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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Correlating processing variables to material properties in recycled polypropylene: A data‐driven approach

Abstract Polypropylene (PP) is one of the most widely used plastics, yet its recycling remains limited, with less than 1% of solid waste PP being reprocessed. Mechanical recycling through extrusion is the most practical method, but inconsistent reprocessing conditions introduce variability in material properties. While temperature, screw speed, and residence time influence the thermomechanical stress applied during reprocessing, there are no standardized guidelines for optimizing these parameters. This study examines how these factors shape the properties of recycled PP, using conditions designed to mimic post‐industrial recycled (PIR) scrap. Residence time was measured using colorimetric tracking and correlated with molecular weight, viscosity, and mechanical properties over multiple extrusion cycles. Data‐driven modeling, including response surface methodology, support vector machines, and artificial neural networks, identified processing temperature as the dominant factor in material degradation, followed by residence time. Mechanical properties remained stable, while viscosity decreased predictably with increasing residence time. By linking reprocessing conditions to property evolution, this study provides a method to optimize processing parameters and reduce variability in recycled PP. These findings help manufacturers improve process control, making recycled PP more predictable for reuse in manufacturing. Highlights Study of PIR‐quality PP without additives or compatibilizers. Residence time analysis shows processing temperature drives PP property changes. Mark‐Houwink enables quick molecular weight checks for quality control. Models predict mechanical and rheological shifts in reprocessing. Optimized processing parameters minimize property degradation in recycling.

Estela‐García, John E. [Polymer Engineering Center↗
DOE OSTI2020

Calibration of CDM-Based Creep Constitutive Model Using Accelerated Creep Test (ACT) Data

In conventional creep testing (CCT) a specimen is subject to constant load and temperature for a long-duration until creep rupture occurs. Conventional testing can be costly when considering the number of experiments needed to characterize the creep response of a material over a range of stress and temperature. To predict long-term creep-rupture properties, the time-temperature-stress superposition principle (TTSSP) approach has been employed where stress and/or temperature is applied at an elevated level; the result of which are extrapolated down to low stress and/or temperature conditions. These methods have been successful in predicting minimum-creep-strain-rate (MCSR) and stress-rupture (SR) but suffer from an inability to predict the creep deformation curve or account for changes in deformation mechanisms or aging that occurs at long-duration. An accelerated technique, termed the Stepped isostress method (SSM) allows the accelerated testing of materials to determine their creep deformation response. Unlike TTSSP tests, the SSM test employs a single specimen where the stress is periodically step increased until rupture. The SSM creep deformation curve is processed (time and strain shifted) to produce an accelerated creep deformation curve that represent the creep deformation curve at the initial stress level in SSM. A processing procedure for metals has yet to be developed. The research objective of this study is to develop a processing procedure for SSM test data using a creep-damage constitutive model. Triplicate SSM tests were conducted on Ni-based superalloy Inconel 718 at 650°C with stress being periodically increased until rupture. Triplicate CCT tests were conducted at the initial stress level of the SSM tests. The Sine-hyperbolic (Sinh) creep-damage model was employed in this study. The Sinh creep-damage constitutive model is based on coupled creep strain rate and damage evolution equations; where both rates are dependent on the current state of damage. Calibration is two-step: analytical and numerical optimization. Each stepped creep deformation curve is tackled quasi-analytically to determine MCSR and SR related material constants and accumulated damage. The damage accumulated at the end of each step was then passed onto subsequent steps to calibrate the MCSR, rupture prediction, and damage evolution. Numerical optimization was applied to optimize model constants involved in the creep strain constitutive equations in order to generate best-fitted Sinh creep deformation curves. The Sinh model predictions were compared to the SSM and CCT data. The Sinh model satisfactorily predicts the SSM data and thus the calibrated material constants provides a good estimate of rupture found in the CCT data. Calibration using SSM data reduces the number of tests needed to calibrate a model; significantly reducing costs. A single SSM test replaces numerous creep tests at different stresses.

