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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 1,639 records · Page 91
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Site-Projected Thermal Conductivity: Application to Defects, Interfaces, and Homogeneously Disordered Materials

With the rapid advance of high-performance computing and electronic technologies, understanding thermal conductivity in materials has become increasingly important. This study presents a novel method: the site-projected thermal conductivity that quantitatively estimates the local (atomic) contribution to heat transport, leveraging the Green–Kubo thermal transport equations. The effectiveness of this approach on disordered and amorphous graphene, amorphous silicon, and grain boundaries in silicon–germanium alloys is demonstrated. Amorphous graphene reveals a percolation behavior for thermal transport. The results highlight the potential of the method to provide new insights into the thermal behavior of materials, offering a promising avenue for materials design and performance optimization.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Performance of lightweight nickel electrodes

The NASA Lewis Research Center is currently developing nickel electrodes for nickel-hydrogen (Ni-H2) batteries. These electrodes are lighter in weight and have higher energy densities than the heavier state-of-the-art (SOA) sintered nickel electrodes. In the present approach, lightweight materials or plaques are used as conductive supports for the nickel hydroxide active material. These plaques (fiber and felt, nickel plated plastic and graphite) are commercial products that are fabricated into nickel electrodes by electrochemically impregnating them with active material. Evaluation is performed in half cells structured in the bipolar configuration. Initial performance tests include capacity measurements at five discharge levels, C/2, 1.0C 1.37C, 2.0C and 2.74C. The electrodes that pass the initial tests are life cycle tested in a low Earth orbit regime at 80 percent depth of discharge. Different formulations of nickel fiber materials obtained from several manufacturers are currently being tested as possible candidates for nickel electrodes. One particular lightweight fiber mat electrode has accumulated over 3000 cycles to date, with stable capacity and voltage. Life and performance data of this electrode were investigated and presented. Good dimensional stability and active material adherence have been demonstrated in electrodes made from this lightweight plaque.

Britton, Doris L.↗
NASA NTRS1988

Performance of lightweight nickel electrodes

The NASA Lewis Research Center is currently developing nickel electrodes for nickel-hydrogen (Ni-H2) batteries. These electrodes are lighter in weight and have higher energy densities than the heavier state-of-the-art (SOA) sintered nickel electrodes. In the present approach, lightweight materials or plaques are used as conductive supports for the nickel hydroxide active material. These plaques (fiber and felt, nickel plated plastic and graphite) are commercial products that are fabricated into nickel electrodes by electrochemically impregnating them with active material. Evaluation is performed in half cells structured in the bipolar configuration. Initial performance tests include capacity measurements at five discharge levels, C/2, 1.0C, 1.37C, 2.0C and 2.74C. The electrodes that pass the initial tests are life cycle tested in a low earth orbit regime at 80 percent depth of discharge. Different formulations of nickel fiber materials obtained from several manufacturers are currently being tested as possible candidates for nickel electrodes. One particular lightweight fiber mat electrode has accumulated over 3000 cycles to date, with stable capacity and voltage. Life and performance data of this electrode were investigated and presented. Good dimensional stability and active material adherence have been demonstrated in electrodes made from this lightweight plaque.

Britton, Doris L.↗
DOE OSTI2021

BATPAC--VERSION 5.0

Argonne National Laboratory has worked on electrochemical energy storage for several decades. The focus on lithium-ion chemistries started in the early 1990s, developing new materials, synthesis methods, and performance characterizations. Sponsored by the U.S. Department of Energy, Energy Efficiency and Renewable Energy, Vehicle Technologies Office (DOE-EERE-VTO), Argonne has led with many advances. The experimental activities were complemented with multi-scale modeling that ranged from the atomic to the system (manufacturing processes and automobiles) level. The Battery Performance and Cost (BatPaC) model is a calculation method based on Microsoft¿ Office Excel spreadsheets that have been developed at Argonne for estimating the performance and manufacturing cost of lithium-ion batteries for electric-drive vehicles including hybrid-electrics (HEV), plug-in hybrids (PHEV) and pure electrics. The effort is being funded by the Vehicle Technology Office (VTO), which is part of the Energy Efficiency and Renewable Energy (EERE) office of the U.S. Department of Energy (USDOE). BatPaC was first developed in 2007, was subsequently peer-reviewed, and it has served Argonne researchers and the greater battery community in studying the impact of material properties on performance at the pack level. With further developments, the model now allows the design of cells and battery packs for automotive applications, to meet performance requirements (power, energy, recharge time), and estimates the cost of manufacturing the designed batteries. Since the cost depends on the materials he design, and the manufacturing process, this bottom-up model/tool enables the user to study their effects. Designed or the lithium-ion cell and battery researcher, BatPaC helps answer many questions by being 1.Transparent in the assumptions made and the method of calculation 2.Capable of designing a battery specifically for the requirements of an application 3.Constrained by the physical limitations that govern battery performance 4. A bottom-up calculation approach to account for every cost factors. BatPaC predicts the impact of promising materials (and their properties) on the performance metrics relevant for the different applications. Researchers can use the specific capacities and the half-cell voltages of a particular set of electrode materials to calculate the mass and volume of a cell to develop a model incorporating the properties of all the other materials in the cell and the design of the cell enclosure. These calculations not only reveal the impact of an improved material but also enable researchers to calculate the material properties that would be needed to meet the performance criteria of a full battery pack. With this information, researchers can provide he battery industry with realistic expectations that will help it more successfully advance novel battery technologies an Applications.

