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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2012

Leaching of indium from obsolete liquid crystal displays: Comparing grinding with electrical disintegration in context of LCA

Highlights: Black-Right-Pointing-Pointer Two pre-treatment methods, prior to leaching of indium from obsolete LCD modules, were described. Black-Right-Pointing-Pointer Conventional grinding and electrical disintegration have been evaluated and compared in the context of LCA. Black-Right-Pointing-Pointer Experimental data on the leaching capacity for indium and the electricity consumption of equipment were inputted into the LCA model in order to compare the environmental performance of each method. Black-Right-Pointing-Pointer An estimate for the environmental performance was calculated as the sum of six impact categories. Black-Right-Pointing-Pointer Electrical disintegration method outperforms conventional grinding in all impact categories. - Abstract: In order to develop an effective recycling system for obsolete Liquid Crystal Displays (LCDs), which would enable both the leaching of indium (In) and the recovery of a pure glass fraction for recycling, an effective liberation or size-reduction method would be an important pre-treatment step. Therefore, in this study, two different types of liberation methods: (1) conventional grinding, and (2) electrical disintegration have been tested and evaluated in the context of Life Cycle Assessment (LCA). In other words, the above-mentioned methods were compared in order to find out the one that ensures the highest leaching capacity for indium, as well as the lowest environmental burden. One of the main findings of this study was that the electrical disintegration was the most effective liberation method, since it fully liberated the indium containing-layer, ensuring a leaching capacity of 968.5 mg-In/kg-LCD. In turn, the estimate for the environmental burden was approximately five times smaller when compared with the conventional grinding.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2014

Analysis of surface integrity of grinded gears using Barkhausen noise analysis and x-ray diffraction

The contribution is focused to present results of study grinded gears made of 18CrNiMo7-6 steel used in the wind power plant for support (service) purposes. These gears were case-hardened due to standard hard case and soft core formation. This heat treatment increases wear resistance and fatigue strength of machine parts. During serial production some troubles with surface integrity have occurred. When solving complex problems lots of samples were prepared. For grinding of gears were used different parameters of cutting speed, number of material removal and lots from different subsuppliers. Material characterization was carried out using Barkhausen noise analysis (BNA) device; X-ray diffraction (XRD) measurement of surface residual stresses was done as well. Depth profile of measured characteristics, e.g. magnetoelastic parameter and residual stress was obtained by step by step layers' removing using electrolytic etching. BNA software Viewscan was used to measure magnetizing frequency sweep (MFS) and magnetizing voltage sweep (MVS). Scanning of Magnetoelastic parameter (MP) endwise individual teeth were also carried out with Viewscan. These measurements were done to find problematic surface areas after grinding such as thermal damaged locations. Plots of the hardness and thickness of case-hardened layer on cross sections were measurered as well. Evaluation of structure of subsurface case-hardened layer and core was made on etched metallographic patterns. The aim of performed measurements was to find correlation between conditions of grinding, residual stresses and structural and magnetoelastic parameters. Based on correlation of measured values and technological parameters optimizing the production of gears will be done.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2018

Modelling of Metal Removal in Reverse Zones in the Process of Internal Grinding

The removal of metal during reverse motion of the grinding wheel at extreme cross sections of holes in the workpiece during internal grinding is considered. In a single double pass of the wheel, the vibration of the contact area and the cutting forces are found to be significantly different in reverse motion within input and output holes. That disrupts the stability of metal removal and the machining precision over the length of the hole being machined. Approaches to the modeling of internal grinding with reverse motion of the grinding wheel are considered.

42 ENGINEERING↗
DOE OSTI2018

Diagnostics of Wheel Life in Grinding

The change in effective grinding power with change in the grinding fluid is studied experimentally, in fixed machining conditions. A method is proposed for assessing the life of the wheels. This method facilitates the choice of the tool, grinding conditions, and composition of the grinding fluid.

