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At least 181 records · Page 10

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DOE OSTI2021

Effect of spatial distribution of polymer fibers on preventing spalling of UHPC at high temperatures

Polypropylene (PP) fibers are commonly used for the prevention of thermal spalling of ultra-high performance concrete (UHPC). In this work, the effect of fiber distribution on permeability and spalling resistance is investigated and an analytical model for permeability at 150 °C is proposed. This model, considering the parameters like fiber dimensions, dosage, and percolation, is based on Kozeny-Carman equation. It was found that the percolation of the interconnecting fiber network resulted in a significant increase in permeability of UHPC. X-ray tomography data on the three-dimensional spatial distribution of fibers reiterated that fiber aspect ratio and dosage (and fiber number density) were critical in increasing the fiber connectivity (percolation). It was also found that a vapor permeability of larger than 0.6 × 10{sup −16} m{sup 2} at 150 °C could eliminate spalling. Further, based on a semi-empirical approach, aspect ratio between 300 and 600 was recommended for spalling prevention with a fiber dosage of 0.3–0.4 vol%.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Fiber orientation effects on ultra-high performance concrete formed by 3D printing

Despite the growing interest in 3D concrete printing, its current progress is limited by reinforcing methods. Inclusion of steel fibers is a potential reinforcing solution; however, the effect of printing process on orientation of the fibers is still unknown. This study aims to quantitatively investigate the orientation distribution of steel fibers in 3D printed ultra-high performance concrete. The effects of extrusion nozzle size, Cartesian print speed, and fiber volume fraction on the orientation of fibers were evaluated using digital image analysis. The consequent effects of the fiber orientation on the mechanical properties of the 3D-printed specimens were also determined. The results were compared with those of the conventionally mold-cast specimens. The results revealed that the smaller nozzle size and higher fiber volume fraction significantly enhanced the fiber alignment parallel to the printing direction. This preferential fiber alignment led to superior mechanical performance of the printed specimens to the mold-cast specimens.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Fiber orientation and porosity in large-format extrusion process: The role of processing parameters

Controlling fiber orientation and porosity in short-fiber thermoplastic composites is important for enhancing mechanical, electrical and thermal properties in large-format additive manufacturing. This study employs a factorial design of experiments (DoE) to assess the effects of nozzle diameter (5.08 mm–10.16 mm), temperature (230–250 °C), and extruder screw speed (150–280 rpm) on flow rate, shear rate, porosity, fiber orientation, fiber length and tensile strength in 20 % carbon fiber-filled acrylonitrile butadiene styrene. ANOVA results show that screw speed significantly impacts flow rate, while nozzle diameter and temperature have lesser effects. Shear rate increases with smaller nozzles and higher speeds. Porosity decreases from 5.58 % with a 10.16 mm nozzle to 3.11 % with a 5.08 mm nozzle at 150 rpm due to increased shear rates, which induce shear thinning, reducing viscosity and facilitating gas escape. Larger nozzles (10.16 mm) produce larger, more heterogeneous pores, while smaller nozzles (5.08 mm) yield smaller, uniform pores. Beads produced with the 5.08 mm nozzle exhibit longer fiber lengths due to reduced residence time, lower shear stress, and better alignment. Fiber orientation improves with smaller nozzles due to higher shear rates but decreases with higher screw speeds (280 rpm) due to shorter residence times. The highest fiber alignment (A xx ∼ 0.65) and low porosity (∼3%) were achieved with a 5.08 mm nozzle at 150 rpm, while equivalent additive manufacturing-compression molding samples exhibited better tensile strength (∼93 MPa) under these conditions. In conclusion, these findings emphasize the importance of optimizing processing parameters to enhance fiber alignment and reduce porosity for improved mechanical performance.

Design of experiments↗

DOE OSTI2023

Silicon carbide fiber manufacturing: Cost and technology

Significant advances have been made in the past decade concerning silicon carbide fiber manufacturing methods resulting in near-stoichiometric small-diameter fibers that meet the property requirements for most of the ceramic matrix composites (CMC) and nuclear applications. The manufacturing cost, however, remained prohibitively high, preventing the use of it in different applications requiring much lower cost. Silicon carbide (SiC) fiber reinforced CMC is dominated by the cost of SiC fiber which comprises more than 50 % of the finished part cost. Here, this article provides insight into the SiC fiber manufacturing costs and highlights the need for an alternative SiC fiber precursor and manufacturing method. Analysis of the existing polycarbosilane (PCS)-based SiC fiber manufacturing shows that the crosslinking (curing) and raw material preparation steps are high-cost steps that need lower cost options. Alternative SiC fiber precursor should be sought for lowering the cost of SiC fibers.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Two-dimensional patterning of mesoscale fibers using acoustophoresis

