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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Allometric-kinetic model predictions of concentration ratios for anthropogenic radionuclides across animal classes and food selection

Protection of the environment from radiation fundamentally relies on dose assessments for non-human biota. These dose assessments use measured or predicted concentrations of radionuclides in soil or water combined with Concentration Ratios (CRs) to estimate tissue concentrations in animals and plants, yet there is a paucity of CR data relative to the vast number of potential taxa and radioactive contaminants in the environment and their taxon-specific ecosystems. Because there are many taxa each having very different behaviors and biology and many possible bioavailable radionuclides, CRs have the potential to vary by orders-of-magnitude, as often seen in published data. Given the diversity of taxa, the International Commission on Radiological Protection (ICRP) has categorized non-human biota into 12 representative organisms (ROs), while the U.S. Department of Energy (DOE) uses the non-taxon specific categories of terrestrial, riparian, and aquatic animals. The question we examine here is: do these categorizations adequately “represent” the broad diversity of animals? To explore this question, here we analyze an Allometric-Kinetic (A-K) model to calculate radionuclide-specific CRs for common animal classes which are then further subcategorized into herbivores, omnivores, carnivores, and invertebrate detritivores. Comparisons in CRs among animal classes exhibited only small differences, but there was order of magnitude differences between herbivores, carnivores, and especially detritivores, for many radionuclides of interest. These findings suggest that the ICRP ROs and the DOE categories are reasonable, but their accuracy could be improved by including sub-categories related to animal dietary ecology. Finally, comparisons of A-K model predicted CR values to published CRs show order-of-magnitude variations, providing justification for additional studies of assimilation across radionuclides and animal classes.

63 RADIATION, THERMAL, AND OTHER ENVIRON. POLLUTAN↗
DOE OSTI2021

Controlling the Aspect Ratios of Au Nanocrystals with Ag+ Addition Time in Seed-Mediated Synthesis: Implications for Surface-Enhanced Raman Scattering

Among various factors playing pivotal roles in the typical seed-mediated growth of Au nanocrystals (NCs), the role of Ag (AgNO3) has remained debatable over time and seminal research efforts have helped us in reaching a consensus, albeit from the standpoint of [Ag+] concentration. This study aims to provide an understanding of the role of Ag+ from the perspective of time. Here, we show that different Au NCs with tunable aspect ratios (ARs) can be generated in one system in high yield simply by varying the time of addition of Ag+ in the growth solution. The generality of the method has been demonstrated in tuning the ARs of anisotropic Au NCs like concave cuboid (CCB, AR = 2) and elongated tetrahexahedra (AR = 2.5), where the delayed addition of Ag+ leads to the formation of their isotropic counterpart concave cube (CC, AR = 1) and tetrahexahedra (AR = 1), respectively. This work, apart from establishing timed addition of Ag+ as a crucial parameter in controlling the AR, may also help in the realization of a universal growth mechanism of Au NCs. The Au NCs with varying ARs (CCB, AR = 2 and CC, AR = 1) have been further explored as potential substrates for surface-enhanced Raman scattering (SERS) due to the presence of their high-index facets and sharp tips.

KEYWORDS:Au nanoparticles seed-mediated growth hig↗
DOE OSTI2022

Bearing Fault Detection on Wind Turbine Gearbox Vibrations Using Generalized Likelihood Ratio-Based Indicators

Studies in condition monitoring literature often aim to detect rolling element bearing faults because they have one of the biggest shares among defects in turbo machinery. Accordingly, several prognosis and diagnosis methods have been devised to identify fault signatures from vibration signals. A recently proposed method to capture the rolling element bearing degradation provides the groundwork for new indicator families utilizing the generalized likelihood ratio test. This novel approach exploits the cyclostationarity and the impulsiveness of vibration signals independently in order to estimate the most suitable indicators for a given fault. However, the method has yet to be tested on complex experimental vibration signals such as those of a wind turbine gearbox. In this study, the approach is applied to the National Renewable Energy Laboratory Wind Turbine Gearbox Condition Monitoring Round Robin Study data set for bearing fault detection purposes. The data set is measured on an experimental test rig of a wind turbine gearbox; hence the complexity of the vibration signals is similar to a real case. The outcome demonstrates that the proposed method is capable of distinguishing between healthy and damaged vibration signals measured on a complex wind turbine gearbox.