AHMED, SHABBIR↗
DOE OSTI2022

Gas Separations using Nanoporous Atomically Thin Membranes: Recent Theoretical, Simulation, and Experimental Advances

Abstract Porous graphene and other atomically thin 2D materials are regarded as highly promising membrane materials for high‐performance gas separations due to their atomic thickness, large‐scale synthesizability, excellent mechanical strength, and chemical stability. When these atomically thin materials contain a high areal density of gas‐sieving nanoscale pores, they can exhibit both high gas permeances and high selectivities, which is beneficial for reducing the cost of gas‐separation processes. Here, recent modeling and experimental advances in nanoporous atomically thin membranes for gas separations is discussed. The major challenges involved, including controlling pore size distributions, scaling up the membrane area, and matching theory with experimental results, are also highlighted. Finally, important future directions are proposed for real gas‐separation applications of nanoporous atomically thin membranes.

2D materials↗
DOE OSTI2024

Material selection and manufacturing for high‐temperature heat exchangers: Review of state‐of‐the‐art development, opportunities, and challenges

Abstract Many energy systems demand heat transfer at high temperatures to keep up with high demand for power, so high‐temperature material that can perform and last under these harsh conditions is needed for heat exchangers. The engineering requirements for these high‐temperature heat exchanger material call for high thermal conductivity, high resistance to fracture, high resistance to creep deformation, environmental stability in environments associated with the application, and high modulus of elasticity while maintaining low cost to make and maintain. Naturally, ceramics are a good solution for this endeavor. In the past, high‐temperature heat exchangers made from ceramics have been used. We provide examples of ceramics in relevant heat exchange applications and provide motivation where additive manufacturing (AM) can improve efficiency. AM for the relevant material is under development, and we provide insight on the AM of ceramic materials and examples of AM heat exchangers keeping cost in mind. The motivation of the review paper is to provide a framework for material and manufacturing selection for high‐temperature heat exchangers for AM to keep up with the demand for better efficiency, better material, better manufacturing, and cost moving forward with AM technology in high‐temperature ceramic heat exchangers.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Critical Review of Brazil Disk Techniques for Tensile Strength Characterization With an Emphasis on High Explosive Materials

Mechanical properties are a critical performance metric for many high explosive (HE) materials and tensile strength properties are particularly important. Direct tensile measurements using dogbone shaped samples are the gold standard but they have the disadvantage that they are fairly large and require samples machined from billets. Diametral compression, more commonly known as Brazil disk (BD) testing, is an indirect method for measuring tensile strength on smaller and more easily fabricated samples. A review of the BD literature is presented with an emphasis on tensile strength measurements in high explosive materials. BD literature is reviewed in three primary areas: (i) rocks and concrete, (ii) pharmaceutical materials, and (iii) high explosive materials. The literature for rocks/concrete is extensive and dates back over 80 years; despite this there is no consensus on the validity/accuracy of the BD technique or the optimal variant of the BD technique to employ. The pharmaceutical literature is the opposite, being limited in scope and quantity of studies. BD literature on high explosive materials falls in between, not as impressive as in the rocks/concrete community but more substantiative than in the pharmaceutical community. After the review of the literature practical parameters for HE BD testing and recommended future work is discussed.