The performance of functional composites can rely critically on the arrangement of secondary phases; for example, patterned networks of conductive particles can impart anisotropic thermal, electric or ionic conductivity while preserving flexibility in the matrix. We demonstrate the use of standing acoustic waves to generate periodic patterns of short fibers. We extend the range of possible patterns with the first demonstration of both rectangular grids and arrays of octagons interspersed with rectangles. These newly demonstrated patterns are rationalized using theoretical models of acoustic forces and torques on fibers that account for two-dimensional spatial variations arising from applied acoustic fields. The models enable simulations of fiber motion, which are used to (i) map out final fiber positions as a function of initial position and orientation, and (ii) corroborate experiments visualizing fiber motion and final patterns. This approach provides a fast and accurate way to predict emergent fiber patterns as a function of excitation modality and fiber length. The theory and experiments clearly indicate strong coupling between the length of the fibers and the spacing of the acoustic nodes. Furthermore, this coupling is used to estimate reductions in percolation thresholds associated with the ratio of fiber length and acoustic wavelength.

25 ENERGY STORAGE↗

DOE OSTI2020

Laser-assisted embedding of all-glass optical fiber sensors into bulk ceramics for high-temperature applications

We develop a laser-assisted sensor embedding process to embed all-glass optical fiber sensors into bulk ceramics for high-temperature applications. A specially designed two-step microchannel was fabricated on an Al 2 O 3 substrate for sensor embedment using a picosecond (ps) laser. An optical fiber Intrinsic Fabry-Perot Interferometer (IFPI) sensor was embedded at the bottom of the microchannel and covered by Al 2 O 3 slurry which was subsequently sintered by a CO 2 laser. The sensor spectrum was in-situ monitored during the laser sintering process to ensure the survival of the sensor and optimize the laser sintering parameters. By testing in furnace through high temperature, the embedded optical fiber shows improved stability after CO 2 laser sealing, resulting in the linear temperature response of the embedded optical fiber IFPI sensor. To improve the embedded IFPI sensor for thermal strain measurement, a dummy fiber was co-embedded with the sensing fiber to improve the mechanical bonding between the sensing fiber and the ceramic substrate so that the thermal strain of the ceramic substrate can apply on the sensing fiber. The response sensitivity, measurement repeatability and high-temperature long-term stability of the embedded optical fiber IFPI sensor were evaluated in this work.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Fiber-optic sensor packaging assessment and benchmarking for embedded sensing applications

Fiber optic-based sensing for non-destructive evaluation (NDE) and structural health monitoring of various infrastructure and energy assets is an increasingly important sensing scheme. Because of their immunity to electromagnetic interferences, versatility in sensing mechanisms and designs as well as capability for distributed sensing, the fiber optic sensing is of great interest for embedding within infrastructures using advanced manufacturing methods. However, the protection of fiber optic sensors during advanced manufacturing-based embedding is an important aspect for infrastructure monitoring in practice. While successful installation of fiber optic sensors has been accomplished through application of epoxy or adhesives on infrastructure surfaces, there has been only limited investigation of fiber protection packaging schemes which are compatible with in-situ repair techniques such as the metallic cold-spray. With increasing interest and importance of cold spray-based repair processes, the integration of fiber optic sensors simultaneously during the repair is equally important. In this work, we focus our efforts on investigating various types of packaging schemes for their compatibility and integrability on the surfaces of metallic structures such as oil and gas pipelines during an in-situ repair coating. First, we consider sandblasting using silica sand particles of various size for optical fibers on the surface of a metallic coupon as a useful proxy test of sensor packaging stability. Structural damage of packaging is characterized by means of optical microscopy and the optical integrity of embedded fiber optic cables is examined using optical backscatter reflectometry (OBR). In addition, initial investigation of metallic cold-spray embedded fiber optic cables under various packaging on metallic substrates is also considered with early conclusions and future directions.