42 ENGINEERING↗
DOE OSTI2016

Impact of ammonia fiber expansion (AFEX) pretreatment on energy consumption during drying, grinding, and pelletization of corn stover

Pretreatment and densification of biomass can increase the viability of bioenergy production by providing a feedstock that is readily hydrolyzed and able to be transported greater distances. Ammonia Fiber Expansion (AFEX) is one such method targeted for use at distributed depots to create a value-added and densified feedstock for bioenergy use. However, the pretreatment process results in a high-moisture material that must be dried, further size reduced, and pelletized; all of which are energy intensive processes. This work quantifies the energy consumption required to dry, grind, and densify AFEX pretreated corn stover compared to non-pretreated stover and explores the potential of reduced drying as a means to conserve energy. The purpose of this work is to understand whether material property changes resulting from AFEX pretreatment influence the material performance in downstream formatting operations. Material properties, heat balance equations, and a rotary drum dryer model were used to model a commercial scale rotary drum dryer for AFEX pretreated corn stover, showing the potential to reduce dryer energy consumption by up to 36% compared to non-pretreated corn stover. Laboratory measured grinding and pelleting energies were both very sensitive to material moisture content. Overall, the total energy required for drying, grinding, and pelleting amounts to a savings of up to 20 kWh/dry ton for the AFEX pretreated material when dried to a low moisture content, equating to up to 0.55 /kg savings for gas and electricity. Grinding and pelleting of high moisture AFEX pretreated stover was shown to be more costly than the savings collected through reduced drying. Furthermore, while the energy and cost savings shown here are modest, the results help to highlight operational challenges and opportunities for continued improvement.

09 BIOMASS FUELS↗
DOE OSTI2011

OBSERVED BINARY FRACTION SETS LIMITS ON THE EXTENT OF COLLISIONAL GRINDING IN THE KUIPER BELT

The size distribution in the cold classical Kuiper Belt (KB) can be approximated by two idealized power laws: one with steep slope for radii R > R* and one with shallow slope for R < R*, where R* {approx} 25-50 km. Previous works suggested that the size frequency distribution (SFD) rollover at R* can be the result of extensive collisional grinding in the KB that led to the catastrophic disruption of most bodies with R < R*. Here, we use a new code to test the effect of collisions in the KB. We find that the observed rollover could indeed be explained by collisional grinding provided that the initial mass in large bodies was much larger than the one in the present KB and was dynamically depleted. In addition to the size distribution changes, our code also tracks the effects of collisions on binary systems. We find that it is generally easier to dissolve wide binary systems, such as the ones existing in the cold KB today, than to catastrophically disrupt objects with R {approx} R*. Thus, the binary survival sets important limits on the extent of collisional grinding in the KB. We find that the extensive collisional grinding required to produce the SFD rollover at R* would imply a strong gradient of the binary fraction with R and separation, because it is generally easier to dissolve binaries with small components and/or those with wide orbits. The expected binary fraction for R {approx}< R* is {approx}<0.1. The present observational data do not show such a gradient. Instead, they suggest a large binary fraction of {approx}0.4 for R = 30-40 km. This may indicate that the rollover was not produced by disruptive collisions, but is instead a fossil remnant of the KB object formation process.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Characterization of the Emissions and Crystalline Silica Content of Airborne Dust Generated from Grinding Natural and Engineered Stones

