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DOE OSTI2020

Optocouplers: Polymer Components, Current Applications and My Project Involvement [Slides]

Optocouplers, also called optoisolators and photocouplers, are devices that use a light emitting diode (LED) to conduct an electrical signal. The LED receives an electrical signal and emits light proportional to that signal. The light is then received by a phototransistor and the signal is propagated. Optocouplers provide a high degree of electrical isolation and are therefore used extensively in commercial electronic equipment. Variations in optocouplers come from the type of photodetector used, the anatomy of the contents and the encapsulating polymers used. Current research involves investigating the tolerance of optocouplers to radiation for the purpose of improving spacecraft and satellites, as well as identifying failure mechanisms and improving design. My project involvement at LANL includes conducting thermal and mechanical tests on three different cure profiles of epoxy to collect data about shrinkage, coefficient of thermal expansion, and degree of cure for a group wanting to produce their own optocoupler.

42 ENGINEERING↗

DOE OSTI2022

Scalable, Infiltration-Free Ceramic Matrix Composite (SIF-CMC) manufacturing for Molten Salt Receiver: Investigation of particle-loaded preceramic resin

Due to their unique combination of high temperature, corrosion resistance, and toughness, Ceramic Matrix Composites (CMC) are the optimal materials to be used in the next generation of Concentrated Solar Power (CSP), which will operate at working temperatures up to 800 °C. However, today, CMC is too costly to be used in CSP applications due to its complex manufacturing process based on repeated infiltration-pyrolysis cycles. To solve this issue, PARC is developing a scalable, infiltration-free method (SIF) to manufacture CMC, which can reduce the production cost, increase batch consistency, and leverage all of the intrinsic advantages of current CMCs. The key to the SIF method is using a flowable preceramic resin with high loading of functional components. The formulation impregnates the fiber during curing and leads to high-density, low-shrinkage parts upon pyrolysis. In this paper, we demonstrate a proof-of-concept of the SIF process and report the relationships between key process parameters in the manufacturing process: functional material loading in the resin vs. resin’s flowability and morphology changes upon pyrolysis.

ceramic matrix composite, concentrated solar power↗

DOE OSTI2023

Laser heating and evaporation of a single droplet

The laser technology is being abundantly studied for controlled energy deposition for a range of applications in aerodynamic flow control, material processing, ignition, and combustion. The absorption of laser radiation by liquid droplets affects further propagation of laser in the atmosphere and causes bleaching of suspended droplets while the ignition and combustion characteristics in combustors are influenced by the evaporation rate of the sprayed fuel. In this work, we present a multi-dimensional mathematical model built on OpenFOAM for laser heating and evaporation of a single droplet in the diffusion dominated regime taking into account absorption of the laser radiation, evaporation process and vapor flow dynamics. The developed solver is validated against available experimental and numerical data for the ethanol and water droplet heating and evaporation. For continuous heating the peak temperature is established by the balance of cooling, evaporation and heating and results in high temperature for larger droplets. It has been shown that for heating by a single laser pulse the maximum temperature of droplets depends only on the peak intensity of the laser radiation. Furthermore, for the peak irradiance close to the transition to the boiling regime, temporal dynamics of the droplet temperature is independent of the droplet size. With proper normalization of time, the dynamics of the droplet shrinkage and cooling is shown to be independent of droplet sizes and peak laser intensities. The influence of cooling and evaporation processes on droplet heating was found to be controlled by the pulse repetition rate for repeated pulse operation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Selective Laser Sintering of Polyolefins

Polyolefins are some of the most produced and used polymers around the globe. They are semi-crystalline thermoplastic polymers known for their low production cost while still exhibiting good mechanical properties and chemical resistance. These polymers are often used in a variety of manufacturing processes, including 3D printing or additive manufacturing (AM). However, due to their semi-crystalline nature, there are often issues with using polyolefins in AM processes (for example, shrinkage leading to dimensional instabilities). One example of an AM process for which polyolefins are of interest is selective laser sintering (SLS), where printability depends on the powdered material’s morphology, flowability, and size. Due to the inherent properties of polyolefins, there are a variety of issues surrounding their use in the SLS process. This paper aims to review the basics of SLS as well the current state of SLS printing of a few polyolefins and what challenges that would need to be overcome to print with these polyolefins.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Framework for Characterizing the Performance of High-Early Strength, High-Volume Fly Ash (HVFA) Concrete Structures

