Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “cell fracture”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Predicting ductility of Mg/SiCp nanocomposite under multiaxial loading conditions based on unit cell modeling

This article presents an investigation on the ductility of Mg/SiCp under nine different multiaxial loading conditions based on a unit cell (or called representative volumetric element, RVE) finite element model. The constitutive relationship of magnesium matrix is characterized by a model combined Lode angle dependent plasticity model with the CPB06 plasticity model, which is able to describe the tension-compression asymmetry in magnesium matrix. The debonding of the matrix-particle interface and matrix fracture are considered by the modified Mohr-Coulomb (MMC) fracture model. Simulation results show that the interface debonding and subsequent matrix fracture are responsible for the ductility and fracture of nanocomposite. The computational results with parametric studies are compared and well correlated with experimental data, and it finally gives a stress-based full fracture locus of Mg/SiCp nanocomposite.

42 ENGINEERING↗
DOE OSTI2026

Improved Mechanical Adhesion Enabled by Bilayer Hole Transport Layers in Perovskite Solar Cells

We investigate buried-interface mechanical integrity in metal-halide perovskite half-cells using carbazole-based self-assembled monolayers (SAMs) and bilayer hole transport layers composed of metal oxide underlayers and SAMs. Combining macroscopic and microscopic characterization, we quantify interfacial fracture energy (Gc) and identify delamination pathways. SAM deposition on NiOx increases Gc by approximately 10-fold compared with ITO, highlighting the importance of oxide underlayer selection. To isolate the effect of removing noncovalently bonded SAM molecules, we use vapor-deposited perovskite as a solvent-free model system, decoupling the rinse step inherent to solution processing. Removing loosely bound SAM molecules increases Gc from 0.94 +- 0.08 J.m-2 to 4.82 +- 0.79 J.m-2. These results show that oxide selection and SAM binding quality are both critical for strengthening buried interfaces and designing mechanically robust perovskite solar cells.

14 SOLAR ENERGY↗
DOE OSTI2022

High‐Efficiency Solar Cells Grown on Spalled Germanium for Substrate Reuse without Polishing

Abstract Radical reduction of III–V device costs requires a multifaceted approach attacking both growth and substrate costs. Implementing device removal and substrate reuse provides an opportunity for substrate cost reduction. Controlled spalling allows removal of thin devices from the expensive substrate; however, the fracture‐based process currently generates surfaces with significant morphological changes compared to polished wafers. 49 single junction devices are fabricated across the spalled surface of full 50 mm germanium wafers without chemo‐mechanical polishing before epitaxial growth. Device defects are identified and related to morphological spalling defects—arrest lines, gull wings, and river lines—and their impact on cell performance using physical and functional characterization techniques. River line defects have the most consistent and detrimental effect on cell performance. Devices achieve a single junction efficiency above 23% and open‐circuit voltage of 1.01 V, demonstrating that spalled germanium does not need to be returned to a pristine, polished state to achieve high‐quality device performance.

14 SOLAR ENERGY↗
DOE OSTI2022

Variable resolution Poisson-disk sampling for meshing discrete fracture networks

Here, we present the near-Maximal Algorithm for Poisson-disk Sampling (nMAPS) to generate point distributions for variable resolution Delaunay triangular and tetrahedral meshes in two and three-dimensions, respectively. nMAPS consists of two principal stages. In the first stage, an initial point distribution is produced using a cell-based rejection algorithm. In the second stage, holes in the sample are detected using an efficient background grid and filled in to obtain a near-maximal covering. Extensive testing shows that nMAPS generates a variable resolution mesh in linear run time with the number of accepted points. We demonstrate nMAPS capabilities by meshing three-dimensional discrete fracture networks (DFN) and the surrounding volume. The discretized boundaries of the fractures, which are represented as planar polygons, are used as the seed of 2D-nMAPS to produce a conforming Delaunay triangulation. The combined mesh of the DFN is used as the seed for 3D-nMAPS, which produces conforming Delaunay tetrahedra surrounding the network. Under a set of conditions that naturally arise in maximal Poisson-disk samples and are satisfied by nMAPS, the two-dimensional Delaunay triangulations are guaranteed to only have well-behaved triangular faces. While nMAPS does not provide triangulation quality bounds in more than two dimensions, we found that low-quality tetrahedra in 3D are infrequent, can be readily detected and removed, and a high-quality balanced mesh is produced.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Experimental and Computational Characterization of a Modified Sioutas Cascade Impactor for Respirable Radioactive Aerosols