Fiber-optic sensors, Sensors packaging, Metallic C↗

DOE OSTI2022

Massively distributed fiber strain sensing using Brillouin lasing

Brillouin based distributed fiber sensors present a unique set of characteristics amongst fiber sensing architectures. They are able to measure absolute strain and temperature over long distances, with high spatial resolution, and very large dynamic range in off-the-shelf fiber. However, Brillouin sensors traditionally provide only modest sensitivity due to the weak dependence of the Brillouin frequency on strain and the high signal to noise ratio required to identify the resonance’s peak frequency to within a small fraction of its linewidth. Recently, we introduced a technique which substantially improves the precision of Brillouin fiber sensors by exciting a series of lasing modes in a fiber loop cavity that experience Brillouin amplification at discrete locations in the fiber. The narrow-linewidth and high intensity of the lasing modes enabled ultra-low noise Brillouin sensors with large dynamic range. However, our initial demonstration was only modestly distributed: measuring strain at 40, non-contiguous positions along a 400 m fiber. In this work, we greatly extend this methodology to enable fully distributed sensing at 1000 contiguous locations along 3.5 km of fiber—an order of magnitude increase in sensor count and range. This highly-multiplexed Brillouin fiber laser sensor provides a strain noise as low as 34 nɛ/√Hz and we analyze the limiting factors in this approach.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

EGS Collab Experiment 2: Distributed Fiber Optic Temperature Data (DTS)

Distributed fiber optic sensing was an important part of the monitoring system for EGS Collab Experiment #2. A single loop of custom fiber package was grouted into the four monitoring boreholes that bracketed the experiment volume. This fiber package contained two multi-mode fibers and four single-mode fibers. These fibers were connected to an array of fiber optic interrogator units, each targeting a different measurement. The distributed temperature system (DTS) consisted of a Silixa XT-DTS unit, connected to both ends of one of the two multi-mode fibers. This system measured absolute temperature along the entire length of fiber for the duration of the experiment at a sampling rate of approximately 10 minutes. This dataset includes both raw data in XML format from the XT-DTS, as well as a processed dataset with the sections of data pertaining only to the boreholes are extracted. We have also included a report that provides all of the relevant details necessary for users to process and interpret the data for themselves. Please read this accompanying report. If, after reading it, there are still outstanding questions, please do not hesitate to contact us. Happy processing.

15 GEOTHERMAL ENERGY↗

DOE OSTI2021

Consortium for Production of Affordable Carbon Fibers in the United States (Final Report)

Various feedstocks from coal, petroleum and bio-based acrylonitrile were investigated for their ability to produce carbon fiber within DOE strength (250 ksi), modulus (25 Msi), elongation (>1%) and cost (≤$5/lb) goals for wider utilization in light-weight vehicles for the automotive industry. The overarching approach was to chemically identify and map the various feedstocks, understand the molecular transformation to produce carbon fiber precursors (mesophase for pitch materials of polyacrylonitrile polymer) and how these impact carbon fiber quality. Predictive models were built to relate the feedstocks and precursors to carbon fiber properties using atomistic and micro-scale modeling within ±15%. Using tow-level carbon fiber epoxy composites, carbon fibers tow-level predictions of elastic components of the carbon fibers were also successfully modeled within ±15%, using finite element analysis to confirm single filament carbon fiber properties. These models were validated with tow-level epoxy composite experiments from carbon fibers produced in this study.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Experimental Validation and Continuous Testing of an On-Purpose High-Yield Pitch Synthesis Process for Producing Carbon Fiber from US Domestic Coal

This project aims to develop technology that converts domestic United States (US) raw coal to high quality, high value, and marketable carbon fiber. More specifically, the project aims to significantly improve the selectivity and yield of carbon fiber produced per ton of coal over conventional coal pitch-based production by using low-severity direct coal conversion technology to maximize the yield of pitch from coal, suitable for production of carbon fiber. To meet the stated objective of developing a technology platform, capable of producing high quality, high-value and marketable carbon fiber from domestic US coal, the proposed scope of work involves testing of a low-severity direct coal liquefaction (LS-DCL) process approach. The isotropic pitch produced from the LS-DCL process will be thermally treated using conventional processes to convert to a liquid crystal or “mesophase” pitch as a precursor for structural carbon fibers. This mesophase pitch will then be melt-spun into fiber, oxygen stabilized, and carbonized using conventional processes. The resulting carbon fiber will be evaluated for mechanical properties and suitability for structural applications such as automotive parts and spars for wind turbine blades. The overall process is expected to significantly lower the cost of fiber compared to state of the art fibers produced from polyacrylonitrile (PAN) precursors.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

Segregation of Chromium and Titanium in Sapphire Optical Fiber Grown via the Laser-Heated Pedestal Growth Technique