condition monitoring↗
DOE OSTI2022

Voltage waveform tailoring for high aspect ratio plasma etching of SiO 2 using Ar/CF 4 /O 2 mixtures: Consequences of ion and electron distributions on etch profiles

The quality of high aspect ratio (HAR) features etched into dielectrics for microelectronics fabrication using halogen containing low temperature plasmas strongly depends on the energy and angular distribution of the incident ions (IEAD) onto the wafer, as well as potentially that of the electrons (EEAD). Positive ions, accelerated to high energies by the sheath electric field, have narrow angular spreads and can penetrate deeply into HAR features. Electrons typically arrive at the wafer with nearly thermal energy and isotropic angular distributions and so do not directly penetrate deeply into features. These differences can lead to positive charging of the insides of the features that can slow etching rates and produce geometric defects such as twisting. In this work, we computationally investigated the plasma etching of HAR features into SiO 2 using tailored voltage waveforms in a geometrically asymmetric capacitively coupled plasma sustained in an Ar/CF 4 /O 2 mixture at 40 mTorr. The tailored waveform consisted of a sinusoidal wave and its higher harmonics with a fundamental frequency of 1 MHz. We found that some degree of control of the IEADs and EEADs is possible by adjusting the phase of higher harmonics φ through the resulting generation of electrical asymmetry and electric field reversal. However, the IEADs and EEADs cannot easily be separately controlled. The control of IEADs and EEADs is inherently linked. The highest quality feature was obtained with a phase angle φ = 0° as this value generated the largest (most negative) DC self-bias and largest electric field reversal for accelerating electrons into the feature. That said, the consequences of voltage waveform tailoring (VWT) on etched features are dominated by the change in the IEADs. Although VWT does produce EEADs with higher energy and narrower angular spread, the effect of these electrons on the feature compared to thermal electrons is not large. Finally, this smaller impact of VWT produced EEADs is attributed to thermal electrons being accelerated into the feature by electric fields produced by the positive in-feature charging.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Designing Li 4 Ti 5 O 12 /LiMn 2 O 4 Cells: Negative-to-Positive Ratio and Electrolyte

Li 4 Ti 5 O12/LiMn2O 4 (LTO/LMO) system is a promising candidate for behind-the-meter storage (BTMS) applications due to its critical-material-free chemistry exhibiting good safety and long lifetime. In this paper we design LTO/LMO cells to mitigate their major degradation mechanism, loss of Li inventory, and improve their long-term cyclability. First, LMO electrodes with different loadings (2.61, 3.29, and 4.26 mAh cm -2 ) are paired with an LTO electrode (3.35 mAh cm -2 ) to create varying negative-to-positive ratios (N/P>1, =1, and <1). Additionally, conventional ethylene carbonate (EC)/ethyl methyl carbonate (EMC) mixture electrolyte and safety enhanced EC-only electrolyte are examined. We show that storing additional Li inventory in the cathode (i.e., using a thicker electrode and having N/P<1) is a convenient method to enhance the capacity retention of LTO/LMO cells, but only if the electrode utilization is not limited by the Li + ion transport. For systems that suffer from limited transport properties, prelithiating the anode will be more effective since LTO (~165 mAh g -1 LTO ) can store the same amount of capacity using less material compared to LMO (~100 mAh g -1 LMO ). In this work, we demonstrate how the electrolyte properties and the electrode thickness of LTO/LMO cells can be designed to enhance their performance.