Abstract In this study, we systematically characterized the airborne dust generated from grinding engineered and natural stone products using a laboratory testing system designed and operated to collect representative respirable dust samples. Four stone samples tested included two engineered stones consisting of crystalline silica in a polyester resin matrix (formulations differed with Stones A having up to 90wt% crystalline silica and Stone B up to 50wt% crystalline silica), an engineered stone consisting of recycled glass in a cement matrix (Stone C), and a granite. Aerosol samples were collected by respirable dust samplers, total dust samplers, and a Micro-Orifice Uniform Deposit Impactor. Aerosol samples were analyzed by gravimetric analysis and x-ray diffraction to determine dust generation rates, crystalline silica generation rates, and crystalline silica content. Additionally, bulk dust settled on the floor of the testing system was analyzed for crystalline silica content. Real-time particle size distributions were measured using an Aerodynamic Particle Sizer. All stone types generated similar trimodal lognormal number-weighted particle size distributions during grinding with the most prominent mode at an aerodynamic diameter of about 2.0-2.3 μm, suggesting dust formation from grinding different stones is similar. Bulk dust from Stone C contained no crystalline silica. Bulk dust from Stone A, Stone B, and granite contained 60, 23, and 30wt% crystalline silica, respectively. In Stones A and B, the cristobalite form of crystalline silica was more plentiful than the quartz form. Only the quartz form was detected in granite. The bulk dust, respirable dust, and total dust for each stone had comparable amounts of crystalline silica, suggesting that crystalline silica content in the bulk dust could be representative of that in respirable dust generated during grinding. Granite generated more dust per unit volume of material removed than the engineered stones, which all had similar normalized dust generation rates. Stone A had the highest normalized generation rates of crystalline silica, followed by granite, Stone B, and Stone C (no crystalline silica), which likely leads to the same trend of respirable crystalline silica (RCS) exposure when working with these different stones. Manufacturing and adoption of engineered stone products with formulations such as Stone B or Stone C could potentially lower or eliminate RCS exposure risks. Combining all the effects of dust generation rate, size-dependent silica content, and respirable fraction, the highest normalized generation rate of RCS consistently occurs at 3.2-5.6 µm for all the stones containing crystalline silica. Therefore, removing particles in this size range near the generation sources should be prioritized when developing engineering control measures.

Public, Environmental & Occupational Health↗
DOE OSTI2024

Study of Mechanical Grinding Effects on Niobium Surface

Mechanical grinding is commonly employed to eliminate surface defects such as scratches and pits from niobium cavity surfaces or sheets before cavity fabrication. Subsequently, chemically buffered polishing or electropolishing is often utilized to completely remove residues of the polishing media and any defects induced by mechanical grinding, ensuring a pristine surface. In this study, we conducted a systematic investigation to assess the influence of mechanical grinding using silicon carbide (SiC) and aluminium oxide (Al2O3) polishing media on niobium surfaces. Additionally, the study examines the effects of post-mechanical grinding chemical treatments on surface quality.

Chouhan, V.↗
NASA NTRS1984

Grinding kinetics and equilibrium states

The temporary and permanent equilibrium occurring during the initial stage of cement grinding does not indicate the end of comminution, but rather an increased energy consumption during grinding. The constant dynamic equilibrium occurs after a long grinding period indicating the end of comminution for a given particle size. Grinding equilibrium curves can be constructed to show the stages of comminution and agglomeration for certain particle sizes.

Opoczky, L.↗
NASA NTRS1989

Effect of grinding on the fatigue life of titanium alloy (5 Al-2.5 Sn) under dry and wet conditions

The principal factors in the performance of aerospace materials are strength-to-weight ratio, fatigue life, fracture toughness, survivability and, of course, reliability. Machining processes and, in particular, grinding under adverse conditions have been found to cause damage to surface integrity and affect the residual stress distribution in the surface and subsurface region. These effects have a direct bearing on the fatigue life. In this investigation the effects of grinding conditions on the fatigue life of Titanium 5 Al-2.5Sn were studied. This alloy is used in ground form in the manufacturing of some critical components in the space shuttle's main engine. It is essential that materials for such applications be properly characterized for use in severe service conditions. Flat sub-size specimens 0.1 inch thick were ground on a surface grinding machine equipped with a variable speed motor at speeds of 2000 to 6000 rpm using SiC wheels of grit sizes 60 and 120. The grinding parameters used in this investigation were chosen from a separate study. The ground specimens were then fatigued at a selected stress and the resulting lives were compared with that of the virgin material. The surfaces of the specimens were examined under a scanning electron microscope, and the roughness and hardness were measured using a standard profilometer and microhardness tester, respectively. The fatigue life of the ground specimens was found to decrease with the increase in speed for both dry and wet conditions. The fatigue life of specimens ground under wet conditions showed a significant increase at the wheel speed of 2000 rpm for both the grit sizes and thereafter decreased with increase profilometry, microhardness measurements and scanning electron microscopic examination.