36 MATERIALS SCIENCE↗
NASA NTRS1994

Raman-shifting an ArF excimer laser to generate new lines for obtaining optical diagnostic based information in flow fields

The application of tunable excimer lasers in combustion and flow diagnostics is almost routine nowadays. The properties of this laser system that enable density and temperature measurements in supersonic and hypersonic flow fields to be conducted are its high power, high repetition rate, and high spectral brightness. The limitation imposed by this system on these measurements is the paucity of lines in the wavelength region, the vacuum-ultraviolet, where species of interest, such as OH, N2, O2, H2, H2O, CO, NO, etc., are susceptible to electronic excitation to high-lying states. To circumvent this problem one normally resorts to nonlinear optical techniques such as frequency conversion via stimulated Raman scattering (SRS), more commonly known as Raman shifting or Raman mixing, to extend these nonintrusive and nonperturbing techniques to the shorter wavelengths in the VUV region and, for that matter, to longer wavelengths in the infrared region, if the need arises. The theoretical basis of SRS and its application are well documented in the literature. In essence, the Raman shift is a consequence of the inelastic scattering of the incident radiation by the sample. Most of the scattered radiation from the molecules of the sample is unchanged in frequency. However, a small fraction of the incident radiation is changed in frequency. This shift is a result of the fact that some of the incident photons on colliding with the molecules of the sample give up some of their energy and emerge with a lower energy resulting in the lower-frequency Stokes radiation. Other incident photons may increase their energy by colliding with the vibrationally excited molecules of the medium and emerge as higher-frequency antistokes radiation. The generation of the latter is the main objective of this project. The process, however, depends on several factors, including the beam quality of the pump laser, the cross-section of the gaseous medium, the gas pressure, and the ambient temperature of the gas near the focal region. Furthermore, since the Raman shifting process is polarization sensitive, it is necessary to have all of the laser energy in a single polarization. These factors were taken into consideration in the execution of the project. The implementation of the Raman shift was accomplished by focusing the 193 nm output of an ArF excimer laser (Lamda-Physik LPX 150) into a 1-meter long high pressure recirculating Raman cell filled with H2 gas. The laser system was modified in order to improve the mode quality of the pump beam to enhance the Raman shifting. To accomplish this feat, a prism beam expander and grating on the oscillator discharge provided wavelength tuning over the excimer gain profile. Furthermore, a triple-pass configuration, as opposed to unstable resonator optics, was employed in the operation of the amplifier cavity so that when the oscillator output radiation, focused by a 51-cm focal length fused silica lens through a 50 micron pinhole (serving as a spatial filter) and recollimated with a 25-cm focal length lens, was fed into the amplifier, it was injection locked, thereby providing tunable radiation with relatively low divergence. The forward scattered radiation emanating from the impingement of the modified pump beam on the Raman cell was detected using an energy meter after the latter had been separated from it using a dispersing prism.

Koker, Edmond B.↗
NASA NTRS1998

Effects of 1997-1998 El Nino on Tropospheric Ozone and Water Vapor

This paper analyzes the impact of the 1997-1998 El Nino on tropospheric column ozone and tropospheric water vapor derived respectively from the Total Ozone Mapping Spectrometer (TOMS) on Earth Probe and the Microwave Limb Scanning instrument on the Upper Atmosphere Research Satellite. The 1997-1998 El Nino, characterized by an anomalous increase in sea-surface temperature (SST) across the eastern and central tropical Pacific Ocean, is one of the strongest El Nino Southern Oscillation (ENSO) events of the century, comparable in magnitude to the 1982-1983 episode. The major impact of the SST change has been the shift in the convection pattern from the western to the eastern Pacific affecting the response of rain-producing cumulonimbus. As a result, there has been a significant increase in rainfall over the eastern Pacific and a decrease over the western Pacific and Indonesia. The dryness in the Indonesian region has contributed to large-scale burning by uncontrolled wildfires in the tropical rainforests of Sumatra and Borneo. Our study shows that tropospheric column ozone decreased by 4-8 Dobson units (DU) in the eastern Pacific and increased by about 10-20 DU in the western Pacific largely as a result of the eastward shift of the tropical convective activity as inferred from National Oceanic and Atmospheric Administration (NOAA) outgoing longwave radiation (OLR) data. The effect of this shift is also evident in the upper tropospheric water vapor mixing ratio which varies inversely as ozone (O3). These conclusions are qualitatively consistent with the changes in atmospheric circulation derived from zonal and vertical wind data obtained from the Goddard Earth Observing System data assimilation analyses. The changes in tropospheric column O3 during the course of the 1997-1998 El Nino appear to be caused by a combination of large-scale circulation processes associated with the shift in the tropical convection pattern and surface/boundary layer processes associated with forest fires in the Indonesian region.