This presentation will highlight the development of a comprehensive framework to characterize the performance of high-volume fly ash (HVFA) concretes at early ages and discuss the resulting implications for concrete structures built using such materials. Achieving high-early compressive and/or flexural strength is often of particular importance for precast and/or prestressed concrete components – due to early age loading demands resulting from lifting, handling, or application of initial prestress – or other types of concrete structures that can significantly benefit from rapid strength development - such as for bridge deck repairs. The framework first includes a methodology for optimizing the strength of HVFA cementitious binders before subsequently scaling up the technology to evaluation of fresh and hardened HVFA concrete performance. A series of trial mix designs will be presented to demonstrate the effectiveness of the framework to achieve not only the desired high-early strength targets but also satisfactory workability, often in the form of self-consolidating concrete. Mechanical performance was evaluated at several age-dependent milestones and, in conjunction with estimating concrete strength using the maturity method, was ultimately used to facilitate the development of novel strength development history curves. By way of these datasets, concrete mechanical properties were utilized in the design of prototype structural components, such as beams and wall panels, for subjection to larger-scale experimental testing. Implications for other pertinent HVFA concrete performance attributes, such as shrinkage or creep, will also be discussed. The framework also includes a comprehensive methodology for evaluating the environmental life-cycle performance of HVFA concrete structures focused on mitigating any unwarranted environmental consequences resulting from beneficial HVFA reuse in concrete. Strategies for more widespread implementation of HVFA concrete materials into construction practice will also be presented. Lastly, the role of the HVFA concrete framework towards the development of new provisions for building codes and/or design standards, and recommendations for future research needs will also be discussed.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Journal paper

Laser technology is being widely studied for controlled energy deposition for a range of applications, including flow control, ignition, combustion, and diagnostics. The absorption and scattering of laser radiation by liquid droplets in aerosols affects propagation of the laser beam in the atmosphere, while the ignition and combustion characteristics in combustion chambers are influenced by the evaporation rate of the sprayed fuel. In this work, we present a mathematical model built on OpenFOAM for laser heating and evaporation of a single droplet in the diffusion-dominated regime taking into account absorption of the laser radiation, evaporation process, and vapor flow dynamics. The developed solver is validated against available experimental and numerical data for heating and evaporation of ethanol and water droplets. The two main regimes—continuous and pulsed laser heating—are explored. For continuous laser heating, the peak temperature is higher for larger droplets. For pulsed laser heating, when the peak irradiance is close to transition to the boiling regime, the temporal dynamics of the droplet temperature does not depend on the droplet size. With the empirical normalization of time, the dynamics of the droplet shrinkage and cooling are found to be independent of droplet sizes and peak laser intensities.

42 ENGINEERING↗

DOE OSTI2024

Near-Net-Shape Hot Isostatic Press Manufacturing Modality for sCO2 CSP Capital Cost Reduction

Through this DOE funded 3.5-year research project, feasibility of fabricating supercritical carbon dioxide (sCO2) turbine components by powder metallurgy (PM) based near-net-shape (NNS) hot isostatic pressing (HIP) was demonstrated in a turbine nozzle ring, a turbine casing with Haynes 282 powder, and a bimetallic pipe with Haynes 282 and SS415 powder. As-HIP microstructure of various powders and HIP processing conditions was studied to downselect a condition for the prototype components. Tensile strength and low cycle fatigue (LCF) capability of PM HIP 282 was found to be superior to cast 282, despite a debit in creep stress capability that could be mitigated by component design modification. Near-Net-shape with minimal post machining was achieved by modeling the non-uniform shrinkage during HIP cycle and designing the HIP tooling to meet dimensional targets. The prototypes of turbine nozzle ring and bimetallic pipe were successful in achieving overall dimension, microstructure, and properties, despite dimensional tolerance affected by chemical milling rate. The prototype of a 1700lbs turbine casing was partially successful in achieving dimension, microstructure in as-HIP state, and providing consistent mechanical properties, however, cracking issue during post heat treatment required further investigation. The estimated manufacturing cost using NNS HIP was a ~50% reduction compared to forging with extensive machining, which translated into ~$100/kWe CAPEX cost reduction for concentrated solar power (CSP) power block.

