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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Modelling the interlayer bond strength of 3D printed concrete with surface moisture

Highlights: • An analytical model for interlayer adhesion of 3DPC is proposed based on the amount of surface moisture on the interlayer. • For this mix, the model accurately (RMSE=2.5%) predicts the reduction in interlayer adhesion from 30% to 50%. • Internal curing with superabsorbent polymers increases the interlayer adhesion by 10% and flexural strength by 19%. • SAPs also improve the initial thixotropy by 49% and buildability by 25% compared to the reference. Providing additional water to the hydrating cementitious particles is essential to achieve the optimal mechanical performance of the low w/b concrete mixes preferred for 3D printing. This study incorporates superabsorbent polymers (SAP) and additional water in 3D printed concrete (3DPC) to promote the hydration process through delayed internal water release. The study shows that a retentive SAP modifies the rheological development by absorbing the pore fluid for a short period after printing. The absorption-induced stiffening increases the thixotropy and buildability by 49% and 25%, respectively. A retentive SAP increases the flexural strength and interlayer adhesion by 19% and 10%, respectively. This is due to the internal water release that promotes hydration. Evaporation of the interlayer moisture during the pass time has the opposite effect— evaporation reduces the interlayer adhesion. Based on this assumption, an analytical model is proposed. The model accounts for the pass time, bleeding, and the environmental evaporation rate to estimate the surface moisture and predict the lack of interlayer adhesion. In this study, the model accurately (RMSE = 2.5%) predicted an interlayer adhesion reduction from 30% to 50%. The interlayer adhesion results of other studies could also be predicted.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Limestone calcined clay cement and concrete: A state-of-the-art review

This article reviews the rapidly developing state-of-the-art literature available on the subject of the recently developed limestone calcined clay cement (LC{sup 3}). An introduction to the background leading to the development of LC{sup 3} is first discussed. The chemistry of LC{sup 3} hydration and its production are detailed. The influence of the properties of the raw materials and production conditions are discussed. The mixture design of concrete using LC{sup 3} and the mechanical and durability properties of LC{sup 3} cement and concrete are then compared with other cements. At the end the economic and environmental aspects of the production and use of LC{sup 3} are discussed. The paper ends with suggestions on subjects on which further research is required.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Characterization of paste microstructure for durability properties of concrete

In this study, paste samples from different cementitious systems were characterized by using X-Ray Micro Computed Tomography (µ-CT) and Fluorescence Microscopy techniques. Quantitative and qualitative aspects of defects from paste samples were investigated to develop indicators of durability related properties of corresponding concrete samples. In the first phase of this study, hour glass shaped 3D printed molds were used to investigate five cementitious combinations consisting of three cement types (Coarse Ground portland cement, Type IL Portland Limestone Cement and Type I/II ordinary portland cement) and fly ash as a supplementary cementitious material. In the second phase, metal molds were used to compare the results of Coarse Ground portland cement with Type I ordinary portland cement, 5% of which was replaced with colloidal nanosilica. Potential correlations between paste and concrete have been presented. This work was supported by US Department of Energy and North Dakota Department of Commerce.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Evaluation of alkali–silica reaction damage in concrete using linear and nonlinear resonance techniques

Here in this study, the initiation and development of alkali–silica reaction (ASR) in concrete prisms containing reactive coarse (RCA) and reactive fine (RFA) aggregates were monitored over one year using linear and nonlinear resonance techniques. Although the linear resonance test could detect initiation and development of ASR damage in RCA specimens, it failed in the RFA specimens. Petrographic analysis confirmed the presence of early-stage ASR damage and the presence of different microcracking patterns in the RFA and RCA specimens, which may explain differences in the linear resonance data. For both RCA and RFA specimens, the nonlinear resonance test results were able to detect the initiation of ASR damage and showed a strong correlation with the ASR expansion for all specimens from different mix designs. The results demonstrate the high sensitivity of the nonlinear resonance test and its potential for quantitative evaluation of the ASR damage state of concrete specimens without a baseline measurement.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Biaxial steel plated concrete constitutive models for composite structures: Implementation and validation