25 ENERGY STORAGE↗
DOE OSTI2025

A Unified Interpretation of Variability in Precipitation Isotope Ratios

Abstract Several mechanisms have been proposed to explain why the isotope ratios of precipitation vary in space and time and why they correlate with other climate variables like temperature and precipitation. Here, we argue that this behavior is best understood through the lens of radiative transfer, which treats the depletion of atmospheric vapor transport by precipitation as analogous to the attenuation of light by absorption or scattering. Building on earlier work by Siler et al., we introduce a simple model that uses the equations of radiative transfer to approximate the two-dimensional pattern of the oxygen isotope composition of precipitation ( δ p ) from monthly mean hydrologic variables. The model accurately simulates the spatial and seasonal variability in δ p within a state-of-the-art climate model and permits a simple decomposition of δ p variability into contributions from gradients in evaporation and the length scale of vapor transport. Outside the tropics, δ p is mostly controlled by gradients in evaporation, whose dependence on temperature explains the positive correlation between δ p and temperature (i.e., the temperature effect). At low latitudes, δ p is mostly controlled by gradients in the transport length scale, whose inverse relationship with precipitation explains the negative correlation between δ p and precipitation (i.e., the amount effect). This suggests that the temperature and amount effects are both mostly explained by the variability in upstream rainout, but they reflect distinct mechanisms governing rainout at different latitudes. Significance Statement The isotopic composition of precipitation has long been used to make inferences about past climates based on its observed relationship with precipitation in the tropics and with temperature at higher latitudes. These relationships—known as the “amount effect” and “temperature effect,” respectively—have been attributed to many different mechanisms, most of which are thought to operate at either high or low latitudes but not both. Here, we present a unified framework for interpreting the isotope variability that can explain the latitude dependence of the temperature and amount effects despite making no distinction between high and low latitudes. Although our results are generally consistent with certain interpretations of the amount effect, they suggest that the temperature effect is widely misunderstood.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Isotope ratio-based quantification of carbon assimilation highlights the role of plastidial isoprenoid precursor availability in photosynthesis

Abstract Background We report a method to estimate carbon assimilation based on isotope ratio-mass spectrometry (IRMS) of 13 CO 2 labeled plant tissue. Photosynthetic carbon assimilation is the principal experimental observable which integrates important aspects of primary plant metabolism. It is traditionally measured through gas exchange. Despite its centrality in plant research, gas exchange performs poorly with rosette growth habits typical of Arabidopsis thaliana , mutant lines with limited biomass, and accounts poorly for leaf shading. Results IRMS-based carbon assimilation values from plants labeled at different light intensities were compared to those obtained by gas exchange, and the two methods yielded similar values. Using this method, we observed a strong correlation between 13 C content and labeling time (R 2 = 0.999) for 158 wild-type plants labeled for 6 to 42 min. Plants cultivated under different light regimes showed a linear response with respect to carbon assimilation, varying from 7.38 nmol 13 C mg −1 leaf tissue min −1 at 80 PAR to 19.27 nmol 13 C mg −1 leaf tissue min −1 at 500 PAR. We applied this method to examine the link between inhibition of the 2 C -methyl- d -erythritol-4-phosphate (MEP) pathway and suppression of photosynthesis. A significant decrease in carbon assimilation was observed when metabolic activity in the MEP pathway was compromised by mutation or herbicides targeting the MEP pathway. Mutants affected in MEP pathway genes 1-DEOXY- d -XYLULOSE 5-PHOSPHATE SYNTHASE (DXS) or 1-HYDROXY-2-METHYL-2-(E)-BUTENYL 4-DIPHOSPHATE SYNTHASE (HDS) showed assimilation rates 36% and 61% lower than wild type. Similarly, wild type plants treated with the MEP pathway inhibitors clomazone or fosmidomycin showed reductions of 52% and 43%, respectively, while inhibition of the analogous mevalonic acid pathway, which supplies the same isoprenoid intermediates in the cytosol, did not, suggesting inhibition of photosynthesis was specific to disruption of the MEP pathway. Conclusions This method provides an alternative to gas exchange that offers several advantages: resilience to differences in leaf overlap, measurements based on tissue mass rather than leaf surface area, and compatibility with mutant Arabidopsis lines which are not amenable to gas exchange measurements due to low biomass and limited leaf surface area. It is suitable for screening large numbers of replicates simultaneously as well as post-hoc analysis of previously labeled plant tissue and is complementary to downstream detection of isotopic label in targeted metabolite pools.