Oak Ridge National Laboratory is collecting and characterizing aerosols released when spent nuclear fuel (SNF) rods are fractured in bending. An aerosol collection system was designed and tested to collect respirable sized (<10 μm aerodynamic diameter [AED]) particulates inside a hot cell facility. The setup is a modified version of the commercially available Sioutas cascade impactor, to which additional stages were added to expand the aerosol collection range from 2.5 to ~15 μm AED. To accommodate the additional stages and specific test conditions, the operating flow rate for aerosol collection was reduced, and testing was conducted by using pressure drop measurements, surrogate dust collection, and particle size characterization. The fluid flow distribution within the cascade and its stages was simulated in STAR-CCM+, and the stage-wise pressure drops obtained using the computational fluid dynamics model were then compared to experimental data. Lagrangian particle simulations were also performed, and stage-wise collection statistics were obtained from the simulation for comparison with the experimental data obtained using SNF-surrogate dust particles. The results provide valuable insights into the stage-wise particle collection characteristics of the modified cascade impactor and can also be used to improve the prediction accuracy of the manufacturer-determined analytical correlations.

aerosol modeling↗
NASA NTRS2019

Dust Abrasion Damage on Martian Solar Arrays: Experimental Investigation and Opportunity Rover Performance Analysis

Here we investigate the effects of erosion and weathering that occur on III-V cover-glass interconnected cells (CICs) after exposure to Mars dust storm conditions. The durability of these materials in a Martian environment is not well characterized so we perform analogous experimentation. To replicate the dust impingement, test coupons were placed in an enclosure and sandblasted with Mars dust simulant. We show the J-V response dependency on both incident angle and exposure times. We find that the simulated Martian dust storm often results in damage to the anti-reflective coating and subsequent reduced short circuit current. Reduction in the open circuit voltage is observed, likely caused by structural damage to the crystal lattice after CIC fracture. We employ data-driven modeling to determine a performance degradation rate that is consistent with zero within uncertainty. We also quantify the soiling contribution and power degradation of the photovoltaic cells on Mars through analysis of 4.95 Martian years of report-out power conditions from the Opportunity rover. We find that atmospheric dust suspended due to a weather event does not result in instantaneous settled dust on the PV cells. We calculate via autocorrelation function that the dust settling rate is approximately 21 Sols from atmospheric dust suspension. The findings presented here deliver a realistic approximation for the insolation values and subsequent PV power expected over time on the Martian surface thus informing future dust abatement systems.

McMillon-Brown, Lyndsey↗
NASA NTRS2019

Dust Abrasion Damage on Martian Solar Arrays: Experimental Investigation and Opportunity Rover Performance Analysis

Here we investigate the effects of erosion and weathering that occur on III-V cover-glass interconnected cells (CICs) after exposure to Mars dust storm conditions. The durability of these materials in a Martian environment is not well characterized so we perform analogous experimentation. To replicate the dust impingement, test coupons were placed in an enclosure and sandblasted with Mars dust simulant. We show the J-V response dependency on both incident angle and exposure times. We find that the simulated Martian dust storm often results in damage to the anti-reflective coating and subsequent reduced short circuit current. Reduction in the open circuit voltage is observed, likely caused by structural damage to the crystal lattice after CIC fracture. We employ data-driven modeling to determine a performance degradation rate that is consistent with zero within uncertainty. We also quantify the soiling contribution and power degradation of the photovoltaic cells on Mars through analysis of 4.95 Martian years of report-out power conditions from the Opportunity rover. We find that atmospheric dust suspended due to a weather event does not result in instantaneous settled dust on the PV cells. We calculate via autocorrelation function that the dust settling rate is approximately 21 Sols from atmospheric dust suspension. The findings presented here deliver a realistic approximation for the insolation values and subsequent PV power expected over time on the Martian surface thus informing future dust abatement systems.

McMillon-Brown, Lyndsey↗
DOE OSTI2022

Exploring the Promise of Multifunctional “Zintl-Phase-Forming” Electrolytes for Si-Based Full Cells

