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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 1,765 records · Page 98
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Rapid and Low Temperature Densification of Gadolinia Doped Ceria Barrier Layers by Photonic Curing

Nanohmics successfully demonstrated the viability of photonic sintering as a method to form densified gadolina doped ceria (GDC) barrier layers. Photonic sintering utilizes short pulses (millisecond regime) of broad spectrum light from a xenon flash lamp to convert densely packed nanoparticle thin films to bulk films through the absorption of optical energy and its subsequent conversion to heat; this results in grain ripening and/or melt and reflow the particles. The transformation of GDC nanoparticle thin films to bulk materials was accomplished by formulating various GDC nanoparticle “inks”, spin casting or tape casting these inks onto yttria stabilized zirconia (YSZ) substrates, brief low temperature (~700°C) bake outs to remove organic binders/plastisizers, and photonically sintering these substrates with a variety of conditions and sintering aids.

03 NATURAL GAS↗
DOE OSTI2016

Benefits of Hot Isostatic Pressure/Powdered Metal (HIP/PM) and Additive Manufacturing (AM) To Fabricate Advanced Energy System Components

Advanced Energy systems require large, complex components produced from materials capable of withstanding severe operating environments (high temperature, pressure, corrosivity). Such parts can be difficult to source, as conventional material processing technologies must be tailored to ensure a safe and cost effective approach to large-scale manufacture of quality structural advanced alloy components that meet the performance specifications of AE systems. (HIP/PM) has shown advantages over other manufacturing methods when working with these materials. For example, using HIP’ing in lieu of casting means significant savings in raw material costs, which for expensive, high-nickel alloys can be considerable for large-scale production. Use of HIP/PM also eliminates the difficulties resulting from reactivity of these materials in the molten state and facilitates manufacture of the large size requirements of the AE industry, producing a part that is defect and porosity free, thus further reducing or eliminating time and expense of post processing machining and weld repair. New advances in Additive Manufacturing (AM) techniques make it possible to further expand the benefits of HIP/PM in producing AE system components to create an even more robust manufacturing approach. Traditional techniques of welding and forming sheet metal to produce the HIP canisters can be time consuming and costly, with limitations on the complexity of part which can be achieved. A key benefit of AM is the freedom of design that it offers, so use of AM could overcome such challenges, ultimately enabling redesign of complete energy systems. A critical step toward this goal is material characterization of the required advanced alloys, for use in AM. Using Haynes 282, a high nickel alloy of interest to the Fossil Energy community, particularly for Advanced-UltraSuperCritical (AUSC) operating environments, as well as the crosscutting interests of the aerospace, defense and medical markets, this research pursued three new methods of manufacturing these advanced alloys: 1) Directly built AM parts; 2) AM cans for HIP/PM; and 3) AM cans produced in the final part material. The project utilized Carpenter atomized A-282 in varied mesh sizes customized for both AM and HIP, ExOne’s binderjet technology, the fastest metal 3D printing technique on the market at the current time, coupled with an alloy specific sintering profile to produce a sufficiently dense part for final HIP by Bodycote. Final parts were subjected to chemical and physical property tests and results were compared to published and gathered data. Chemistry results for all the parts were within the published criteria. Furthermore, the AM and HIP/PM parts showed measurable improvement over previous A282 HIP/PM results, in part due to an improved HT spec, and a marked improvement over results from A282 castings. These results indicate that combining AM and HIP/PM in the manner set forth in this project provides a credible manufacturing approach of these activities are set forth in this Final Technical Report.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

Manufacturing Nondestructive Evaluation Final Report CRADA No. TC-0351-92

The goaI of this project is the design, test, and fielding of automated NDE systems throughout the KTC. In the casting plant, activities were divided into four tasks i) development of quantitative tools for calculating measures of porosity by area from digital radiographic (DR) images, ii) upgrade of existing digital radiographic equipment (non-functional in 1995), iii) design and fielding of an on-the-floor unit capable of digital radiography for aluminum parts as an unattended “baggage scanner” (working with VIJAY technologies on this effort), and iv) connecting digital radiographic results to a central database which includes shot profiles, die temps, and metal temps from the pressure die casting machines.

