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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 1,729 records · Page 96
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Parameter estimation in a thermoelastic composite problem via adjoint formulation and model reduction

Advances in nondestructive material characterization are providing a wealth of information that could be exploited to gain insight into general aspects of material performance and, in particular, discover relationships between microstructure and thermo-mechanical properties in polycrystalline and other complex composite materials. Here, in order to facilitate the integration of such measurements into existing models, as well as inform new physics-based predictions, we developed a C++/MPI computational framework for sensitivity analysis and parameter estimation. The framework utilizes a micro-mechanical modeling based on fast Fourier transforms, direct and adjoint formulations, and Markov chain Monte Carlo sampling techniques. We illustrate the characteristics of this framework and demonstrate its utility by computing the residual stresses arising from thermal expansion of an elastic composite and using data from simulated experiments. Lastly, we show that the availability of nondestructive 3-D measurements is crucial to reduce the uncertainty in predictions, emphasizing the importance of an integrated experimental/modeling/data analysis approach for improved material characterization and design.

36 MATERIALS SCIENCE↗
DOE OSTI2019

The Effect of HVOF Bond Coating with APS Flash Coating on TBC Performance

To study the benefit of ~ 50-µm-thick air-plasma-sprayed (APS) ‘flash’ bond coatings, NiCoCrAlYHfSi high-velocity oxygen fuel (HVOF) bond coatings were deposited on alloy 247 disk substrates with APS yttria-stabilized zirconia topcoatings. Using 1-h cycles at 1100 °C in air with 10% H 2 O and HVOF-only bond coatings as a baseline, APS flash coatings extended the average coating lifetime by > 10% using NiCoCrAlYHfSi and > 70% using NiCoCrAlY powder. Coatings were characterized after 0, 100 and 300 cycles and after failure. Residual stress in the thermally grown alumina scale was mapped every 100 cycles using photo-stimulated luminescence piezospectroscopy. The flash coating created an interlocked metal–alumina layer that appeared to inhibit critical crack formation, and the underlying HVOF layer prevented further internal oxidation and appeared to supply the APS flash coating with Al. Furthermore, the addition of Hf and Y to the flash coating increased internal oxidation and accelerated Al consumption, thereby reducing the benefit of the flash coating.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Residual Stress in Cold Spray SS304L Measured Via Neutron Diffraction and Comparison of Analytical Models to Predict the Residual Stress

Here, this study employs neutron diffraction to investigate the relationship between residual stress and coating thickness in cold sprayed 304L austenitic stainless steel. Results show that shot peening predominantly impacts the residual stress profile, leading to substantial in-plane compressive force. The impact of laser heating, a widely used method to alter cold spray's microstructural properties, on the coating's residual stress is also analyzed. The findings indicate that the maximum compressive residual stress in the in-plane component is mainly independent of coating thickness, which suggests that the material properties determine the maximum residual stress. The cold sprayed deposits possessed compressive, nearly biaxial strain and stresses. After laser heating, these stresses were replaced by tensile residual stresses. Two analytical models, the Tsui and Clyne and the Boruah models, for predicting residual stresses are also evaluated, and both models provide reasonable fits to the experimental data. At this point, the deviations between the experimental results and the models are principally caused by the inability of the current models to address plastic deformation and relaxation, and the residual stresses generated by thermal gradients.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Coupled modeling of a directly heated tubular solar receiver for supercritical carbon dioxide Brayton cycle: Structural and creep-fatigue evaluation

A supercritical carbon dioxide (sCO 2 ) Brayton cycle is an emerging high energy-density cycle undergoing extensive research due to the appealing thermo-physical properties of sCO 2 and single phase operation. Development of a solar receiver capable of delivering sCO 2 at 20 MPa and 700 °C is required for implementation of the high efficiency (~50%) solar powered sCO 2 Brayton cycle. In this work, extensive candidate materials are review along with tube size optimization using the ASME Boiler and Pressure Vessel Code. Moreover, temperature and pressure distribution obtained from the thermal-fluid modeling (presented in a complementary publication) are used to evaluate the thermal and mechanical stresses along with detailed creep-fatigue analysis of the tubes. For resulting body stresses were used to approximate the lifetime performance of the receiver tubes. A cyclic loading analysis is performed by coupling the Strain-Life approach and the Larson-Miller creep model. The structural integrity of the receiver was examined and it was found that the stresses can be withstood by specific tubes, determined by a parametric geometric analysis. The creep-fatigue analysis display the damage accumulation due to cycling and the permanent deformation on the tubes showed that the tubes can operate for the full lifetime of the receiver.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Mechanics of vitrimer particle compression and fusion under heat press