Brazil disk↗
DOE OSTI2025

What Is the Limit of Quantification for the Minor Phase in Time-of-Flight Neutron Diffraction? A Case Study on Fe and Ni Powder Mixtures at VULCAN

A phase present in small quantities within materials may not simply serve as a secondary component; it can play a crucial role in determining the integrity, properties, and performance of the material. These minor but important phases usually draw attention in material design and processing for fundamental understanding as well as material quality control. Accurately quantifying a minor phase amid a majority phase, especially at extremely low fractions, remains a challenging task. Time-of-flight neutron diffraction, coupled with advanced pattern analysis techniques like Rietveld refinement, is a powerful tool for crystal structure identification and phase quantification. The deep penetrating capability of neutrons enables the detection and quantification of trace phases within materials. In this study, the quantification limits of time-of-flight neutron diffraction were explored using the VULCAN diffractometer at the Spallation Neutron Source, using Fe–Ni powder mixtures as a sample system. By comparing the refinement results to the known weighed values, it was determined that the reliable quantification of a minor Ni phase is achievable down to about 0.1 wt% while a Ni fraction as low as 0.02 wt% is difficult to trace. Effective control of the refinement parameters, especially the profile function parameters, are found to significantly influence the convergence of fittings and the accuracy of phase quantification.

Rietveld refinement↗
NASA NTRS2017

The MISSE-9 Polymers and Composites Experiment Being Flown on the MISSE-Flight Facility

Materials on the exterior of spacecraft in low Earth orbit (LEO) are subject to extremely harsh environmental conditions, including various forms of radiation (cosmic rays, ultraviolet, x-ray, and charged particle radiation), micrometeoroids and orbital debris, temperature extremes, thermal cycling, and atomic oxygen (AO). These environmental exposures can result in erosion, embrittlement and optical property degradation of susceptible materials, threatening spacecraft performance and durability. To increase our understanding of space environmental effects such as AO erosion and radiation induced embrittlement of spacecraft materials, NASA Glenn has developed a series of experiments flown as part of the Materials International Space Station Experiment (MISSE) missions on the exterior of the International Space Station (ISS). These experiments have provided critical LEO space environment durability data such as AO erosion yield values for many materials and mechanical properties changes after long term space exposure. In continuing these studies, a new Glenn experiment has been proposed, and accepted, for flight on the new MISSE-Flight Facility (MISSE-FF). This experiment is called the Polymers and Composites Experiment and it will be flown as part of the MISSE-9 mission, the inaugural mission of MISSE-FF. Figure 1 provides an artist rendition of MISSE-FF ISS external platform. The MISSE-FF is manifested for launch on SpaceX-13.

De Groh, Kim K.↗
DOE OSTI2024

Environmentally Assisted Fatigue in Light Water Reactor Environment

This report summarizes the Environmentally Assisted Fatigue (EAF) research conducted at ANL under the US DOE Light Water Reactor Sustainability (LWRS) program. Starting from a rich background in theoretical and experimental EAF, ANL previously developed an approach to evaluate fatigue performance of reactor materials in light water reactor environments with the correction factor F en . The approach was based on a large body of experimental work performed at ANL and elsewhere, and was consistent with American Society of Mechanical Engineers (ASME)’s methodology governing the design and construction of reactor components. In recent years, the program was focused on component fatigue prediction and made several major and fundamental contributions in this area. These accomplishments help meet the needs identified by the industry concerning component level fatigue predictions in complex, transient conditions. The main contribution of the ANL program involved the development of a system-level model for estimating residual strain and life of nuclear reactor coolant system components under connected-system-thermal-mechanical boundary conditions. The goal was to predict the stress hotspots, strain residuals, strain amplitudes and the resulting fatigue lives. Thermal-mechanical stress analysis was performed considering thermal stratification and a design-basis reactor loading cycle. Based on the finite element (FE) model results, the strain residuals, strain amplitudes and resulting fatigue lives of reactor coolant system (RCS) components were predicted. The results show that some of the RCS components can have significantly different strain amplitudes, residual strain, and fatigue lives, despite having similar geometry and material. In addition, the simulated component-level strain profile can guide the selection of appropriate test inputs for conducting laboratory-scale EAF tests. Building upon the system-level model, ANL developed a digital twin (DT) framework to predict the structural states and associated fatigue life of components in real-time. This framework is a comprehensive system designed to predict the structural states and fatigue lives of reactor components. It includes multiple models and integrates artificial intelligence (AI), machine learning (ML), and FE based modeling tools to evaluate the structural states and fatigue lives.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