36 MATERIALS SCIENCE↗
DOE OSTI2018

FY2017 Materials Annual Progress Report

The Materials Technology subprogram supports the Vehicle Technology Office’s mission to help consumers and businesses reduce their transportation energy costs while meeting or exceeding vehicle performance expectations. The Propulsion Materials research portfolio seeks to develop higher performance materials that can withstand increasingly extreme environments and address the future properties needs of a variety of high efficiency powertrain types, sizes, fueling concepts, and combustion modes. Advanced Lightweight Materials research enables improvements in fuel economy by providing properties that are equal to or better than traditional materials at a lower weight. Because it takes less energy to accelerate a lighter object, replacing cast iron and traditional steel components with lightweight materials such as high-strength steel, magnesium (Mg), aluminum (Al), and polymer composites can directly reduce a vehicle’s fuel consumption. Materials technology activities focus on the following cost and performance targets: (1) enable a 25 percent weight reduction for light-duty vehicles including body, chassis, and interior as compared to a 2012 baseline at no more than a $5/lb-saved increase in cost; and (2) validate a 25 percent improvement in high temperature (300°C) component strength relative to components made with 2010 baseline cast Al alloys (A319 or A356) for improved efficiency light-duty engines.

36 MATERIALS SCIENCE↗
DOE OSTI2017

U-10Mo Mechanical Property Study Results

A uranium-10wt% molybdenum billet was cast using a vacuum induction meting furnace. The uranium was retrieved from ZPPR stockpiles and had previously been coated with a polymeric coating to prevent oxidation. The coating was removed by mechanically removing the exterior surfaces. After casting total carbon analysis, tensile testing, and microstructural testing was performed. Based on the characterization results ZPPR stockpile depleted uranium can be used as a source of depleted uranium if all coating materials are fully removed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Fabrication of Enhanced Pinch Weld Electrodes

Savannah River Site uses brazed copper / tungsten electrodes for a specialized weld referred to as a pinch weld. As part of an internally funded PDRD program, an alternative method to produce the pinch weld electrodes was sought to improve quality and to reduce the manufacturing steps. Back casting of pinch weld electrodes was selected as such a process. During preliminary testing, deformation of the electrodes was observed. A failure analysis was conducted, and the strength of the electrodes was found to be significantly less than required to enable welding of the tubes. This assessment includes compression testing metallographic analysis. The pinch weld electrodes fabricated by back casting do not meet the requirements with respect to strength. In addition, a minimum strength requirement for conventionally prepared electrodes is recommended.

42 ENGINEERING↗
DOE OSTI2018

Low Density Gold Nanowire Aerogels: Synthetic Control through Ligand Exchange

Gold nanowire aerogels have been formed through freeze casting aqueous suspensions of high quality gold nanowires (AuNW). Since the properties of the final aerogel are highly dependent upon the freeze casting conditions, moving from aqueous to organic suspensions would open a new parameter space for optimization of aerogel properties and processing conditions. In this study, the surface chemistry of gold nanowires was modified through ligand exchange in order to improve their colloidal stability in nonpolar organic solvents.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Density of U-10wt%Zr Materials

There is very little information published concerning the density of U-Zr alloys (uranium-rich). The following information presents a portion of what has been published, as well as additional information recorded by Argonne National Laboratory-West while casting U-10Zr fuel for use in the Experimental Breeder Reactor-II. The fuel was injection-cast into ZrO 2 -coated quartz molds, quenching the molten fuel alloy very quickly. The fuel was produced to specifications in which mass/weight, diameter, and length of the fuel slugs were all controlled. Density was not controlled.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Uranium Annealing Analysis

