SEARCH · Engineering Papers

Results for “FABRICATION”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 361 records · Page 20

All sources NASA NTRS DOE OSTI

DOE OSTI2016

Wafer scale fabrication of carbon nanotube thin film transistors with high yield

Carbon nanotube thin film transistors (CNT-TFTs) are promising candidates for future high performance and low cost macro-electronics. However, most of the reported CNT-TFTs are fabricated in small quantities on a relatively small size substrate. The yield of large scale fabrication and the performance uniformity of devices on large size substrates should be improved before the CNT-TFTs reach real products. In this paper, 25 200 devices, with various geometries (channel width and channel length), were fabricated on 4-in. size ridged and flexible substrates. Almost 100% device yield were obtained on a rigid substrate with high out-put current (>8 μA/μm), high on/off current ratio (>10{sup 5}), and high mobility (>30 cm{sup 2}/V·s). More importantly, uniform performance in 4-in. area was achieved, and the fabrication process can be scaled up. The results give us more confidence for the real application of the CNT-TFT technology in the near future.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2014

Fabrication Control Plan for ORNL RH-LOCA ATF Test Specimens to be Irradiated in the ATR

The purpose of this fabrication plan is (1) to summarize the design of a set of rodlets that will be fabricated and then irradiated in the Advanced Test Reactor (ATR) and (2) provide requirements for fabrication and acceptance criteria for inspections of the Light Water Reactor (LWR) – Accident Tolerant Fuels (ATF) rodlet components. The functional and operational (F&OR) requirements for the ATF program are identified in the ATF Test Plan. The scope of this document only covers fabrication and inspections of rodlet components detailed in drawings 604496 and 604497. It does not cover the assembly of these items to form a completed test irradiation assembly or the inspection of the final assembly, which will be included in a separate INL final test assembly specification/inspection document. The controls support the requirements that the test irradiations must be performed safely and that subsequent examinations must provide valid results.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

WTP Waste Feed Qualification: Glass Fabrication Unit Operation Testing Report

The waste feed qualification program is being developed to protect the Hanford Tank Waste Treatment and Immobilization Plant (WTP) design, safety basis, and technical basis by assuring waste acceptance requirements are met for each staged waste feed campaign prior to transfer from the Tank Operations Contractor to the feed receipt vessels inside the Pretreatment Facility. The Waste Feed Qualification Program Plan describes the three components of waste feed qualification: 1. Demonstrate compliance with the waste acceptance criteria 2. Determine waste processability 3. Test unit operations at laboratory scale. The glass fabrication unit operation is the final step in the process demonstration portion of the waste feed qualification process. This unit operation generally consists of combining each of the waste feed streams (high-level waste (HLW) and low-activity waste (LAW)) with Glass Forming Chemicals (GFCs), fabricating glass coupons, performing chemical composition analysis before and after glass fabrication, measuring hydrogen generation rate either before or after glass former addition, measuring rheological properties before and after glass former addition, and visual observation of the resulting glass coupons. Critical aspects of this unit operation are mixing and sampling of the waste and melter feeds to ensure representative samples are obtained as well as ensuring the fabrication process for the glass coupon is adequate. Testing was performed using a range of simulants (LAW and HLW simulants), and these simulants were mixed with high and low bounding amounts of GFCs to evaluate the mixing, sampling, and glass preparation steps in shielded cells using laboratory techniques. The tests were performed with off-the-shelf equipment at the Savannah River National Laboratory (SRNL) that is similar to equipment used in the SRNL work during qualification of waste feed for the Defense Waste Processing Facility (DWPF) and other waste treatment facilities at the Savannah River Site. It is not expected that the exact equipment used during this testing will be used during the waste feed qualification testing for WTP, but functionally similar equipment will be used such that the techniques demonstrated would be applicable. For example, the mixing apparatus could use any suitable mixer capable of being remoted and achieving similar mixing speeds to those tested.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Holographic Fabrication of 3D Moiré Photonic Crystals Using Circularly Polarized Laser Beams and a Spatial Light Modulator

A moiré photonic crystal is an optical analog of twisted graphene. A 3D moiré photonic crystal is a new nano-/microstructure that is distinguished from bilayer twisted photonic crystals. Holographic fabrication of a 3D moiré photonic crystal is very difficult due to the coexistence of the bright and dark regions, where the exposure threshold is suitable for one region but not for the other. In this paper, we study the holographic fabrication of 3D moiré photonic crystals using an integrated system of a single reflective optical element (ROE) and a spatial light modulator (SLM) where nine beams (four inner beams + four outer beams + central beam) are overlapped. By modifying the phase and amplitude of the interfering beams, the interference patterns of 3D moiré photonic crystals are systemically simulated and compared with the holographic structures to gain a comprehensive understanding of SLM-based holographic fabrication. We report the holographic fabrication of phase and beam intensity ratio-dependent 3D moiré photonic crystals and their structural characterization. Superlattices modulated in the z-direction of 3D moiré photonic crystals have been discovered. This comprehensive study provides guidance for future pixel-by-pixel phase engineering in SLM for complex holographic structures.