2C‑methyl‑d‑erythritol 4‑phosphate pathway↗
DOE OSTI2023

Challenges in correlating oxygen stable isotope ratios of hydrates on uranium ore concentrates to process waters

Exchange of oxygen stable isotopes (δ 18 O values) between precipitation waters and uranium oxides is governed by thermodynamics or kinetics. It has been assumed that meteoric waters can be related to precipitation waters in uranium ore concentrates and their calcination and reduced uranium oxide products. With this assumption, the δ 18 O values of uranium materials could provide forensic signatures that identify the production history and geolocation of nuclear materials. To further exploit the potential of δ 18 O values in nuclear material analysis, this study examines the oxygen stable isotope exchange in two UOCs, magnesium diuranate (MDU) and sodium diuranate (SDU). MDU and SDU were synthesized from solutions of uranyl nitrate hexahydrate using precipitation waters with unique oxygen isotope compositions. The structures of the MDU and SDU were analyzed using powder X-ray diffraction (p-XRD) and thermal mass loss curves, while the δ 18 O values of waters generated during thermal decomposition were analyzed using a thermogravimetric analyzer coupled to an isotope ratio infrared spectrometer (TGA-IRIS). By p-XRD, the MDU was uniform and amorphous across all syntheses with residual crystalline material incorporated as a minor component. Combined with the TGA results, all of the MDU is likely amorphous MgU 2 O 7 ·3H 2 O with MgO impurities present throughout. In contrast, the SDU synthesis resulted in multiple phases with many samples exhibiting crystalline phases including a combination of Na(UO 2 ) 4 O 2 (OH) 5 ·5H 2 O and Na 2 (UO2) 6 O 4 (OH) 6 ·8H 2 O with a Na 2 U 2 O 7 minor phase. A small fraction of the SDU samples were amorphous with no crystalline XRD peaks observed. Mass loss curves of the SDU samples revealed that the amorphous samples contained inclusions of similar crystalline phases compared to the crystalline materials. The uniformity of the MDU samples enabled highly reproducible measurements of δ 18 O values of the water vapor yielded for two dehydration events at 170 °C and 500 °C. In contrast, the multiphase composition of the SDU samples resulted in poor reproducibility in δ 18 O values. In conclusion, neither system revealed any correlation between the δ 18 O values of precipitation water, and the waters released during dehydration of the UOCs.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2021

Imaging the Shallow Structure of the Yucca Flat at the Source Physics Experiment Phase II Site with Horizontal-to-Vertical Spectral Ratio Inversion and a Large- N Seismic Array

The Source Physics Experiment (SPE) is a series of chemical explosions at the Nevada National Security Site (NNSS) with the goal of understanding seismic-wave generation and propagation of underground explosions. To understand explosion source physics, accurate geophysical models of the SPE site are needed. Here, we utilize a large-N seismic array deployed at the SPE phase II site to generate a shallow subsurface model of shear-wave velocity. The deployment consists of 500 geophones and covers an area of, approximately, 2.5 × 2 km. The array is located in the Yucca Flat in the northeast corner of the NNSS, Nye County, Nevada. Using ambient-noise recordings throughout the large-N seismic array, we calculate horizontal-to-vertical spectral ratios (HVSRs) across the array. We obtain 2D seismic images of shear-wave velocities across the SPE phase II site for the shallow structure of the basin. In this work the results clearly image two significant seismic impedance interfaces at ~150–500 and ~350–600 m depth. The shallower interface relates to the contrast between Quaternary alluvium and Tertiary volcanic rocks. The deeper interface relates to the contrast between Tertiary volcanic rocks and the Paleozoic bedrock. The 2D subsurface models support and extend previous understanding of the structure of the SPE phase II site. This study shows that the HVSR method in conjunction with a large-N seismic array is a quick and effective method for investigating shallow structures.

