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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

RELAP5-3D Solutions to Exercise 1 of the OECD-NEA HTTF Benchmark

The high-temperature gas-cooled reactor (HTGR) is an advanced reactor concept that has received considerable attention over the last 60 years. HTGRs boast high coolant outlet temperatures, passive safety, and large margins to fuel failure. Recent years have seen increasing interest in HTGRs, whether large-scale HTGRs for electricity or process heat applications or as microreactors serving remote communities. HTGRs have considerable potential to fulfill these applications, but modeling and simulation tools typically used for reactor safety analysis have not been validated for HTGR modeling. The High-Temperature Test Facility (HTTF) was constructed at Oregon State University (OSU) to provide validation data for HTGR modeling. Recently, Idaho National Laboratory (INL), OSU, Argonne National Laboratory, Canadian Nuclear Laboratories, and the University of Tennessee Knoxville have collaborated to develop an HTGR thermal hydraulics benchmark based on HTTF experiments. This summary presents results from a portion of that benchmark using RELAP5-3D

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Effect of Inlet Throttling on Thermohydraulic Instability in a Large Scale Waterbased RCCS: A System-Level Analysis with RELAP5-3D

This paper presents results from system -level modeling of a water -based reactor cavity cooling system using RELAP5-3D. The computational model is benchmarked with experimental data from a half -scale RCCS test facility at Argonne National Laboratory. The model prediction is first compared with a two-phase oscillatory baseline experimental case where mixed accuracy is obtained. The model shows reasonable prediction of mass flow rate, pressure, and temperature but significant overprediction of void fraction. The model prediction is then compared with a fault case where the inlet of the risers is gradually reduced using a throttling valve. As the valve is closed, the model is able to predict some major flow phenomena observed in the experiment such as the dampening of oscillations, the reintroduction of oscillations, as well as boiling, flashing, and geysering in the risers. However, the timeline of these events are not well captured by the model. The model is also used to investigate the evolution of flow regime in the chimney. This work highlights that the semiempirical constitutive relations used in RELAP-3D could have a strong influence on the accuracy of the model in two-phase oscillatory flows.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

A Study of Propane Combustion in a Spark-Ignited Cooperative Fuel Research (CFR) Engine

Liquefied petroleum gas (LPG), whose primary composition is propane, is a promising candidate for heavy-duty vehicle applications as a diesel fuel alternative due to its CO 2 reduction potential and high knock resistance. To realize diesel-like efficiencies, spark-ignited LPG engines are proposed to operate near knock-limit over a wide range of operating conditions, which necessitates an investigation of fuel-engine interactions that leads to end-gas autoignition with propane combustion. This work presents both experimental and numerical studies of stoichiometric propane combustion in a sparkignited (SI) cooperative fuel research (CFR) engine. Engine experiments are initially conducted at different compression ratio (CR) values, and the effects of CR on engine combustion are characterized. A three-pressure analysis (TPA) model based on the two-zone combustion concept is developed in GT-Power and validated using test results to estimate in-cylinder wall temperatures, residual gas fraction, etc. This model is further utilized to examine end-gas chemistry by enabling the SI turbulent flame combustion and unburned gas chemical kinetics modules. Finally, a three-dimensional (3D) computational fluid dynamic (CFD) model of the CFR engine is developed in CONVERGE, where the G-equation and SAGE detailed chemical kinetics models are implemented for combustion modeling. Here, a 153 species reduced chemical kinetics mechanism derived from the detailed NUIGMech1.1 mechanism based on the ignition delay and laminar flame speed (LFS) studies is used to generate an LFS lookup table and to describe end-gas autoignition chemistry. Multi-cycle Reynolds-averaged Navier-Stokes (RANS) simulations are then performed for the tested CRs, and the numerical model is shown to be capable of predicting the propane combustion characteristics, particularly the end-gas autoignition behavior.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Insights on Simulating Summer Warming of the Great Lakes: Understanding the Behavior of a Newly Developed Coupled Lake-Atmosphere Modeling System

