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At least 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Achieving clean production with nanostructured coated milling tools dry machining low carbon steel

The advancement of clean production using nanostructured materials in subtractive manufacturing processes has focused on replacing the use of liquid lubrication with solid lubricants coated to conventional cutting tools machining low carbon steel (~ 0.2 wt. % carbon). However, little is known about the wear mechanisms that dominate such tools when coated with functional graded nanostructured coatings. The present study follows an international standard for characterizing such wear (ISO 8688) but uses advanced measurement techniques such as x-ray fluorescence technology to measure the diffusion of chemical species from tool to workpiece and vice versa, that contributes to tool wear with the view to enhance the principles of cleaner production. The results show that when commercially-available tools coated with the appropriate functionally graded industrial coating, diffusion does not take place and creates an effective chemical barrier during machining. The experimental methods used in the study include machining workpieces using a CNC milling machine, tachometer for measuring spindle speed, dynamometer for measuring cutting forces, infra-red camera for measuring cutting temperatures, chemical species diffusion wear using x-ray florescence detector, and an optical microscope for measuring tool wear. Coupled with the physical measurement of wear, it is concluded that mechanical wear dominates the milling of a low carbon steel and that thermal properties of the coatings do not correlate with such wear. It is also concluded that flank wear as a function of volume of workpiece removed and machining duration (machining index) is a sound method for assessing the transition of the stages of wear during clean machining operations. The present study not only has implication for the design of better cutting tools, but also advances dry machining processes that eliminate the use of liquid lubricants making subtractive production processes cleaner. The main conclusions drawn from this study show that coated tools have a longer life under dry conditions compared to uncoated tools and that there is no correlation between coating properties and tool wear. In conclusion, diffusion of chemical species into the cut chips did not occur because of the lack of thermally induced chemical wear of the cutting tool and that wear is caused by the gradual erosion of the flank face due to the chip abrading the cutting tool.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Field experiments of surface water to groundwater recharge to characterize the mobility of uranium and vanadium at a former mill tailing site

Characterizing the mobility of uranium and vanadium in groundwater with a hydraulic connection to surface water is important to inform the best management practices of former mill tailing sites. In this study, the recharge of river water to the unsaturated and saturated zones of a uranium-contaminated alluvial aquifer was simulated in a series of forced-gradient single- and multi-well injection-extraction tests. The injection fluid (river water) was traced with natural and artificial tracers that included halides, fluorobenzoates, lithium, and naphthalene sulfonate to characterize the potential mass transport mechanisms of uranium and vanadium. The extraction fluid (river water/groundwater mixture) was analyzed for the tracers, uranium, and vanadium. The results from the tracers indicated that matrix diffusion was likely negligible over the spatiotemporal scales of the tests as evident by nearly identical breakthrough curves of the halides and fluorobenzoates. In contrast, the breakthrough curves of lithium and naphthalene sulfonate indicated that sorption by cation exchange and sorption to organic matter, respectively, were potential mass transport mechanisms of uranium and vanadium. Uranium was mobilized in the saturated zone containing gypsum (gypsum-rich zone), the vadose zone (vadose-rich zone), and the saturated zone containing organic carbon (organic-rich zone) whereas vanadium was mobilized only in the saturated gypsum-rich zone. The mechanisms responsible for the mobilization of uranium and vanadium were likely dissolution of uranium- and vanadium-bearing minerals and/or desorption from the gypsum-rich zone, flushing of uranium from the vadose-rich zone, and desorption of uranium from the organic-rich zone due to the natural contrast in the geochemistry between the river water and groundwater. The experimental design of this study was unique in that it employed the use of multiple natural and artificial tracers coupled with a direct injection of native river water to groundwater. Here, these results demonstrated that natural recharge and flooding events at former mill tailing sites can mobilize uranium, and possibly vanadium, and contribute to persistent levels of groundwater contamination.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Scalable fabrication of high activity nanoporous copper powders for electrochemical CO 2 reduction via ball milling and dealloying