14 SOLAR ENERGY↗

DOE OSTI2024

Soil Sensors in Agriculture: From Unsustainable to Biodegradable

Commercially available bi-metallic temperature sensors have long exploited differential thermal expansions between materials to produce an actuation-induced readout from a bi-metal helix. When dispersed in agricultural land, electronic components are used to transmit information at the cost of an increased environmental footprint. This paper briefly recaps the proposed sensor, which employs a biodegradable bi-material helix composed of a polymer and metal. Proposed polymer sheetings of cellulose acetate and polylactic acid are characterized via TGA, DMA, and DSC to evaluate plasticizer content, shrinkage, and an appropriate sensor work-use range. Finally, the deflection of non-biodegradable bi-polymer strips is quantified for various combinations to determine if bi-polymer deflection is possible.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Assessment of InSAR Seasonal Movements at Bayou Choctaw SPR Site

Ground deformation is important to monitor for the ongoing safety and stability of underground caverns. Implementing InSAR technology to monitor site-wide surface deformation at the Strategic Petroleum Reserve has revealed seasonal ground movements at Bayou Choctaw in Louisiana. The cyclic, seasonal pattern shows soil shrinkage during the spring and summer months and soil expansion during the fall and winter months. Prior to this report, no in-depth investigation was conducted to explain this seasonal phenomenon. However, the ground movement is believed to be near-surface and not geological due to the relatively insignificant movement between years. To better understand seasonality movements, soil properties, land cover, and climatic conditions are assessed to relate near-surface water and soil interactions. The soil, land, and climatic properties all contribute to seasonal ground movement, and vegetation cover and the soil's water capacity contribute to the spatial variability of InSAR seasonal measurements at Bayou Choctaw.

02 PETROLEUM↗

DOE OSTI2024

Production of Readily Compressible Dies for the Enhanced Sintering of Solids (PRESS) Preliminary Investigations

Non-oxide ceramics, which consist of predominantly carbides, borides, and nitrides, are of great interest to modern engineering because of their resistance to extreme conditions. Properties of such materials include high temperature resistance, high hardness, chemical resistance, and high fracture toughness. However, the main method for manufacturing parts of these materials is by machining cylindrical billets to the desired geometry. Not only does this produce waste, but the cost of machining is high since the part materials are of such high hardness. This method is used because these non-oxide ceramics must be sintered to high density using simultaneous heat and pressure within a hot-pressing unit. These units are inherently restricted to cylindrical geometries. A proposed way to expand the capabilities of a hot-press is by using intermediate compressible dies. This method consists of surrounding a ceramic part green body with a material that will shrink at the same rate as the part and survive the hot-pressing conditions. At the end, the compressible die material would be removed leaving a nearly net shaped hot-pressed part. In this study, graphite powder was investigated as the compressible die material with its shrinkage rate being controlled by particle size mixing. Both ceramic materials and graphite were then cast into parts and compressible dies respectively to show the feasibility of the compressible die hot-pressing method.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Strongback Validation in Compact Particle Accelerator

To achieve superconductivity, RF cavities must operate under cryogenic conditions. These low temperatures cause thermal shrinkage, posing a challenge in maintaining the position of the RF coupler, a vital component of the particle accelerator. The solution to this issue includes a passive design that minimizes heat transfer to the cavity while also withstanding loads encountered during transport. A mock-up was constructed to demonstrate the effectiveness of the solution in maintaining proper RF coupler alignment under thermal contraction. The results confirm the feasibility of the design for maintaining operational integrity during cryogenic conditions.

