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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 1,675 records · Page 93
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Cold Spray NDE for Porosity and Other Process Anomalies

This paper describes a technology review of non-destructive examination (NDE) methods that can be applied to cold spray coatings. Cold spray is a process for depositing metal powder at high velocity so that it bonds to the substrate metal without significant heating that would be likely to cause additional residual tensile stresses. Coatings in the range from millimeters to centimeters are possible at relatively high deposition rates. Cold spray coatings that may be used for hydroelectric components that are subject to erosion, corrosion, wear, and cavitation damage are of interest. The topic of cold spray NDE is treated generally however and may be considered applicable to virtually any cold spray application except where there are constraints of the hydroelectric component application that bear special consideration. Hydroelectric turbine components are primarily made from low carbon and austenitic stainless steels. They are typically very large components that are partially assembled on-site. Transport of these components within the hydroelectric facility and away from the hydroelectric facility is challenging due to the component’s size and weight, high cost of disassembly, and the confined space of the dam. One method for prolonging component life is application of cold spray and thermal powder metal coatings to the components most susceptible to erosion, corrosion, cracking, and mechanical wear. Process controls and visual inspections have historically been applied to cold spray application; however, quantitative NDE could detect anomalies not readily apparent from such a visual examination. Optical profilometry, Eddy current, ultrasound, and hardness tests are shown for one set of good, fair, and poor Nickle-Chrome (NiCr) on 304 stainless steel (304SS) cold spray samples to demonstrate inspection possibilities. The primary indicator of cold spray quality is the cold spray porosity that is most directly measured with witness-sample destructive examinations (DE) – mostly photo-micrographs. These DE generated porosity values are correlated with optical profilometry, eddy current, ultrasound, and hardness test NDE methods to infer the porosity and other Information of interest. These parameters of interest primarily include: • Porosity primarily caused by improper process conditions (temperature, gas velocity, spray standoff, spray angle, powder size, condition, surface cleanliness, surface oxide, etc.). • Presence/absence of the cold spray coating including possible over-sprayed voids • Coating thickness Optical profilometry measurements of surface roughness trended with porosity plus if compared with a reference measurement or reference drawing would provide information on the coating thickness. Ultrasound could provide similar surface profile information plus attenuation measurements trended with porosity. The ultrasound measurements however may be limited to geometries where the substrate back-wall is normal to the cold spray surface and not too thick. Eddy current showed a strong correlation with porosity. Eddy currents can also be sensitive to cracks and do not need fluid coupling to make measurements. Eddy currents however are not sensitive to coating thicknesses in most cases. Vickers hardness measurements also tracked well with porosity. These types of hardness measurements however are also not sensitive to coating thickness. An NDE program may include multiple measurements. Acknowledgement: This work is sponsored by Bonneville Power Administration (BPA) under their technology innovation project program. Such support does not constitute BPA endorsement of views expressed in this work.

Glass, Samuel W.↗
DOE OSTI2018

How shear increments affect the flow production branching ratio in CSDX

In this study, the coupling of turbulence-driven azimuthal and axial flows in a linear device absent magnetic shear (Controlled Shear Decorrelation Experiment) is investigated. In particular, we examine the apportionment of Reynolds power between azimuthal and axial flows, and how the azimuthal flow shear affects axial flow generation and saturation by drift wave turbulence. We study the response of the energy branching ratio, i.e., ratio of axial and azimuthal Reynolds powers, P z R / P y R , to incremental changes of azimuthal and axial flow shears. We show that increasing azimuthal flow shear decreases the energy branching ratio. When axial flow shear increases, this ratio first increases but then decreases to zero. The axial flow shear saturates below the threshold for parallel shear flow instability. The effects of azimuthal flow shear on the generation and saturation of intrinsic axial flows are analyzed. Azimuthal flow shear slows down the modulational growth of the seed axial flow shear, and thus reduces intrinsic axial flow production. Azimuthal flow shear reduces both the residual Reynolds stress (of axial flow, i.e., Π x z R e s ) and turbulent viscosity ( χ z D W ) by the same factor | < v y > ' | - 2 Δ x - 2 L n - 2 ρ s 2 c s 2 , where Δ x is the distance relative to the reference point where < v y > = 0 in the plasma frame. Therefore, the stationary state axial flow shear is not affected by azimuthal flow shear to leading order since < v z > ' ~ Π x z R e s / χ z D W .