The Laurentian Great Lakes are the world's largest freshwater system and regulate the climate of the Great Lakes region, which has been increasingly experiencing climatic, hydrological, and ecological changes. An accurate mechanistic representation of the Great Lakes thermal structure in Regional Climate Models (RCMs) is paramount to studying the climate of this region. Currently, RCMs have primarily represented the Great Lakes through coupled one-dimensional (1D) column lake models; this approach works well for small inland lakes but is unable to resolve the realistic hydrodynamics of the Great Lakes and leads to inaccurate representations of lake surface temperature (LST) that influence regional climate and weather patterns. This work overcomes this limitation by developing a fully two-way coupled modeling system using the Weather Research and Forecasting model and a three-dimensional (3D) hydrodynamic model. The coupled model system resolves the interactive physical processes between the atmosphere, lake, and surrounding watersheds; and validated against a range of observational data. The model is then used to investigate the potential impacts of lake-atmosphere coupling on the simulated summer LST of Lake Superior. By evaluating the difference between our two-way coupled modeling system and our observation-driven modeling system, we find that coupled-lake atmosphere dynamics can lead to a higher LST during June-September through higher net surface heat flux entering the lake in June and July and a lower net surface heat flux entering the lake in August and September. The unstratified water in June distributes the entering surface heat flux throughout the water column leading to a minor LST increase, while the stratified waters of July create a conducive thermal structure for the water surface to warm rapidly under the higher incoming surface heat flux. This research provides insight into the coupled modeling system behavior, which is critical for enhancing our predictive understanding of the Great Lakes climate system.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Volumetric recombination in EMC3-EIRENE: Implementation and first application to the pre-fusion power operation phase in ITER

An upgrade to the 3D plasma boundary model EMC3-EIRENE for detached divertor plasmas is introduced and evaluated. Stabilization of the iterative approximation of a self-consistent plasma–neutral gas solution is required at low divertor plasma temperatures, and this has been achieved by linearization of the energy loss term associated with the electron–neutral gas interaction. An implicit method for volumetric recombination has been implemented, which improves agreement with SOLPS-ITER results for the pre-fusion power operation phase in ITER. Resonant magnetic perturbations for control of edge localized modes are found to result in a partially detached divertor plasma with a significantly broader reduction of particle loads in the traditional strike zone, which is attributed to volumetric recombination. The additional non-axisymmetric far scrape-off layer strike points, on the other hand, remain attached at relatively high temperature so that volumetric recombination is not effective there.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

Bentonite buffer under high temperature: laboratory experiments and coupled process modeling

Abstract. Bentonite buffer in a geological repository will be simultaneously heated from decaying radioactive waste and hydrated from the surrounding host rock, triggering complex and coupled THMC (thermal–hydrological–mechanical–chemical) processes. Understanding the THMC behavior of bentonite-based engineered barrier system (EBS) is key to the evaluation and prediction of its long-term performance. Studies on the THMC process have been focused on conditions under 100 ∘C, as most design concepts impose a thermal limit of 100 ∘C in bentonite. Recently, studies under high-temperature conditions have been conducted to evaluate the possibility of raising the thermal limit and expanding the data/knowledge base to increase the confidence level. In this abstract, we present a series of bench-scale laboratory experiments at high temperatures (up to 200 ∘C) and the corresponding modeling work. Two sets of column tests were conducted, and each set consisted of two test columns: a control column undergoing only hydration (non-heated) and an experiment column experiencing both heating and hydration (heated). During the experiment, frequent X-ray computed tomography (CT) images were collected to provide a 3D visualization of the density distribution and present the spatiotemporal evolution of (1) hydration/dehydration, (2) clay swelling/shrinkage, (3) displacement, and (4) mineral precipitation. The two sets of tests differ with respect to several experimental conditions, such as bentonite type, compacted density and water content, water chemistry, and hydration pressure, but the important difference is that the first set used bentonite powder with a dry density of 1.28 g cm−3, whereas the second set used granulated bentonite (mixture of pellets and powder) with a dry density of 1.45–1.5 g cm−3. In both sets of experiments, a comprehensive post-dismantling characterization of bentonite samples was carried out after the column tests had been running for 1.5 years. Comparing non-heated and heated columns, the temperature gradient led to lower degree of homogenization of bentonite after bentonite became fully saturated; comparing the first and second sets, granulated and powdered bentonite exhibited drastically different hydration behavior. A THM model with a 2D axisymmetric grid system was used to interpret the data from the first set of tests. The model considers the combined impact of saturation, fluid pressure, and porosity change due to swelling/compression on the spatiotemporal distribution of bulk density and movement of the thermocouple modules. Observations from the tests help us understand the early perturbation of bentonite buffer under high temperature, and data from these tests improve the calibration of key constitutive hydrological and mechanical models and, therefore, enhance the modeling capability with respect to calculating the long-term evolution of bentonite buffer.