A deep learning and finite element approach for exploration of inverse structure–property designs of lightweight hybrid composites

Hybrid composites have important applications, such as high-performance and lightweight materials in aerospace and automotive industries. Hybrid composites utilize the synergy of diverse fillers to achieve desired material properties, but usually have more complicated microstructures. While topology optimization can optimize a particular property, designing hybrid composites for customized mechanical performances, e.g. full-range stress–strain curve, remains challenging. Here, a computational framework that integrated finite element analysis (FEA) and artificial intelligence (AI) methods of Conditional Generative Adversarial Networks (cGAN) deep learning and transfer learning was developed to establish inverse structure–property relationships and design tailor-made hybrid composites. Based on FEA-generated datasets of hybrid fiber-particle–matrix microstructures and their corresponding full-range stress–strain curves, a cGAN architecture was trained to generate tailored microstructures and establish structure–property relationships. Similarity in microstructural features and well-matched stress–strain curves based on the AI-generated composites were achieved. In conclusion, transfer learning was used to expand the pre-trained model for designing different materials systems.

Hybrid composites↗
DOE OSTI2022

Specimen Size and Geometry Effects on the Master Curve Fracture Toughness Measurements of EUROFER97 and F82H Steels

EUROFER97 and F82H are two leading reduced-activation ferritic-martensitic (RAFM) steels for fusion blanket applications. Exposure to the harsh environment of fusion reactors can result in severe degradation of materials fracture toughness (FT). Thus, the post-irradiation evaluation of FT is critical to understanding the material behavior. Due to the space constraint of irradiation facilities, the development of small specimen test techniques (SSTT) is necessary to evaluate the performance of irradiated materials. In this study, we evaluated the specimen size and geometry effects on the ductile-to-brittle transition FT of EUROFER97 batch-3 and F82H-BA12 steels. The specimen thicknesses ranged from 1.65 to 12.7 mm and the geometries included 1.65 mm bend bar, 4 mm mini-compact tension (miniCT), and 0.5T compact tension (CT) specimens. Fracture toughness testing and evaluations were performed using the Master Curve method in the ASTM E1921-19 standard. After size correction to 1T size using the Master Curve method, no specimen size effect was observed between the 4 mm miniCT and 0.5T CT specimens for the Master Curve reference temperature T0Q, while the bend bars yielded a higher T0Q. A strong effect of fatigue precrack front straightness on T0Q for 0.5T CT specimens was observed. The minimum number of specimens needed for each specimen geometry has been determined.

Chen, Xiang↗
NASA NTRSDate not supplied

Material Compatibility Study of Coated Metals to Maintain Biocidal Silver in a Spacecraft Potable Water System

Ionic silver-based biocide remains an option of choice for microbial control in spacecraft potable water systems. However, depletion of silver ions by wetted materials readily reduces ionic silver to nonbiocidal levels. This phenomenon occurs via various transport mechanisms at the liquid-solid interfaces between the silver-containing water and adjacent surfaces. Consequently, challenges remain in the design and/or selection of materials that can be used for the wetted system components that will help ensure silver is maintained at biocidal levels. Since silver has been baselined, and/or remains, as a potable water biocide option for several future spacecraft potable water systems, a multitiered approach is being investigated, looking at heritage materials, new processes, and/or alterative materials. This study conducted the application of eleven chemically-resistant coatings onto coupons that were cut out from three types of spacecraft-grade metals (Titanium Grade 2, Inconel 718, and 316L Stainless Steel) to investigate the performance of this material strategy as a barrier against silver depletion. In this investigation, the coated metals were immersed in a static 400 parts per billion silver biocide solution at a surface-area-to-volume ratio of 2.0 cm^(-1) and left to soak for predefined time periods. The concentration of the solution in contact with the coated samples was analyzed at various points via inductively coupled plasma mass spectrometry, and the measurements were interpreted as silver retention percentages over time. This paper summarizes the coating selection process, the configuration of the test, and the performance of each coating-metal combination at diminishing silver depletion. The preliminary results demonstrate that some of the selected coatings succeeded at maintaining biocidal silver concentrations far beyond the corresponding base metal in a similar test. The knowledge acquired through this investigation supports the deploying of coatings on plumbing lines for the integration of biocidal silver in the water system architecture of a spacecraft. Nevertheless, further testing must be continued to assess the performance of these coatings on other wetted geometries and any implications of unifying this material strategy with traditional and developmental engineering design processes for spacecraft potable water systems.