The Steel-plated Concrete (SC) technique is an alternative construction technique with faster onsite construction speed, reduced construction time, and increased structural performance. Aiming to predict the force transfer mechanism of SC elements, an innovative constitutive model package is proposed by implementing experimental-based biaxial steel plate concrete models into the nonlinear finite element (FE) model “Membrane Model of SC (MM-CS).” First, the formulation and implementation of the MM-SC is illustrated in detail, including the equilibrium and compatibility equations and the implementation of constitutive models. Next, various experimental data of SC members are selected and simulated using the proposed MM-SC model. In this research, two types of structures, SC panels and framed SC shear walls, and three types of loading conditions, including uniaxial compression, pure shear, and combined axial-flexural-shear tests, are analyzed respectively. Good agreements were obtained between the reported results and the FE simulation results in terms of yield capacity and ultimate capacity, proving the reliability of the implemented analytical constitutive material models and the biaxial membrane model formulations.

42 ENGINEERING↗
DOE OSTI2024

Reassessing early-age strength development of high-volume fly ash concretes for precast buildings

Increasing beneficial use of fresh or landfilled fly ash as a replacement for Portland cement can be more challenging for the construction of precast buildings or similar applications requiring rapid strength development. Therefore, the framework presented in this paper aims to reassess high-volume fly ash concretes but in the context of facilitating more sustainable precast buildings. More specifically, the framework was used to characterize strength development of concrete mixes with a target minimum 24-hour compressive strength of 24.1 MPa (3500 psi), selected as an example strength development metric to demonstrate the framework, and comprised of 40% Class C, Class F, and landfilled (harvested) fly ash – as a high-volume replacement of Type III or Type IL cement. High-early strength was driven by optimized dosages of commercial grade gypsum and accelerating admixtures, in addition to optimal aggregate packing and mix proportioning strategies. Early-age mechanical properties including compressive strength, modulus of rupture, and modulus of elasticity were reevaluated within 24 hours of batching with respect to common precast production demands. Simple data analyses were then used to highlight cases where currently accepted design provisions for the aforementioned properties are either overly-conservative or unconservative with respect to test data. Furthermore, the framework and demonstration of example mixes presented herein aim to promote confidence for using larger fractions of fresh or landfilled fly ashes for precast buildings to further enhance environmental benefits without sacrificing pertinent early-age structural performance.

42 ENGINEERING↗
DOE OSTI2023

Life cycle cost, energy, and carbon emissions of molds for precast concrete: Exploring the impacts of material choices and additive manufacturing

Molds for precast concrete are commonly used to create simple- to complex-shaped concrete products away from construction sites. These molds are often handmade from wood; however, additively manufacturing (AM, or 3D printing) fiber-reinforced polymer composites is an advantageous alternative, producing significantly more durable, highly complex molds faster, but likely at a higher cost. Here, this study explores the impact of material and production variables on the cost, energy, and carbon emissions of employing composite AM molds over the full lifecycle. The case study employed techno-economic and life cycle assessments to show that using wood flour–poly(lactic acid) or recycled carbon fiber–acrylonitrile butadiene styrene for AM molds can be less expensive than conventional wood molds, especially when considering use phase costs. While wood molds have the least environmental impacts due to wood's higher biogenic carbon sequestration and minimal processing, optimizing AM designs could reduce energy demand, carbon emissions, and cost.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Reactive binder and aggregate interfacial zones in the mortar of Tomb of Caecilia Metella concrete, 1C BCE, Rome

Integrated spectroscopic analyses and synchrotron X-ray microdiffraction investigations provide insights into the long-term reactivity of volcanic aggregate components and calcium-aluminum-silicate-hydrate (C-A-S-H) binder in mortar samples from the robust concrete of the sepulchral corridor of the Tomb of Caecilia Metella, 1st C BCE, Rome. The results of innovative micrometer-scale analytical maps indicate that Pozzolane Rosse tephra components–scoria groundmass, clinopyroxene, and leucite crystals–contributed to pozzolanic production of C-A-S-H binder and then remained reactive long after hydrated lime (Ca(OH) 2 ) was fully consumed. The C-A-S-H binding phase is reorganized into wispy halos and tendril-like strands, some with nanocrystalline preferred orientation or, alternatively, split into elongate features with short silicate chain lengths. These microstructures apparently record chemical and structural destabilization of C-A-S-H during excessive incorporation of Al 3+ and K + released through leucite dissolution. Resistance to failure may result from the intermittent toughening of interfacial zones of scoriae and clinopyroxene crystals with post-pozzolanic strätlingite and Al-tobermorite mineral cements and from long-term remodeling of the pozzolanic C-A-S-H binding phase. Roman builders’ selection of a leucite-rich facies of Pozzolane Rosse tephra as aggregate and construction of the tomb in an environment with high surface and ground water exposure apparently increased beneficial hydrologic activity and reactivity in the concrete.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Heating and Cooling Energy Modeling of 3D-Printed Concrete Construction of Residential Buildings [Slides]