58 GEOSCIENCES↗
DOE OSTI2023

Role of Simple Spatial Gradient in Reinforcing the Accuracy of Temperature Determination of HED Plasma via Spectral Line-Area Ratios

We report on the simulation of temperature gradients in tamped NaFMgO target-foil plasma, heated and backlit by z-pinch dynamic hohlraum radiation. Our approach compares the spectroscopic output of a collisional-radiative model (prismspect) with soft X-ray absorption spectra collected on Sandia National Laboratories’ (SNL) Z Pulsed Power Facility. The pattern of minimum χ2 is seen to agree with an efficient, three-parameter model. Results show that a negligible gradient in electron temperature Te is consistent with experimental data, justifying the assumptions of previous work. The predicted sensitivity of line spectra to the gradient-aligned profile of Te is documented for each spectral feature, so that the line-area ratio between a pair of spectral features may be assessed as a proxy for the existence and quantification of such gradients.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

A Model to Account for the Effects of Load Ratio and Hydrogen Pressure on the Fatigue Crack Growth Behavior of Pressure Vessel Steels

A phenomenological model for estimating the effects of load ratio R and hydrogen pressure P H2 on the hydrogen-assisted fatigue crack growth rate (HA–FCGR) behavior in the transient and steady-state regimes of pressure vessel steels is described. The “transient regime” is identified with crack growth within a severely embrittled zone of intense plasticity at the crack tip. The “steady-state” behavior is associated with the crack growing into a region of comparatively lower hydrogen concentration located further away from the crack tip. The model treats the effects of R and P H2 as being functionally separable. In the transient regime, the effects of the hydrogen pressure on the HA–FCGR behavior were negligible but were significant in the steady-state regime. The hydrogen concentration in the steady-state region is modeled as being dependent on the kinetics of lattice diffusion, which is sensitive to pressure. Experimental HA–FCGR data from the literature were used to validate the model. The new model was shown to be valid over a wide range of conditions that ranged between –1 ≤ R ≤ 0.8 and 0.02 ≤ P H2 ≤ 103 MPa for pressure vessel steels.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Early Results from GLASS-JWST. XI. Stellar Masses and Mass-to-light Ratio of z > 7 Galaxies

We exploit James Webb Space Telescope (JWST) NIRCam observations from the GLASS-JWST-Early Release Science program to investigate galaxy stellar masses at z > 7. We first show that JWST observations reduce the uncertainties on the stellar mass by a factor of at least 5–10, when compared with the highest-quality data sets available to date. We then study the UV mass-to-light ratio, finding that galaxies exhibit a a two orders of magnitude range of M / L UV values for a given luminosity, indicative of a broad variety of physical conditions and star formation histories. As a consequence, previous estimates of the cosmic stellar-mass density—based on an average correlation between UV luminosity and stellar mass—can be biased by as much as a factor of ~6. Our first exploration demonstrates that JWST represents a new era in our understanding of stellar masses at z > 7 and, therefore, of the growth of galaxies prior to cosmic reionization.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Release-to-Birth Ratios for AGR-5/6/7 Operating Cycles 162B–168A

This engineering calculations and analysis report (ECAR) documents the release-to-birth ratios of the Advanced Gas Reactor (AGR) experiment, AGR-5/6/7, which was irradiated in the Advanced Test Reactor (ATR) Northeast Flux Trap from February 16, 2018 to July 22, 2020.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Bearing Fault Detection on Wind Turbine Gearbox Vibrations Using Generalized Likelihood Ratio-Based Indicators: Preprint

