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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Cummins Electric Truck with Range-Extending Engine (ETREE) Project (Final Technical Report)

The Cummins Electric Truck with Range Extending Engine (ETREE) program designed, developed, and demonstrated a range extending electric vehicle that employs an electrified propulsion system installed in a class 6 commercial vehicle (Peterbilt 220). This project was relevant to industry and the greater public because at the time of the project there were two keys to widespread electrified commercial vehicle adoption yet to be realize: 1) For pure electrified vehicle adoption, battery improvements are needed: Cost must decrease, and energy density must increase. 2) Electric vehicles must overcome fleet operator risks such as: operations in cold climates, hilly terrain, or where majority of conventional trucks are replaced with electrified vehicles. In the near to medium term these adoption hurdles were address by the objectives of this project. A plug-in hybrid vehicle that could be operated in all electric mode for most of its workday optimizing the use of grid energy with the ability to supplement energy demand with the onboard range extending engine. This project’s architecture provided ability to match a conventional class 6 commercial vehicle range and performance characteristics prior to the ubiquitous adoption of battery electric vehicle charging infrastructure as well. Additionally, the vehicles produced as part of this project can be considered a prototype for a commercially viable heavily electrified commercial vehicle because most of the physical hardware used for the project is commercially available in the market today. The ETREE program met its main objectives and demonstrated 65% fuel consumption reduction as compared to a conventional class 6 vehicle while meeting performance and range expectations. This was achieved by drawing upon the strengths of the assembled team: Cummins, PACCAR, the Ohio State University, Argonne National Laboratory and the National Renewable Energy Laboratory.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Particle Track Classification Using Quantum Associative Memory (Final Technical Report)

This project explored the use of quantum-assisted algorithms for pattern matching in sub-atomic physics experiments. Pattern matching algorithms are commonly employed to prune data of random noise and to help discriminate between signals generated by particle tracks of interest and signals generated by background events. The quantum-assisted algorithms explored in this project were based on an Ising formulation of quantum associative model (QAMM) recall and quantum content-addressable memory (QCAM) recall. The recall is performed by comparing a probe pattern with those stored in a library of patterns encoded in the QAMM/QCAM model. The classification accuracy of QAMM and QCAM recall was determined as a function of detector resolution, noise, and efficiency and pattern density, where pattern density is defined as the ratio of the number of reference signal patterns encoded in the library to each pattern’s length. We found that QAMM achieved high classification accuracy when applied to datasets with low pattern density. QCAM achieved high classification accuracy for datasets with high pattern density and was found to be more robust to detector noise. The project methodology and results are described in detail in our arXiv preprint (arXiv:2011.11848) . This project was conducted by scientists at the Johns Hopkins University Applied Physics Laboratory and Oak Ridge National Laboratory from August 2018 to August 2020 and was supported by DOE grant DE-SC0019497.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2020

Enabling Efficiencies > 22.5% with Metal Oxide Passivating Contacts using Low-Cost Spatial Atomic Layer Deposition (Final Technical Report)

In this project, the University of Central Florida (UCF) worked to both increase module efficiency and reduce manufacturing cost by driving demonstrated lab-scale passivating contact technology using materials and processes compatible with high-volume manufacturing for crystalline silicon (c-Si) photovoltaic (PV) cells. Passivating contacts have garnered significant attention in recent years. They provide a means of suppressing contact recombination, a loss mechanism that limits the performance of industrially relevant cell architectures like Al back surface field (Al-BSF) cells and passivated emitter and rear cells (PERC). Most of the development of passivating contact technology has focused on the use of doped amorphous silicon or doped polysilicon contacts, but both suffer from parasitic optical absorption amongst other issues. Our team developed fully transparent hole-selective heterojunctions, deposited using atomic layer deposition (ALD), and showed how they could be incorporated into c-Si PV cells. The team conducted experiments to understand the process-structure-property relationship of hole-selective oxides, surface passivation oxide materials, and transparent conductive oxides deposited by ALD, and use that understanding to reduce contact recombination, contact resistivity, and parasitic optical absorption within c-Si PV cells. Before getting into the details of the report, we would like to note that COVID-19 has made it more challenging to conduct experimental research at UCF. UCF has a number of mandatory policies in place to ensure social distancing, testing, and contact tracing are all carried out in day-to-day operations. Despite these challenges, we worked diligently to make progress on this project in a manner that was as safe as possible. Over the course of the project, the UCF team and its collaborators have made the following discoveries and developments.

