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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Development of an Extremely Durable Concrete (EDC) - A Novel approach coupling Chemistry and Autogenous Crack Width Control (Final Report)

Concrete cracking is a challenging issue and a constant threat to the durability of modern physical infrastructure. It is most commonly produced by mechanical loading and environmental deformations endured under field conditions, and structural deterioration accelerates at large crack widths. There is an urgent need for dramatic reductions in O&M cost, energy use, and emissions for infrastructure. The goal of this project is to fundamentally design an Extremely Durable Concrete (EDC) with a life expectancy at least five times that of current concrete by deploying a coupled micromechanical and chemical approach in material design. EDC is expected to embody an autogenously tight crack width (<50μm), high ductility (>3%), and stable chemistry using a green binder based on Limestone Calcined Clay Cement (LC3), which together will produce a resilient formulation with self-healing capability.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Crack width control and mechanical properties of low carbon engineered cementitious composites (ECC)

Engineered Cementitious Composites (ECC) have superior properties with high tensile ductility and tight crack width compared to conventional concrete. The properties of ECC are significantly influenced by the material composition which can be tailored to enhance the sustainability of ECC. Towards this goal, recycled crumb rubber (CR) and silica fume (SF) were used to tailor the properties of a polypropylene-fiber reinforced ECC with a low carbon binder based on limestone calcined clay cement (LC3) in this study. Crumb rubber was found to be effective in enhancing strain-hardening performance and reducing the width of the multiple microcracks. However, a loss of compressive strength was accompanied by an increasing amount of CR. While silica fume or lower w/b ratio enhanced the compressive strength, the crack width of ECC increased at higher SF content or lower w/b. The underlying mechanisms of these trends were traced to the alteration of the matrix fracture toughness and fiber/matrix interfacial bond. Rubber particle bridging was found to contribute to crack width control. Finally, the combined use of the LC3 green binder and CR led to a lowering of the embodied and operational carbon footprint of ECC.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Seawater sea-sand engineered/strain-hardening cementitious composites (ECC/SHCC): Assessment and modeling of crack characteristics

Highlights: • A probabilistic model was proposed to model the crack width evolution of SS-ECC at different strain levels. • The Weibull distribution fit the crack width distribution better than the log-normal distribution. • A 5-D representation was proposed to assess the SS-ECC by considering both cracking and mechanical performance. • Larger sea-sand size and lower fiber dosage led to larger crack widths in SS-ECC under the same tensile strain. • 18-mm PE fiber led to larger crack widths in SS-ECC at strain >2%, due to a large fraction of fiber rupture. Seawater sea-sand Engineered Cementitious Composites (SS-ECC) is a new version of ECC for marine constructions facing the scarcity of freshwater and river/manufactured sand. This study aims to assess and model the crack characteristics of SS-ECC, which are critical for its applications with non-corrosive reinforcements. The influence of sea-sand size, fiber length and fiber dosage on the crack characteristics of SS-ECC was explored. A five-dimensional representation was proposed to assess the overall performance of SS-ECC, by comprehensively considering both the crack characteristics (i.e., crack width and its variation) and the mechanical properties (i.e., compressive and tensile properties). A probabilistic model was also proposed to describe the stochastic nature and evolution of crack width, and it can be used to estimate the critical tensile strain on SS-ECC for a given crack-width limit and cumulative probability. The findings and proposed methods can facilitate the design of SS-ECC in marine and coastal structures.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Material processing, microstructure, and composite properties of low carbon Engineered Cementitious Composites (ECC)