Zheng, Liange↗
DOE OSTI2021

A measure of active interfaces in supported catalysts for high-temperature reactions

Formulating knowledge of structure-function relationships in heterogeneous catalysis is central to the design of efficient catalysts; yet, the elucidation of dominant reaction sites has remained as a challenge. Here, in this paper, we present a methodology that can be used to visualize metal-gas and metal-oxide-gas interfaces in three dimensions and to quantify their catalytic activity levels. As a case study, CH 4 oxidation occurring in a Pt/CeO 2 system is chosen. By employing thermally robust Pt@CeO 2 model catalysts with size-tunable and monodisperse cores, and gas-permeable shells, we reconstruct a series of structures in 3D via electron tomography and match the information to activity data and theoretical calculations. This strategy reveals that two different interfaces catalyze the CH 4 oxidation and that their contribution to the overall rate changes with the Pt size, temperature, and gas atmosphere. Our results provide an analytic platform on which to explore reaction pathways and mechanisms applicable to multiple reactions and materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Modeling Nondestructive Defect Detection in Additively Manufactured Metallic Structures for Nuclear Applications

The future of quickly, economically produced metallic nuclear reactor parts with minimal supply-chain dependence lies in Laser Powder Bed Fusion (LPBF) Additive Manufacturing (AM): a 3D printing method involving laser melting and net shaping stainless steel and Inconel metallic powder into a solid structure. However, intrinsic features in LPBF frequently leads to the formation of materials defects, such as pores, within 3D printed structures. As safe long-term use in energy applications requires knowledge of all relevant defects before deployment in a reactor, we must develop methods for nondestructive detection of these defects. We are investigating Pulsed Thermal Tomography (PTT), which is a non-contact nondestructive imaging method scalable to arbitrary structure size. Thermal tomography (TT) is a computational method for 3D spatial reconstruction of material thermal effusivity from flash or pulsed thermography temperature data cube. Thermography data cube consists of 2D surface temperature measurements at different times. The objective of the present work is to investigate limits on defect detection in AM metallic structures with PTT. To this effect, we modeled PTT with COMSOL heat transfer computer simulations. We developed a layered media COMSOL simulation consisting of a Stainless Steel 316 (SS316) plate with an internal layer of un-sintered SS316 powder. Thermophysical properties of the powder layer were modeled with equivalent volume mixing model. To account for partial sintering at the boundary of the defect, the transition between solid and powder layers was modeled as a Gaussian. Using data from COMSOL simulations, we reconstructed depth-dependent thermal effusivity, which allowed defect visibility estimation. A series of parametric studies determined that at 1mm depth, 50µm is the smallest detectable defect. In addition, classification of the defects which can lead to early fatigue of the metallic structure in a reactor is briefly discussed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Artificial correlation heating in PIC simulations