Electrochemical CO 2 reduction (ECR) is a promising technology to close the anthropic CO 2 circle using renewable energy to achieve carbon neutrality. Future commercialization of ECR will require the development of new catalyst synthesis routes that will allow significant upscaling of catalyst production from current research-level milligram quantities to the kilogram scale and beyond while maintaining the activity and selectivity demonstrated at the research level. Here, we report on generating and testing submicron-sized nanoporous copper (npCu) particles by using a scalable approach consisting of ball milling brittle Cu-based intermetallics followed by dealloying to add nanoporosity for high surface area. The resulting npCu particles have been tested in an industry-relevant large area (25 cm 2 ) electrolyzer platform and showed Faraday efficiencies (FE) for ethylene up to 34 % at current densities of 75–100 mA/cm 2 while keeping FE for hydrogen less than 30 %. Our results demonstrate that a combination of ball milling and dealloying is a promising approach to generate large quantities of high activity and high surface area npCu particles for ECR at an industry-relevant scale.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2017

Investigation of nanostructured Al-10 wt.% Zr material prepared by ball milling for high temperature applications

Ground chips of as-cast Al-10 wt.% Zr alloy were subjected to mechanical alloying (MA) with 5 vol.% of nanodiamond addition in a high energy planetary ball-mill. The aim of this work was to investigate the microstructure, phase transformation and mechanical properties of the material both after MA and after subsequent annealing. Optical and transmission electron microscopes were used for morphological and microstructural analysis. The effect of milling time on powder microhardness, Al lattice parameter, lattice microstrain and crystallite size was determined. It was shown that mechanical alloying of as-cast Al-10wt.%Zr alloy during 20 h leads to a complete dissolution of the primary tetragonal Al{sub 3}Zr crystals in aluminum. At the same time, the powder microhardness increases to 370 HV. Metastable cubic Al{sub 3}Zr phase nanoparticles precipitate from the Al solution due to its decomposition after annealing, however, the Al solid solution remains supersaturated and nanocrystalline. Compression tests at room temperature and at 300 °C showed that the strength values of the hot-pressed samples reach 822 MPa and 344 MPa, respectively. - Highlights: •As-cast Al-10 wt.% Zr alloy was mechanically alloyed with 5 vol.% nanodiamond. •The primary tetragonal Al{sub 3}Zr crystals were completely dissolved in Al after 20 h. •Cubic Al{sub 3}Zr phase nanoparticles precipitated from Al solution after aging. •The aged bulk material showed a high strength at room and elevated temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Dielectric and photocatalytic properties of sulfur doped TiO{sub 2} nanoparticles prepared by ball milling

Graphical abstract: - Highlights: • Designing of visible light responsive photocatalyst utilizing ball milling. • Sulphur used as dopant in commercial TiO{sub 2} P25 at different atomic percentage. • S doping resulted in an intense increase in absorption in the visible light region. • Newly design photocatalyst exhibited excellent photocatalytic performance. • 0.11 at.% S-doped TiO{sub 2} shows 3-times higher activity than that of TiO{sub 2} P25. - Abstract: Sulfur (S) doped commercial TiO{sub 2} P-25 has been achieved by changing the amount of thiourea using ball milling technique. The results of XRD clearly reveal biphasial anatase and rutile mixtures for all prepared samples and doping of S does not change the morphology of the TiO{sub 2}. The optical absorption edge of S-doped TiO{sub 2} was red shifted with indirect bandgap energy of 2.8 eV. The dielectric studies confirm that the dielectric constant of TiO{sub 2} increases after doping, however it becomes more conductive. Newly designed S-doped TiO{sub 2} photocatalysts exhibited excellent photocatalytic performance for the degradation of methylene blue (MB) under visible light. The overall photocatalytic activity of 0.11 at.% S-doped TiO{sub 2} was significantly 3-times higher than that of commercial TiO{sub 2} P-25 and complete degradation of MB has taken place after 90 min of irradiation under visible light while only 35% dye degraded when the reaction has been carried out in the presence of undoped TiO{sub 2}.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Highly Al-doped TiO{sub 2} nanoparticles produced by Ball Mill Method: structural and electronic characterization