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Ultrathick Boron Carbide Coatings for Nuclear Fusion Targets

Boron carbide is an attractive ablator for next-generation inertial confinement fusion (ICF) targets. Here we describe several aspects of our ongoing systematic studies of the deposition and processing of B 4 C coatings for ICF targets. We show that residual compressive stress in films can be reduced and the deposition rate increased by N-doping. Further, we also demonstrate successful Si substrate etching and surface polishing and discuss remaining challenges and offer potential solutions to the buildup of particulates in the deposition chamber during prolonged coating runs, control of nodular growth defects, and lateral nonuniformity of film properties for deposition conditions with relatively low target-to-substrate distances.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Effects of cyclic plasma heating on surface damage of micro-porous tungsten

The operating temperature window of solid tungsten (W) is dictated by its Ductile to Brittle Transition Temperature (DBTT) and re-crystallization temperature; roughly between 300-1300 °C. The brittleness of W at lower temperatures is exasperated when it undergoes recrystallization. We investigate here the thermal shock resistance of micro-porous W as a meta-material fabricated in a 3D open-cell network structure. We present experimental results for the effects of cyclic high-enthalpy arc-jet plasma on surface damage in three testing categories. Observed damage includes surface ablation of asperities, melting and solidification of W-fuzz on samples that have been exposed to a prior helium plasma, and micro-cracks at ligament triple junctions. Scanning electron microscope (SEM) observations show more micro-cracking on 54% and 23% foams compared to the 43% ones. In all tested samples, thermal expansion/contraction displacements were accommodated by ligament rotation and a network of micro-cracks. Furthermore, no large through-thickness crack were observed.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Anisotropic fluid dynamics for Gubser flow

Investigating a variety of closing schemes to the infinite hierarchy of momentum moments of the exactly solvable Boltzmann equation for systems undergoing Gubser flow, we study the precision with which the resulting hydrodynamic equations reproduce the exact evolution of hydrodynamic moments of the distribution function. We find that anisotropic hydrodynamics, obtained by expanding the distribution function around a dynamically evolving locally anisotropic background whose evolution is matched to exactly reproduce the macroscopic pressure anisotropy caused by the different longitudinal and transverse expansion rates in Gubser ow, provides the most accurate macroscopic description of the microscopic kinetic evolution. This confirms a similar earlier finding for Bjorken ow [Molnar, Niemi and Rischke, Phys. Rev. D 94, 125003 (2016)]. Also, we explain the physics behind this optimal matching procedure and show that one can efficiently correct for a nonoptimized matching choice by adding a residual shear stress to the energy-momentum tensor whose evolution is again determined by the Boltzmann equation. Further insights to guide the optimal choice of a macroscopic anisotropic hydrodynamic framework for strongly-coupled systems that do not admit a microscopic kinetic description are reported.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

Material Needs and Measurement Challenges for Advanced Semiconductor Packaging: Understanding the Soft Side of Science

This Perspective builds upon insights from the National Institute of Standards and Technology (NIST)-organized workshop, “Materials and Metrology Needs for Advanced Semiconductor Packaging Strategies,” held at the 35th annual Electronics Packaging Symposium in Binghamton, NY, on September 5, 2024. It outlines critical challenges and opportunities related to polymer-based “soft” materials in advanced semiconductor packaging, with emphasis on polymer science, measurement science (metrology), and the strategic development of Research-Grade Test Materials (RGTMs). These efforts, led by the NIST CHIPS team, aim to advance the fundamental understanding of structure-property-processing relationships, promote standardized guidelines and innovative methods for material characterization, and accelerate the development, qualification, and adoption of next-generation packaging materials. The Perspective also distills key insights from the panel discussion with industry experts, emphasizing the need for close collaboration among materials scientists, process engineers, and metrology experts to enable a holistic strategy, further highlighting the importance of cross-sector partnerships among industry, academia, and government to address pressing challenges in packaging materials and processes.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Computational Modeling of Multi-Pass Rolling Parameters Effect on Resulting Fuel Foil Shape