Traditional PVA fiber-reinforced Engineered Cementitious Composites (ECC) show high tensile ductility and superior durability with tight crack width, but the high cost and embodied carbon can hinder its wider application in infrastructures. The objective of this study is to develop a better understanding of the fresh and hardened properties of an ECC that employs a lower embodied-carbon binder, Limestone Calcined Clay Cement (LC3), and lower-cost PP fiber that is widely available. Specifically, the interrelations between material processing, microstructure, and composite properties were studied experimentally. The results showed that ECC with high tensile ductility up to 9% tensile strain and tight crack width with 50 μm at 2% tensile strain can be achieved. It was found that a matrix paste with higher viscosity generally enhanced fiber dispersion uniformity and robustness in tensile strain-hardening. The paste viscosity is increased when OPC is replaced by LC3 and can be tuned with superplasticizer content. Larger maximum flaw size leads to lower first crack strength, beneficial for microcrack initiation and multiple cracking. This study generates fundamental knowledge linking processing-microstructure-performance of PP-LC3-ECC. This class of low embodied carbon ECC with tight crack width is expected to contribute to reducing the carbon footprint of the built environment.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The Impact of Carbonation Curing on the Fatigue Behavior of Polyvinyl Alcohol Engineered Cementitious Composites (PVA-ECC)

Use of Engineered Cementitious Composites (ECC) has been proven to enhance structural fatigue resistance and reduce the use-phase emissions for transportation infrastructure. Carbonation curing offers an opportunity to reduce the embodied carbon of ECC via direct CO 2 sequestration. In this study, the impact of carbonation curing on ECC’s fatigue resistance was examined. ECC’s CO 2 uptake, static flexural behavior, flexural fatigue performance, and single fiber pull-out behavior were studied experimentally. Midspan deflection up to 3 million cycles under fatigue load, fatigue stress-life relationship, and failure mechanism for carbonation-cured and air-cured ECC were investigated. Carbonation curing was found to significantly improved the fatigue life of ECC and lowered the midspan deflection under the same stress. Further, CO 2 -cured ECC can achieve >20% CO 2 uptake per cement mass after 24-hour carbonation curing. Carbonation curing increased ECC’s flexural strength by 32% and promoted crack width control capability, with maximum post-fatigue crack width reduced from 148 μm to 76 μm. As a result, the positive impact of carbonation curing on the fatigue behavior of ECC simultaneously lowers the embodied and operational carbon of ECC structural members subjected to fatigue loading during service.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Engineered Cementitious Composites (ECC) with limestone calcined clay cement (LC 3 )

Recent research have recognized that coupled use of calcined clay, limestone and cement clinker in concrete is viable to reduce environmental footprints at manufacture and to enhance material durability. In this study, a novel application of the limestone calcined clay cement (LC 3 ) is demonstrated by substituting the Ordinary Portland Cement (OPC) in Engineered Cementitious Composites (ECC). The composite mechanical properties including σ-δ and σ-ε relationships and residual crack widths were evaluated to 28 days under uniaxial tension. Matrix chemistry was characterized using thermogravimetric analysis and X-ray diffraction, while the pore structure of matrices and composites was analyzed using mercury intrusion porosimetry. The LC 3 -based ECC showed more rapid early strength development but lower 28-day strength (~32 MPa) due to a 20% higher water-to-solid ratio for attaining adequate workability and fiber dispersion. Nevertheless, the tensile strain capacity of LC 3 -based ECC achieved over 6% with an average residual crack width less than 50 μm. Additionally, the composite pore structure exhibited a decreasing volume fraction of large pores and voids (>100 nm) after substituting LC 3 for OPC. Here, the use of LC 3 marginally decreased the embodied material energy and cost, but led to about 32% and 28% reductions in CO 2 emissions compared to traditional OPC-based ECC and concrete, respectively. As a preliminary study, LC 3 -based ECC shows promise as a greener ductile concrete compared with OPC-based ECC.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Automatic identification and quantification of dense microcracks in high-performance fiber-reinforced cementitious composites through deep learning-based computer vision

