE OSTI2012

Extreme temperature robust optical sensor designs and fault-tolerant signal processing

Silicon Carbide (SiC) probe designs for extreme temperature and pressure sensing uses a single crystal SiC optical chip encased in a sintered SiC material probe. The SiC chip may be protected for high temperature only use or exposed for both temperature and pressure sensing. Hybrid signal processing techniques allow fault-tolerant extreme temperature sensing. Wavelength peak-to-peak (or null-to-null) collective spectrum spread measurement to detect wavelength peak/null shift measurement forms a coarse-fine temperature measurement using broadband spectrum monitoring. The SiC probe frontend acts as a stable emissivity Black-body radiator and monitoring the shift in radiation spectrum enables a pyrometer. This application combines all-SiC pyrometry with thick SiC etalon laser interferometry within a free-spectral range to form a coarse-fine temperature measurement sensor. RF notch filtering techniques improve the sensitivity of the temperature measurement where fine spectral shift or spectrum measurements are needed to deduce temperature.

47 OTHER INSTRUMENTATION↗
DOE OSTI2017

Additive Manufacturing at LANL: Advanced Characterization to Explore the Science of a New Manufacturing Method

Additive manufacturing (AM), or three-dimensional (3D) printing as it is more commonly known, is defined as the process of joining materials and creating objects by melting, sintering, or fusing material in a layer-by-layer fashion coordinated via 3D model data.1 Subtractive, or traditional, manufacturing methodologies often consist of machining/removing material—like a sculptor—or forming material through the application of pressure—like a potter. Conversely, in an AM process, material is added in individual volume elements and built up in a way similar to interlocking building blocks, but with volume elements that are typically the size of a grain of sand. The additive process often involves less waste when compared to subtractive techniques because material is only added when and where it is needed. Adjustments to the final structure are relatively straightforward and can be simply achieved by adjusting the 3D computer model. This makes the technology much more flexible than traditional, subtractive techniques where new tooling or forming equipment is usually needed to accommodate design changes. Also, the AM processes are beneficial because they permit the fabrication of unique geometries, such as miniaturized metal lattice structures, that cannot be achieved using traditional techniques. An example of a metal lattice structure is the Eiffel Tower with its Figure 1. Schematic showing required linkages between experimental and modeling thrusts in order to achieve science-based qualification. Arrows showing linkages are color-coded according to the funded projects listed. geometric, interconnecting struts that reduce the overall weight of the tower while maintaining strength. In AM, the size of the struts can be made smaller than the diameter of a human hair, which further reduces weight while maintaining strength—a combination of properties that can benefit many applications.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Mechanical characterization of fine-grain dispersion-strengthened tungsten as a plasma facing material

Field-Assisted Sintering Technology (FAST) was used to produce fine-grained, dispersion-strengthened tungsten (W) materials. Investigated materials 4138, 4353, and 4355 composed of 3 wt% ZrC sintered at 1800 °C, 5 wt% ZrC sintered at 1800 °C, and 3 wt% ZrC sintered at 2000 °C, respectively. They were compared against ITER-grade W. A series of mechanical and thermal property testing and microstructure studies were conducted to study them as a potential plasma facing material (PFM) for fusion reactors. Hardness testing showed that manufacturing conditions substantially altered hardness. Material 4355 had an average HV10 value of 497.2 ± 16.8, slightly higher than ITER-grade at 378.5 ± 40.3. However, material 4353 was substantially higher with an HV10 value of 738.9 ± 31.7 over the investigated temperature range. Electron Backscatter Diffraction (EBSD) analysis showed that FAST produced substantially smaller grains than the hot-rolled ITER-grade W material, offering notable control over grain size. Materials 4353 and 4355 had grain sizes of 0.44 ± 0.20 µm and 3.67 ± 0.89 µm, respectively, whereas ITER-grade 27.14 ± 19.76 µm at room temperature. The fine grain structures showed no net coarsening after 1 hr. anneals up to 1800 °C, several hundred degrees above the 1100 – 1500 °C recrystallization range reported for conventional W. Inverse application of the Zener pinning relationship to the measured grain sizes indicates that these two FAST sintering conditions produce markedly different effective dispersoid populations, with effective particle diameters of approximately 90 nm at a peak sintering temperature of 1800 °C and approximately 460 nm at 2000 °C, respectively. This result demonstrates that the FAST thermal condition itself, and not the nominal ZrC content alone, governs the pinning effectiveness of the dispersion. Thermal diffusivity measurements support this finding independently. Materials of identical composition sintered at different temperatures differ by approximately 19% in measured thermal diffusivity with statistically indistinguishable density, while materials of different composition and sintering temperature converge to within approximately 2%. At a representative divertor heat flux of 10 MW/m², the lower thermal conductivity of the fine-grained materials corresponds to approximately 28 to 33 °C per millimeter of armor thickness relative to ITER-grade W, traded against a substantially larger margin to recrystallization-driven degradation. While high temperature tensile testing revealed likely contamination that motivates refinement of the manufacturing process, FAST-produced, fine-grained, dispersion-strengthened W offers process-controlled microstructural stability well above the operating temperatures of conventional W and supports its continued development as a PFM for economically viable commercial fusion power.