This report describes tests completed at INL on depleted uranium samples of surplus shield block from the Zero Power Physics Reactor (ZPPR). Tests involved annealing individual samples in molten salt for periods ranging from 30 minutes to 4 hours, with variations on conditions as described in the report. Some samples were also left as cast. After annealing, samples were cooled either in water or air. Annealing and as-cast samples were measured and analyzed for hardness, oxide layer, and rind thickness.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Enhancement of Structural Health Monitoring Framework by Optimizing Vibro-Acoustic Modulation Technique to Localize Alkali-Silica Reaction Degradation in Medium-Sized Concrete Samples

Assessment and management of aging concrete structures in nuclear power plants require a more systematic approach than simple reliance on existing code margins of safety. Health monitoring of concrete structures is performed to understand the current condition of a structure based on heterogeneous measurements and then produce high confidence actionable information regarding structural integrity. This information can then be used to support operational and maintenance decisions. The objectives of this ongoing research project focus on health monitoring and data analytics of concrete slabs containing reactive aggregates and thus subjected to degradation due to alkali-silica reaction (ASR). A controlled concrete slab with four pockets of reactive aggregates (pure silica, wells, placitas, and spratt) was cast at Vanderbilt University and cured in representative conditions to accelerate degradation due to ASR. A set of four concrete samples were also cast and cured at the University of Alabama for ASR testing. Of these four samples, two slabs contained reactive aggregates while the other two had the non-reactive aggregate counterparts mixed throughout the samples. Vibro-acoustic methods were used on these slabs to locate large pockets of ASR within the reactive samples and determine the effects of rebar using the non-reactive slabs. Vibro-acoustic modulation (VAM) is a vibration-based NDE method that utilizes signatures of nonlinear dynamic interactions on contact surfaces of crack or delamination damage to detect and localize the damage. VAM analysis was conducted on both Vanderbilt and Alabama’s samples using multiple variables for damage detection and localization. The results from the data analysis of the NDE vibro-acoustic techniques on concrete slabs cured at Vanderbilt University and the University of Alabama are discussed in detail in this report. The major outcome of the analysis suggests that the VAM method can be used to detect damage within the concrete samples by comparing the results found in different sections of the samples. Results for damage localization are dependent on multiple variables used in the vibro-acoustic modulation experiments. Digital image correlation (DIC) is a three-dimensional, full-field, optical NDE technique to measure contour, deformation, vibration, and strain. The application of the digital image correlation technique to study ASR-related degradation on a large concrete sample at the University of Tennessee Knoxville is discussed and observations are presented in this report.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2018

Uncertainty Quantification in Vibro-Acoustics Diagnosis of Alkali-Silica Reaction Degradation in Medium-Sized Concrete Samples

The objectives of this ongoing research project focus on health monitoring and data analytics of concrete slabs containing reactive aggregates and thus subjected to degradation due to alkali-silica reaction (ASR). A controlled concrete slab with four pockets of reactive aggregates (pure silica, wells, placitas, and spratt) was cast at Vanderbilt University and cured in representative conditions to accelerate degradation due to ASR. A set of four concrete samples were also cast and cured at the University of Alabama for ASR testing. Of these four samples, two slabs contained reactive aggregates while the other two had the non-reactive aggregate counterparts mixed throughout the samples. Vibro-acoustic testing was used on these slabs to locate ASR damage within the reactive samples. Vibro-acoustic modulation (VAM) is a vibration-based NDE method that utilizes signatures of nonlinear dynamic interactions on contact surfaces of crack or delamination damage to detect and localize the damage. VAM analysis was conducted on both the Vanderbilt and Alabama samples using multiple variables for damage detection and localization. The results from the data analysis of the vibro-acoustic testing on concrete slabs cured at Vanderbilt University and the University of Alabama are discussed in detail in this report. Results for damage localization are dependent on multiple variables used in the vibro-acoustic modulation experiments. A major focus of this report is to quantify the uncertainty in the diagnosis due to multiple factors and uncertainty sources. The uncertainty quantification methodology presented in this report was applied to VAM-based diagnosis and prognosis. However, the methodology is general, and is capable of being applied to multiple technique that collect spatially distributed data. Future work needs to investigate the incorporation of uncertainty quantification in developing a robust Prognostics and Health Management framework. Digital image correlation is a three-dimensional, full-field, optical NDE technique to measure contour, deformation, vibration, and strain. The application of the digital image correlation technique to study ASR-related degradation on a large concrete specimen at the University of Tennessee is discussed and observations are presented in this report.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2019

