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At least 325 records · Page 18

All sources NASA NTRS DOE OSTI

DOE OSTI2023

High conductivity magnesium alloy

A castable, moldable, or extrudable magnesium-based alloy that includes one or more insoluble additives. The insoluble additives can be used to enhance the mechanical properties of the structure, such as ductility and/or tensile strength. The final structure can be enhanced by heat treatment, as well as deformation processing such as extrusion, forging, or rolling, to further improve the strength of the final structure as compared to the non-enhanced structure. The magnesium-based composite has improved thermal and mechanical properties by the modification of grain boundary properties through the addition of insoluble nanoparticles to the magnesium alloys. The magnesium-based composite can have a thermal conductivity that is greater than 180 W/m-K, and/or ductility exceeding 15-20% elongation to failure.

Sherman, Andrew J.↗

DOE OSTI2023

High conductivity magnesium alloy

Sherman, Andrew J.↗

DOE OSTI2019

Extrusion Parameters for Foaming of a β-Glucan Concentrate

Plastics is a group of materials commonly encountered on a daily basis by many people. They have enabled rapid, low-cost manufacturing of products with complicated geometries and have contributed to the weight reduction of heavy components, especially when produced into a foamed structure. Despite the many advantages of plastics, some drawbacks such as the often fossil-based raw-material and the extensive littering of the material in nature, where it is not degraded for a very long time, needs to be dealt with. One way to address at least one of the issues could be to use polymers from nature instead of fossil-based ones. Here, a β-glucan concentrate originating from barley was investigated. The concentrate was processed into a foam by hot-melt extrusion, and the processing window was established. The effect of different blowing agents was also investigated. Water or a combination of water and sodium bicarbonate were used as blowing agents, the latter apparently giving a more uniform pore structure. The porous structure of the foamed materials was characterized mainly by using a combination of confocal laser scanning microscope and image analysis. The density of the samples was estimated and found to be in a similar range as some polyurethane foams. A set of 3D parameters were also quantified on two selected samples using X-ray microtomography in combination with image analysis, where it was indicated that the porous structure had a pre-determined direction, which followed the direction of the extrusion process.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Warpage-Resistant, Under-Extrusion-Free, High-Surface-Quality Additive Manufacturing Process for Polyethylene-Based Composite Radiation Shielding Material

Polyethylene (PE) is one of the best shielding materials for primary space radiation due to its high hydrogen content. For effective secondary neutron shielding, boron-rich fillers are incorporated to enhance performance. The semicrystalline nature and high thermal expansion coefficient of PE impede its adoption for in situ additive manufacture in space via the fused deposition modeling (FDM) 3D printing. Here, we developed an optimized PE blend to mitigate the effects of under-extrusion and warpage. Guided by studies on extrusion and warpage, we developed an optimal set of printing parameters for the proposed PE blend. The optimum PE blend─both in its pure form and when doped with fillers─has been tested on different FDM printers. The printed structures exhibit high and uniform density, smooth surfaces, no warpage, and competitive mechanical properties. The FDM-printed plates demonstrate efficient shielding from thermal neutrons, predicted via modeling and confirmed experimentally using extended Q-range small-angle neutron scattering.

additive manufacturing↗

DOE OSTI2016

Co-Extrusion: Advanced Manufacturing for Energy Devices

The development of mass markets for large-format batteries, including electric vehicles (EVs) and grid support, depends on both cost reductions and performance enhancements to improve their economic viability. Palo Alto Research Center (PARC) has developed a multi-material, advanced manufacturing process called co-extrusion (CoEx) to remove multiple steps in a conventional battery coating process with the potential to simultaneously increase battery energy and power density. CoEx can revolutionize battery manufacturing across most chemistries, significantly lowering end-product cost and shifting the underlying economics to make EVs and other battery applications a reality. PARC’s scale-up of CoEx for electric vehicle (EV) batteries builds on a solid base of experience in applying CoEx to solar cell manufacturing, deposition of viscous ceramic pastes, and Li-ion battery chemistries. In the solar application, CoEx has been deployed commercially at production scale where multi-channel CoEx printheads are used to print viscous silver gridline pastes at full production speeds (>40 ft/min). This operational scale-up provided invaluable experience with the nuances of speed, yield, and maintenance inherent in taking a new technology to the factory floor. PARC has leveraged this experience, adapting the CoEx process for Lithium-ion (Li-ion) battery manufacturing. To date, PARC has worked with Li-ion battery materials and structured cathodes with high-density Li-ion regions and low-density conduction regions, documenting both energy and power performance. Modeling results for a CoEx cathode show a path towards a 10-20% improvement in capacity for an EV pouch cell. Experimentally, we have realized a co-extruded battery structure with a Lithium Nickel Manganese Cobalt (NMC) cathode at print speeds equivalent to conventional roll coating processes. The heterogeneous CoEx cathode enables improved capacity in thick electrodes at higher C-rates. The proof-of-principle coin cells demonstrate the feasibility of the CoEx technology and a path towards higher energy and higher power EV pouch cells.