The Particle-in-Cell (PIC) method, a cornerstone in plasma modeling, is widely employed for its ability to simulate kinetic phenomena in device-scale domains. Part of what makes this possible is that computational macroparticles represent many physical particles. It converges under certain constraints, including a grid spacing that resolves the Debye length and a time step small enough to respect the Courant–Friedrichs–Lewy condition and plasma frequency stability limit. Here, we introduce a new constraint necessary to avoid Artificial Correlation Heating (ACH). This requires that the macroparticle coupling strength be smaller than one, Γ ω < 1, where Γ ω ≡ Γω 2/3 ⁠, Γ = Z 2 e 2 /(4πε 0 ak B T) is the physical coupling strength, and w is the macroparticle weight. This is particularly relevant to 3D simulations of dense plasmas, which are becoming common with modern computing power. If this condition is violated, the finite macroparticle weight artificially enhances the coupling strength and causes the plasma to heat until the macroparticle coupling strength is near unity, depending on the grid resolution. A comprehensive model of ACH is developed that incorporates electron density, temperature, macroparticle weight, and grid resolution. It is then tested using PIC simulations, delineating the boundaries of the method's applicability and offering a predictive framework for ACH. Moreover, the research explores a runaway heating process induced by ACH in the presence of ionization, which can lead to numerical instability. A conclusion of this study is that the onset of ACH can impose a more stringent constraint on the macroparticle weight and average number of macroparticles per cell than what is typically expected, particularly in 3D simulations of dense plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Hybrid AI-ML and FE-based Digital Twin Predictive Modeling Framework for a PWR Coolant System Components: Updates on Multi-Time-Series-3D-Location Dependent Usages Factor Prediction

The long-term operation (LTO) of nuclear power plants (NPP) beyond their original design life of 40 years can lead to more material damage associated with cyclic fatigue under thermal-mechanical loading cycles and associated long-term exposure of reactor material to the deleterious reactor-coolant environments. However, under this LTO condition, the reactor components can still safely operate but may require more frequent Nondestructive Evaluation (NDE) of reactor components. Requiring frequent NDE inspections may lead to frequent NPP shutdowns which can lead to power outages and additional NDE inspection cost-related economic loss. The economic loss can be minimized by reducing uncertainty in life estimation of safety-critical pressure boundary components and by implementing a more digital approach such as using upcoming digital-twin (DT) technology for predicting the structural states (e.g., time and location dependent inside/outside thickness temperature, stress, strain, plastic deformation, etc.) and associated fatigue life of a component in real time. The DT framework is based on limited experimental data, Artificial-intelligence (AI)-Machine-Learning (ML) and multiphysics-computationalmechanics such as finite element- (FE) based models. Given the real-time thermal-hydraulic process measurements from several existing plant sensors, the overall goal of the DT framework is to predict the cumulative usages factors or equivalent fatigue lives in real time and at any random 3D location of the components. This includes inaccessible locations such as inside the thickness or location of a component. This prediction can be at thousands to millions of 3D point clouds or locations like conventional FE-based models, but without running an FE model in real time.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Evaluating crown scorch predictions from a computational fluid dynamics wildland fire simulator

Abstract Background Crown scorch—the heating of live leaves, needles, and buds in the vegetative canopy to lethal temperatures without widespread combustion—is one of the most common fire effects shaping post-fire canopies. Despite the ability of computational fluid dynamic models to finely resolve fire activity and buoyant plume dynamics including heterogenous 3D distributions of forest canopy heating, these models have had only limited use in simulating fire effects and have not been used to evaluate crown scorch. Here, we demonstrate a method of evaluating crown scorch using a computational fluid dynamics model, FIRETEC, and validate this approach by simulating the experiments that were used to develop Van Wagner’s 1973 crown scorch model. Results The average scorch height prediction from FIRETEC compares well with the empirical model derived by Van Wagner, which is the most widely used empirical model for crown scorch. We further find that the 3D buoyant plume dynamics from a steady and homogeneous idealized heat source on the ground results in a spatially heterogenous crown scorch pattern reflecting complex heating dynamics that are best represented by percent scorch rather than height of scorch. Conclusions The ability of the computational fluid dynamics model to capture variation in crown scorch due to 3D buoyant plume dynamics provides direct links between forest structure, fire behavior, and fire effects that can be used by forest managers and researchers to better understand how fires result in crown damage under various environmental and management scenarios.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

DRACO: An Overview [Slides]