Characterization of Covetic Materials for Process Control. Final CRADA report

GDC Industries LLC has been performing process research on covetic materials since its formation in February 2015. With assistance from DOE and the Air Force via SBIR projects, GDC focused on the enhancement of aluminum alloys to covetics to replicate a previously reported electrical conductivity of about 67% IACS (International Annealed Copper Standard). GDC has established a joint development agreement with General Cable Corporation, wherein General Cable agreed to perform numerous extrusions of as cast covetics and subsequent tensile and electrical conductivity tests on the resultant wire. Covetics conversion was proven but the significant improvement is yet to be replicated. To control the experiments towards enhanced process control, a series of designed experiments was created by an expert in process control from the automotive industry. Six process variables were identified and a designed experiment matrix requiring 18 independent conversions was created at GDC. The result of those designed experiments has now allowed GDC to focus on two process variables, namely, residence time and DC current in the conversions with the other four variable held constant. While this work is useful in replicating the earlier enhancements, GDC feels it will not be sufficient for the necessary process knowhow for scale up required by industry as GDC still does not have a direct correlation of the process variables to the actual carbon in the finished covetics. Since 2015, GDC has been aware of the capabilities existing at Argonne National Laboratory for performing carbon analysis that exceeds the precision commonly available to Industry. GDC and ANL submitted a proposal in response to the DOE-EERE – Small Business Vouchers Pliot Program announcement and the proposal was selected for funding. GDC will melt-process covetic aluminum samples following their design of experiment criteria and have the as-casted samples extruded by their partner, General Cable. Argonne will measure the conductivity, analyze carbon content, perform X-ray diffraction, and examine the microstructural features of the samples. Careful process variable measurements will be recorded by each party such that correlations can be developed indicating process parameters that yield the best carbon concentration in covetics.