14 SOLAR ENERGY↗
DOE OSTI2021

Dense Pair and Gamma-Ray Creation Using Ultra-Intense Lasers (Final Technical Report)

Lasers with intensity >1.4x10 18 W.cm -2 irradiating solid targets couple 10-50% of its energy to “hot electrons” near the critical surface, with temperature kT > mc 2 . When these hot electrons impact high-Z target ions (e.g. Au, Pt), they emit copious bremsstrahlung gamma-rays and create e + e - pairs via the Trident process. For targets thicker than ~0.1mm, the gamma-rays create secondary pairs via the Bethe-Heitler processes. The concept of using lasers to create pairs was first studied by Shearer et al (1973). Motivated by the rapid advance of short-pulse ultra-intense lasers based on chirped-pulse amplification, Liang (1994) first proposed irradiating solid Au targets with laser intensity ≥10 20 W.cm -2 to create dense e + e - pairs. Using particle-in-cell (PIC, Birdsall and Langdon, 1991) simulations, Liang et al (1998, 2002) estimated that high-energy PW lasers can in principle achieve ultra-high in-situ pair densities. Subsequent studies supported this idea and found that for gold foils thicker than ~50 μm, the pair yield is dominated by the Bethe-Heitler (BH, Heitler 1954) process. Cowan et al (1999, 2000) using the LLNL Nova PW-laser to irradiate 125μm gold foils first observed pair creation, followed by Chen et al (2009) who demonstrated copious BH pair creation using the Titan, Omega-EP and Orion lasers. However, the emerging e + /e - ratio of these experiments was ≤ few %, and the pair density was only 10 13 /cc so that the pair jet transverse size R(~mm) was < pair skin depth c/ω + (=8πn+e 2 /m) 1/2 ). This was insufficient to qualify as a bona fide ”pair plasma”.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Performance of Scintillation Detectors Based on Quantum Dots in a Semiconductor Matrix (Final Technical Report)

InAs Quantum Dots (QDs) embedded into GaAs semiconductor waveguide have unique scintillation properties, valuable for nuclear security, medical imaging, and high energy physics. In this work, we developed thick (~25um) epitaxial heterostructres with high luminescence efficiency composed of self-assembled nano-engineered InAs QDs grown by molecular beam epitaxy. In this type of detector, the GaAs matrix acts as a stopping material for charged particles or photons generating electrons captured by the QDs acting as luminescence centers. The QD medium is designed to provide fast capture of electrons into QDs (few ps), high QD luminescence efficiency at room temperature (>50%), and strong red-shift of photoluminescence (PL) from the GaAs absorption edge (>250nm). Typical devices consist of a 10-25um thick GaAs layer with embedded sheets of modulation p-type doped InAs QDs and an InGaAs photodetector tuned to the QD emission wavelength. The thick GaAs layer acts also as a waveguide when layer-transferred onto a low-index substrate. Waveguiding and self-absorption (~1cm -1 ) were studied using photoluminescence with scanning laser excitation and modeled with ray optics approximation and geometrical coupling of high-index waveguide to a collection fiber. Scintillating signals from α-particles were analyzed with both an external photodiode (PD) and an integrated PD which provided an improved optical coupling. In the former case, the external InGaAs PD was air-coupled to the scintillator and had the light collection efficiency of about 1% corresponding to limited light extraction through a planar interface with air due to total internal reflection. The mean charge collected by the integrated PD was in the range of (3÷5)×10 4 photoelectrons per 1 MeV of deposited energy, or ~13-20% of the theoretically achievable light yield. Timing of the integrated device was measured by wire-bonding it to the input of an 8 GHz IC. The scintillation response shows an extremely fast 0.3-0.6 ns decay constant and about 40-70 ps time resolution, limited by the system noise. The combined light yield and decay time makes the InAs/GaAs QD heterostructures the fastest high yield scintillation material reported making it valuable for high energy physics and medical imaging applications.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2021