The compression and fusion of vitrimer particles is a fundamental problem underlying the recycling of vitrimers. Incomplete particle compression can lead to voids in the fused vitrimer, thereby impacting its mechanical property. In this work, we present a two-dimensional finite element model to capture the interplay of multiple complex mechanisms including random particle packing, large deformation, inter-particle contact, thermally activated bulk stress relaxation, and interface healing. Specifically, we focus on understanding two key components of this problem: i) evolution of porosity during compression and fusion of randomly packed vitrimer particles, and ii) effective tensile modulus and strength of fused vitrimer. Using the finite element model, we first show that using smaller particles can reduce the porosity in the fused vitrimer, which only slightly increases the effective modulus, but the increase in tensile strength is more pronounced. In addition, under the same processing conditions, particles with mixed sizes can achieve better densification and higher tensile strength after fusion than uniformly sized particles with the same average radius. Regarding the effects of processing conditions, we discuss how the porosity and effective modulus of the fused vitrimer depend on the processing time, temperature and pressure, and find a general trend consistent with experimental observations, i.e. longer processing time, higher temperature or higher pressure can lead to lower porosity and higher modulus of the fused vitrimer. Finally, the theoretical insights towards the compression and fusion process as well as the simulation framework can be useful in optimizing the powder-based heat press process of vitrimer and its composites.

42 ENGINEERING↗
DOE OSTI2021

A constitutive model for glass–ceramic materials

Glass–ceramics have received recent attention for use in glass–ceramic to metal hermetic seals. Due to their heterogeneous microstructure, these materials exhibit a number of advantageous responses over conventional glass based seals. Key amongst them is the possibility of a controllable thermal strain response and apparent coefficient of thermal expansion which may be used to minimize thermally induced residual stresses for aforementioned seals. Furthermore, these behaviors result from an inorganic glass matrix and variety of crystalline ceramic phases including silica polymorph(s) that may undergo reversible solid-to-solid transformations with associated inelastic strain. Correspondingly, these materials exhibit complex thermomechanical responses associated with multiple inelastic mechanisms (viscoelasticity and phase transformation). While modeling these behaviors is essential for developing and analyzing the corresponding applications, no such model exists. Therefore, in this work a three-dimensional continuum constitutive model for glass–ceramic materials combining these various inelastic mechanisms is developed via an internal state variable approach. A corresponding fully implicit three dimensional numerical formulation is also proposed and implemented. The model is used to simulate existing experiments and validate the proposed formalism. As an example, the simple seal problem of a glass–ceramic seal inside a concentric metal shell is explored. Finally, the impact of the cooling rates, viscoelastic shift factors, and inelastic strain on final residual stress state are all investigated and the differing contributions highlighted.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Robust Unencapsulated Perovskite Solar Cells Protected by a Fluorinated Fullerene Electron Transporting Layer

The emergent perovskite photovoltaics technology faces challenges like the long-term durability combining moisture, thermal, and photo stresses that prevents them from competing with established technologies. In this work, we introduce a series of new fluorinated fullerenes as an electron-transporting layer (ETL) for robust perovskite photovoltaics that deliver a high power conversion efficiency of 21.27% with substantially improved durability against environmental stressing. The hydrophobic nature of the new fullerene protects the unencapsulated perovskite cell with stability over 1400 h in 85% relative humidity. Notably, the unencapsulated device maintained 80% of their original performance (T-80) after being immersed in water for over 10 min. Detailed characterizations suggest that the fluorinated fullerene can immobilize the cations in perovskites and passivate the surface traps. Therefore, the T-80 lifetime of the devices under constant illumination reached 1920 h. On the basis of the accelerated test, we estimate a lifetime approaching 10 years with encapsulation. The successful demonstration of the new ETL can stimulate further research and momentum for future photovoltaic technology development.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Highly Reliable Superhydrophobic Protection for Organic Field-Effect Transistors by Fluoroalkylsilane-Coated TiO 2 Nanoparticles