3D printed concrete construction (C3DP) is an emerging technology that comes with the associated benefits of high thermal mass walls. We investigated using BEopt software the heating and cooling energy use of a single story C3DP-constructed house. We then compared the heating/cooling energy use of the C3DP house against the corresponding energy use in a traditional timber (wood) frame construction (WFC), as well as a concrete masonry unit (CMU) construction. Both peak energy use for heating and cooling (Btu), as well as base energy use for both heating and cooling (MMBtu/yr) of the C3DP design were compared against the WFC and CMU baseline construction of identical geometries and orientations across all eight climate zones defined in the International Energy Conservation Code (IECC). The BEopt models for all three constructions (C3DP, WFC, and CMU) were built to comply with the 2018 IECC code. Results indicate that C3DP construction has significant heating and cooling energy benefits in certain climate zones, with the highest peak cooling energy savings (9% compared to WFC, and 5% compared to CMU) in the IECC Climate Zone 1 in the month of July. The peak heating and cooling energy demand reduction of C3DP were found to be more significant than the base heating and cooling energy demand in all IECC climate zones. The 2018 IECC compliance-related U-Factor adjustments of all models also resulted in more peak energy savings of the C3DP design in the cooling-dominated climate zones (climate zones 1 and 2), moderate energy savings in moderate climate zones (climate zones 3, 4, and 6), and little to no change in energy savings in very cold climates (climate zones 7 and 8).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Extremely Durable Concrete using Methane Decarbonization Nanofiber Co-products with Hydrogen

This project successfully developed a scalable, low-cost co-production process for hydrogen (H₂) and carbon nanofibers (CNFs) using methane through catalytic chemical vapor deposition (CVD). CNFs are high-value materials with exceptional mechanical, electrical, and chemical properties, while hydrogen is a critical clean energy resource. By leveraging vapor deposition to create highly dispersed metal catalysts, this work addressed the dual challenge of producing low-cost hydrogen and enhancing the durability of concrete using co-produced CNFs. Unlike prior approaches, which required separating the carbon product from the catalyst, this innovative method integrated the carbon product, catalyst, and silica support as a crack-bridging additive for Portland cement. This novel application aimed to advance the performance of high-performance concrete (HPC) by improving its flexural toughness, durability, and resistance to environmental degradation.

08 HYDROGEN↗
DOE OSTI2025

Feasibility Assessment and Preliminary Design of a Low Cost, Modular Concrete, Suction Pile Support Structure and Heavy Lift Vessel Alternative (CRADA Final Report)

The project goal is to prove the feasibility and advance the development of a low-cost, modular concrete suction pile support structure and heavy lift vessel alternative for offshore wind deployment in the United States. These technology developments are critical to alleviating specific challenges faced by the United States market, including a limited number of Jones Act-compliant installation vessels and environmental restrictions associated with using conventional offshore wind foundations. The first phase of this project is a conceptual design and feasibility assessment of modular concrete substructure options for NREL’s 15 MW reference turbine.

17 WIND ENERGY↗
DOE OSTI2021

A Computational Study of the Shear Behavior of Reinforced Concrete Beams Affected from Alkali–Silica Reactivity Damage

In this study, an investigation of the shear behavior of full-scale reinforced concrete (RC) beams affected from alkali–silica reactivity damage is presented. A detailed finite element model (FEM) was developed and validated with data obtained from the experiments using several metrics, including a force–deformation curve, rebar strains, and crack maps and width. The validated FEM was used in a parametric study to investigate the potential impact of alkali–silica reactivity (ASR) degradation on the shear capacity of the beam. Degradations of concrete mechanical properties were correlated with ASR expansion using material test data and implemented in the FEM for different expansions. The finite element (FE) analysis provided a better understanding of the failure mechanism of ASR-affected RC beam and degradation in the capacity as a function of the ASR expansion. The parametric study using the FEM showed 6%, 19%, and 25% reduction in the shear capacity of the beam, respectively, affected from 0.2%, 0.4%, and 0.6% of ASR-induced expansion.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Integrating Predictions for Improving Defect Classification Accuracy in NDT-based Assessment of Concrete - 20229