2019 Conference on Science at the Sanford Underground Research Facility (Final Technical Report)

The 3rd Conference on Science at the Sanford Underground Research Facility took place on May 14th to 17th, 2019 at the South Dakota School of Mines and Technology. Eighty researcher from all over the U.S., from Europe and from Australia attended the conference and presented on the status of research related to current and future projects at the Sanford Underground Research Facility in Lead, South Dakota. Topics covered by presentations from experts in their field (plenary talks) and contributed oral presentations by junior scientists were neutrino oscillations with focus on science with the Deep Underground Neutrino Experiment (DUNE), dark matter search with priority on the LUX-Zeplin (LZ) experiment, neutrinoless double beta-decay search (Majorana Demonstrator), nuclear astrophysics (CASPAR and DIANA), and geology research (SIGMA-V). Complementary experiments locate at other research facilities were also well represented in the conference program. A public lecture on research in dark matter search for local high school students was organized as part of the conference program and was presented by one of the dark matter plenary speakers.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

Net Metering Expansion on the Winnebago Tribe of Nebraska Reservation (Final Technical Report)

The Winnebago Tribe of Nebraska, through their affiliated economic development entity Ho-Chunk, Inc; their affiliated non-profit Ho-Chunk Community Development Corporation; and an additional project partner Nebraska Renewable Energy Systems conducted a community scale renewable energy project on their reservation in Nebraska. Over the two-year project period, we installed PV Solar systems on ten tribally owned commercial/retail/office facilities, which included both six roof mounted and four pole mount installations. The project was undertaken as a part of the Tribe’s broader initiative to increase renewable energy production on the reservation, reduce the Tribe’s financial obligations for purchasing energy, and lessen our reliance upon outside sources of energy to meet our basic needs. The project enabled us to formalize and strengthen community collaborations and build our capacity to pursue additional renewable energy opportunities that will enhance our energy sovereignty.

14 SOLAR ENERGY↗
DOE OSTI2020

Technical report: Design of the accessor

As we have seen the arithmetic power of hardware architectures growing much faster than the memory bandwidth, there is an urgent need to rethink the way we operate, communicate, and store data. A promising strategy for overcoming the “memory wall” is the decoupling of memory precision from arithmetic precision as proposed in Anzt et al. Such a decoupling of memory precision and arithmetic precision requires an “accessor” that handles the conversion between formats (resp. compression of the data) on the fly in registers. Such an accessor has to be general in the sense that it can handle a wide range of floating point formats and compression strategies, and still allows for further extension. At the same time, is important that the use of the accessor is not a burden for the developer. Therefore, it is important to abstract all implementation details from the user, hide the underlying storage format from the user, and make the accessor cross-platform portable. In this document we present the design of an accessor that aims at fulfilling all these requirements.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

“Transition from dissipative fluid dynamics to particles in heavy ion collisions”(Final Technical Report)

This report summarizes research activities and achievements made under Award No. DE-SC00016524. We advanced the following areas: i) self-consistent bulk viscous and baryon number diffusion corrections from kinetic theory, ii) hadron gas bulk viscosity determination, and iii) discovery of novel mechanisms of elliptic flow generation and suppression in heavy-ion collisions.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

Center for direct catalytic conversion of biomass to biofuels (Final Technical Report)

Lignocellulosic biomass has only one-third the energy density of crude oil and lacks petroleum’s versatility as a feedstock for fuels and chemicals. Since 2009, the Center for direct Catalytic Conversion of Biomass to Biofuels (C3Bio) has recognized the potential of chemical catalysis and fast-pyrolysis to overcome such limitations by transforming the main components of biomass (cellulose, xylan, and lignin) from grasses and trees directly to liquid hydrocarbons and aromatic co-products. In 2014, C3Bio proposed to develop critical systems-level understanding of how biomass structural complexity at molecular, nanoscale, and mesoscale levels impacts the yields and selectivities of desired products from catalytic and pyrolytic transformations. Our long-term goal was to gain unprecedented control of effective routing of carbon: we aimed to specify both the structures within, and the reaction products from, lignocellulosic biomass. Enabled by the EFRC high-risk, high-reward approach to grand challenge science, our interdisciplinary team of plant biologists, chemists, and chemical engineers disrupted the conventional paradigm of the cellulosic biorefinery into a new future of “no carbon left behind” - the full utilization of carbon from plant cell walls in energy-dense fuels.