One of the long-standing problems in the field of organic electronics is their instability in an open environment, especially their poor water resistance. For the reliable operation of organic devices, introducing an effective protection layer using organo-compatible materials and processes is highly desirable. In this paper, we report a facile method for the depositing of an organo-compatible superhydrophobic protection layer on organic semiconductors under ambient conditions. The protection layer exhibiting excellent water-repellent and self-cleaning properties was deposited onto organic semiconductors directly using a dip-coating process in a highly fluorinated solution with fluoroalkylsilane-coated titanium dioxide (TiO 2 ) nanoparticles. The proposed protection layer did not damage the underlying organic semiconductors and had good resistance against mechanical-, thermal-, light-stress-, and water-based threats. The protected organic field-effect transistors exhibited more-reliable electrical properties, even when exposed to strong solvents, due to its superhydrophobicity. This study provides a practical solution with which to enhance the reliability of environmentally sensitive organic semiconductor devices in the natural environment.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Fabrication of high-performance ultra-thin-body SnO{sub 2} thin-film transistors using microwave-irradiation post-deposition annealing

We report on the fabrication of high-performance ultra-thin-body (UTB) SnO{sub 2} thin-film transistors (TFTs) using microwave-irradiation post-deposition annealing (PDA) at a low process temperature (<100 °C). We confirm that the electrical characteristics of SnO{sub 2} TFTs become drastically enhanced below a body thickness of 10 nm. The microwave-annealed UTB SnO{sub 2} TFTs with a thickness of 5 nm exhibited increased optical transmittance, as well as remarkable transfer characteristics: a high mobility of 35.4 cm{sup 2} V{sup −1} s{sup −1}, a drain current on/off ratio of 4.5 × 10{sup 7}, a steep subthreshold gate voltage swing of 623 mV/dec, and a clear enhancement-mode behavior. Additionally, the microwave-annealed SnO{sub 2} TFTs exhibited a better positive gate-bias stress/negative gate-bias stress immunity than thermally annealed SnO{sub 2} TFTs. Therefore, the thickness of the UTB SnO{sub 2} TFTs, as well as the microwave-annealing process, are both shown to be essential for transparent and flexible display technology.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Experimental analysis of the material degradation of PET on a co-rotating twin-screw extruder for varying vacuum pressures

Plastics, starting from inexpensive mass-produced articles to technical high-end applications, are being used in ever more areas of life. The main drivers are their flexible product properties and the resultant broad application possibilities. To be able to offer plastic products inexpensively and conserve the environment at the same time, more and more attention is being paid to plastics recycling. Polyethylene terephthalate – in short PET – is of particular significance here because of its frequent application in the film and packaging industry and its special material properties. The recycling of PET, however, can only be carried out a limited number of times because it’s processing necessarily results in both thermal and mechanical stresses on the material. This is the basis for the reactions at molecular level, which result in a shortening of the molecule chains (material degradation) and exert a negative effect on the product properties. The aim of this study is to identify the factors that influence the material degradation of PET in twin-screw extrusion. To do this, various screw configurations and different speed and throughput conditions are examined in a series of experiments. Furthermore, material specimens are removed along the length of the screw in order to evaluate the influence of individual screw sections. By determining the intrinsic viscosity of the specimens, it is possible to measure the mean molecular weight and thus the material damage. Based on the test results, guidelines are drawn up for the compounding of PET so as to ensure as little damage as possible to the material.