Parker, Gabe [ORNL] (ORCID:0000000190394100)↗
DOE OSTI2024

Sintering-based Metal Additive Manufacturing Methods for Magnetic Materials

In this chapter, we review the relationship between solid-state sintering and additive manufacturing (AM) methods for fabricating soft and hard magnetic materials. Heat treatment as a post-processing method has been done in conjunction with AM as a method to improve density and/or mechanical properties. In binder jetting (BJT) of metal powders, sintering is a crucial post-processing step and is necessary for obtaining the final product. This is because the parts are only in the “green” state when they leave the BJT printer, with poor mechanical properties and high porosity. Sintering densifies and strengthens the green part into the final product. A potential industrial application for sintering-based AM is the fabrication of magnetic materials. The motivation for doing so, the process and properties of the AM magnets, and the potential applications of post-sintered AM magnets are explored.

Wang, Haobo↗
DOE OSTI2015

Complete Initial Scoping Tests on the Incorporation of Novel Loaded Iodine Getters into GCM

This study encompasses initial scoping tests on the incorporation of a novel iodine loaded getter material into the Sandia developed low temperature sintering glass ceramic material (GCM) waste form. In particular, we studied the PNNL Ag-I-Aerogel. Optical microscopy indicates inhomogenous samples based on particle sizes and variations in color (AgI vs Ag/AgO on silica). TGA/MS data when heated in air indicates loss of iodine and organics (CO2) between 250-450°C a total of ~15wt% loss, with additional / small iodine loss when during 550°C hold for 1 hr. TGA/MS data when heated in N2 indicates less organic and slightly less iodine loss below 550°C, with no loss of iodine in 550°C 1 hour hold. Furthermore, a substantial mass loss of sulfur containing compounds is observed (m/e of 34 and 36) between 150 – 550°C in both air and N2 sintering atmospheres. In an effort to capture iodine lost to volatilization during heating (at temps below glass sintering temperature of 550°C), we added 5 wt% Ag flake to the AgIaerogel. Resulting data indicates the iodine is retained with the addition of the Ag flake, resulting in only a small iodine loss (< 1wt%) at ~350°C. No method of curtailing loss of sulfur containing compounds due to heating was successful in this scoping study.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1977

Electrically-nonlinear composite material

Low-temperature sinter of semiconductor and polymer resin is useful in manufacture of circuit boards, cables, and electroexplosive devices. Material can absorb large amounts of heat and can withstand repeated exposures to electrostatic discharges with little deteriorating effects. These characteristics offer significant advantages over high-temperature-sintered, metal-oxide semiconducting materials.

Menichelli, V. J.↗
NASA NTRS1978

Friction and wear of several compressor gas-path seal movements

Rub interaction experiments were conducted on a series of sintered and plasma sprayed compressor gas path seal materials in contact with Ti-6Al-4V blade tip and knife edge rotors. The most rub tolerant materials investigated were sintered Nichrome and plasma sprayed nickel 25 percent graphite. The effectiveness of providing a compliant substrate for dense seal material coatings was also demonstrated. In general, it was observed that rotor wear and high frictional energy generation rates accompanied smearing or surface densification of the materials investigated. The onset of smearing was sensitive to rub interaction parameters and seal geometry. Two complementary models were proposed to account for the smearing trends. One is based on thermal effects, the other on particulate escape effects. They were shown to be consistent with the experimental evidence at hand, and together they predict that smearing, with the onset of high energy rub conditions, is favored when incursion rates (radial motion) are low, incursion depths are high, the seal geometry is of a knife-edge character, and the seal particle size is small.

Bill, R. C.↗