09 BIOMASS FUELS↗
DOE OSTI2021

The Wonders of Physics -- Public Outreach (Final Technical Report)

The mission of The Wonders of Physics (TWoP) outreach program is to generate interest in physics among people of all ages and backgrounds. The objective is to generate interest in physics, increase appreciation for the significance of physics in our lives, and encourage children to consider careers in science and plasma physics. The primary means for achieving that objective is to make entertaining presentations to audiences that would not normally be motivated to attend a lecture on physics or plasmas, while at the same time introducing some of the fundamental concepts and applications. During this reporting period, the students Michael Hall, Megan Tabbutt and Connor Sullivan, Director of Communications Sarah Perdue, Director of Undergraduate Program Jim Reardon, and Senior Information Processing Consultant Paul Wilhite worked to make outreach programs a success and prepare for the future of The Wonders of Physics, which will continue. Because of the curtailment of public events due to Covid-19, there will not be an in person Annual Show or Physics Fair in 2021, but a video competition has already been announced and planning continues for The Wonders of Physics in 2022 and beyond. The annual shows and Physics Fair are scheduled for February 12-13 and February 19-20, 2022. These continue to be our premier outreach events, engaging diverse audiences in real hands-on science. Further shows and exploration stations are planned.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Nanoporous weakly coordinating anionic frameworks (Final Technical Report)

Under this award, we synthesized and characterized new weakly coordinating, anionic covalent organic frameworks. The motivation was to expand the class of covalent organic frameworks though the introduction of the first weakly coordinating anionic ones. The significance of the weakly coordinating anionic character of these frameworks is associated with the character of the counter (metal) cations in their pores. Those counter-cations, due to the inability to effectively coordinate to the pore walls, have a “naked”, and thus highly electrophilic, Lewis acidic character. Such properties are expected to translate to a number of interesting physical properties that can be potentially used for a range of energy-relevant applications. One of these applications is gas adsorption, separation, and storage. The electrophilic, Lewis acidic character of the counter-cations are expected to strongly bind to gas molecules entering the pores leading to higher gas sorption capacities. Other applications include heterogeneous catalysis, ion exchange, and solid state ion conduction. Within the project we explored a range of chemical blocks, and tested synthesis conditions to polymerize these building blocks to form the target materials. In particular, we focused on materials with group 15 elements like phosphorus in the oxidation state +5 and the coordination number 6, that have a formal -1 charge. The synthesis of such materials is challenging because its success depends on the absence of residual monomeric and oligomeric side-products in the pores, and the absence of significant framework interpenetration. Crystalline forms of these materials require sufficient reversibility of the polymerization reaction (which is difficult to achieve because group 15 elements like P tend to make strong covalent bonds with neighbored elements), as well as suitable polymerization rates that prevent the formation of kinetically controlled products. We had success with the preparation of anionic porous organic frameworks with anionic building blocks containing P(V)O6 octahedra synthesized through Yamamoto coupling reactions. These materials are non-crystalline because of the irreversible nature of the Yamamoto coupling reaction, but show porosity. The porosity and surface area can be significantly increased by co-reaction with electrostatically neutral co-reactants. Very high porosity and surface areas can be achieved when the materials are washed with hydrochloric acid. This method is commonly used to free products from Yamamoto coupling reactions from by-products. Indeed, this method removed by products from the pores of our materials, however it also led to the hydrolysis of the PO6 octahedra to form pending phosphonic acid groups (-PO3H)-groups in the frameworks (PA-POFs) which was actually not desired. Nonetheless, these materials showed high CO2 sorption capacities. In addition, they show extremely high (actually record) sorption capacities for the removal of a range of common micropollutants such as bisphenol A (BPA) and 4-nitrophenol in water. BPA is a wide-spread organic pollutant and a known endocrine disruptor. The maximum adsorption capacity of BPA at equilibrium is found to be as high as 3,366 mg g-1 by Langmuir adsorption model, which is more than 10 times greater than peer materials. The polymer also rapidly removes various other organic micropollutants with more than 90% removal efficiencies. In addition, the PA-POF material can be regenerated at least five times by mild washing using methanol without significant loss in removal efficiency. This is significant advantage over commonly used activated carbon materials (that are in Brita water faucet filters, for example). Comparison studies showed that only materials with the phosphonate groups show extreme sorption although the number of PA group is actually small according to solid state NMR and EDX data. More research would be needed to investigate why this is (a possibility is that the phosphonate groups have a multiplying effect in which a PA-induced initial adsorption leads to the adsorption of much more adsorbate). The extreme sorption capabilities can also be visually seen when colored adsorbates such as 4-nitrophenol are used, as the adsorption of the nitrobenzene leads to the decoloration of the solution. We have produced three short videos that illustrate the sorption capabilities compared to two peer materials (activated carbon from dismantled Brita water filters, and a electrostatically neutral, chemically related, porous organic polymer, respectively).