25 ENERGY STORAGE↗

DOE OSTI2025

Friction-based recycling: an evaluation of friction extrusion for fabricating Ti-6Al-4 V wire fabricated from machining chip feedstock

Abstract Titanium and its alloys are used in aviation and automobile industries due to their remarkable strength to weight ratio, but machining loss commonly is high with ~ 80 wt% of the material being converted to scrap. Recycling post-consumer Ti scrap directly into solid bulk products is a potential solution for repurposing valuable material. Further, eliminating fresh Ti sponge during recycling might lead to lower energy and greenhouse gas emissions. In this study, a solid-phase process known as friction extrusion was utilized to recycle Ti-6Al-4 V machining chips into solid wires which could be used as feedstock in additive manufacturing. The friction consolidation technique was first used to convert chips with varying degrees of oxygen content into solid billets for its use as feedstock material in subsequent friction extrusion. The extrudates were fabricated above the beta transition temperature, which was achieved by selecting the rotation rate and feed rate, to process the billets near 1000 °C using a tungsten-lanthana extrusion die. This work presents the first occurrence of friction extruded titanium alloy wires. The effect of friction extrusion on microstructural features, tensile properties, and texture are reported. Overall, the friction extrusion method is capable of directly recycling Ti-6Al-4 V scrap into extruded wire.

Friction Extrusion↗

NASA NTRS2001

Extensional Rheology Experiment Developed to Investigate the Rheology of Dilute Polymer Solutions in Microgravity

A fundamental characteristic of fluid is viscosity; that is, the fluid resists forces that cause it to flow. This characteristic, or parameter, is used by manufacturers and end-users to describe the physical properties of a specific material so that they know what to expect when a material, such as a polymer, is processed through an extruder, a film blower, or a fiber-spinning apparatus. Normally, researchers will report a shear viscosity that depends on the rate of an imposed shearing flow. Although this type of characterization is sufficient for some processes, simple shearing experiments do not provide a complete picture of what a processor may expect for all materials. Extensional stretching flows are common in many polymer-processing operations such as extrusion, blow molding, and fiber spinning. Therefore, knowledge of the complete rheological (ability to flow and be deformed) properties of the polymeric fluid being processed is required to accurately predict and account for the flow behavior. In addition, if numerical simulations are ever able to serve as a priori design tools for optimizing polymer processing operations such as those described above, an accurate knowledge of the extensional viscosity of a polymer system and its variation with temperature, concentration, molecular weight, and strain rate is critical.