36 MATERIALS SCIENCE↗
DOE OSTI2015

New active asteroid 313P/Gibbs

We present initial observations of the newly discovered active asteroid 313P/Gibbs (formerly P/2014 S4), taken to characterize its nucleus and comet-like activity. The central object has a radius ∼0.5 km (geometric albedo 0.05 assumed). We find no evidence for secondary nuclei and set (with qualifications) an upper limit to the radii of such objects near 20 m, assuming the same albedo. Both aperture photometry and a morphological analysis of the ejected dust show that mass-loss is continuous at rates ∼0.2–0.4 kg s{sup −1}, inconsistent with an impact origin. Large dust particles, with radii ∼50–100 μm, dominate the optical appearance. At 2.4 AU from the Sun, the surface equilibrium temperatures are too low for thermal or desiccation stresses to be responsible for the ejection of dust. No gas is spectroscopically detected (limiting the gas mass-loss rate to <1.8 kg s{sup −1}). However, the protracted emission of dust seen in our data and the detection of another episode of dust release near perihelion, in archival observations from 2003, are highly suggestive of an origin by the sublimation of ice. Coincidentally, the orbit of 313P/Gibbs is similar to those of several active asteroids independently suspected to be ice sublimators, including P/2012 T1, 238P/Read, and 133P/Elst–Pizarro, suggesting that ice is abundant in the outer asteroid belt.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

Design improvements to cables and connectors in the Majorana Demonstrator

The Majorana Demonstrator is an experiment constructed to search for neutrinoless double-beta decays in germanium-76 and to demonstrate the feasibility to deploy a ton-scale experiment in a phased and modular fashion. It consists of two modular arrays of natural and 76 Ge-enriched germanium p-type point contact detectors totaling 44.1 kg, located at the 4850 level of the Sanford Underground Research Facility in Lead, South Dakota, USA. The Demonstrator uses custom high voltage cables to bias the detectors, as well as custom signal cables and connectors to read out the charge deposited at the point contact of each detector. These low-mass cables and connectors must meet stringent radio purity requirements while being subjected to thermal and mechanical stress. A number of issues have been identified with the currently installed cables and connectors. An improved set of cables and connectors for the Majorana Demonstrator are being developed with the aim of increasing their overall reliability and connectivity. In conclusion, we will discuss some of the issues encountered with the current cables and connectors as well as our improved designs and their initial performance.

42 ENGINEERING↗
DOE OSTI2021

Ensemble Learning, Prediction and Li-Ion Cell Charging Cycle Divergence

In recent years, the pervasive use of lithium ion (Li-ion) batteries in applications such as cell phones, laptop computers, electric vehicles, and grid energy storage systems has prompted the development of specialized battery management systems (BMS). The primary goal of a BMS is to maintain a reliable and safe battery power source while maximizing the calendar life and performance of the cells. To maintain safe operation, a BMS should be programmed to minimize degradation and prevent damage to a Li-ion cell, which can lead to thermal runaway. Cell damage can occur over time if a BMS is not properly configured to avoid overcharging and discharging. To prevent cell damage, efficient and accurate cell charging cycle characteristics algorithms must be employed. In this paper, computationally efficient and accurate ensemble learning algorithms capable of detecting Li-ion cell charging irregularities are described. Additionally, it is shown using machine and deep learning that it is possible to accurately and efficiently detect when a cell has experienced thermal and electrical stress due to cell overcharging by measuring charging cycle divergence.

25 ENERGY STORAGE↗
DOE OSTI2021

Computational Modeling of Photovoltaic Mini-Modules Undergoing Accelerated Stress Testing

A finite element model of a four-cell photovoltaic mini-module was developed and compared to experimental results from an accelerated stress test protocol in order to validate that computational models can accurately represent their physical counterparts when subjected to mechanical loading and to assess mini-module representativeness against full scale photovoltaic modules. Deflected shapes across the simulated mini-modules were compared to measured mini-module shapes when subjected to various pressure loads. Displaced mini-module shape results constrained to the experimental protocols of 0.4 mm and 1.1 mm of displacement at the mini-module center were compared to experimental results of full-size modules subjected to module qualification test load levels of 1.0 kPa and 2.4 kPa, to assess if the bending of mini-modules was representative of full-sized modules under the load. Temperature cycling was incorporated into the model to simulate the impacts of stress due to thermal expansion of the backsheet and cells. A preliminary uncertainty analysis was performed to show how variations in material properties and geometric parameters change the simulation results.

computational modeling↗
DOE OSTI2021

UV-Fluorescence Imaging of Silicon PV Modules After Outdoor Aging and Accelerated Stress Testing