A focus of the U.S. Department of Energy is to improve production yield and reduce the cost of Low Enriched Uranium (LEU)-molybdenum alloy (U-10Mo) monolithic fuel plates that will be replacing High Enriched Uranium (HEU) oxide dispersion fuels used currently in the United States High Performance Research Reactors (USHPRR). One area of improvement is lowering the high transverse waviness and longitudinal waviness currently present within rolled foils prior to cladding to produce fuel plates. Traditional rolling manufacturing techniques for other metal foils use winders to pull and straighten the foil as it is rolled back and forth to the final thickness. This approach cannot be used to roll thin U-10Mo foils (0.008-0.025” thick) because only small castings can be rolled due to nuclear criticality safety concerns. As a result, the fuel foils are too short (1 m in length) to use traditional winders. Therefore, it is crucial to identify other rolling parameters (i.e., roller friction, axial tension load, roller diameter, and roll pass reduction percent) that might reduce transverse waviness and longitudinal waviness in the rolled fuel foil and develop a high-yield, low-cost multi-pass rolling manufacturing process. This report documents a systematic finite element modeling study to investigate the effects of numerous rolling parameters to reduce resulting transverse waviness and longitudinal waviness in the fuel foil during multi-pass rolling of U-10Mo foils. The rolling of a U-10Mo plate with initial dimensions of 1”x1”x 0.048” is modeled using Abaqus CAE. This rolling is modeled to undergo eight 20% reduction roll passes to a final fuel foil thickness of 0.01”. The elastic-plastic constitutive model of the U-10Mo alloy was input to the fuel foil rolling model. The rollers were modeled as rigid bodies. A comparison of rolling friction coefficients of 0.3 and 0.7 over a wide range of applied axial tension loads were investigated in order to evaluate the effect of using a lubricant during rolling. The effect of roller diameter on the resulting transverse waviness and longitudinal waviness of the fuel foil over a wide range of axial tension loads were also investigated by modeling rollers 7/8” and 3.75” in diameter. The results of this systematic finite element method study will aid manufacturers in producing low transverse waviness and reduced longitudinal waviness in U-10Mo fuel foils.

U-10Mo, FEA, Rolling, Residual Stress, Fuel Foil↗
DOE OSTI2019

Growing III–V Semiconductor Heterostructures on SiC/Si Substrates

A three-layer heterostructure consisting of AlN (∼0.72 μm thick), AlGaN (∼ 1.82 μm thick), and GaN (∼2.2 μm thick) layers has been grown by hydride–chloride vapor phase epitaxy (HVPE) method on a Si substrate with a SiC buffer nanolayer. The heterostructure was studied using scanning electron microscopy, energy-dispersive X-ray spectroscopy, and other techniques. The results showed that SiC/Si substrates can be used for growing films of III–V semiconductor compounds by HVPE at a high rate (~66 μm/h) free of cracks and with small residual elastic stresses (~160 MPa).

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Evaluation of In-Situ AM Process Monitoring Techniques and Potential for Detecting Process Anomalies and Undesirable Microstructures

The US Department of Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program is pursuing rapid qualification of new materials for fabrication of nuclear relevant components using advanced manufacturing techniques. Particular interest is placed on code-qualifying stainless steel (SS) 316H processed by laser powder bed fusion (LPBF) additive manufacturing. A paradigm that incorporates data from in-situ sensing during the printing, ex-situ characterization, and advanced artificial intelligence–based models was established under the Transformation Challenge Reactor (TCR) program to develop a pedigree for each fabricated component that could be tracked from the feedstock to the component’s release for application. Under the TCR program, the Peregrine software was developed as a tool for incorporating the vast amounts of in-situ and ex-situ characterization data collected; all data stored on a rapidly growing digital platform. The digital platform allows for users to link site-specific process anomalies to the macro- and microstructure. The platform will eventually be able to predict component performance, which will be crucial to qualifying materials and components in risk-averse industries such as those supporting and building nuclear reactors. Current in-situ process monitoring techniques that are already integrated with software like Peregrine are advantageous for identifying process anomalies including powder spatter, component edge swelling, recoating-build interactions, and so on. However, additional data are required to fully predict the resulting microstructures needed for identifying relationships to component performance. The rapid cooling rates observed in LPBF are some of the highest of any bulk manufacturing process, resulting in heterogenous microstructures and typically causing anisotropy in mechanical properties. Moreover, evolved residual thermal stresses are high, which can cause severe defects such as delamination or cracking. Therefore, other in-situ monitoring methods are warranted for exploration to measure and map the thermal history, and potentially the stress state, of each build. This report summarizes different in-situ monitoring strategies proposed for LPBF with a focus on the more developed sensor systems. Novel capabilities for measuring melt pool temperatures are also addressed to better inform modeling efforts.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Analysis of Molten Salt Thermal Energy Storage Tank Sizing and Preheating

Molten Salt Thermal energy storage (TES) is essential for concentrating solar power (CSP) plants, enhancing their capacity factor and dispatchability to ultimately reduce electricity costs. This technology is becoming more important for other technologies including nuclear power, thermal-electrical storage, and concentrating solar thermal (CST). While molten salt TES tanks have been successfully deployed in lower-temperature parabolic-trough plants, the current state-of-the-art central receiver systems operating at temperatures up to 565 degrees Celsius have experienced costly and frequent failures. These failures are associated with the immaturity of the technology and problems in tank design, fabrication, commissioning and, sometimes, aggressive operation. A primary contributing factor is the absence of a dedicated technical standard for high-temperature molten nitrate TES tanks; designers must currently rely on existing codes like API 650 and ASME Section II, which are insufficient because they fail to account for the unique demands of high temperatures, thermal cycling, and transient conditions.