Chandra, S.↗
NASA NTRS2004

Transitional Bubble in Periodic Flow Phase Shift

One particular characteristic observed in unsteady shear layers is the phase shift relative to the main flow. In attached boundary layers this will have an effect both on the instantaneous skin friction and heat transfer. In separation bubbles the contribution to the drag is dominated by the pressure distribution. However, the most significant effect appears to be the phase shift on the transition process. Unsteady transition behaviour may determine the bursting of the bubble resulting in an un-recoverable full separation. An early analysis of the phase shift was performed by Stokes for the incompressible boundary layer of an oscillating wall and an oscillating main flow. An amplitude overshoot within the shear layer as well as a phase shift were observed that can be attributed to the relatively slow diffusion of viscous stresses compared to the fast change of pressure. Experiments in a low speed facility with the boundary layer of a flat plate were evaluated in respect to phase shift. A pressure distribution similar to that on the suction surface of a turbomachinery aerofoil was superimposed generating a typical transitional separation bubble. A periodically unsteady main flow in the suction type wind tunnel was introduced via a rotating flap downstream of the test section. The experiments covered a range of the three similarity parameters of momentum-loss-thickness Reynolds-number of 92 to 226 and Strouhal-number (reduced frequency) of 0.0001 to 0.0004 at the separation point, and an amplitude range up to 19 %. The free stream turbulence level was less than 1% .Upstream of the separation point the phase shift in the laminar boundary layer does not appear to be affected significantly bay either of the three parameters. The trend perpendicular to the wall is similar to the Stokes analysis. The problem scales well with the wave velocity introduced by Stokes, however, the lag of the main flow near the wall is less than indicated analytically. The separation point comes closest to the Stokes analysis but the phase is still 20 degrees lower at the wall.

Talan, M.↗
DOE OSTI2017

Understanding and controlling chromaticity shift in LED devices

Chromaticity shift in light-emitting diode (LED) devices arises from multiple mechanisms, and at least five different chromaticity shift modes (CSMs) have been identified to date. This paper focuses on the impacts of irreversible phosphor degradation as a cause of chromaticity shifts in LED devices. The nitride phosphors used to produce warm white LEDs are especially vulnerable to degradation due to thermal and chemical effects such as reactions with oxygen and water. As a result, LED devices utilizing these phosphors were found to undergo either a green shift or, less commonly, a red shift depending on the phosphor mix in the LED devices. These types of chromaticity shifts are classified as CSM-2 (green shift) and CSM-5 (red shift). This paper provides an overview of the kinetic processes responsible for green and red chromaticity shifts along with examples from accelerated stress testing of 6” downlights. Both CSMs appear to proceed through analogous mechanisms that are initiated at the surface of the phosphor. A green shift is produced by the surface oxidation of the nitride phosphor that changes the emission profile to lower wavelengths. As the surface oxidation reaction proceeds, reactant limitations slow the rate and bulk oxidation processes become more prevalent. We found that a red chromaticity shift arises from quenching of the green phosphor, also possibly due to surface reactions of oxygen, which shift the emission chromaticity in the red direction. In conclusion, we discuss the implications of these findings on projecting chromaticity.