Logsdon, Kirk A.↗

DOE OSTI2021

Direct ink writing of boron carbide monoliths

Direct ink writing – an extrusion-based additive manufacturing process – followed by pressureless sintering was investigated to produce boron carbide monoliths. The effects of ceramic powder loading and Pluronic binder concentration on the rheology of boron carbide pastes were studied and linked to both processing behaviour and final outcome in terms of sintered density and hardness. The effects of printing parameters, in particular orifice diameter and printing speed, were also investigated. Reducing the size of the extrusion nozzle from 584 μm to 406 μm led to significantly better shape retention, lower surface roughness, as well as higher density and hardness. A 203 μm printing orifice was also trialled but was unsuccessful due to faster drying kinetics that occurred with smaller ceramic struts resulting in rapid warping and nozzle clogging. Carbon-black – 8 wt% relative to B 4 C – acted as an effective sintering aid to increase both density and hardness. After optimisation of feedstock and printing parameters, few-layer samples (3–5 layers) had a density as high as ~ 97 % TD and a hardness of ~ 30 GPa. On the other hand, 18-layer specimens had a sintered density of ~ 87 % TD, despite a fully dense microstructure, due to the formation of a 3D array of inter-strut pores. Nevertheless, several issues that arose during manufacturing and post-processing were detrimental to the density and structural integrity of printed specimens; these issues were identified, discussed, and suggestions for future work are provided in this report.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Assessing Manufacturability of the Oxide Dispersion Strengthened (ODS) 14YWT Alloy Fuel Cladding Tube Using SolidStir™ Technology

The 14YWT (Fe–14Cr–3W–0.4Ti–0.3Y2O3 (wt.%)) alloy is a potential candidatematerial for fabricating fuel cladding tubes and other structural components to be used in next-generation advanced nuclear reactors. Due to inherent limitations of current processing routes, this research explored a new variant of friction stir processing, commercially referred to as SolidStir™ Extrusion (patent pending) technology from Enabled Engineering to consolidate and extrude 14YWT powder into a fuel cladding tube. Several single-layer and multiple-layer consolidation experiments were carried out in an Inconel 625 die to determine the suitable processing parameters for SolidStir™ extrusion of the 14YWT alloy cladding tube. With these processing parameters, a 16–18 mm long tube of the 14YWT alloy with no visible defects was successfully extruded using this novel technology. Microstructural characterization results obtained using optical microscopy, scanning electron microscopy, energy dispersive spectroscopy, electron backscatter diffraction, and transmission electron microscopy will be presented.

Advanced Materials and Manufacturing Technology↗

NASA NTRS1993

Characterization of the microstructure of Nb-1wt.%Zr-0.1wt.%C tubes as affected by thermomechanical processing

Microstructure of Nb-1Zr-0.1C tubes were characterized as affected by extrusion temperature of the tube shell and its thermomechanical processing to tubing. Two tube shells of about 40-mm outside diameter (OD) and 25-mm inside diameter (ID) were extruded 8:1 from a vacuum arc-melted ingot at 1900 and 1550 K. Two different OD tubes of approximately 0.36-mm wall thickness were fabricated from each tube shell by a series of 26 cold drawing operations with two in process anneals. The microstructure of tube shells and the tubing before and after a 2-step heat treatment were characterized. Residue extracted chemically from each sample was also analyzed to identify the precipitates. The results concerning the effect of the initial extrusion temperature and subsequent processing on the microstructure of the tubes are presented together with a review of results from similar work on Nb-1Zr-0.1C sheet stock.

Uz, Mehmet↗

DOE OSTI2018

Alleviation of Mechanical Anisotropy in Ultrafine/Nano-grained AZ31 Magnesium Alloy

An ultrafine/nano-grained AZ31 magnesium alloy was processed through multipass accumulative back extrusion at 280 and 380 °C. Texture analysis was conducted to determine preferred crystallographic orientations developed during multipass deformation. The anisotropy in mechanical properties of the processed materials was studied by compressive and tensile testing. The results implied that the accumulative back extrusion effectively reduces the anisotropy of yield strength, ultimate strength and strain-to-fracture during compressive and tensile loading. The operations of different twinning/slip systems during compressive and tensile deformation were discussed using Schmid factors measurements. A decrease in twinning-related anisotropy, as well as the contribution of different slip systems in strain accommodation, could reduce the mechanical anisotropy of ultrafine/nano-grained AZ31 alloy. The compressive strength of the two-pass processed material was lower along extrusion direction than transverse direction; however, the result was reverse after four passes. The tensile behavior implied that the contribution of basal slip might accommodate strain along length as well as the thickness of the specimen, while prismatic slip may assist in narrowing the width of the specimen and elongating the length.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Microstructure, Texture, and Mechanical Properties of Continuously Extruded and Rolled AZ31 Magnesium Alloy Sheets