Rangaswamy, Partha↗
NASA NTRS2003

Production of Near-Mirror Surface Quality by Precision Grinding

Mechanical components such as gears and bearings operate with the working surfaces in intimate contact with a mating part. The performance of such components will be influenced by the quality of the working surface. In general, a smoother surface will perform better than a rougher surface since the lubrication conditions are improved. For example, surfaces with a special near-mirror quality finish of low roughness performed better than ground surfaces when tested using a block-on-ring arrangement. Bearings with near-mirror quality have been tested and analyzed; lower running torques were measured and improved fatigue life was anticipated. Experiments have been done to evaluate the performance of gears with improved, low roughness surface finishing. The measured performance improvements include an increased scuffing (scoring) load capacity by a factor of 1.6, a 30-percent reduction of gear tooth running friction, and longer fatigue lives by a factor of about four. One can also anticipate that near-mirror quality surface finishing could improve the performance of other mechanical components such as mechanical seals and heavily loaded journal bearings. Given these demonstrated benefits, capable and economical methods for the production of mechanical components with near-mirror quality surfaces are desired. One could propose the production of near-mirror quality surfaces by several methods such as abrasive polishing, chemical assisted polishing, or grinding. Production of the surfaces by grinding offers the possibility to control the macro-geometry (form), waviness, and surface texture with one process. The present study was carried out to investigate the possibility of producing near-mirror quality surfaces by grinding. The present study makes use of a specially designed grinding machine spindle to improve the surface quality relative to the quality produced when using a spindle of conventional design.

Dimofte, Florin↗
DOE OSTI2024

Study of Mechanical Grinding Effects on Niobium Surface

Mechanical grinding is commonly employed to eliminate surface defects such as scratches and pits from niobium cavity surfaces or sheets before cavity fabrication. Subsequently, chemically buffered polishing or electropolishing is often utilized to completely remove residues of the polishing media and any defects induced by mechanical grinding, ensuring a pristine surface. In this study, we conducted a systematic investigation to assess the influence of mechanical grinding using silicon carbide and aluminum oxide polishing media on niobium surfaces. Additionally, the study examines the effects of post-mechanical grinding chemical treatments on surface quality.

Chouhan, V.↗
DOE OSTI2011

Grinding Wear Behaviour of Stepped Austempered Ductile Iron as Media Material During Comminution of Iron Ore in Ball Mills

An attempt has been made to evaluate the suitability of austempered ductile iron (ADI) as media material for grinding iron ore in a ball mill. Spheroidal graphite (S.G) iron balls are austenitised at 900 deg. C for 60 minutes and given stepped austempering treatment at 280 deg. C for 30 minutes and 60 minutes followed by 380 deg. C for 60 minutes in each case. These materials are characterised by measuring hardness, analysing X-ray diffraction (X-RD), studying microstructure using optical and scanning electron microscope (SEM). Grinding wear behaviour of these materials was assessed for wear loss in wet condition at different pH value of the mineral slurry and found that the wear rate of grinding media material decreases with increase in pH of the slurry. The wear resistance of ADI balls were compared with forged En31 steel balls and found that the stepped austempered ductile iron is superior to forged En31 steel balls.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Effect of wet grinding on structural properties of ball clay

In this paper, the effect of wet grinding on structural properties of ball clay is undertaken. The wet grinding treatment was performed employing ball and vibro mills for different time spells of 2, 4, 8 and 16 hours. The structural properties were carried out using X-ray diffraction (XRD). The structure of ground samples is found to be simple cubic. The crystallographic parameters are calculated and slight change in lattice constant, inter planner spacing and particle size is observed with grinding treatment. The results are in agreement with the available literature.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Impact of Fractionation Process on the Technical and Economic Viability of Corn Dry Grind Ethanol Process

Use of corn fractionation techniques in dry grind process increases the number of coproducts, enhances their quality and value, generates feedstock for cellulosic ethanol production and potentially increases profitability of the dry grind process. The aim of this study is to develop process simulation models for eight different wet and dry corn fractionation techniques recovering germ, pericarp fiber and/or endosperm fiber, and evaluate their techno-economic feasibility at the commercial scale. Ethanol yields for plants processing 1113.11 MT corn/day were 37.2 to 40 million gal for wet fractionation and 37.3 to 31.3 million gal for dry fractionation, compared to 40.2 million gal for conventional dry grind process.