Davis, Lynn↗
DOE OSTI2016

The role of fission on neutron star mergers and its impact on the r-process peaks

The comparison between observational abundance features and those obtained from nucleosynthesis predictions of stellar evolution and/or explosion simulations can scrutinize two aspects: (a) the conditions in the astrophysical production site and (b) the quality of the nuclear physics input utilized. Here we test the abundance features of r-process nucleosynthesis calculations using four different fission fragment distribution models. Furthermore, we explore the origin of a shift in the third r-process peak position in comparison with the solar r-process abundances which has been noticed in a number of merger nucleosynthesis predictions. We show that this shift occurs during the r-process freeze-out when neutron captures and β-decays compete and an (n,γ)-(γ,n) equilibrium is not maintained anymore. During this phase neutrons originate mainly from fission of material above A = 240. We also investigate the role of β-decay half-lives from recent theoretical advances, which lead either to a smaller amount of fissioning nuclei during freeze-out or a faster (and thus earlier) release of fission neutrons, which can (partially) prevent this shift and has an impact on the second and rare-earth peak as well.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2017

Investigation of the Influence of Heat Balance Shifts on the Freeze Microstructure and Composition in Aluminum Smelting Bath System: Cryolite-CaF{sub 2}-AlF{sub 3}-Al{sub 2}O{sub 3}

In an aluminum electrolysis cell, the side ledge forms on side walls to protect it from the corrosive cryolitic bath. In this study, a series of laboratory analogue experiments have been carried out to investigate the microstructure and composition of side ledge (freeze linings) at different heat balance steady states. Three distinct layers are found in the freeze linings formed in the designed Cryolite-CaF{sub 2}-AlF{sub 3}-Al{sub 2}O{sub 3} electrolyte system: a closed (columnar) crystalline layer, an open crystalline layer, and a sealing layer. This layered structure changes when the heat balance is shifted between different steady states, by melting or freezing the open crystalline layer. Phase chemistry of the freeze lining is studied in this paper to understand the side ledge formation process upon heat balance shifts. Electron probe X-ray microanalysis (EPMA) is used to characterize the microstructure and compositions of distinct phases existing in the freeze linings, which are identified as cryolite, chiolite, Ca-cryolite, and alumina. A freeze formation mechanism is further developed based on these microstructural/compositional investigations and also thermodynamic calculations through the software—FactSage. It is found that entrapped liquid channels exist in the open crystalline layer, assisting with the mass transfer between solidified crystals and bulk molten bath.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Photocatalytic activity of erbium-doped TiO{sub 2} nanoparticles immobilized in macro-porous silica films

Highlights: Black-Right-Pointing-Pointer Erbium-doped TiO{sub 2} nanoparticles were immobilized on macro-porous silica films. Black-Right-Pointing-Pointer The films were obtained by a phase separation process. Black-Right-Pointing-Pointer The samples exhibited photo-catalytic activity under visible light. Black-Right-Pointing-Pointer The sensitization of TiO{sub 2} was attributed to a red shift in the TiO{sub 2} band-gap. -- Abstract: A macro-porous silica film served as mechanical support to immobilize TiO{sub 2} nanoparticles, which were doped with erbium. The films and the nanoparticles were prepared by sol-gel route. The nanoparticles exhibited photocatalytic activity under visible light. We obtained a degradation rate of methylene blue that followed first order kinetics. The sensitization of the nanoparticles to visible light was attributed to a red shift in the band-gap of the TiO{sub 2} due to the addition of erbium ions.

36 MATERIALS SCIENCE↗
DOE OSTI2016

DOE-HEP Final Report for 2013-2016: Studies of plasma wakefields for high repetition-rate plasma collider, and Theoretical study of laser-plasma proton and ion acceleration

There were two goals for this funded project: 1. Studies of plasma wakefields for high repetition-rate plasma collider, and 2. Theoretical study of laser-plasma proton and ion acceleration. For goal 1, an analytical model was developed to determine the ion-motion resulting from the interaction of non-linear “blow-out” wakefields excited by beam-plasma and laser-plasma interactions. This is key to understanding the state of the plasma at timescales of 1 picosecond to a few 10s of picoseconds behind the driver-energy pulse. More information can be found in the document. For goal 2, we analytically and computationally analyzed the longitudinal instabilities of the laser-plasma interactions at the critical layer. Specifically, the process of “Doppler-shifted Ponderomotive bunching” is significant to eliminate the very high-energy spread and understand the importance of chirping the laser pulse frequency. We intend to publish the results of the mixing process in 2-D. We intend to publish Chirp-induced transparency. More information can be found in the document.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Additive manufacturing of a metastable high entropy alloy: Metastability engineered microstructural control via process variable driven elemental segregation