Highlights: • Highly Al-doped TiO{sub 2} nanoparticles were synthesized using a Ball Mill Method. • Al doping delayed anatase to rutile phase transformation. • Al doping allow controlling the structural and electronic properties of nanoparticles. - Abstract: This study presents an easy method for synthesizing highly doped TiO{sub 2} nanoparticles. The Ball Mill method was used to synthesize pure and Al-doped titanium dioxide, with an atomic percentage up to 15.7 at.% Al/(Al + Ti). The samples were annealed at 773 K, 973 K and 1173 K, and characterized using ICP-AES, XRD, Raman spectroscopy, FT-IR, TG, STEM, XPS, and UV–vis spectroscopy. The effect of doping and the calcination temperature on the structure and properties of the nanoparticles were studied. The results show high levels of internal doping due to the substitution of Ti{sup 4+} ions by Al{sup 3+} in the TiO{sub 2} lattice. Furthermore, anatase to rutile transformation occurs at higher temperatures when the percentage of doping increases. Therefore, Al doping allows us to control the structural and electronic properties of the nanoparticle synthesized. So, it is possible to obtain nanoparticles with anatase as predominant phase in a higher range of temperature.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2016

Microstructure and mechanical properties of Ti–6Al–4V: Mill-annealed versus direct metal laser melted alloys

Additive manufacturing processes such as direct metal laser melting (DMLM) are known to produce highly anisotropic microstructures. The present work compares the microstructure and mechanical properties of DMLM Ti–6Al–4V with that of mill-annealed alloys. Results show that the yield and hardening response of DMLM Ti–6Al–4V does not depend on the testing direction relative to the build direction, while the response of mill-annealed Ti–6Al–4V strongly depends on the testing direction. In conclusion, these results are discussed in light of the microstructure, texture, and polycrystal plasticity modeling.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Entanglement entropy of a color flux tube in (1+1)D Yang–Mills theory

In recent work Amorosso et al. (2024), we computed a novel flux tube entanglement entropy (FTE) of the color flux tube stretched between a heavy quark-antiquark pair on a Euclidean lattice in (2+1)D Yang–Mills theory. Our numerical results suggested that FTE can be partitioned into an internal color entanglement entropy and a vibrational entropy corresponding to the transverse excitations of a QCD string, with the latter described by a thin string model. Since the color flux tube does not have transverse excitations in (1+1)D Yang–Mills theory, we use this simpler framework to perform an exact analytical computation of the contribution of the internal color degrees of freedom to FTE. For the multipartite partitioning of the color flux tube, we find the remarkable result that FTE depends only on the dimension of the color group representation and the number of times the flux tube crosses the boundary between the traced and untraced spatial regions but not on the string length. Our proof is independent of whether the replica and region boundaries on the lattice are placed on vertices or in plaquette centers.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2018

Effect of Pre-reaction Ball Milling on Kinetics of Lanthanum Phosphate Roasting with Sodium Carbonate

To design economic roasting processes for the recovery of rare earth phosphates from coal-derived feedstocks, it is convenient to study model systems of rare earth phosphate plus a reactant. In this work, the kinetics of the high-temperature roasting of lanthanum phosphate with sodium carbonate were studied. It is typically necessary to heat the reaction mixture above the melting point of Na 2 CO 3 (851 °C) to observe appreciable reaction to form La 2 O 3 . Furthermore, grinding the reactants reduces the necessary temperature to as low as 625 °C. It is believed that this increase in reactivity occurs because the ball milling process reduces the reactant particle size in addition to ensuring that the reaction mixture is thoroughly mixed. XRD hot stage results suggest a two-reaction mechanism is the route by which La 2 O 3 is produced from the ball milled sample upon reaction. Apparent activation energy and Arrhenius prefactor for each reaction were determined from TGA experiments.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Wedge-Shaped Hopper Design for Milled Woody Biomass Flow

The bioenergy industry has been challenged by unstable flow and transport of milled biomass in material handling operations. Handling issues such as hopper clogging and auger jamming are attributed to knowledge gaps between existing handling units designed for bulk solids and their suitability for milled biomass with high compressibility. This work investigates various flow behaviors of granular woody biomass in wedge-shaped hoppers. Herein, hopper flow physical experiments and numerical simulations are conducted to study the influence of the critical material attributes and critical processing parameters on the flow pattern, arching, and throughput. The results show that (1) the preferred flow pattern, mass flow, can be achieved by controlling the material’s internal friction angle, hopper inclination, and hopper wall friction; (2) hopper arching, governed by the competing gravity-driven force against flow resistance from material internal friction and material–wall friction, can be controlled by the hopper wall friction angle and the inclination angle; and (3) flow throughput can be accurately estimated from our empirical equation with inputs of hopper outlet geometry and particle-scale to bulk-scale material attributes. This study elucidates woody biomass flow physics and provides guidance for industrial equipment design.