There is an increasing need to create predictive models for defect classification in concrete using the output of non-destructive testing (NDT) techniques. Recent advancement of machine-learning algorithms has offered several techniques for developing classification models for different types of data sets. However, the performance of these algorithms is very uncertain, mainly when applied to small and noisy datasets. For example, when human access is limited (e.g., nuclear facility), robot-based NDT is preferred. But compared to manual tests with humans present on site, the data sets are small, and more noise can exist. Therefore, it is imperative to develop new approaches to ensure a consistently high classification accuracy for inadequate data sets. This study explores the classification performance on NDT dataset using classifiers from different machine-learning algorithms, namely k-Nearest Neighbor (kNN), Decision Tree, Naive Bayes, Logistic Regression, and Support Vector Machine (SVM). The authors further integrated the predictions from these classifiers using proposed methods. The integration strategy combines the output of the classifiers based on two different measures, accuracy, and performance (ACC and PERF), using equations such as sum, average, and square-root-of-sums-of-squares (SRSS). Our results reveal varying classification accuracies across individual classifiers with different misclassifications across the test data set. The integration strategy provided significant improvement in the classification accuracy compared to the individual classifiers. Furthermore, the results indicate minimal variation across the integration methods as compared to the variation across the individual classifiers. To conclude, prediction integration offers a unique approach for combining the output of multiple classifiers to create redundancies with the potential of achieving high classification performance and improved reliability in predictive models for defect detection in concrete. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Test for Reconditioning RA Waste with Simulated Bitumen and Concrete in a 1,2 MW Plasma Test Facility - 20092

The operation and maintenance of nuclear power plants, the non nuclear fuel cycle, etc generate low-level radioactive waste which, along with the historical radioactive waste from past nuclear activities, needs to be treated and stored, awaiting final disposal. Plasma technology offers a very effective way of treating this waste with a high volume reduction factor (VRF), free from organics, liquids and moisture, and meets without a doubt the acceptance criteria for safe storage and disposal. By means of a plasma beam of approximately 5000 deg. C, the inorganic materials are melted into a glassy slag, containing most of the radioactive isotopes while the organic material is gasified, oxidized and purified in an off-gas cleaning system. First the paper describes the new full-scale Plasma Melting Facility (PMF) at the Kozloduy Nuclear Power Plant in Bulgaria which was taken in nuclear operation In May 2018. The plant has a capacity of 250 tons per year and the maximum contact dose rates of the incoming waste is 2 mSv/h. Different mixtures of radioactive waste packed in 200 l drums were successfully treated resulting in a glassy slag free from liquids and organic material with an important volume reduction factor (VRF). The Project was co-financed through a grant by Kozloduy International Decommissioning fund (KIDSF) administrated by the EBRD through Bulgarian national funding. Plasma is a suitable technology for treatment of problematic waste or even reconditioning waste so Belgoprocess was contracted to do plasma tests with simulated conditioned waste types. One can do tests on a laboratory scale on smaller samples and torch capacities of e.g. 50 kW but Belgoprocess wanted to do more realistic and reliable tests. So Belgoprocess contracted Phoenix Solutions Co who has a full-scope test facility equipped with a 1200 kW plasma torch for full-scope treatment of simulated conditioned waste. For a first confidential contract simulated 200 l (55 gallon) bitumen drums were treated. The drums contained different pucks of compacted waste such as rags, used filters, granulates, etc. The pucks were stacked in the 200 l drums and subsequently embedded with bitumen. A total of 6 drums were treated in the plasma facility. For a second contract simulated homogeneous 200 l (55 gallon) concrete drums with on the one hand concentrates and on the other hand spent resins were selected. A total of 6 drums with concrete and spent resins were treated and melted in the plasma testing facility. The paper describe the test facility, volume reduction factor (VRF) of different waste streams and most important parameters. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Transfer learning for probabilistic localization of hidden cracks in concrete structures