Compositional paradigm shift in high entropy alloys (HEAs) provided new opportunities for microstructural engineering, whereas process control during laser powder bed fusion (LPBF) additive manufacturing (AM) enable fine microstructure tailoring. Metastability engineering in transformation induced plasticity (TRIP) HEAs by addition of minor alloying elements is an attractive strategy for fine microstructural tuning. This study explored in detail the microstructural evolution during LPBF AM of a metastable Fe 40 Mn 20 Co 20 Cr 15 Si 5 (at.%) dual phase HEA (CS-HEA). LPBF processing window for CS-HEA was established based on quantitative analysis and experiments. Based on melt pool overlap lack of fusion pores were observed at lower energy densities (J) of $\textit{J}$ ≤ 31.25 J/mm 3 and key-hole formation by melt pool destabilization in case of $\textit{J}$ ≥ 75 J/mm 3 . The microstructure of CS-HEA consists of metastable FCC-γ and HCP-ε phases; LPBF process parameters governed the final phase fraction in the alloy which has been correlated to metastability alteration of the high temperature γ phase. Final microstructural engineering was devised by LPBF process control which enabled cooling rate manipulation to guide Mn and Si segregation at the cell boundaries, thereby controlling the matrix metastability and final phase fraction. Additionally, high resolution transmission electron microscopy (TEM) revealed disparity in stacking fault morphology in CS-HEA with LPBF process variable alterations associated with local variations in chemical composition and stacking fault energy. Further, the phase evolution with process parameters also affected the nanomechanical behavior of the alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Poly(vinylidene fluoride) (PVDF) Binder Degradation in Li–O 2 Batteries: A Consideration for the Characterization of Lithium Superoxide

We show that a common Li–O 2 battery cathode binder, poly(vinylidene fluoride) (PVDF), degrades in the presence of reduced oxygen species during Li–O 2 discharge when adventitious impurities are present. This degradation process forms products that exhibit Raman shifts (~1133 and 1525 cm –1 ) nearly identical to those reported to belong to lithium superoxide (LiO 2 ), complicating the identification of LiO 2 in Li–O 2 batteries. We show that these peaks are not observed when characterizing extracted discharged cathodes that employ poly(tetrafluoroethylene) (PTFE) as a binder, even when used to bind iridium-decorated reduced graphene oxide (Ir-rGO)-based cathodes similar to those that reportedly stabilize bulk LiO 2 formation. We confirm that for all extracted discharged cathodes on which the 1133 and 1525 cm –1 Raman shifts are observed, only a 2.0 e – /O 2 process is identified during the discharge, and lithium peroxide (Li 2 O 2 ) is predominantly formed (along with typical parasitic side product formation). In conclusion, our results strongly suggest that bulk, stable LiO 2 formation via the 1 e – /O 2 process is not an active discharge reaction in Li–O 2 batteries.

25 ENERGY STORAGE↗
DOE OSTI2017

Electrical and seismic response of saline permafrost soil during freeze - Thaw transition