Fast, non-destructive, outdoor-compatible methods for photovoltaic module characterization are essential for monitoring module quality without disrupting energy production. UV-fluorescence (UVF) imaging of the encapsulant layer can be used for crack detection in the field. We show that UVF patterns vary widely between modules and types of applied stress. We propose that combining accelerated stress testing (e.g. thermal cycling and damp heat) with field investigations can help build understanding of different types of UVF, which are formed and subsequently quenched at varying rates. Ultimately, such understanding could enable estimating when cracks were formed.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2019

Bond Wire Damage Detection and SOH Estimation of a Dual Pack IGBT Power Module using Active Power Cycling and Reflectometry

High thermal and electrical stress, over a period of time tends to cause deterioration of the health of power electronic switches. A huge fraction of research efforts involves the study of power electronic device reliability and development of novel techniques with higher accuracy in health estimation of such devices. Until today, no other existing techniques can determine the number of lifted bond wires and their locations in a live IGBT module. Through this paper, a new method for online condition monitoring of IGBTs and IGBT modules using SSTDR has been proposed. Unlike traditional methods, this research work concentrates at the gate terminals of the device instead of looking at the collector side. In addition, the RL-equivalent circuit to represent a bond wire has been developed for the DUT and simulated in CST Studio Suite to measure the reflection amplitudes. Both the experimental and simulation results have been compared. These results prove that a single measurement is sufficient to predict the failure of the device instead of looking at the traditional precursor parameter. With only two sets of measurements, it is possible to locate the aged device inside a module and detect the number of bond wire lift offs associated to that device.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

Vibrational spectroscopy analysis of silica and silicate glass networks

Vibrational spectroscopy has been widely used to investigate various structural aspects of the glass network, and there are a plethora of papers reporting subtle but consistent changes in infrared and Raman spectral features of glass upon alterations of glass compositions, thermal histories, mechanical stresses, or surface treatments. However, interpretations of such spectral features are still obscured due to the lack of well-established physical principles accurately describing vibrational modes of the non-crystalline glass network. Due to the non-equilibrium nature of the glass network, three-dimensionally connected without any long-range orders, vibrational spectral features of glass cannot be interpreted using the analogy with those of isolated molecular moieties or crystalline counterparts. Here, this feature article explains why such comparisons are outdated and describes the recent advances made from theoretical calculations of vibrational spectral features of amorphous networks or comparisons of computational results with experimental data. For the interpretation of vibrational spectral features of silica and silicate glasses, the following empirical relationships are suggested: (i) the intensity-weighted peak position of the Si-O-Si stretch mode negatively correlates with the weighted average of the Si-O bond length distribution, and (ii) the broad band of the Si-O-Si bending mode negatively correlates with the Si-O-Si bond angle distribution. Selected examples of vibrational spectroscopic imaging of surface defects are discussed to deliberate the implication of these findings in the structure-property relationship of silica and silicate glass materials. Unanswered questions and continuing research challenges are identified.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Evaluating the Influence of Rotor-Casing Eccentricity on Turbine Efficiency Including Time-Resolved Flow Field Measurements

Abstract The clearance that exists between the casing and turbine blade tips is one of the key drivers of efficiency in gas turbine engines. For this reason, engine manufacturers utilize precise manufacturing techniques and may use clearance control systems to minimize tip clearances to reduce associated losses. Despite these efforts, turbines typically exhibit some nominal casing ovality or rotor-casing eccentricity, and changes to blade tip clearance during operation commonly occur due to thermal and mechanical stresses. The present study investigates non-axisymmetric tip clearance effects by creating a rotor-casing eccentricity in a one-stage axial test turbine operating in a continuous-duration mode at engine-relevant conditions with engine representative hardware. A magnetic levitation bearing system was leveraged to move the turbine shaft to vary the rotor-casing eccentricity without test section disassembly. The results of this study indicate that rotor-casing eccentricity does not affect overall turbine efficiency over the range that was tested, but does locally influence efficiency and the rotor exit flow field. Comparisons of flow angle and secondary flow kinetic energy (SKE) agreed with previous studies and existing analytical methods, respectively. Collectively, these results indicate that tip clearance can be studied locally on an eccentric rotor.

Engineering↗