Jakopin, Alexander [Northern Illinois U.]↗

DOE OSTI2024

Improved digital construction binder solution utilizing calcium aluminate additive for Infrastructure Scale Additive Manufacturing

Oak Ridge National Laboratory (ORNL) worked with Kerneos Inc., a Division of Imerys USA, Inc. to develop an improved digital construction binder using calcium aluminate additives produced by Kerneos along with locally available concrete materials. When the two-stage (2K) binder formulation was added to commercially available Portland Limestone Cement and sand to form a digital construction mortar, its strength exceeded a number of commercially available digital construction binders both at early and later ages. At the same time, the developed formulation showed precise control of setting time after addition and showed very low shrinkage making it a strong, reliable, and easily customizable alternative to fixed proprietary digital construction binders.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Defect Detection Model Development for Large Scale Thermoplastic Printing

Large-format additive manufacturing (LFAM) offers several advantages, including high throughput, cost-effective pellet-fed extrusion, and the capability to produce large-scale structures. The main pain points of LFAM include start and stops during the printing process, warpage, long layer times that lead to bead freezing, and bead separation due to shrinkage. These issues can lead to overfill, underfill and buildup of material in different sections of a print. This can lead to hidden defects embedded within the printed layers, or even ultimate failure of the printed structure. This ensures these defects can only be identified through nondestructive testing (NDT) inspection methods after printing, which can be timely and costly. Aligned Vision work specializes in 2D projectors with visual inspection systems and machine learning. Traditionally system is used for composite layup and layup inspections. In this work we used the LFAM system at Oak Ridge National Laboratory to create defect rich samples. The Aligned Vision inspection system then performed in-situ monitoring of the print process after each part was printed. This in-situ vision inspection system was used to develop a layer-by-layer inspection model that looks for overfill, underfill, and the buildup of defects using only a camera-based vision system. This leads to the assurance of high-quality production components.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Improved digital construction binder solution utilizing calcium aluminate additive for Infrastructure Scale Additive Manufacturing

36 MATERIALS SCIENCE↗

DOE OSTI2023

Complete Performance Comparison Between the Optimized Image Construction Algorithm (U-MBIR) and the Existing Reconstruction Algorithm for Detecting Defects and Damage in Concrete

Reinforced concrete (RC) is a composite material subjected to mechanical, thermal, and chemical loads throughout its service life. Because of these external stressors and the susceptibility of RC structural members to shrinkage and microcracking, the material degrades throughout its life cycle. This deterioration can lead to a decrease in member capacity and, ultimately, poses a threat to the structural integrity. Thus, it is crucial that the damage caused by aging and degradation be monitored and assessed at regular intervals throughout the material’s service life. Since coring of the material is typically not feasible for in-service structural systems, non-destructive evaluation (NDE) methodologies are used to assess remaining structural capacity. NDE methods enable surface and subsurface examination without damaging or degrading the medium. Moreover, RC is a critical component of nuclear power plants; thus, its safety and reliability must be thoroughly examined throughout the life cycle of the structural system. Ultrasonic measurements have been an industry standard for both surface and subsurface inspections. To this end, Oak Ridge National Laboratory (ORNL) has researched and developed advanced image reconstruction algorithms to capture internal damage. The results and discussion presented herein summarize the current state of the ultrasonic model–based iterative reconstruction (U-MBIR) algorithm developed at ORNL. More specifically, this report presents a comparison between reconstruction images produced via a widely employed ultrasonic NDE technique—the synthetic aperture focusing technique (SAFT)—and the ORNL-developed U-MBIR algorithm. These NDE methodologies are demonstrated using ultrasonic data collected from four concrete specimens. Overall, the U-MBIR algorithm eliminates artifacts and noise that are typically present within the SAFT reconstructions, and it shows defects and anomalies more clearly than the SAFT images. In conclusion, this algorithm is suitable for identifying concrete defects, although more improvements and optimization could be done to better define internal defects.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Scale up production of carbon fibers from petroleum mesophase pitch