36 MATERIALS SCIENCE↗
DOE OSTI2021

Emergent Collective Phenomena in Artificial Spin Ice (Final Technical Report)

This program encompassed studies of lithographically fabricated “artificial spin ice” arrays of nanometer-scale single-domain ferromagnetic islands in which the array geometry results in frustration of the magnetostatic interactions between the islands. Artificial spin ice offers a wide range of opportunities for studying the mechanism by which nature accommodates frustration and accesses physics associated with frustration in ferromagnetic nanostructures. Since the arrays are created lithographically, we can easily vary the array characteristics, including the geometry of the lattice and the level and type of lattice disorder. We can probe both the local properties of the arrays by imaging individual moments, and we can also probe thousands of moments simultaneously, allowing us to gain insight into the collective properties of the system. The research funded by this program included studies of unusual frustrated lattices, studies of magnetotransport in these systems, studies of perpendicular anisotropy moments, and a range of other related experimental measurements.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Where Have All of the Electrons Gone? Understanding the Role of Alternative Electron Flow and O 2 Reduction in Balancing Cellular Redox (Final Technical Report)

An informed understanding of the fundamentals of light-driven electron transfer reactions in photoautotrophic organisms is necessary to enable improved photosynthetic efficiencies for the production of renewable fuels and novel biomaterials. To obtain high photosynthetic yields, light energy must be efficiently coupled to the fixation of CO 2 . Sub-optimal environmental conditions and metabolic routing (caused by blocks in biosynthetic routes) can severely impact the conversion of light energy to biomass and lead to reactive oxygen production, which in turn can cause cellular damage and productivity losses. Hence, plants, algae, and photosynthetic bacteria have evolved a network of alternative outlets to sustain the flow of photosynthetically derived-electrons. Our research was focused on the nature and integration of these outlets. The data obtained in this project will inform efforts to rationally engineer crop plants and algae to improve photosynthetic yields by enhancing electron transfer reactions to CO 2 reduction and targeted biomass accumulation. A major project research thrust was focused on identifying and quantifying the flow of photosynthetic reductant through electron transfer circuits that result in the light-dependent reduction of O 2 . New energy management strategies were identified that are used when normal carbon assimilation pathways are compromised due to nutrient deprivation, and/or by a reduction in starch synthesis/carbon storage, all conditions resulting in highly reduced intracellular redox pools. The green alga Chlamydomonas reinhardtii, and likely many other algae, have multiple O 2 -reducing pathways that play critical roles in maintaining cellular metabolic balance and scavenging electrons that could potentially cause cellular damage, which in some instances leads to reduced photosynthetic yields but increased fitness. We explored the activities of three essential outlets associated with Chlamydomonas reinhardtii photosynthetic electron transport: (1) reduction of O 2 to H 2 O through Flavodiiron proteins (FLVs) and (2) Plastid Terminal Oxidases (PTOX), and (3) the synthesis of starch. Real-time measurements of O 2 exchange demonstrated that FLVs immediately engage during dark to light transitions, allowing electron transport when the CBBC is not fully activated. Under these conditions, we quantified, for the first time, maximal FLV activity and its overall capacity to direct photosynthetic electrons towards O 2 reduction. However, when starch synthesis is compromised, a greater proportion of electrons is directed toward O 2 reduction through the FLVs, while PTOX, which is sensitive to the PQ pool redox state, is activated. This suggests, that starch synthesis has an important role in priming/regulating CBBC and electron transport. We also identified a biological ‘switch’ in the green alga Chlamydomonas reinhardtii that reversibly restricts photosynthetic electron transport (PET) at the cytochrome b 6 f complex when reductant and ATP generated by PET are in excess of the capacity of carbon metabolism to utilize these products; we specifically show a restriction at this switch when sta6 mutant cells, which cannot synthesize starch, are limited for nitrogen (growth inhibition) and subjected to a dark to light transition. This restriction causes diminished electron flow to PSI, which prevents PSI photodamage, and the plastid alternative oxidase (PTOX) becomes fully activated, serving as an electron valve that dissipates excitation energy absorbed by PSII, thereby lessening PSII photoinhibition. Furthermore, illumination of the cells following the dark acclimation gradually diminishes the restriction at the switch. Future engineering of these switches may allow more effective electron transfer to lipid (biofuel) pathways and diminish the number of electrons “wasted” in the reduction of O 2 to water. Lastly, we explored metabolic routing of electrons during algal fermentation and discovered multiple novel pathways that are activated when the preferred anoxic routes are blocked. These provide valuable products (e.g. lactate, glycerol) that can be used in broad portfolio of biotechnological applications.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Spin-Coherent Transport under Strong Spin-Orbit Interaction (Final Technical Report)