water↗
DOE OSTI2021

GW band structure of monolayer MoS 2 using the SternheimerGW method and effect of dielectric environment

Monolayers of transition-metal dichalcogenides (TMD) hold great promise as future nanoelectronic and optoelectronic devices. An essential feature for achieving high device performance is the use of suitable supporting substrates, which can affect the electronic and optical properties of these two-dimensional (2D) materials. Here, we perform many-body GW calculations using the SternheimerGW method to investigate the quasiparticle band structure of monolayer MoS 2 subject to an effective dielectric screening model, which is meant to approximately describe substrate polarization in real device applications. We show that, within this model, the dielectric screening has a sizeable effect on the quasiparticle band gap, for example the gap renormalization is as large as 250 meV for MoS 2 with model screening corresponding to SiO 2 . Within the G 0 W 0 approximation, we also find that the inclusion of the effective screening induces a direct band gap, in contrast to the unscreened monolayer. We also find that the dielectric screening induces an enhancement of the carrier effective masses by as much as 27% for holes, shifts plasmon satellites, and redistributes quasiparticle weight. Our results highlight the importance of the dielectric environment in the design of 2D TMD-based devices.

36 MATERIALS SCIENCE↗
NASA NTRS1975

A survey of the economics of materials processing in space

A survey of the economics of space materials processing has been performed with the objectives of identifying those areas of space materials processing that give preliminary indication of significant economic potential, and to identify possible approaches to quantify the economic potential. It is concluded that limited economic studies have been performed to date, primarily in the area of the processing of inorganic materials, but that the economics of space processing of biological material has not received adequate attention. Specific studies are recommended to evaluate the economic impact of human lymphocyte subgroup separation on organ transplantation, and on the separation and concentration of urokinase producing cells.

Miller, B. P.↗
DOE OSTI2026

pCAM precursor produced from electroextraction technology and its application in synthesis of NMC 811 cathode material

The synthesis and characterization of LiNi 0.8 Co 0.1 Mn 0.1 O 2 (LNMC811) cathodes produced from recycled hydroxide precursors obtained from spent lithium-ion batteries is evaluated. Two precursor batches (Sample 1 and Sample 2) are prepared using modified recycling processes to examine how residual impurities and processing conditions influence the properties of the regenerated materials. Structural and compositional characterization by X-ray diffraction, ICP and SEM shows that the recycled precursors exhibit layered hydroxide structures containing both α Ni(OH) 2 and β Ni(OH) 2 phases. Trace impurities including sodium, boron, and aluminum are detected and partially mitigated during processing, with boron found to play a beneficial role in electrochemical behavior. Following lithiation with lithium carbonate and lithium hydroxide at 800 °C under an oxygen rich atmosphere, the resulting LNMC811 materials show electrochemical performance comparable to conventionally synthesized cathodes. Sample 2, which contains higher boron levels and improved cation ordering, delivers an initial discharge capacity of 174 mAh g -1 and retains more than 93 percent of its capacity after 50 cycles. The stable cycling behavior and structural integrity of these materials demonstrate that recycled precursors can be converted into high performance layered cathodes and support recycling as a practical and sustainable route for lithium-ion battery manufacturing.

25 ENERGY STORAGE↗
DOE OSTI2021

Materials Scorecards, Phase 1: Advanced Materials and Manufacturing Technology

This report presents preliminary material score cards (Phase 1) based on a survey of industry experts and the limited literature available on the state of advanced manufacturing of materials for nuclear applications. Seven reactor types were considered, and the data is presented in tabular form. The caveat is that the scores are based on limited data and expert judgement. Considerable work remains to be done to prioritize materials for advanced manufacturing to support existing and advanced reactors. A central database of processing conditions, resulting microstructure, post processing, properties, and performance of these materials is needed to support the accelerated adoption of advanced manufacturing by the industry.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Cost Effectiveness of Laser Powder Bed Fusion for Heavy Duty Applications

ORNL (Contractor) and Cummins Inc. (Participant) collaborated to determine the cost effectiveness of laser powder bed fusion (LPBF) for heavy duty applications. The team demonstrated that coupons can be fabricated with two distinct process parameters i.e., different process parameters for the bulk and surface of the material. This is important for enabling the manufacturing of components in a production environment where the bulk of the material can be processed rapidly while high quality surface finish can minimize post-process machining as well as enable superior fatigue performance if the material were to be used in as-deposited condition.

36 MATERIALS SCIENCE↗