36 MATERIALS SCIENCE↗
DOE OSTI2018

HIGH-STRENGTH LIGHTWEIGHT ENGINES FOR HEAVY-DUTY DIESEL TRUCKS

This project with Cummins supports the development of next generation heavy duty diesel engines that can achieve a 50% or better Break Thermal Efficiency (BTE). The fuel efficiency roadmap for the 50% BTE engine considers six main areas for efficiency improvement in the baseline engine, several of which involve making more efficient use of thermal energy (heat) in the engine. Increased operating temperatures and improved thermal management are expected to enable significant increases in $power$ $density$, thus resulting in greater power output for the same sized engine or engine downsizing (or light weighting) for the same power output. However, it has become apparent that several key components will be exposed to temperatures beyond the capabilities of current engine and exhaust materials, requiring the availability of the next generation of high temperature materials to allow the engine to reach the targeted efficiencies, commercially viable durability, and emission targets. The objective of this project was to identify and/or develop key materials, and evaluate their critical properties to enable the design and development of a lightweight, higher efficiency engine, with enhanced temperature capability and reduced heat-loss to the atmosphere in order to facilitate waste heat recovery and improved efficiency. An increase in the temperature capability of exhaust manifold materials, and piston materials were identified as having a positive influence on the efficiency of the next generation diesel engines. Since the current materials (High SiMo cast irons used in exhaust manifolds, and 4140 steel in pistons) are already operating near their limits of their temperature and strength capabilities, it was determined that new materials with the right combination of properties are required for these components. Oxidation and constrained thermal fatigue tests were used to down-select CF8C plus (CF8CP), a cast austenitic stainless steel, for exhaust manifolds capable of operating at higher temperatures. A prototype exhaust manifold was fabricated using CF8CP and successfully tested in a marine engine. A functionally graded multiple-layer thermal barrier coating system was designed with four layers of mixed bondcoat alloy (NiCoCrAlYHfSi) and yttria stabilized zirconia (YSZ) and was shown to reduce the effective thermal conductivity of the coating-substrate (steel and Ti-6Al-4V) system. The graded alloy and YSZ mixture were intended to achieve better match of thermal expansion coefficient (CTE) and minimize thermal stresses. Such coatings can increase the temperature capability of pistons fabricated from steel and Ti-alloys. Effect of oil additives and friction conformal contact friction tests showed there was a 15-30% reduction in friction by the polymer-graphite composite coating compared to the uncoated steel piston. Standalone Mn-P coating had little beneficial impact. Changing the oil from CJ-4 to PC-11 had little impact on the friction behavior in boundary lubrication. Wear behavior was tested under a point contact configuration with a high contact pressure. The candidate CK-4 oil showed similar or slightly better lubricity compared to the CJ-4 oil while the candidate FA-4 oil decisively increased the piston skirt wear. Although both coatings prevented scuffing failure observed for the uncoated steel skirt in a base oil without an additive package, they surprisingly caused a higher piston wear rate when tested in any of the fully formulated engine oil. The detrimental impact was attributed to the Mn-P film, either as a standalone coating, or a coating interlayer. The porous and brittle Mn-P film was broken during the wear test and the released hard Mn-P grains are suspected to cause third-body abrasion to accelerate the wear process. This work also evaluated the feasibility of developing an improved high temperature, low mass, cost-neutral turbocharger compressor wheel for heavy-duty engine applications from TiAl using additive manufacturing, utilizing its unique ability to fabricate high strength, low weight structures. This work has shown that the phase transforming nature of the TiAl alloys enable obtaining equiaxed microstructures in the as-built state without the need for tedious beam parameter manipulations. The HIPed structures have good RT tensile properties that will enable them to be surface machined to the required tolerance that can 2 then be heat treated to obtain the desired microstructures. Additionally, the negligible residual stresses stemming from the high build chamber temperatures ensure the parts are formed without cracks (one of the major issues in traditional manufacturing of these intermetallics).

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2019

Materials 2018 Annual Progress Report

The Materials Technology Program supports the Vehicles Technologies Office’s mission to help consumers and businesses reduce their transportation energy costs while meeting or exceeding vehicle performance expectations. The propulsion materials research portfolio seeks to develop higher performance materials that can withstand increasingly extreme environments and address the future properties needs of a variety of high-efficiency powertrain types, sizes, fueling concepts, and combustion modes. Advanced lightweight materials enable improvements in fuel economy by providing properties that are equal to or better than traditional materials at a lower weight. Because it takes less energy to accelerate a lighter object, replacing cast-iron and traditional steel components with lightweight materials such as high-strength steel, magnesium (Mg), aluminum (Al), and polymer composites can directly reduce a vehicle’s fuel consumption. Materials technology activities focus on the following cost and performance targets: (1) enable a 25% weight reduction for light-duty (LD) vehicles including body, chassis, and interior as compared to a model year 2012 baseline at no more than a $\$$5/lb-saved increase in cost; and (2) validate a 25% improvement in high-temperature (300°C) development of engine exhaust catalyst materials strength relative to components made with 2010 baseline cast Al alloys (A319 or A356) for improved efficiency LD engines.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2019

Investigation of the impact of particle size on properties and applications of a ceramic slurry

Importance of ceramics, therefore important to optimize resin for various apps. Additive content and ceramic loading is important but so it particle size. Eg rheology and cure depth (equation). Introduce applications: tape casting and PuSL. Ceramic materials have a wide array of applications due to their desirable properties such as chemical resistance, low thermal conductivity, and mechanical toughness. Ceramics are typically manufactured by combining a ceramic nanoparticle with some combination of binders and additives, shaping the slurry using methods such as tape casting and additive manufacturing, and heating to remove the organic components and sinter the ceramic particles together. Optimizing the slurry is an important step for being able to shape it and apply appropriate heat treatment.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Development and Characterization of Cementitious Waste Forms for Immobilization of Granular Activated Carbon, Silver Mordenite, and HEPA Filter Media Solid Secondary Waste