The major goals of the project consisted of acquiring insight in spin-dependent quantum coherent electronic transport phenomena arising from spin-orbit interaction, via experiments on semiconductor heterostructures and thin film semimetals patterned into mesoscopic and nanoscale geometries. The solid-state physics findings contain insight potentially useful for the creation of new quantum states of matter, for spin operations in quantum information processing, for future spin electronics, and for other future functionalities of power-saving electronic devices. The subject was of fundamental interest, but was also of long-term applied interest for quantum devices, spintronics devices, and general electronic devices. The experiments were conducted by low-temperature electronic magnetotransport in nanoscale structures of length scales similar to the quantum phase- and spin-coherence lengths and the carrier mean-free paths in the materials. Emphasis was placed on quantum coherence and spin coherence, to understand coherent spin-dependent electronic processes, on transport of electrons with very long mean-free path (ballistic transport), on the transfer of electron spin to nuclear spin (dynamic nuclear spin polarization in bismuth), and on the study of materials with quantum states emerging from spin-orbit interaction and electron-electron interaction (bismuth iridates). In two-dimensional electron systems in quantum wells of the narrow-bandgap semiconductors InAs and InGaAs the objectives included the characterization of quantum states arising from the Aharonov-Casher quantum-mechanical phase as an electromagnetic dual of the Aharonov-Bohm phase. Objectives also included quantum electronic transport at the mesoscopic scale on the semimetal bismuth in thin film form, and particularly on its strongly spin-orbit coupled surface states. An almost-strain-free method was developed to grow high-quality bismuth thin films. Devices fabricated on these films were then used to study a novel nuclear spin torque, whereby the bismuth carrier spin was transferred to the bismuth nuclei by the agency of both spin-orbit interaction and hyperfine interaction. Aspects of ballistic transport were studied in GaAs/AlGaAs heterostructures of very high mobility, and a hitherto unsuspected similarity was discovered between ballistic transport and hydrodynamic transport, of potential use in future power-saving electronic devices.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Materials Development and Advanced Process Simulation for Additive Manufacturing with Fiber-Reinforced Thermoplastics (Final Technical Report)

DuPont, Local Motors, and the Composites Manufacturing and Simulation Center (CMSC) at Purdue worked together to advance process simulation capabilities for Additive Manufacturing (AM) and develop printable short fiber reinforced semi-crystalline engineering thermoplastics suitable for vehicle components. DuPont provided one candidate thermoplastic material, which was evaluated against the following three criteria: 1) Printability using extrusion additive manufacturing processes. 2) Suitability for vehicle applications based on mechanical coupon screening tests. 3) Predictive capability of process simulations. Indiana Manufacturing Institute provided modeling and simulation technology and access to Purdue’s lab scale AM printer. Local Motors provided mechanical property requirements and printed demonstration prototype components using their Thermwood Large Scale Additive Manufacturing (LSAM) printer. To meet the performance and cost requirements of the automotive industry, high fiber content semi-crystalline engineering materials are required. Printing experience and property data for a 50% by weight short glass fiber reinforced material were gathered. Further, material properties required for simulating the printing process with the glass-fiber reinforced material were characterized. Knowledge was acquired with regards to the processability and performance of this thermoplastic material. Predictions of part deformation and crystallinity level were verified against experimental observations. Any significant results other than verification of simulation, e.g., novel material identified here would be impactful.

36 MATERIALS SCIENCE↗