It is difficult to fabricate magnesium alloy sheets at room temperature due to their hexagonal close-packed structure. In this paper, we proposed a new process that can be used to fabricate AZ31 magnesium alloy sheets with fine-grained microstructure and good mechanical properties. AZ31 magnesium alloy sheets with dimensions of 160 mm × 8 mm were obtained successfully by a continuous extrusion technique. The extruded sheets were then rolled by two different rolling routes, Route 1: the extruded sheet was heated at 350 °C and then rolled without heating of rolls and Route 2: the sheet was rolled without any previous heating by heating rolls at 280 °C. The microstructure and texture evolution as well as mechanical properties of the continuously extruded and rolled sheets were examined experimentally. The magnesium alloy sheets with relatively fine grains of 4.5-8.3 µm were obtained by continuous extrusion followed by rolling processes. The tensile strength of continuously extruded AZ31 Mg alloy sheets can be effectively increased by rolling using heating rolls (Route 2), while the ductility was enhanced by rolling heated sheets (Route 1). The mixed microstructure, consisting of refined DRX grains and deformed grains, contributes to enhancement in tensile strength of the sheet samples rolled by Route 2 due to grain-boundary strengthening and work hardening. Lower temperature and larger rolling reduction are two main factors for improving the tensile strength of AZ31magnesium alloy sheets.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Experimental tests on commercial Sweet Product Residue (SPR) as a suitable feed for anaerobic bioenergy (H2 + CH4) production

Highlights: • Post-sale refuses was tested as feed for two-step-Anaerobic Digestion (TSAD). • Extrusion was assessed at pilot plant scale process to remove the packaging. • NaOH Pretreatment was evaluated in order to increase the refuses digestibility. • H{sub 2} + CH{sub 4} production via TSAD process was experimentally evaluated. • Energy Sustainability Index were used to evaluate the process: pretreatment + TSAD. - Abstract: Food stores can find themselves in the position of having to dispose of different types of products, such as snacks, confectionery, prepackaged food, drinks and others, Sweet Product Residue (SPR), which presents a great opportunity to produce energy through Anaerobic Digestion (AD), due to its high sugar, carbohidrate and fat contents. In order to valorise SPR, this paper takes into consideration the all necessary treatments; owing the fact that the refuses are constitute by an organic part and packaging (plastic, paper and their combinations), a pretreatment able to remove the latter is necessary. SPR refuse was initially subjected to novel pretreatment approach: extrusion at 200 atm to remove the packaging, and a Basic Pre-treatment (BP) then tested through a Two-Stage AD (TSAD) process, for H{sub 2} and CH{sub 4} productions. The experimental results were analysed considering three parameters: Efficiency (ξ), which takes into account the quantity of the energy produced as hydrogen plus methane that the bioreaction is able to extract; Efficacy (η), which takes into account the efficiency of the actual test, compared with that obtained from a reference test carried out with glucose; Energy Sustainability Index (ESI), which takes into account the total amount of energy produced as H{sub 2} plus CH{sub 4}, and the amount of energy consumed to pre-treat the refuse. The effectiveness of the extrusion process in removing the packaging was very high: about 80% of the organic part present in the SPR was recovered. The obtained results have pointed out that SPR is suitable for energy valorization process: ξ = 50%, η = 0.67 and ESI = 24.4, without the need of basic pre-treatment.

09 BIOMASS FUELS↗

DOE OSTI2025

Extrusion‐Spheronization of Mock Energetic Materials

The primary method for producing plastic bonded explosive (PBX) granules, or “prills”, has remained relatively unchanged for 70 years despite the complex nature of the process. In this work, we demonstrate the feasibility of using an extrusion‐spheronization technique to produce prills for PBX applications. We begin by detailing an inert formulation with similar properties of PBXs and then demonstrate the extrusion‐spheronization processing of these materials. A study is then performed where the spheronization process time of the extruded materials is varied and the resultant prills are morphologically characterized. Further, these prills are then pressed into high‐density articles and subject to compression testing to elucidate trends in process, properties, and performance. It was found that, for our formulation (95 wt.% melamine/5 wt.% polymer binder) and process, a spheronization time of 60 s yielded relatively uniform particles that exhibited improved poured, tapped, and pressed densities. Mechanical strength did not have a strong trend with process time as all spheronized materials had similar peak compression stress at failure. After further optimization, extrusion‐spheronization may be a promising path for future PBX formulation.