Studies in condition monitoring literature often aim to detect rolling element bearing faults because they have one of the biggest shares among defects in turbo machinery. Accordingly, several prognosis and diagnosis methods have been devised to identify fault signatures from vibration signals. The underlying idea behind traditional indicators often revolves around tracking both cyclostationarity and abnormal impulses in the vibration signals without distinguishing the two. A recently proposed method to capture the rolling element bearing degradation lays out the groundwork for new indicator families utilizing generalized likelihood ratio test. This novel approach exploits the cyclostationarity and the impulsiveness of vibration signals independently in order to estimate the most suitable indicators for a given fault. However, the method has yet to be tested on complex experimental vibration signals such as those of a wind turbine gearbox. In this study, the approach is applied to the NREL Wind Turbine Gearbox Condition Monitoring Round Robin Study data set for bearing fault detection purposes. The data set is measured on an experimental test rig of a wind turbine gearbox, hence the complexity of the vibration signals is similar to a real case. Furthermore, the new indicators are also tested with signals that carry multiple fault signatures. The outcome demonstrates that the proposed method is capable of distinguishing between healthy and damaged vibration signals measured on a complex wind turbine gearbox.

condition monitoring↗
DOE OSTI2022

AGR-5/6/7 Final Release-to-Birth Ratio Data Analysis

AGR-5/6/7 is the last of a series of Advanced Gas Reactor (AGR) experiments conducted in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) in support of development and qualification of tristructural isotropic (TRISO) low-enriched fuel for use in the high-temperature gas cooled reactor (HTGR). AGR configuration and irradiation conditions are based on prismatic HTGR technology that is distinguished primarily through the use of helium coolant, a low-power-density ceramic core capable of withstanding very high temperatures, and TRISO-coated particle fuel. The AGR tests provide valuable irradiation-performance data to support fuel process development, qualify fuel for normal operation and accident conditions, and support development and validation of fuel performance and fission-product (FP) transport models and codes. Each AGR test consists of multiple independently controlled and monitored capsules containing fuel compacts placed in a graphite cylinder shrouded by a steel shell. Release-to-birth ratios (R/B) for fission-gas isotopes released from each capsule are calculated from release rates, measured by germanium detectors in the Fission Product Monitoring System (FPMS) installed downstream from each capsule, and birth rates calculated using numerical models of FG generation. The R/Bs are a critical measure of the ability of the fuel kernel, the particle coating layers, and the compact matrix to retain fission-gas atoms, preventing their release into the sweep-gas flow, and the impact of initially defective particles and/or particle-coating failures that occur during irradiation. For fission-gas isotopes, particle failure is defined as failure of all coating layers, allowing gaseous fission atoms to escape from a particle. During the first five cycles (162B ? 165A), R/Bs were stable in the 10-8?10-6 range, and no in-pile particle failures were observed, based on the gross gamma counts. The maximum R/B value of around 2 ? 10-6 for Kr-85m resulted from the presence of as-fabricated exposed kernels (based on the high exposed kernel fraction), the dispersed uranium, and high fuel particle temperatures in Capsule 1. Comparison of capsule-measured R/Bs from these early cycles to predictions using the previously developed AGR R/B model demonstrated FG release from the AGR-5/6/7 TRISO fuel was comparable to that of previous experiments. In addition, the Kr-85m R/B per-exposed-kernel values are comparable to R/B values obtained in AGR-3/4 irradiation experiment and four irradiation experiments performed during 1980s: (1) HRB-17/18, (2) COMEDIE-BD1, (3) HFR B1, and (4) HRB-21. In contrast, all measured R/B values are lower than predictions by the commonly used Richards and German models, which are intentionally conservative. A large number of in-pile particle failures occurred in Capsule 1 by the end of Cycle 166A. During the final four cycles (166A ? 168A), apparent damage to the Capsule 1 gas line appeared to cause FG leakage from that capsule into the other four capsules, resulting in an increase in fission gas (FG) detected in the effluent for all capsules. Isolation of the Capsule 1 gas line during the last three cycles also prevented measurement of its FG release. Thus, R/Bs in all capsules after Cycle 166A are highly uncertain because of undefined amount of leakage from Capsule 1, especially for long-lived isotopes. A few hundred in-pile particle failures were estimated for Capsule 1 before the end of Cycle 166A, but the total number of failures is unknown due to the lack of FG release data in the later cycles. Based primarily on evidence from the gross gamma counts during Cycle 168A, approximately 15 particles failed in Capsule 3 and four particles failed in Capsule 2. In-pile failures in Capsule 3 were anticipated because this capsule was designed to operate beyond the HTGR normal operating temperature range. In contrast, no in-pile failures were identified in the top two capsules (4 and 5) based on the absence of the typical spikes in gross gamma counts and low failure estimates using the AGR model, developed in INL/EXT-14-32970, for R/B of the short-lived isotopes (Kr-89 and Xe-137) with minimal leakage from Capsule 1.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Electric Vehicle Efficiency Ratios for Light-Duty Vehicles Registered in the United States