Abstract The utility of discriminative supervised learning models built using multiple training-data sources is investigated for hidden crack localization in concrete. Feed-forward neural network (FFNN) is chosen as the model architecture, and transfer learning is used to assimilate the information obtained from different sources (computational physics simulations and laboratory experiments). The labeled training data consists of values of a damage index and the known locations of hidden cracks. The classification models need to learn how the presence of damage (hidden cracks) affects the damage index at different sensors for different test conditions. To this end, diagnostic FFNN models are built by sequentially adding and training new hidden layers to assimilate labeled information from computer models (different model geometries, test conditions, crack lengths, crack locations) and laboratory experiments on a plain cement slab. These transfer learning-based models are then used to localize damage in concrete specimens that reflect real-world conditions (i.e., specimens with steel reinforcement and randomly distributed aggregate). The actual damage state in these specimens is determined by extracting cores and performing petrographic studies on the extracted cores. The damage probability estimated by transfer learning-based models is compared with the petrographic damage rating index (DRI) to identify the most suitable approach to train the diagnostic models. The transfer learning-based diagnostic methodology shows promise and could be used in various structural health monitoring applications, where sufficient labeled data are typically not available from a single data source.

Miele, S.↗
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 OSTI2022

Evaluation and beneficiation of high sulfur and high alkali fly ashes for use as supplementary cementitious materials in concrete

Coal-fuel power plants with semi-dry or dry flue gas desulfurization (FGD) systems produce high sulfur and/or high alkali fly ashes due to comingling of fly ash with FGD products. Such fly ashes do not meet the SO 3 content limit (5.0% max.) of ASTM C618 or are unable to mitigate the alkali-silica reaction. The mineralogy of the sulfur present in these ashes can vary significantly (e.g., CaSO 4 , CaSO 3 , Na2SO 4 ) based on the FGD technology used and this affects the performance of these fly ashes in concrete. Thus, the single SO 3 % limit of ASTM C618 is unable to capture the complexity and performance of fly ash, and this results in elimination of potentially viable pozzolans for concrete. Here this study performs a systematic investigation of the effect of SO 3 type and content in fly ash on various performance parameters of cement-fly ash pastes and mortars, including workability (flow and flow retention), pore fluid pH, setting time, strength development, and potential for deleterious expansion. To better quantify and understand these effects, the study considers both real and doped fly ashes (i.e., a blend of specification-compliant fly ash with target sulfur compounds). The poor performance observed in the case of setting time and pore fluid pH was successfully mitigated using chemical admixtures.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Radiation-induced alteration of sandstone concrete aggregate

This study investigates the alteration of felsic sandstone-type rock, which is used as a coarse aggregate in concrete, subject to the effects of gamma-ray and neutron irradiation. The effects of three gamma-ray doses (27, 55, and 108 MGy) and four neutron fluence levels (1.22, 2.19, 6.99, and 14.30 × 10 19 n/cm 2 , $E$ ≥ 0.01 MeV) were investigated. Quartz and albite were found to be the major rock-forming minerals, with microcline intermediates, chlorite, and muscovite as the minors. Gamma rays caused no significant changes to the physical properties of the sandstone aggregates, even at high doses (108 MGy). In contrast, neutron irradiation caused alterations that became more pronounced at higher neutron fluences. The solid was confirmed to expand through metamictization of the rock-forming minerals. Quartz and muscovite were the most affected phases, whereas albite and microcline intermediates were only slightly affected, and chlorite was almost unaffected. The decrease in density was measured by He and water pycnometry, and this value was almost reproduced by calculations using the rock-forming mineral composition of the pristine sample measured using X-ray powder diffraction/Rietveld analysis and the cell volume change of the major forming minerals. In addition, light optical microscopy and scanning electron microscopy images confirmed the presence of intergranular and intragranular cracks. Intergranular cracks appeared to have initiated from the quartz grains, which expanded significantly. The intragranular cracks were frequently observed in the albite and microcline intermediates. These cracks can be described as radial cracks starting from the expanding quartz, caused by enforced displacement for deformation consistency with quartz expansion. The crack area ratio quantified by SEM image analysis corresponds to the discrepancy of the volume expansion difference calculated by He or water pycnometry and dimensional change measurements. In conclusion, an evaluation of solid expansion and crack openings in aggregates is important to estimate concrete degradation.

36 MATERIALS SCIENCE↗