extrusion spheronization↗

NASA NTRS1982

Development of powder metallurgy Al alloys for high temperature aircraft structural applications, phase 2

In this continuing study, the development of mechanically alloyed heat resistant aluminum alloys for aircraft were studied to develop higher strength targets and higher service temperatures. The use of higher alloy additions to MA Al-Fe-Co alloys, employment of prealloyed starting materials, and higher extrusion temperatures were investigated. While the MA Al-Fe-Co alloys exhibited good retention of strength and ductility properties at elevated temperatures and excellent stability of properties after 1000 hour exposure at elevated temperatures, a sensitivity of this system to low extrusion strain rates adversely affected the level of strength achieved. MA alloys in the Al-Li family showed excellent notched toughness and property stability after long time exposures at elevated temperatures. A loss of Li during processing and the higher extrusion temperature 482 K (900 F) resulted in low mechanical strengths. Subsequent hot and cold working of the MA Al-Li had only a mild influence on properties.

Chellman, D. J.↗

NASA NTRS1996

Processing of nutritious, safe and acceptable foods from CELSS candidate crops

A controlled ecological life-support system (CELSS) is required to sustain life for long-duration space missions. The challenge is preparing a wide variety of tasty, familiar, and nutritious foods from CELSS candidate crops under space environmental conditions. Conventional food processing technologies will have to be modified to adapt to the space environment. Extrusion is one of the processes being examined as a means of converting raw plant biomass into familiar foods. A nutrition-improved pasta has been developed using cowpea as a replacement for a portion of the durum semolina. A freeze-drying system that simulates the space conditions has also been developed. Other technologies that would fulfill the requirements of a CELSS will also be addressed.

NASA Discipline Number 93-10↗

DOE OSTI2023

Reactive Extrusion of Waste Plastics with Compatibilizer and Lightly Pyrolyzed Crumb Rubber for Asphalt Modification

Modifying asphalt is a potentially high-value application for reusing waste plastics because of the high-volume usage of asphalt in highway construction. However, simply blending hot plastics and asphalt encounters difficulties related to the poor solubility of polymers, which limits the formation of a swollen network with asphalt molecules. The polymer phases also tend to coalesce and separate from asphalt during high-temperature storage in static conditions. The present study developed an innovative process to stabilize waste plastics in asphalt and improve binder storage stability by using lightly pyrolyzed crumb rubber together with a chemical compatibilizer. Both polymers were extruded to produce a thermoplastic elastomer (TPE) for asphalt modification. The mechanical performance and chemical reactions of TPEs were characterized via tension test and Fourier transform infrared spectroscopy. The storage stability and rheological properties of modified binder blends were evaluated through laboratory asphalt stability test and dynamic shear rheometer test. Polymer phases and network structures were characterized through optical microscopy. It was found that the pyrolyzed and reactive extrusion process improved the rubber solubility and polymer interaction, and therefore the storage stability of modified binder blends. The co-existence of rigid plastic and soft rubbery regimes in an entangled network provided a promising pathway to improve the mechanical performance of asphalt binders in both high- and low-temperature domains.

Ma, Yuetan↗

NASA NTRS1998

Friction Stir Weld Tooling Development for Application on the 2195 Al-Cu-Li Space Transportation System External Tank

Friction Stir Welding (FSW) is a new and innovative solid-state joining process which can be applied to difficult-to- weld aluminum alloys. However, the large forces involved with the process have posed a production tooling challenge. Lockheed Martin Michoud Space Systems has overcome many of these challenges on the Super Lightweight External Tank (ET) program. Utilizing Aluminum-Copper-Lithium alloy 2195 in the form of plate and extrusions, investigations of FSW process parameters have been completed. Major loading mechanisms are discussed in conjunction with deflection measurements. Since the ET program is a cryogenic application, a brief comparison of cryogenic material properties with room temperature material properties is offered for both FSW and fusion welds. Finally, a new approach to controlling the FSW process from a load perspective is introduced. Emphasis will be put on tooling development, as well as the impact of tooling design and philosophy on Friction Stir Weld success probability.

Loftus, Zachary↗