DRACO (Diffusion ReACtiOn) is a diffusion and chemistry code designed to: 1) Operate on 3D with an unstructured grid defining an arbitrary geometry of interacting parts. 2) Generate its own meshes and use meshes created by other software. 3)Model the transport of any number of diffusing quantities: Concentrations, pressures, temperature, etc. 4) Allow diffusion coefficients to depend in an arbitrary way on concentration, temperature, position, time, etc. 5) Model general chemistry between concentrations with arbitrary reaction rates. 6) Allow arbitrary initial conditions, boundary conditions, and sources/sinks. 7) Allow all of the above to be specified by the user.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Validation Simulations for Multi-Component Mixture Model [Slides]

Set up and ran a large, 3D, 3 component Rayleigh-Taylor Mixing Simulation: Match initial conditions from; Run with multiple mesh sizes to demonstrate convergence to expected mixing layer growth rate. Wrote and tested new FLAG capability to enforce a specified temporal temperature profile.

42 ENGINEERING↗
DOE OSTI2025

Kinetic modeling of hot tail runaway electron generation during plasma disruptions using the JOREK code

The generation of runaway electrons (REs) during disruptions poses a significant challenge for the operation of tokamaks. The production of these high-energy electrons can cause substantial damage, particularly when the plasma current is high, making it a critical concern for ITER. For the high-temperature plasmas anticipated in ITER, the primary generation of REs may be dominated by the hot tail mechanism, which consists of the acceleration of hot electrons from the pre-disruption population which have not yet thermalized with the bulk following the rapid cooling of the plasma. To account for the significant 3D effects on RE production, a hot tail modeling framework has been developed within the non-linear 3D extended MHD code JOREK. This paper presents the structure of this framework, which is based on test electrons evolving in MHD fields. The verification of the method shows good agreement with the reference DREAM code for 0D test cases, as well as for axisymmetric simulations of 15 MA ITER H-mode disruption scenarios. Furthermore, a proof-of-principle application to a DIII-D case demonstrates the framework’s capability to capture for the first time the hot tail generation in 3D MHD simulations in realistic geometry. Preliminary results suggest that the production of REs is significantly reduced by stochastic losses.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Advanced Multiphysics Code Coupling for Cladding Surface Thermocouples During Two-Phase Heat Transfer from Nuclear Fuel

Transient testing of nuclear fuel involves the evaluation of fuel performance under off-normal and accident conditions and is essential for proving design performance. Instrumentation included in such experiments commonly includes thermocouples attached to the outer surface of the cladding to provide temperature measurements throughout the transient. However, the presence of thermocouples on the cladding surface can alter the local heat transfer characteristics with the surrounding coolant. These localized effects can influence the temperature of the nearby cladding surface and introduce uncertainties in interpreting the thermocouple data. Understanding the impact of thermocouples attached to the outer surface of the cladding is crucial for accurate data interpretation as well as its effect on the thermomechanical behavior of the cladding. This paper presents a novel methodology for simulating the impact of outer cladding thermocouples during transient testing of nuclear fuels. The simulation framework leverages the thermal-hydraulic capabilities of RELAP5-3D coupled to the BISON fuel performance code through the RELAPCouplingApp interface. The methodology is compared against Accident Tolerant Fuel Reactivity Initiated Accident-1-E experiment performed at Idaho National Laboratory. The results reveal approximately 100°C difference between thermocouple-altered temperature and virgin cladding surface. The model overpredicts surface rewet time due to conservative correlations.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Spin correlations in the nematic quantum disordered state of FeSe

The quantum-disordered state in FeSe, intertwined with superconductivity and nematicity, has been a research focus in iron-based superconductors. However, the intrinsic spin excitations across the entire Brillouin zone in detwinned FeSe, crucial for understanding its magnetism and superconductivity, have remained unresolved. Using inelastic neutron scattering, we reveal that stripe spin excitations (Q = (1, 0)/(0, 1)) exhibit the C 2 symmetry, while Néel spin excitations (Q = (1, 1)) retain C 4 symmetry within the nematic state. Temperature-dependent differences between Q = (1, 0) and (0, 1) spin excitations above the structural transition unambiguously reveals the nematic quantum disordered state. Comparison with NaFeAs suggests the Néel excitations originate from enhanced 3d xy orbital correlations. Modeling the stripe dispersions using a J 1 -K-J 2 Heisenberg Hamiltonian, we establish a spin-interaction phase diagram, positioning FeSe near a crossover regime between the antiferroquadrupolar, Néel, and stripe orders. Our results provide key insights into the microscopic spin interactions and their role in the intertwined orders in iron-based superconductors.