Highlights: • A method is presented to detect, locate, quantify, and visualize dense microcracks in HPFRCC. • Quantification of dense microcracks is realized using deep learning method for the first time. • The presented method uses deep learning models that are trained using a realistic dataset size. • The presented method has a high computation efficiency for identifying and quantifying cracks. • The presented method provides crack width with errors up to 50 μm and a R{sup 2} value of 0.984. High-performance fiber-reinforced cementitious composites (HPFRCCs) feature high mechanical strengths, crack resistance, and durability. Under excessive loading, HPFRCCs demonstrate dense microcracks that are difficult to identify using existing methods. This study presents a computer vision method for identification, quantification, and visualization of microcracks in HPFRCCs based on deep learning. The presented method integrates multiple deep learning models and computer vision techniques in a hierarchical architecture. The crack pattern (e.g., number, width, and spacing of cracks) are automatically determined from pictures without human intervention. This study shows that the presented method achieves an accuracy of 0.992 for crack detection and an accuracy finer than 50 μm (R{sup 2} > 0.984) for quantification of crack width when deep learning models are trained using only 200 pictures of HPFRCCs and 200 pictures of conventional concrete with incorporation of data augmentation. The presented method is expected to be also applicable to other materials featuring complex cracks.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Mechanical behavior of carbonated MgO-based Engineered Cementitious Composite (ECC) after high temperatures exposure

Carbonated MgO-based Engineered Cementitious Composite (ECC) has ultrahigh tensile ductility and tight crack width control behavior. However, the expectation of improved fire-resistant has not been confirmed. This study explored the alterations to mechanical and microstructure characteristics of this material after exposure to temperatures up to 500 °C. Material mass loss, compressive strength, tensile strength, strain capacity, and matrix fracture toughness were measured. Scanning electron microscopy, mercury intrusion porosimetry, thermogravimetric analysis, and X-ray diffraction were used to probe the degradation of the cement matrix and fibers. The effect of elevated temperature on carbonated MgO-based ECC was further assessed via examination of the micromechanical behavior of the fiber-matrix. The objective of this research was to assess the performance of carbonated MgO-based ECC exposed to fire hazards. The tensile ductility of carbonated MgO-based ECC was found to be enhanced when exposed to ~100 °C as compared with those at room temperature ~20 °C. Further increase in exposure temperature, however, posed a negative impact on the composite compressive strength, ultimate tensile strength, and ability to control crack width. Here the results provide a useful database for further investigations into carbonated MgO-based ECC for fire safety enhancement.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fundamentals of Using Cracked Film Lithography to Pattern Transparent Conductive Metal Grids for Photovoltaics

The fundamentals of using cracked film lithography (CFL) to fabricate metal grids for transparent contacts in solar cells were studied. The underlying physics of drying-induced cracks were well-predicted by an empirical correlation relating crack spacing to capillary pressure. CFL is primarily controlled by varying the crack template thickness, which establishes a three-way tradeoff between the areal density of cracks, crack width, and spacing between cracks, which in turn determine final grid transmittance, grid sheet resistance, and the semiconductor resistance for a given solar cell. Since CFL uses a lift-off process, an additional constraint is that the metal thickness must be less than 1/3 of the crack template thickness. Furthermore, the transmittance/grid sheet resistance/wire spacing tradeoffs measured in this work were used to calculate solar cell performance: CFL-patterned grids should outperform screen-printed grids for narrow cells (0.5–2 cm wide) and/or cells with high semiconductor sheet resistance (=100 O/sq), making CFL attractive for monolithically integrated thin-film photovoltaic modules.

14 SOLAR ENERGY↗
DOE OSTI2024

Investigation of Debonding Effect in Internal Replacement Pipe System Under Lateral Loading