Solid secondary waste materials expected to be generated during Hanford Waste Treatment and Immobilization Plant (WTP) operations were characterized (using representative materials) with respect to their ability to retain technetium-99 (Tc), iodine-129 (I), and mercury (Hg) as input to future updates to the Integrated Disposal Facility (IDF) performance assessments (PAs). The waste materials included granular activated carbon (GAC), silver mordenite (AgM), and high-efficiency particulate air (HEPA) filter media; all are used for removal of contaminants and radionuclides from the gaseous effluent treatment systems within the WTP. It is expected that the GAC and AgM will be mixed into a cementitious waste form in which the GAC and AgM particles will be blended/stabilized into the cementitious material. It is also expected that the HEPA filter media will be compacted and placed in a container that is then backfilled with a grout to macroencapsulate the medium. Here we report Kds for all waste materials of interest, examine the physical properties of grout specimens containing the waste materials, and provide solid-state characterization information to further understand the interaction of the waste materials with the encapsulating grout. The Kds are used in PA calculations that estimate contaminant release from the disposal site. Monolithic test specimens were prepared with the GAC and AgM mixed in either a Cast Stone grout formulation (8 weight percent [wt%] ordinary Portland cement [OPC], 45 wt% fly ash [FA], 47 wt% blast furnace slag [BFS]) or a Hanford grout mix 5 (HGM-5) formulation (25 wt% OPC, 75 wt% FA). As the specimens were being prepared, the fluid grout mixes were characterized for processing properties including flowability, set time, and the presence of free liquids during curing. After curing, compressive strengths of the waste forms were measured; the compressive strengths were above 2000 psi, easily exceeding the 500 psi minimum requirement. The cured waste forms were also characterized for their density, porosity, hydraulic conductivity, and water characteristic curve—all properties needed in PA calculations of radionuclide release from the waste forms in the IDF. Finally, EPA Method 1315 leach tests were conducted on the GAC and AgM waste materials encapsulated in the Cast Stone and HGM-5 grouts to determine the rate of release of contaminants from the waste forms. Effective diffusivities are provided, which can be used in future PA analyses of the disposal of these solid secondary waste materials.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Alloying titanium and niobium via electron beam cold hearth melting

Electron beam cold hearth melting of titanium and niobium was performed to assess the feasibility of this technique for uranium processing and to determine system requirements for LLNL applications. The demonstration consisted of (1) alloying titanium and niobium, (2) feeding and melting scrap of various forms and (3) consolidating powder feedstock. Emphasis was placed on the former, with focused efforts to produce and deliver stoichiometric amounts of titanium and niobium to the hearth for alloying. This effort demonstrated the ability to melt via electron beam and cast titanium into a thin-walled (~0.06”) niobium tube. This process was performed repeatably and an optimal set of operational parameters was identified through an iterative approach. Three alloyed ingots were produced using niobium tubes filled with titanium, by casting and slip-fit. The alloyed ingots were characterized using multiple approaches and were shown to be comprised of columnar grains, low inclusion amounts and a small degree of ordered (center to edge, top to bottom) variation in niobium concentration. Based on these findings, it is concluded that alloying can be accomplished in a single step, without the need for an additional melting step after electron beam cold hearth melting. Details of these analyses, along with efforts to adopt cold hearth melting technology for scrap and powder recycle are provided herein.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

GRMAG-1-12-360 Core, Revision 2 [Datasheet]

The GRMAG-1-12-360 tape-wound core is manufactured with a custom iron-based metal amorphous nanocomposite. NASA Glenn Research Center (GRC) cast and fabricated the core. The ribbon is cast in a standard 1” / 25 mm wide ribbon width and annealed with a transverse field for a square BH loop. While targeting a 10 kW, 20 kHz three port active bridge application this core material can generally be used for transformers, pulse power cores, motors, and high frequency inductors. The 12 and 360 in the name specify the Bsat in T*10 and the low frequency permeability divided by 100, respectively.

24 POWER TRANSMISSION AND DISTRIBUTION↗