We conducted laboratory studies on the geophysical signals from Arctic saline permafrost soils to help understand the physical and mechanical processes during freeze-thaw cycles. Our results revealed low electrical resistivity (< 20 Ωm) and elastic moduli (7.7 GPa for Young's modulus and 2.9 GPa for shear modulus) at temperatures down to ~- 10 °C, indicating the presence of a significant amount of unfrozen saline water under the current field conditions. The spectral induced polarization signal showed a systematic shift during the freezing process, affected by concurrent changes of temperature, salinity, and ice formation. An anomalous induced polarization response was first observed during the transient period of supercooling and the onset of ice nucleation. Seismic measurements showed a characteristic maximal attenuation at the temperatures immediately below the freezing point, followed by a decrease with decreasing temperature. The calculated elastic moduli showed a non-hysteric response during the freeze – thaw cycle, which was different from the concurrently measured electrical resistivity response where a differential resistivity signal is observed depending on whether the soil is experiencing freezing or thawing. The differential electrical resistivity signal presents challenges for unfrozen water content estimation based on Archie's law. Using an improved formulation of Archie's law with a variable cementation exponent, the unfrozen water content estimation showed a large variation depending on the choice of the resistivity data during either a freezing or thawing cycle. Combining the electrical and seismic results, we suggest that, rather than a large hysteresis in the actual unfrozen water content, the shift of the resistivity response may reflect the changes of the distribution pattern of the unfrozen water (or ice) in the soil matrix during repeated freeze and thaw processes. Collectively, our results provide an improved petrophysical understanding of the physical and mechanical properties of saline permafrost during freeze – thaw transitions, and suggest that large uncertainty may exist when estimating the unfrozen water content using electrical resistivity data.

58 GEOSCIENCES↗
NASA NTRS2012

Mars in Situ Resource Utilization Technology Evaluation

We have examined the technologies required to enable Mars In-Situ Resource Utilization (ISRU) because our understanding of Mars resources has changed significantly in the last five years as a result of recent robotic missions to the red planet. Two major developments, (1) confirmation of the presence of near-surface water in the form of ice in very large amounts at high latitudes by the Phoenix Lander and (2) the likely existence of water at lower latitudes in the form of hydrates or ice in the top one meter of the regolith, have the potential to change ISRU technology selection. A brief technology assessment was performed for the most promising Mars atmospheric gas processing techniques: Reverse Water Gas Shift (RWGS) and Methanation (aka Sabatier), as well as an overview of soil processing technology to extract water from Martian soil.

Muscatello, Anthony C.↗
DOE OSTI2026

Data for Zheng et al. (2025), "AquaMEND: Reconciling multiple impacts of salinization on soil carbon biogeochemistry"

Soil salinization, exacerbated by climate change, poses a global threat to coastal ecosystems and soil function. Salinity affects soil carbon cycling by directly impacting microbial activity and indirectly altering soil physicochemical properties, but current models inadequately represent these complexities. This dataset contains the observational and modeling data from Zheng et al. (2025), which described a process-based modeling framework that couples soil solution chemistry with microbial carbon cycling reactions to study the impacts of soil salinization. This conceptual model is implemented numerically into the open-source geochemical program PHREEQC 3.0 (Parkhurst and Appelo, 2013). This dataset consists of: - Figure2_AquaMEND_salinity_buffer: Contains model simulation outputs to assess the impact of three different cation exchange and surface complexation processes on salinity buffering (Fig. 2 from Zheng et al. 2025). - Figure3_Salinity_function: Contains salinity function fitting for literature data (Fig. 3 from Zheng et al. 2025). - Figure4_AquaMEND_microbial_mechanisms: Contains model simulation outputs for testing various microbial process-based hypotheses related to soil salinization, including microbial mortality, carbon use efficiency (CUE), extracellular enzyme activity, and other microbial mechanisms (Fig. 4 from Zheng et al. 2025). - Figure5_AquaMEND_Redox: Contains on model simulation outputs to evaluate shifts among key redox processes, such as aerobic respiration, sulfate reduction, and methanogenesis (Fig.5 from Zheng et al. 2025). - Figure6_AquaMEND_sorption: Contains on model simulation outputs for investigating the effects of salinity on dissolved organic matter (DOM) sorption and desorption processes (Fig. 6 from Zheng et al. 2025). - Figure7_AquaMEND_process_couple: Contains on model simulation outputs for exploring coupled biotic-abiotic processes and their interactions (Fig. 7 from Zheng et al. 2025). - data: Includes datasets used to develop salinity response functions and evaluate salinity buffering capacity. Datasets for MEND model calibration. - database: Contains the `.dat` file required by PHREEQC for model execution. - README.md: A Markdown plain text file describing the computational tools and directories. Files are a mixture of plain text CSV (comma-separated value) and plain text *.dat files written by the model; no special software is required to read them.