Li-M-Si ternary Zintl phases have gained attention recently due to their high structural stability, which can improve the cycling stability compared to a bulk Si electrode. Adding multivalent cation salts (such as Mg 2+ and Ca 2+ ) in the electrolyte was proven to be a simple way to form Li-M-Si ternary phases in situ in Si-based Li-ion cells. To explore the promise of Zintl-phaseforming electrolytes, we systematically investigated their application in pouch cells via electrochemical and multiscale postmortem analysis. The introduction of multivalent cations, such as Mg 2+ , during charging can form Li x M y Si ternary phases. They can stabilize Si anions and reduce side reactions with electrolyte, improving the bulk stability. More importantly, Mg 2+ and Ca 2+ incorporate into interfacial side reactions and generate inorganic-rich solid- electrolyte interphase, thus enhancing the interfacial stability. Therefore, the full cells with Zintl-phase-forming electrolytes achieve higher capacity retentions at the C/3 rate after 100 cycles, compared to a baseline electrolyte. Additionally, strategies for mitigating the electrode-level fractures of Si were evaluated to make the best use of Zintl-phase-forming electrolytes. In conclusion, this work highlights the significance of synergistic impact of multifunctional additives to stabilize both bulk and interface chemistry in high-energy Si anode materials for Li-ion batteries.

25 ENERGY STORAGE↗
DOE OSTI2022

Fracturing in Wet Granular Media Illuminated by Photoporomechanics

Here, we study fluid-induced deformation and fracture of granular media and apply photoporomechanics to uncover the underpinning grain-scale mechanics. We fabricate spherical photoelastic particles of 2-mm diameter to form a monolayer granular pack in a circular Hele-Shaw cell that is initially filled with a viscous fluid. The key distinct feature of our system is that, with spherical particles, the granular pack has a connected pore space, thus allowing for pore-pressure diffusion and the study of effective stress in coupled poromechanical processes. We inject air into the fluid-filled photoelastic granular pack, varying the initial packing density and confining weight. With our recently developed experimental technique, photoporomechanics, we find two different modes of fluid invasion: fracturing in fluid-filled elastic media (with strong photoelastic response) and viscous fingering in frictional fluids (with weak or negligible photoelastic response). We directly visualize the evolving effective stress field and discover an effective stress shadow behind the propagating fracture tips, where the granular pack exhibits undrained behavior. We conceptualize the behavior of the system by means of a mechanistic model for a wedge of the granular pack bounded by two growing fractures. The model captures the pore-pressure build-up inside the stress shadow region and the grain compaction in the annular region outside. Our model reveals that a jamming transition determines the distinct rheological behavior of the wet granular pack, from a friction-dominated to an elasticity-dominated response.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Internal short circuit and failure mechanisms of lithium-ion pouch cells under mechanical indentation abuse conditions: An experimental study

Electromechanical structural integrity and thermal stability dictate the safety performance of lithium-ion batteries. Progressive deformation and failure across microscopic and macroscopic lengths scales that are responsible for internal short circuit (ISC) in lithium-ion cells under mechanical abuse conditions remains elusive. In this study, a series of indentation tests were conducted on lithium-ion cells with different capacities up to the occurrence of ISC. The external response and internal configuration of these cells were investigated. It is discovered that cells with different capacities and state of charges exhibited different behaviors. Maximum temperature, which is often regarded as the most important parameter related to thermal runaway (TR), varied considerably due to the complicated contact configurations. X-ray computed tomography (XCT) showed that ISC was a collective result of shear band or other strain-localization modes in the electrode assembly, shear offsets in the granular coatings of electrodes, and the accompanying ductile fracture in the metal foils. We believe that the irregular strain-localization modes (kinks, cusps, and buckles), radical mismatches in mechanical properties of different layers, and geometric features of the indenter eventually lead to the tearing/puncture of cell separator at various locations. Furthermore, the results could provide useful guidance for the micromechanical modeling of lithium-ion cells.

25 ENERGY STORAGE↗
DOE OSTI2025

Toward Fullerene-Free PIN Perovskite Solar Cells

We highlight opportunities for a transformative shift in perovskite solar cell design by expanding electron transport layers (ETLs) beyond fullerenes. Fullerenes have known limitations, including constraints on open-circuit voltage, stability, and mechanical integrity. Recently, fullerene-free p-i-n cells with power conversion efficiencies exceeding 25% have been demonstrated via both naphthalene diimide-SnO x bilayers and nonfullerene acceptor-based ETLs. Despite successes, fullerenes remain the de facto ETLs for perovskites. Drawing lessons from organic photovoltaics, where it took decades to transition from fullerenes to more broadly available and efficient materials, we explore pathways to accelerate the development and adoption of fullerene-free ETLs. This requires understanding the similarities and differences between organic and perovskite solar cells, which will necessitate carefully designing fullerene replacements with both, high efficiency and also, critically, durability under operation. Here, we incorporate literature data to facilitate comparisons, and independently conduct fracture energy measurements for alternative ETL configurations to motivate their adoption.