Our research involves growth of single crystal (SC) optical fibers to be used for sensing applications in harsh environments. Silica optical fibers are an affordable and reliable option for a wide variety of applications including optical fiber sensors and fiber lasers. However, for applications in harsh environments, such as high temperatures, radioactivity, corrosivity, etc., silica fibers are not suitable due to their instability under such conditions. Fibers composed of SC materials such as sapphire and YAG are mechanically, chemically, and thermally more robust to harsh conditions, and thus are more appropriate for sensing applications in environments such as nuclear reactors, jet engines, and boiler. However, SC fibers grown via the laser-heated pedestal growth (LHPG) technique do not intrinsically have a functional cladding layer. A cladding layer is required to reduce the modal volume for distributed sensing applications, to reduce frustrated total internal reflection induced by surface contact of the fiber in certain applications, and to improve transmissivity. Our lab investigates introduction of dopant materials during LHPG to induce an effective core-cladding structure while maintain the crystallinity of the host material. This process results in optical fiber that is not only robust to harsh environments, but also has improved optical properties for distributed sensor applications.

distributed sensing↗

DOE OSTI2024

Rapid Prototyping for Nanoparticle-Based Photonic Crystal Fiber Sensors

The advent of nanotechnology has motivated a revolution in the development of miniaturized sensors. Such sensors can be used for radiation detection, temperature sensing, radio-frequency sensing, strain sensing, and more. At the nanoscale, integrating the materials of interest into sensing platforms can be a common issue. One promising platform is photonic crystal fibers, which can draw in optically sensitive nanoparticles or have its optical properties changed by specialized nanomaterials. However, testing these sensors at scale is limited by the the need for specialized equipment to integrate these photonic crystal fibers into optical fiber systems. Having a method to enable rapid prototyping of new nanoparticle-based sensors in photonic crystal fibers would open up the field to a wider range of laboratories that could not have initially studied these materials in such a way before. This manuscript discusses the improved processes for cleaving, drawing, and rapidly integrating nanoparticle-based photonic crystal fibers into optical system setups. The method proposed in this manuscript achieved the following innovations: cleaving at a quality needed for nanoparticle integration could be done more reliably (≈100% acceptable cleaving yield versus ≈50% conventionally), nanoparticles could be drawn at scale through photonic crystal fibers in a safe manner (a method to draw multiple photonic crystal fibers at scale versus one fiber at a time), and the new photonic crystal fiber mount was able to be finely adjusted when increasing the optical coupling before inserting it into an optical system (before, expensive fusion splicing was the only other method).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Segregation of Chromium and Titanium in Sapphire Optical Fiber Grown via the Laser-Heated Pedestal Growth Technique

distributed sensing↗

DOE OSTI2021

Chemo–mechanical properties of carbon fiber reinforced geopolymer interphase

Geopolymers, as a potentially environmentally friendly alternative to Portland cement, are increasingly attracting attention in the construction industry. Various methods have been applied for customizing the properties of geopolymers and improving their commercial viability. One of the promising methods for refining the properties of geopolymers such as their toughness is the use of short fibers. The effectiveness of a high-strength short fiber in the geopolymer matrix is largely dependent on the interfacial bonding between the fiber and its surrounding matrix. While the importance of this interfacial chemistry is highlighted in the literature, the characteristics of this bonding structure have not been fully understood. In this paper, we aim to investigate the bonding mechanism between the carbon fiber and metakaolin-based geopolymer matrix. For the first time, the existence and nature of the chemical bonding at the interfacial region (interphase) between carbon fiber and geopolymer matrix has been revealed. X-ray pair distribution function computed tomography (PDF-CT), field emission-scanning electron microscopy imaging, and nanoindentation techniques are employed to discern the chemo-mechanical properties of the interphase. PDF-CT results show the emergence of a new atom-atom correlation at the interfacial region (around 1.82 angstrom). This correlation is a characteristic of interfacial bonding between the fiber and its surrounding matrix, where the existence of chemical linkages (potentially Al-V-O-C) between fibers and the matrix contributes to the adhesion between the two constituents making up the composite. Due to such chemical bonding, the nanomechanical properties of the interfacial region fall between that of the carbon fiber and geopolymer. The combination of advanced techniques is proved useful for enhancing our understanding of the interfacial chemistry between fibers and the binding matrix. This level of knowledge facilitates the engineering of composite systems through the manipulation of their nanostructure.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Review—Electrospun Inorganic Solid-State Electrolyte Fibers for Battery Applications