09 BIOMASS FUELS↗
DOE OSTI2015

Microstructure and magnetic properties of MFe{sub 2}O{sub 4} (M = Co, Ni, and Mn) ferrite nanocrystals prepared using colloid mill and hydrothermal method

Three kinds of spinel ferrite nanocrystals, MFe{sub 2}O{sub 4} (M = Co, Ni, and Mn), are synthesized using colloid mill and hydrothermal method. During the synthesis process, a rapid mixing and reduction of cations with sodium borohydride (NaBH{sub 4}) take place in a colloid mill then through a hydrothermal reaction, a slow oxidation and structural transformation of the spinel ferrite nanocrystals occur. The phase purity and crystal lattice parameters are estimated by X-ray diffraction studies. Scanning electron microscopy and transmission electron microscopy images show the morphology and particle size of the as-synthesized ferrite nanocrystals. Raman spectrum reveals active phonon modes at room temperature, and a shifting of the modes implies cation redistribution in the tetrahedral and octahedral sites. Magnetic measurements show that all the obtained samples exhibit higher saturation magnetization (M{sub s}). Meanwhile, experiments demonstrate that the hydrothermal reaction time has significant effects on microstructure, morphologies, and magnetic properties of the as-synthesized ferrite nanocrystals.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Optical and electrical characterizations of a single step ion beam milling mesa devices of chloride passivated PbS colloidal quantum dots based film

Colloidal Quantum Dots (CQDs) are of increasing interest, thanks to their quantum size effect that gives rise to their usage in various applications, such as biological tagging, solar cells and as the sensitizing layer of night vision devices. Here, we analyze the optical absorbance of chloride passivated PbS CQDs as well as revealing a correlation between their photoluminescence and sizes distribution, using theoretical models and experimental results from the literature. Next, we calculate the CQDs resistivity as a film. Although resistivity can be calculated from sheet resistance measurement using four point probes, such measurement is usually carried-out on the layer’s surface that in most cases has dangling bonds and surface states, which might affect the charges flow and modify the resistivity. Therefore; our approach, which was applied in this work, is to extract the actual resistivity from measurements that are performed along the film’s thickness (z-direction). For this intent, we fabricated gold capped PbS mesas devices using a single step Ion Beam Milling (IBM) process where we milled the gold and the PbS film continually, and then measured the vertical resistance. Knowing the mesas’ dimensions, we calculate the resistivity. To the best of our knowledge, no previous work has extracted, vertically, the resistivity of chloride passivated PbS CQDs using the above method.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Simulated Aging of Metal Tritides by Ball Milling Induced Gas Incorporation

The study of tritium aging effects on materials requires a significant time commitment as a consequence of its 12.3-year half-life, making developmental studies prohibitively difficult and expensive. However, detailed knowledge of long-term aging effects is critical to the development of structural and storage materials for future fusion reactor technologies. As a result, multiple approaches to simulated aging effects have been investigated. Here, we report a method of simulated tritium aging achieved though the incorporation of trapped gases via high-energy ball milling of LaNi 4.25 Al 0.75 alloy storage material. Experimental results verify the presence of trapped gases by a combination of temperature programmed desorption and LECO chemical analysis. Following gas incorporation, we find that many of the degraded hydrogen sorption properties found in aged storage materials are reproduced by the ball milled powders.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

A topological way of finding solutions to the Yang–Mills equation

We propose a systematic way of finding solutions to the classical Yang–Mills equation with nontrivial topology. This approach is based on one of the Wightman axioms for quantum field theory, which is referred to as the form invariance condition in this paper. For a given gauge group and a spacetime with certain isometries, thanks to this axiom that imposes strong constraints on the general ansatz, a systematic way of solving the Yang–Mills equation can be obtained in both flat and curved spacetimes. In order to demonstrate this method, we recover various known solutions as special cases, as well as producing new solutions not previously reported in the literature.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2018