The aging pipeline infrastructure around the world necessitates immediate rehabilitation. Internal replacement pipe (IRP) is a trenchless system offering a versatile and cost-effective solution across a variety of industries, including oil, natural gas, water, and wastewater. As a structural pipeline repair system, IRPs are subject to lateral deformation because of surface traffic loading. The present study evaluates the impact of adhesion between the host pipe and the IRP, with a focus on assessing the debonding effect on the behavior of the repair system under lateral deformation and bending. This was achieved using a comprehensive approach, including experimental, numerical, and analytical techniques. Varying levels of adhesive strength resulting from different methods of surface preparation were considered. The effectiveness of the IRP system on both discontinuous host pipes with various crack widths and continuous host pipes was also investigated. The results demonstrate that adhesive strength exerts a significant influence on the repair system, especially in the case of narrow circumferential cracks, while its impact on the continuous system is minimal. For optimal performance, it is essential to choose adhesives that possess sufficient shear strength while also accounting for the required debonding length. This approach ensures that minor discontinuities are effectively controlled, thereby enhancing the system′s fatigue life. The reliable determination of the maximum allowable shear strength for the adhesive or the debonding length can ensure that it does not negatively affect fatigue life. The findings presented in this study offer new insights into the development of trenchless repair techniques that can enhance system performance and extend service life.

Tien, Tri C. M.↗
DOE OSTI2020

Impact of Laboratory-Accelerated Aging Methods to Study Alkali–Silica Reaction and Reinforcement Corrosion on the Properties of Concrete

This study focuses on two separate investigations of the main aging mechanisms: alkali–silica reactivity (ASR) and the corrosion of reinforcing steel (rebar) concrete, both of which may result in a premature failure to meet the serviceability or strength requirements of a concrete structure. However, these processes occur very slowly, spanning decades. The impact of direct chemical additives to fresh concrete to accelerate ASR and the corrosion of reinforcing steel on the fresh and hardened properties of the ensuing material are investigated to inform the potential use of chemicals in large-scale studies. The deterioration of reinforced concrete (RC) is determined by means of expansion, cracking, bulk diffusivity and surface resistivity measurements, and compressive, split tensile and flexural strength tests. The results indicate that the addition of sodium hydroxide and calcium chloride can effectively accelerate the crack formation and propagation in concrete due to ASR and the corrosion of rebar, respectively. The ASR-induced cracks maintained a constant crack width from 0.05 mm to 0.1 mm over the measurement period regardless of the intensity of aging acceleration. Adding 4% chloride by weight of cement for accelerating rebar corrosion resulted in an average crack that was 82% larger than in the case of ASR accelerated with the addition of sodium hydroxide. The addition of alkali resulted in an increase in early-age (7-day) strength. At a total alkali loading of 2.98 kg/m3, 3.84 kg/m3 and 5.57 kg/m3, the 28-day compressive strength of concrete decreased by 3%, 10% and 24%, respectively. Similarly, a higher early-age strength and a lower later-age strength was observed for the concrete in the presence of corrosive calcium chloride. The results from this research are expected to inform future studies on the long-term performance of RC structures under accelerated ASR and corrosion.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Quantifying the Impact of Charge Rate and Number of Cycles on Structural Degeneration of Li-Ion Battery Electrodes

A quantitative link between crack evolution in lithium-ion positive electrodes and the degrading performance on cells is not yet well established nor is any single technique capable of doing so widely available. Here, we demonstrate a widely accessible high-throughput approach to quantifying crack evolution within electrodes. The approach applies super-resolution scanning electron microscopy (SEM) imaging of cross-sectioned NMC532 electrodes, followed by segmentation and quantification of crack features. Crack properties such as crack intensity, crack width and length are quantified as a function of charge rate (1C, 6C, and 9C) and cycle number (25, 225, and 600 cycles). Hundreds of particles are characterized for statistical confidence in the quantitative crack measurements. The data on crack evolution is compared to electrochemical data from full cells and half cells with the NMC532 positive electrodes. We show that while crack evolution strongly correlates with capacity fade in the first 25 cycles, it does not correlate well for the following hundreds of cycles indicating that cracking may not be the dominant cause of capacity fade throughout the cycle-life of cells.