Electric vehicles (EVs) use energy more efficiently than gasoline vehicles. This is one of their primary attributes, enabling other benefits such as improved torque and reduced operating costs and greenhouse gas emissions. An electric vehicle efficiency ratio (EVER) is therefore important when calculating the financial and environmental benefits of EVs, calculating the impact that EVs have on a manufacturer's Corporate Average Fuel Economy rating, calculating credits in trading schemes such as California's Low Carbon Fuel Standard, fuel price leveling, designing electricity tariffs from utility-owned public charging infrastructure, creating EV alternatives to gasoline excise taxes, and more.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Novel Fast Cure Silicone Inks for Single-Step, Support-Free 3D Printing of Tall, Overhanging, and High Aspect Ratio Structures

Silicone elastomers have a broad variety of applications, such as soft robotics, biomedical devices, and structural metamaterials. The extrusion-based method known as direct ink write (DIW) has enabled the production of additively manufactured silicone structures. However, this method is limited to manufacturing mostly planar or pseudo-3D structures. Due to the low self-supporting capabilities of extruded strands for traditional silicone-based “inks,” obtaining tall or overhanging structures, or structures comprised by thin walls is not feasible. Here, in this study, a novel Fast Cure silicone-based ink is demonstrated that enables manufacturing of complex 3D structures. The Fast Cure ink is a two-part mixture and silicone structures are produced by inline mixing and coextrusion of a part containing a catalyst (part A) and a part containing a crosslinker (part B). By the virtue of crosslinking, the extruded strands rapidly rigidize, increasing their self-supportive capacity. Hence, structures can be obtained with superior shape retention and previously unobtainable parts are realized that are tall, with aspect ratios higher than 3, and have overhanging features, achieving inclination angles smaller than 35° with respect to the printing plane. These minimal sag parts are achieved without requiring extra curing or mechanisms, support structures, or suspension baths.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Unlocking Larger Scales and Aspect Ratios in 3D Printed Glass: Coupling Active Mixing and UV Curing for Advanced Printability and Crack Resistance

Recent developments in additive manufacturing (AM) of glass via silica-filled inks have facilitated fabrication of previously unattainable geometries and compositions. However, the maximum processable size of 15 mm limits the use of these prints in applications such as optics. A key limitation lies in the trade-off between material printability and green strength: increasing silica content in the feedstock improves crack resistance and reduces shrinkage but results in dramatic changes in viscoelastic properties that hinder flowability. Here, this paper presents a novel approach that offers expanded versatility in processable size, feedstock formulation, and printing. Described here is a direct ink writing (DIW) system coupled with an active high-shear micromixer and UV light source, capable of simultaneously printing multiple inks with a wide range of rheological properties. Choice of silica sourc, solvent, UV-curable binder, and dispersant is used to tune the ink rheology and improve printability and mechanical properties. Imparting high shear with the micromixer while UV-curing the extrudate allows for increased ink viscosities and reduced nozzle diameters, enabling printing finer feature sizes. With these advances, thin-walled high-aspect ratio structures and a crack-free glass disk measuring 44 mm in diameter are demonstrated, an increase of 3× in the greatest dimension compared to current state-of-the-art.

36 MATERIALS SCIENCE↗