Design, fabrication, and high-gradient testing of an X -band, traveling-wave accelerating structure milled from copper halves

A prototype 11.994 GHz, traveling-wave accelerating structure for the Compact Linear Collider has been built, using the novel technique of assembling the structure from milled halves. The use of milled halves has many advantages when compared to a structure made from individual disks. These include the potential for a reduction in cost, because there are fewer parts, as well as a greater freedom in choice of joining technology because there are no rf currents across the halves’ joint. Here we present the rf design and fabrication of the prototype structure, followed by the results of the high-power test and post-test surface analysis. During high-power testing the structure reached an unloaded gradient of 100 MV / m at a rf breakdown rate of less than 1.5×10 –5 breakdowns / pulse / m with a 200 ns pulse. Furthermore, this structure has been designed for the CLIC testing program but construction from halves can be advantageous in a wide variety of applications.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Nonperturbative phase diagram of two-dimensional N = ( 2 , 2 ) super-Yang-Mills theory

We consider two-dimensional N = ( 2 , 2 ) Yang-Mills theory with gauge group SU ( N ) in Euclidean signature compactified on a torus with thermal fermion boundary conditions imposed on one cycle. We perform nonperturbative lattice analyses of this theory for large 12 ≤ N ≤ 20 . Although no holographic dual of this theory is yet known, we conduct numerical investigations to check for features similar to the two-dimensional N = ( 8 , 8 ) Yang–Mills theory, which has a well-defined gravity dual. We perform lattice field theory calculations to determine the phase diagram, observing a spatial deconfinement transition similar to the maximally supersymmetric case. However, the transition does not continue to low temperature, implying the absence of a topology-changing transition between black hole geometries in any holographic dual for this four-supercharge theory. Published by the American Physical Society 2024

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Surface Kinematics and the Canonical Yang-Mills All-Loop Integrand

It has been a long-standing challenge to define a canonical loop integrand for nonsupersymmetric gluon scattering amplitudes in the planar limit. Naive integrands are inflicted with 1 / 0 ambiguities associated with tadpoles and massless external bubbles, which destroy integrand-level gauge invariance as well as consistent on-shell factorization on single loop cuts. In this Letter, we show that this essentially kinematical obstruction to defining “the” integrand for Yang-Mills theory has a structural solution, handed to us by the formulation of gluon amplitudes in terms of curves on surfaces. This defines “surface kinematics” generalizing momenta, making it possible to define the integrand satisfying both a (surface generalized) notion of gauge-invariance and consistent loop cuts. The integrand also vanishes at infinity in appropriate directions, allowing it to be recursively computed for nonsupersymmetric Yang-Mills theory in any number of dimensions. We illustrate these ideas through one loop for all multiplicity, and for the simplest two-loop integrand. Published by the American Physical Society 2025

Arkani-Hamed, Nima↗
DOE OSTI2016

Repair of a Mirror Coating on a Large Optic for High Laser Damage Applications using Ion Milling and Over-Coating Methods.

When an optical coating is damaged, deposited incorrectly, or is otherwise unsuitable, the conventional method to restore the optic often entails repolishing the optic surface, which can incur a large cost and long lead time. We propose three alternative options to repolishing, including (i) burying the unsuitable coating under another optical coating, (ii) using ion milling to etch the unsuitable coating completely from the optic surface, and then recoating the optic, and (iii) using ion milling to etch through a number of unsuitable layers, leaving the rest of the coating intact, and then recoating the layers that were etched. Repairs were made on test optics with dielectric mirror coatings according to the above three options. The mirror coatings to be repaired were quarter wave stacks of HfO 2 and SiO 2 layers for high reflection at 1054 nm at 45° incidence in P-polarization. One of the coating layers was purposely deposited incorrectly as Hf metal instead of HfO 2 to evaluate the ability of each repair method to restore the coating’s high laser-induced damage threshold (LIDT) of 64.0 J/cm 2 . Finally, the repaired coating with the highest resistance to laser-induced damage was achieved using repair method (ii) with an LIDT of 49.0 – 61.0 J/cm 2 .

42 ENGINEERING↗