09 BIOMASS FUELS↗
DOE OSTI2017

Grinding-induced metallurgical alterations in the binder phase of WC-Co cemented carbides

The metallic binder phase dictates the toughening behavior of WC-Co cemented carbides (hardmetals), even though it occupies a relative small fraction of the composite. Studies on deformation and phase transformation of the binder constituent are scarce. Grinding represents a key manufacturing step in machining of hardmetal tools, and is well-recognized to induce surface integrity alterations. In this work, metallurgical alterations of the binder phase in ground WC-Co cemented carbides have been assessed by a combination of electron back scattered diffraction and transmission electron microscopy techniques. The Co-base binder experiences a martensitic phase transformation from fcc to hcp crystal structure, predominantly in the first 5 μm below the surface. The hcp fraction decreases gradually along a depth of 10 μm. Surface Co displays severe plastic deformation under the highest strain, resulting in formation of nanocrystalline grains in the first micrometer below the surface. Microstructural refinement within the binder phase is observed even at greater depth. Stacking faults were detected in most of the refined grains. The metallurgical alterations of the binder phase modify the local stress distribution during grinding, which affects the discerned subsurface microcracking. The resulting residual stress profile is the sum of multiple subsurface changes, such as phase transformation, severe plastic deformation and grain refinement, where it is discerned that the depth profile of the transformed hcp-Co fraction coincides with the grinding-induced residual stress profile.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Joint influence of γ–irradiation and high temperature shear grinding on the IR spectra and surface–energy properties of polyethylene

The optical and surface-energy properties of polyethylene (PE) subjected to γ-irradiation and post-radiation, high temperature, shear grinding are presented. Comparison of the IR spectra of the initial and γ-irradiated PE shows that oxygen-containing groups and unsaturated bonds in the polymer macromolecules are formed and accumulate during their radiolysis in air, increasing with γ-irradiation dose. A redistribution of the products of radiation-chemical conversion on the surface of the polymer granules throughout the entire volume of the powder occurs after high-temperature shear milling to a powder as observed in the IR spectrum. Polar functional groups due to oxidation reactions are observed on the surface layer of the sample after post-radiation grinding. Furthermore, the initial polymer surface is weakly basic with an acidity parameter of -0.34. The value of the acidity parameter of the sample made of ground irradiated PE has an acidic surface with an acidity parameter of 0.65. γ irradiation of the secondary processing of PE waste with high-temperature shear grinding is a promising approach to obtain a secondary PE powder with specified parameters and different degrees of functionalization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2013

Westinghouse modular grinding process - improvement for follow on processes

In nuclear power plants (NPP) ion exchange (IX) resins are used in several systems for water treatment. The resins can be in bead or powdered form. For waste treatment of spent IX resins, two methods are basically used: Direct immobilization (e.g. with cement, bitumen, polymer or High Integrity Container (HIC)); Thermal treatment (e.g. drying, oxidation or pyrolysis). Bead resins have some properties (e.g. particle size and density) that can have negative impacts on following waste treatment processes. Negative impacts could be: Floatation of bead resins in cementation process; Sedimentation in pipeline during transportation; Poor compaction properties for Hot Resin Supercompaction (HRSC). Reducing the particle size of the bead resins can have beneficial effects enhancing further treatment processes and overcoming prior mentioned effects. Westinghouse Electric Company has developed a modular grinding process to crush/grind the bead resins. This modular process is designed for flexible use and enables a selective adjustment of particle size to tailor the grinding system to the customer needs. The system can be equipped with a crusher integrated in the process tank and if necessary a colloid mill. The crusher reduces the bead resins particle size and converts the bead resins to a pump able suspension with lower sedimentation properties. With the colloid mill the resins can be ground to a powder. Compared to existing grinding systems this equipment is designed to minimize radiation exposure of the worker during operation and maintenance. Using the crushed and/or ground bead resins has several beneficial effects like facilitating cementation process and recipe development, enhancing oxidation of resins, improving the Hot Resin Supercompaction volume reduction performance. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