EARTH SCIENCE > AGRICULTURE > SOILS > SOIL SALINIT↗
NASA NTRSDate not supplied

Generative Design and Digital Manufacturing: Using AI and Robots to Build Lightweight Instruments

Digital Engineering technologies are transforming long-stagnant development processes by applying the tremendous advancements in Information Technology (IT) to classical engineering tasks such as design, analysis, and fabrication of space-flight instrument structures. Generative Design leverages developments in Artificial Intelligence (AI) and Cloud computing to enable a paradigm shift in the design process, allowing the engineer to focus on defining the requirements and objectives of the design while AI generates optimized designs which comply with the input requirements. Digital Manufacturing allows these complex lightweight designs to be efficiently manufactured by directly fabricating from the resulting 3D models. The development of these two Digital Engineering technologies realizes significant mass savings while simultaneously reducing structure development time from months to days. This paper describes the development of the Evolved Structures process applying these technologies to spaceflight optical instrument structures including an example demonstrating greater than 10x reduction in development time/cost and greater than 3x improvement in structural performance.

Ryan McClelland↗
DOE OSTI2024

Microchannel reactive distillation for the conversion of aqueous ethanol to ethylene

Here we demonstrate the proof-of-concept for microchannel reactive distillation for alcohol-to-jet application: combining ethanol/water separation and ethanol dehydration in one unit operation. Ethanol is first distilled into the vapor phase, converted to ethylene and water, and then the water co-product is condensed to shift the reaction equilibrium. Process intensification is achieved through rapid mass transfer—ethanol stripping from thin wicks using novel microchannel architectures—leading to lower residence time and improved separation efficiency. Energy savings are realized with integration of unit operations. For example, heat of condensing water can offset vaporizing ethanol. Furthermore, the dehydration reaction equilibrium shifts towards completion by immediate removal of the water byproduct upon formation while maintaining aqueous feedstock in the condensed phase. For aqueous ethanol feedstock (40% w ), 71% ethanol conversion with 91% selectivity to ethylene was demonstrated at 220 °C, 600 psig, and 0.28 h -1 wt hour space velocity. 2.7 stages of separation were also demonstrated, under these conditions, using a device length of 8.3 cm. This provides a height equivalent of a theoretical plate (HETP), a measure of separation efficiency, of ~3.3 cm. By comparison, conventional distillation packing provides an HETP of ~30 cm. Thus, 9.1× reduction in HETP was demonstrated over conventional technology, providing a means for significant energy savings and an example of process intensification. Finally, preliminary process economic analysis indicates that by using microchannel reactive distillation technology, the operating and capital costs for the ethanol separation and dehydration portion of an envisioned alcohol-to-jet process could be reduced by at least 35% and 55%, respectively, relative to the incumbent technology, provided future improvements to microchannel reactive distillation design and operability are made.

10 SYNTHETIC FUELS↗
DOE OSTI2017

Heat Treatment of Iron-Carbon Alloys in a Magnetic Field (Phase 2)

Thermomagnetic processing was shown to shift the phase transformation temperatures and therefore microstructural evolution in the high performance engine valve spring 9254 steel alloy by applying a high magnetic field during cooling. These effects would be anticipated to improve performance such as high cycle fatigue as demonstrated in prior projects. Thermomagnetic processing of gears and crank shafts was constrained by the size of the prototype equipment currently available at ORNL. However, the commercial procurement viability of production scale 9-Tesla, 16-inch diameter bore thermomagnetic processing equipment for truck idler gears up to ~11-inch diameter and potential crank shaft applications was shown, as multiple superconducting magnet manufacturing companies (in conjunction with an induction heat treating company, AjaxTOCCO Magnethermic) offered cryogen-free or cryocooler equipment designs to Cummins.

36 MATERIALS SCIENCE↗