Electronic properties and materials↗
DOE OSTI2021

Computational Tools for Additive Manufacture of Tailored Microstructure and Properties

Additive manufacturing has the potential to revolutionize industrial hardware and unlock efficiency gains through the fabrication of geometries and architectures not possible by conventional processing. Currently most additive builds use a single set of process parameters (e.g. laser power and scan speed) which results in a part with a homogenous microstructure that provides a singular performance level. To move beyond this state, Raytheon Technologies Research Center worked to create a set of computational tools to track material evolution through each step of the additive process. Computational fluid dynamics and phase field models for microstructure evolution as a function of processing parameters, and crystal plasticity models fully coupling microstructure and mechanical properties for performance predictions were leveraged to establish a connection between additive parameters and the final microstructure. This framework was utilized to tailor spatially-varying mechanical properties in a part by appropriately controlling the microstructure evolution during the additive process. Specifically, a turbine blade was 3D printed from nickel superalloy IN718 using laser powder bed fusion with coarse grains in the airfoil section which experiences the highest temperatures and is creep limited while finer grains were printed in the root of the blade which experience higher stresses but at lower temperatures and is therefore fatigue limited. The benefit of being able to intentionally insert coarse grains in the high temperature region of the blade was showcased with a microstructure sensitive creep model that indicates longer creep life for coarser grains.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Development of Additively Manufactured Complex Tools for Autoclave Cure Composites