25 ENERGY STORAGE↗
DOE OSTI2024

The influence of electrode crack dimensions on the durability of polymer electrolyte membrane fuel cells

Electrode cracks in polymer electrolyte membrane fuel cells (PEMFCs) are correlated with early onset failures. Here, in this work we investigate the influence of cracked gas diffusion electrodes (GDEs) on the durability of the membrane electrode assembly (MEA) using a combined chemical-mechanical accelerated stress test (AST). Electrode crack dimensions were systematically tuned using ink formulations and material selection strategies. A parameter to describe the crack width areal density (Φ CW ) was used to quantify the degree of discontinuity in the electrode surfaces. Open circuit voltage (OCV) transient analyses were used to benchmark and characterize the failure mechanisms in the MEAs as a function of the Φ CW . While smaller electrode-level cracks, on the order of microns, yielded a 28 % decrease in operating lifetime, larger cracks that propagated from a discontinuous, microporous layer (MPL) coating, decreased the operating lifetime by 56 %. This work emphasizes the need for material processing strategies that consider defect tolerances to limit membrane failures in PEMFCs.

08 HYDROGEN↗
DOE OSTI2021

Mechanism of drying-induced change in the physical properties of concrete: A mesoscale simulation study

Although many studies have found that drying alters the mechanical properties of concrete, the mechanism behind this change remains unclarified. The aim of this study is to elucidate the mechanism of change in properties of concrete after drying through the numerical calculation: a 3D mesoscale rigid-body-spring model (RBSM) with three phases, i.e. mortar, aggregate, and the interfacial transition zone while considering the properties changes of mortar due to drying. Based on the RBSM results, it is concluded that the change in compressive strength due to drying and heating is determined by a balance of the impact of drying-induced microcracking around coarse aggregates and the change in mechanical properties of the mortar due to drying. These mechanisms change the applied load required to reach the critical crack width and distribution, at which rim of the specimen begins to isolate from the core region and the load sustained by the rim decreases.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Evolution of thermo-mechanical properties of concrete with calcium aluminate cement and special aggregates for energy storage

Highlights: • CAC Concrete with stable aggregates is suitable for high temperatures with cycles. • Concrete suffered performance changes after the first thermal cycle (dehydration). • Subsequent thermal cycles showed stabilization and slight performance decreases. With the ever-expanding presence of solar energy, the design of cost-efficient heat energy storage systems is becoming increasingly relevant. Concrete is a potential solid material for these systems but raises questions of its response at high temperatures in operating conditions. This work studies concrete designed with calcium aluminate cement and three types of aggregates that are stable at high temperatures. The designed concrete mixes were exposed to thermal cycles (290–550 °C), and their thermal fatigue response was evaluated with mechanical, cracking, thermal, and microstructural analyses at room temperature after heat cycles. The obtained results show that the main changes are mostly produced after the first thermal cycle and are stabilized during successive thermal cycles, with only a slight decrease in the thermo-mechanical properties. The results showed stabilization of cracking, crack widths between 10 and 80 μm, reduction of compressive strength, around 50–65%, and reduction of the thermal conductivity by 30%.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Strain hardening magnesium-silicate-hydrate composites (SHMSHC) reinforced with short and randomly oriented polyvinyl alcohol microfibers

Magnesium-silicate-hydrate (M-S-H) cement has emerged as an alternative binder with potentially lower energy requirements and emissions. Due to the intrinsically low pH values of its matrix, however, normal steel reinforcement is not appropriate for M-S-H system. To toughen the matrix and to overcome the brittle nature of the material, a new strain hardening magnesium-silicate-hydrate composite (SHMSHC) is developed for the first time by incorporating 2 vol% short and randomly oriented polyvinyl alcohol (PVA) microfibers. The resulting SHMSHC exhibits significant strain hardening with a tensile strain capacity of more than 3%, a compressive strength beyond 50 MPa and a tensile strength of around 3 MPa. Remarkably, saturated multiple cracking with a tight crack width less than 10 μm invisible to the human naked eyes was observed. The newly developed SHMSHC addresses the fundamental challenge of M-S-H binder and is expected to widen possible application areas of M-S-H system.

36 MATERIALS SCIENCE↗