This work investigates the scale-up of pitch precursors for the carbon fiber market using mesophase pitch formulated and produced by Advanced Carbon Products Technologies’ (ACPT’s) patented mesophase pitch processing technology. Through use of its patented process, ACPT developed strategic materials by converting petroleum-based pitch into a high-value, low-cost, carbon-rich feedstock for carbon fiber and other materials critical to our national security. The team successfully developed processing criteria for the tailored mesophase pitch material that can be processed further into precursor and carbon fiber. Processability of the mesophase pitch into precursor and carbon fiber was demonstrated at scale. The resulting materials sequester the carbon that would otherwise be burned and released into the atmosphere, making this an environmentally friendly way to produce these materials in the United States.Pitch-based carbon fibers offer a promising pathway toward cost-effective, high-performance materials for structural and high-modulus composite applications; however, adoption has been limited by challenges in precursor processability and scale-up. In this work, tailored isotropic and mesophase petroleum-derived pitch materials were developed and evaluated for precursor and carbon fiber production through a collaborative effort between Oak Ridge National Laboratory (ORNL) and ACPT. Processing conditions were established at ORNL’s Carbon Fiber Technology Facility to enable stable melt-blowing of pitch-based precursors under continuous operation. Mesophase pitch precursor fibers were produced following oxidation and carbonization, corresponding to a diameter shrinkage of approximately 12%–13% and an estimated mass yield of about 75%–80%. Continuous melt-blowing steady-state operation was demonstrated over time, indicating robust process stability. Melt-blowing was achieved at throughput rates of approximately 20 lb/h⁻¹, validating the commercial viability of petroleum-derived pitch feedstocks for fiber production. Further studies are required to tailor carbon fiber microstructure and properties for specific composite applications.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2023

Near-Net-Shape HIP Manufacturing for sCO2 Turbomachinery Cost Reduction

sCO2 turbomachinery that operates above 650°C requires the use of γ' strengthened Ni-based superalloys, leading to high cost and barrier of market adoption. Near-net-shape (NNS) HIP manufacturing with 282® alloy powder is being developed for sCO2 turbine components, with a significant estimated cost reduction. Tensile, creep, low cycle fatigue properties of argon gas atomized and plasma atomized powders were evaluated and compared to sand cast HAYNES® 282®. While tensile strength and fatigue life outperformed sand cast material, a 10~25% debit in the creep stress capability was observed due to the fine grain size and presence of prior particle boundaries (PPBs). Finite element model calibrated by powder rheological properties accurately predicted the nonuniform shrinkage during HIP, providing HIP tooling design to achieve the target dimension. A 20 lbs. turbine nozzle ring was successfully demonstrated within 0.01 inch dimensional tolerance at the vanes. A 1700lbs. turbine casing with complex internal struts and manifolds was also demonstrated being close to the target dimension.

14 SOLAR ENERGY↗

DOE OSTI2023

Discovering useful genetic variation in the seed parent gene pool for sorghum improvement

Multi-parent populations contain valuable genetic material for dissecting complex, quantitative traits and provide a unique opportunity to capture multi-allelic variation compared to the biparental populations. A multi-parent advanced generation inter-cross (MAGIC) B-line (MBL) population composed of 708 F 6 recombinant inbred lines (RILs), was recently developed from four diverse founders. These selected founders strategically represented the four most prevalent botanical races (kafir, guinea, durra, and caudatum) to capture a significant source of genetic variation to study the quantitative traits in grain sorghum [Sorghum bicolor (L.) Moench]. MBL was phenotyped at two field locations for seven yield-influencing traits: panicle type (PT), days to anthesis (DTA), plant height (PH), grain yield (GY), 1000-grain weight (TGW), tiller number per meter (TN) and yield per panicle (YPP). High phenotypic variation was observed for all the quantitative traits, with broad-sense heritabilities ranging from 0.34 (TN) to 0.84 (PH). The entire population was genotyped using Diversity Arrays Technology (DArTseq), and 8,800 single nucleotide polymorphisms (SNPs) were generated. A set of polymorphic, quality-filtered markers (3,751 SNPs) and phenotypic data were used for genome-wide association studies (GWAS). We identified 52 marker-trait associations (MTAs) for the seven traits using BLUPs generated from replicated plots in two locations. We also identified desirable allelic combinations based on the plant height loci (Dw1, Dw2, and Dw3), which influences yield related traits. Additionally, two novel MTAs were identified each on Chr1 and Chr7 for yield traits independent of dwarfing genes. We further performed a multi-variate adaptive shrinkage analysis and 15 MTAs with pleiotropic effect were identified. The five best performing MBL progenies were selected carrying desirable allelic combinations. Since the MBL population was designed to capture significant diversity for maintainer line (B-line) accessions, these progenies can serve as valuable resources to develop superior sorghum hybrids after validation of their general combining abilities via crossing with elite pollinators. Further, newly identified desirable allelic combinations can be used to enrich the maintainer germplasm lines through marker-assisted backcross breeding.

59 BASIC BIOLOGICAL SCIENCES↗