IACMI Project 4.9, Tooling for Composites with Washout Features Produced by Additive Manufacturing, assembled a team including the industry lead, Ability Composites, NREL and Colorado State University (CSU). Ability Composites had originally expressed interest in alternate methods of producing tooling for composite parts. In follow-up discussions, it became clear that one of the bigger tooling challenges revolved around small production volume composite parts that were tooled on washout material due to the complex geometry. To build an understanding of the potential, both from a technology and a cost perspective, for replacing conventional washout tooling with 3D printed thermoplastic tooling, a number of commercially available dissolvable FDM printing materials were evaluated, leading to tooling representative of commercial articles of interest to Ability Composites. Ultimately, Ability Composites was able to directly compare autoclave processed prepreg composite parts produced on conventional washout tooling to composite parts molded on 3D printed dissolvable tooling produced at CSU. Small, laboratory test specimens were developed to investigate the structural performance of the candidate materials under autoclave processing conditions, which were nominally 121 °C (250 °F) and 345 kPa (50 psi). In addition, several internal structural configurations (infills) were evaluated under autoclave conditions using model materials. The results of these tests indicated that two materials, Stratasys ST 130 and Infinite Materials Solutions Aquasys 180 (AQ 180), were the best candidates, given the specified autoclave processing conditions. ST-130 was slightly more robust than AQ-180; however, the AQ-180 was carried forward as it was dissolvable in water, not requiring the basic solution needed to dissolve ST-130. Based on the preliminary material and 3D printed structures evaluations, larger tools with a truncated square pyramid geometry were created to produce prepreg composite test articles for 3D printed dissolvable tool evaluation under standard autoclave fabrication conditions. Two tools were manufactured using ST-130 and one tool using traditional ceramic washout tooling media. The tools were evaluated for geometric fidelity and surface roughness changes before and after carbon fiber/epoxy prepreg composites were manufactured on the tooling. The autoclave processing did not impact the geometry significantly and was completed at 121 °C and 345 kPa, indicating satisfactory tool performance. The results from surface roughness testing of both the resulting composite and the associated tooling indicated that an adequate surface resulted without the need for a surface sealing step, as was required for the conventional washout tooling. Based on results of the truncated pyramid tests as a basis, ST-130, AQ-120 and AQ-180 materials were carried forward to the tool geometry of interest to Ability Composites. These hollow rectangular bent ducts, which were complex in nature and not extractable after cure, were used to understand the impacts of tool material and thickness. One ST-130 tool was produced as a partially solid part, with an enclosed 40% dense infill region to reduce weight and material use. This was the same approach evaluated in the truncated pyramid portion of the study. This tool was to be envelope vacuum bagged and directly compared to a monolithic tool of conventional washout material. The traditional monolithic ceramic tool was manufactured by Ability composites using CNC-based subtractive methods. An additional five dissolvable polymer tools, manufactured from ST-130, AQ-120, and AQ-180, using a hollow design were 3D printed and used to produce carbon fiber/epoxy composite evaluation articles. These hollow dissolvable tools were expected to be less influenced by the autoclave conditions as the wall was solid and vacuum bagging was inside and outside the tool. This alternative geometry was also evaluated as an option in techno-economic modeling. Print times were reduced from in excess of 3 days to under 30 hours, while surface quality and and tool integrity were substantially improved in the transition from the partially solid tool to the hollow tooling concept. Ability Composites produced autoclave-cured prepreg ducts on each of these tools. The autoclave conditions utilized were more severe than those of the initial trials, reaching temperatures of 160 °C and a pressure of 414 kPa. Under these conditions, the partially solid 3D printed tool with skin and 40% dense infill crushed significantly; however, the thicker ST-130 hollow tool showed good promise, deforming only slightly. The thinner hollow tool walls were unsuccessful as were the other materials. Overall, the hollow tool manufacturing process saved significant amounts of time and material in manufacturing as compared to the solid ducts and produced composite surface quality improvements compared to the traditional washout tooling. The TEM was developed to allow direct comparisons between conventional washout tool manufacturing processes and those developed at CSU. It also allowed for two separate 3D printed tool geometries to be analyzed and compared. In this case, the square bent duct tool geometry was determined to be representative of common washout tools. This geometry was compared with a scaled-up version of it to assess differences in the two manufacturing processes based on tool size. The model was developed to make use of user input in the form of geometry details, process steps, manufacturing parameters, bulk material costs, capital equipment costs, and general costs to calculate overall labor, material, capital equipment, and energy costs per manufactured tool for the conventional and additive manufacturing processes for the two representative geometries. It was also able to estimate step-by-step process times for the manufacturing process and geometries. Based on significant input from Ability Composites and CSU from their knowledge gained from hands-on manufacturing of the 3D printed bent duct tool geometry, costs and process times were calculated for the two manufacturing processes. Results showed that the additive manufacturing techniques developed at CSU can substantially reduce the costs of tool manufacturing by reducing labor times and material usage. This is because additive manufacturing is a relatively hands-off process and allows for the tool design to be optimized to reduce material usage. The disadvantage, however, is that process times for additive manufacturing are significantly longer. The three-dimensional (3D) printing process is slow if tight tolerances are required, but the analysis did show that print times could be reduced with the hollow tool geometry. Also, further advances in additive manufacturing could expedite the process. Costs and process times for the tool washout process were calculated separately. They showed that costs are relatively insignificant when compared to the overall tool manufacturing processes, but with increases in tool size, costs for the conventional manufacturing approach are larger than for additive manufacturing. Again, the washout process for conventional tools is very hands-on, whereas for additively manufactured tools the print medium is dissolved in an automated detergent bath at the sacrifice of process time. The analysis showed that optimizing the additively manufactured tools may also reduce washout times. Overall, Project 4.9 demonstrated that commercially available dissolvable 3D printing materials exist that can be used to produce dissolvable tooling capable of surviving prepreg composites fabrication under autoclave conditions of 121 °C (250 °F) and 345 kPa (50 psi). An alternative hollow dissolvable tool design was developed which was structurally superior to the initial concept and was cost and time effective versus conventional washout tooling. The 3D printed sacrificial tool required no added surface sealing steps prior to composite part layup and cure, offering a significant advantage over the porous conventional washout tooling.

36 MATERIALS SCIENCE↗