14 SOLAR ENERGY↗
DOE OSTI2022

Improving the Thermomechanical Stability of High Efficiency Perovskite Solar Cells via Polymeric Nanofiber Reinforcement

We show that the mechanical stability of perovskite thin films can be increased by an order of magnitude by nanocompositing with polymeric nanofibers using a scalable method. We discuss the increase in fracture resistance energy, Gc, in the nanocomposite samples with respect to nanofiber orientation. We demonstrate this platform with commodity polymeric nanofibers including nylon-6,6 and polyvinyl alcohol. The fiber network reduces the mechanical fragility of the PSCs by increasing their fracture energy several-fold, while maintaining comparable morphology, chemical composition, and device efficiencies to pristine perovskite. Improved power conversion efficiency stability of the nanocomposites under accelerated aging conditions is demonstrated. This platform is a promising advance toward the commercial viability of PSCs.

Samoylov, Anton↗
DOE OSTI2023

24% Single-Junction GaAs Solar Cell Grown Directly on Growth-Planarized Facets Using Hydride Vapor Phase Epitaxy

A 24%-efficient single-junction GaAs solar cell grown directly on a faceted, spalled (100) GaAs substrate after in situ planarization growth by hydride vapor phase epitaxy (HVPE) is achieved. Controlled spalling, a promising low-cost substrate reuse technique, produces large facets in (100)-oriented GaAs substrates due to the orientation of the fracture planes used for lift-off. Planarization by HVPE offers a path toward direct use of these spalled substrates without costly polishing steps. In this report the growth rate anisotropy enabling planarization arising from diffusion and differences in the adsorption of growth species on {n11}B-type facets relative to (100) is determined. Consecutive planarization and device growth that results in a solar cell with a minimal performance difference relative to a control cell grown on an epitaxy-ready substrate are demonstrated. These results show that controlled spalling coupled with HVPE planarization is a viable pathway for lowering the cost of III-V photovoltaics.

14 SOLAR ENERGY↗
DOE OSTI2021

A mechanistic damage model for solid oxide fuel cell ceramic materials - Part I: Constitutive modeling

A multiscale mechanistic damage model for solid oxide fuel cell (SOFC) ceramics that combines micromechanics of stiffness reduction due to material porosity change and microcracking with a continuum damage mechanics (CDM) description for the evolution of microcracks up to fracture is developed in this work. The model also accounts for volumetric swelling of the anode due to redox cycling. Porosity change and swelling during redox combined with normal operating thermomechanical loads could increase the stress, strain and damage distributions in SOFC stacks leading them to failure. The proposed model involves three governing parameters: (i) the porosity in terms of the pore or void volume fraction, (ii) material swelling magnitude prescribed at a given loading step, and (iii) the damage variable that describes microcracking caused by thermomechanical loads and swelling. Pores and microcracks in the ceramics are modeled as randomly distributed ellipsoidal inclusions with negligible stiffness by an Eshelby-Mori-Tanaka formulation combined with an inclusion orientation distribution method. Microcracking damage evolution is described by a CDM formulation. Volumetric swelling is treated in a similar way to thermal expansion in the constitutive relations. After validation and numerical checks, the damage model is used to analyze a simplified SOFC positive-electrode/electrolyte/negative-electrode (PEN) structure subjected a redox cycle in addition to thermomechanical loads experienced during normal operation of a SOFC stack.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS2007

Capabilities and History of NASA Marshall Space Flight Center's Hydrogen Test Facility

The Hydrogen Test Facility (HTF) has conducted mechanical testing for aerospace materials at NASA's Marshall Space Flight Center for many years. One of the first facilities of its kind to run high-pressure cryogenic permeability tests in liquid hydrogen, HTF is now characterized as a unique national resource capable of overcoming hazardous conditions to perform tests directly in various hydrogen environments. At HTF, custom test systems are operated in eight structurally reinforced test cells from 0 to 68,948 kPa (0 to 10,000 psi) at -253 to 982 C (--423 to 1800 F) in hydrogen, air, helium, and nitrogen, with other environments available upon request. Standard mechanical procedures include compression, fatigue crack growth rate, four-point bend, high/low cycle fatigue, fracture toughness, shear, strain-to-crack, and tensile testing. Cryogenic permeability and thermal conductivity and gaseous creep testing are offered, as well as simulated service under different combinations of operating environment(s), stress, pressure, and ambient-to-extreme temperatures. Advanced tests are routinely developed upon demand, and special component testing is also available. Current efforts include the renovation of two high-pressure gaseous test cells to generate data for a J-2X engine designed for Constellation's Ares I and V vehicles. In the past, HTF has supported other critical NASA programs, such as Apollo, Space Shuttle, and Next Generation Launch Technologies. During the 1990's, hundreds of tests were conducted in liquid hydrogen and liquid nitrogen during development of the Space Shuttle's super lightweight tank, which provided the thrust required to achieve low Earth orbit for the International Space Station. This facility was designed and built in 1963. Originally called the Low Temperature Test Facility, it became known as the Cryogenic Test Facility in the late 1980's and HTF in the early 1990's.