Inorganic solid-state electrolytes (SSEs), especially Li 7 La 3 Zr 2 O 12 (LLZO), are promising candidates for all solid-state batteries. Generally, SSEs are synthesized by solid-state reactions at high temperatures. The high temperature required to synthesize useful polymorphs (e.g., cubic phase, in the case of LLZO) increases their production cost. To lower the synthesis temperature, several approaches, including doping and crystallite size control via sol-gel processes, have been explored. Recently, electrospinning was used to synthesize the inorganic SSE fibers to control the crystallite size and lower the calcination temperature. Several publications followed that investigated the properties of fibers and demonstrated the use of these fibers in inorganic-polymer composite SSEs. This paper presents a concise discussion of electrospinning, the parameters that control fiber morphology, the synthesis of inorganic SSE fibers, the effect of sintering conditions on the fiber morphology and composition, and the recent use of these fibers in making composite SSEs and other battery applications. Additionally, most of the discussion focuses on LLZO, but this paper also discusses applications of other types of electrospun inorganic electrolyte fibers, the challenges of using these fibers, and possible future directions in this research field.

25 ENERGY STORAGE↗

DOE OSTI2024

Assessing the Expansion of Ground-Motion Sensing Capability in Smart Cities via Internet Fiber-Optic Infrastructure

Monitoring ground motion in smart cities can improve the public safety by providing critical insights on natural and anthropogenic hazards, for example, earthquakes, landslides, explosions, infrastructure failures, and so forth. Although seismic activity is typically measured using dedicated point sensors (e.g., geophones and accelerometers), techniques such as distributed acoustic sensing have demonstrated the utility of using fiber-optic cable to detect seismic activity over comparable distances. In this article, we present the results of a study that quantifies the expansion in an area monitored for low-amplitude ground-motion events by augmenting existing point sensors with the internet fiber-optic cable infrastructure. Here we begin by describing our methodology, which utilizes geospatial data on point sensors and internet optical fiber deployed in metropolitan statistical areas (MSAs) in the United States. We extend these data to identify the area that can be monitored by (1) considering the observed seismic noise data in target locations, (2) applying the model from Wilson et al. (2021) to understand the potential coverage area gains using optical fiber sensing, and (3) optimizing the selection of fiber segments to maximize coverage and minimize deployment costs. We implement our methodology in ArcGIS to assess the additional area that can be monitored for low-amplitude ground-motion events (i.e., magnitude >0.5) by utilizing internet fiber-optic cables in the 100 most populous MSAs in the United States. We find that the addition of internet fiber-based sensors in MSAs would increase the area monitored on average by over an order of magnitude from 1% to 12%, if the subset of fiber cable segments that maximize coverage and minimize deployment costs is chosen even if only 20% of all fibers are used.

58 GEOSCIENCES↗

DOE OSTI2021

Fiber optic system for direct detection of CO 2 leakage in carbon storage wells (Abbreviated Final Report)

The feasibility study focused on the development of new fiber for distributed chemical sensing that will allow direct detection of CO2 leakages in the environment. This is particularly important for monitoring well integrity for carbon capture and storage (CSS), which can provide early warning for an incoming well failure and potential CO2 leaking through it. We proposed Raman or IR interrogation within gas-filled Holey Fibers (HoFs) interleaved with Fiber Bragg Grating (FBG) sections, so that the location and concentration of the gases would be provided simultaneously. The methodology would overcome current roadblocks to using fiber optics for CO2 (and other gases) detection in wells with direct in-situ measurements of concentration along with other important parameters such as temperature and pressure. We were able to assess commercially available IR/Raman hollow core fiber and demonstrated detection of CO2 through them in our controlled environment setups at various pressure conditions. We have also established the ability of drilling precisely with fs-lases side holes to enable penetration of CO2 into the hollow core fiber and reduce diffusion rates. Open joint collars were also explored with double functionality: to obtain splice to solid core fiber critical for field deployment and create gas ingress locations. Both diffusion-only and pressurized fiber system have been constructed following COMSOL based semi-hybrid optical /fluidodynamics models. FBGs have been identified and procured and characterized. Along the work we leveraged internal modeling/design, photonics/laser characterization, optical fiber fabrication, and AM lab capabilities to design, develop and test in-house components or assemblies. Our results indicate the potential of HoF for CO2 downhole direct detection.

25 ENERGY STORAGE↗