25 ENERGY STORAGE↗
DOE OSTI2019

Improving Rivet Performance by Ultrasonic Shock Treatment

The reliability of rivets is improved if the residual compressive stress is uniformly distributed over the joint thickness, with simultaneous decrease in the riveting forces required. The possibility of improving rivet performance by ultrasonic shock treatment is considered. On that basis, a riveting method is proposed. Its effectiveness is analyzed.

42 ENGINEERING↗
DOE OSTI2016

TURBULENCE, TRANSPORT, AND WAVES IN OHMIC DEAD ZONES

We use local numerical simulations to study a vertically stratified accretion disk with a resistive mid-plane that damps magnetohydrodynamic (MHD) turbulence. This is an idealized model for the dead zones that may be present at some radii in protoplanetary and dwarf novae disks. We vary the relative thickness of the dead and active zones to quantify how forced fluid motions in the dead zone change. We find that the residual Reynolds stress near the mid-plane decreases with increasing dead zone thickness, becoming negligible in cases where the active to dead mass ratio is less than a few percent. This implies that purely Ohmic dead zones would be vulnerable to episodic accretion outbursts via the mechanism of Martin and Lubow. We show that even thick dead zones support a large amount of kinetic energy, but this energy is largely in fluid motions that are inefficient at angular momentum transport. Confirming results from Oishi and Mac Low, the perturbed velocity field in the dead zone is dominated by an oscillatory, vertically extended circulation pattern with a low frequency compared to the orbital frequency. This disturbance has the properties predicted for the lowest order r mode in a hydrodynamic disk. We suggest that in a global disk similar excitations would lead to propagating waves, whose properties would vary with the thickness of the dead zone and the nature of the perturbations (isothermal or adiabatic). Flows with similar amplitudes would buckle settled particle layers and could reduce the efficiency of pebble accretion.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2016

Method to Determine Maximum Allowable Sinterable Silver Interconnect Size

The use of sintered-silver for large-area interconnection is attractive for some large-area bonding applications in power electronics such as the bonding of metal-clad, electrically-insulating substrates to heat sinks. Arrays of different pad sizes and pad shapes have been considered for such large area bonding; however, rather than arbitrarily choosing their size, it is desirable to use the largest size possible where the onset of interconnect delamination does not occur. If that is achieved, then sintered-silver's high thermal and electrical conductivities can be fully taken advantage of. Toward achieving this, a simple and inexpensive proof test is described to identify the largest achievable interconnect size with sinterable silver. The method's objective is to purposely initiate failure or delamination. Copper and invar (a ferrous-nickel alloy whose coefficient of thermal expansion (CTE) is similar to that of silicon or silicon carbide) disks were used in this study and sinterable silver was used to bond them. As a consequence of the method's execution, delamination occurred in some samples during cooling from the 250 degrees C sintering temperature to room temperature and bonding temperature and from thermal cycling in others. These occurrences and their interpretations highlight the method's utility, and the herein described results are used to speculate how sintered-silver bonding will work with other material combinations.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS1964

Cumulative damage.

Cumulative fatigue damage of structural parts subjected to variable amplitude loading

LOAD TEST↗
NASA NTRS1973

Thick silicon growth techniques

Hall mobility measurements on a number of single crystal silicon ribbons grown from graphite dies have shown some ribbons to have mobilities consistent with their resistivities. The behavior of other ribbons appears to be explained by the introduction of impurities of the opposite sign. Growth of a small single crystal silicon ribbon has been achieved from a beryllia dia. Residual internal stresses of the order of 7 to 18,000 psi have been determined to exist in some silicon ribbon, particularly those grown at rates in excess of 1 in./min. Growth experiments have continued toward definition of a configuration and parameters to provide a reasonable yield of single crystal ribbons. High vacuum outgassing of graphite dies and evacuation and backfilling of growth chambers have provided significant improvements in surface quality of ribbons grown from graphite dies.

Bates, H. E.↗