Malone, T. W.↗
NASA NTRS2013

Does Aspartic Acid Racemization Constrain the Depth Limit of the Subsurface Biosphere?

Previous studies of the subsurface biosphere have deduced average cellular doubling times of hundreds to thousands of years based upon geochemical models. We have directly constrained the in situ average cellular protein turnover or doubling times for metabolically active micro-organisms based on cellular amino acid abundances, D/L values of cellular aspartic acid, and the in vivo aspartic acid racemization rate. Application of this method to planktonic microbial communities collected from deep fractures in South Africa yielded maximum cellular amino acid turnover times of approximately 89 years for 1 km depth and 27 C and 1-2 years for 3 km depth and 54 C. The latter turnover times are much shorter than previously estimated cellular turnover times based upon geochemical arguments. The aspartic acid racemization rate at higher temperatures yields cellular protein doubling times that are consistent with the survival times of hyperthermophilic strains and predicts that at temperatures of 85 C, cells must replace proteins every couple of days to maintain enzymatic activity. Such a high maintenance requirement may be the principal limit on the abundance of living micro-organisms in the deep, hot subsurface biosphere, as well as a potential limit on their activity. The measurement of the D/L of aspartic acid in biological samples is a potentially powerful tool for deep, fractured continental and oceanic crustal settings where geochemical models of carbon turnover times are poorly constrained. Experimental observations on the racemization rates of aspartic acid in living thermophiles and hyperthermophiles could test this hypothesis. The development of corrections for cell wall peptides and spores will be required, however, to improve the accuracy of these estimates for environmental samples.

cellular↗
DOE OSTI2024

DNA Strand Displacement Driven Molecular Additive Manufacturing (DSD-MAM)

The goal of this project was to validate two-dimensional molecular printers, initially selfassembled from DNA and then actuated by externally driven cycles of DNA strand displacement, as prototype integrated nanosystems for molecular additive manufacturing. Novel functionalities of these nanomachines were explored during this project, including the following: nanometer-precision positioning mechanisms based on DNA strand displacement with multivalent interactions for discrete stepping or else diffusive capture; integration of independently moving layers of DNA origami to achieve 2D controllable motion; integration of spatial positioning with deposition functionality. The principal importance of this project was to provide an essential step in the development of a new technology for atomically precise manufacturing. Our first generation molecular 2D printer offers several advantages over conventional DNA-origami patterning, such as faster prototyping, faster dynamic rearrangement of patterns, and the ability to respond with feedback. We anticipate that our first-generation molecular printers may inspire future generations of molecular printers with iterative improvements in robustness and throughput. Potential applications of atomically precise manufacturing include the following: photovoltaics; photosynthetic and fuel cells; thermoelectrics and anisotropic heat spreaders; solid-state lighting; molecular electronic and plasmonic circuits; selectively preamble membranes; self-repairing materials with high strength-to-weight and fracture resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Damage Modeling of Solid Oxide Fuel Cells Accounting for Redox Effects

This work applies a multiscale mechanistic damage model developed for brittle ceramics and implemented in commercial finite element (FE) packages via user subroutines to study progressive damage in solid oxide fuel cells (SOFC) subjected to thermomechanical loading under normal operating and shutdown conditions including redox effects. The damage model captures the micromechanics of stiffness reduction due to material porosity change and microcracking and integrates the as-obtained stiffness reduction law into a continuum damage mechanics (CDM) formulation for the evolution of microcracks up to fracture. The volumetric “swelling” that occurs during redox is treated in constitutive modeling similarly to thermal expansion, but swelling strains are irreversible. Furthermore, this damage model was first validated through predictions of strength and stress-strain response for the SOFC electrode materials. Next, it has been applied to predict the potential for degradation in a generic planar SOFC stack with large active area cells. Multicell stack models were simulated in both co-flow and counter-flow configurations. In addition, a constant temperature redox cycle was also simulated to capture overall cell electrode damage due to volumetric swelling of the nickel (Ni)-based anode in the anode-supported cells.

25 ENERGY STORAGE↗