42 ENGINEERING↗

NASA NTRS2009

Explicit Finite Element Modeling of Multilayer Composite Fabric for Gas Turbine Engine Containment Systems, Phase II: Material Model Development and Simulation of Experiments - Part 3

A team consisting of Arizona State University, Honeywell Engines, Systems & Services, the National Aeronautics and Space Administration Glenn Research Center, and SRI International collaborated to develop computational models and verification testing for designing and evaluating turbine engine fan blade fabric containment structures. This research was conducted under the Federal Aviation Administration Airworthiness Assurance Center of Excellence and was sponsored by the Aircraft Catastrophic Failure Prevention Program. The research was directed toward improving the modeling of a turbine engine fabric containment structure for an engine blade-out containment demonstration test required for certification of aircraft engines. The research conducted in Phase II began a new level of capability to design and develop fan blade containment systems for turbine engines. Significant progress was made in three areas: (1) further development of the ballistic fabric model to increase confidence and robustness in the material models for the Kevlar(TradeName) and Zylon(TradeName) material models developed in Phase I, (2) the capability was improved for finite element modeling of multiple layers of fabric using multiple layers of shell elements, and (3) large-scale simulations were performed. This report concentrates on the material model development and simulations of the impact tests.

Zylon↗

NASA NTRS2016

Development of a Direct Fabrication Technique for Full-Shell X-Ray Optics

Future astrophysical missions will require fabrication technology capable of producing high angular resolution x-ray optics. A full-shell direct fabrication approach using modern robotic polishing machines has the potential for producing high resolution, light-weight and affordable x-ray mirrors that can be nested to produce large collecting area. This approach to mirror fabrication, based on the use of the metal substrates coated with nickel phosphorous alloy, is being pursued at MSFC. The design of the polishing fixtures for the direct fabrication, the surface figure metrology techniques used and the results of the polishing experiments are presented.

W.Arnold↗

DOE OSTI2023

Report on FY 2023 Experimental Results in Developing the Fabrication Parameters for Alloy 709 in Different Product Forms

The Advanced Reactor Technologies (ART) Program has established a multi-year plan to develop Alloy 709 advanced stainless steel (A709), generate the data package and develop material-specific design parameters in qualifying it as a new structural material for Class A construction in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors (ASME 2023). In collaboration with material vendors, the Advanced Materials Development activities under ART have successfully scaled the A709 plate form production from a laboratory heat of 500 pounds to commercial heats totaling 133,000 pounds of A709 plate fabricated from three heats. The goal of the overall A709 development program is to establish the necessary microstructural and mechanical properties relationship for A709 to ultimately develop fabrication parameters for other product forms such as bars, pipes, and forgings using the available ART A709 materials. The objective of this A709 development work in FY 2023 is to experimentally determine grain coarsening behavior for the A709 heats and to experimentally generate the continuous cooling precipitation (CCP) diagram for A709 using the as-rolled commercial heat plate materials. Integral to this work is the characterization of the as-rolled materials and the determination of an effective solution-annealing process, which was reported in Y. Wang et al., 2023. This report summarizes the results of the high-speed dilatometry project to develop the CCP diagram using the commercial heat 58776-3RB fabricated by G. O. Carlson and heat 529900-02 fabricated by Allegheny Technologies Incorporated (ATI) Specialty Rolled Products.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Illumination correction of dyed fabric based on extreme learning machine with improved ant lion optimizer

Abstract In order to eliminate the influence of scene illumination on the evaluation of the color difference of dyed fabrics, this paper proposes a dyed fabric illumination correction algorithm based on the extreme learning machine (ELM) with grey wolf optimizer (GWO)‐optimized ant lion optimizer (ALO). Firstly, the Grey Edge framework is used to extract the features of the dyed fabric image as the input vector. Then, to improve the optimization ability of the ALO algorithm, the GWO algorithm is used to provide a set of optimized initial populations to the ALO algorithm, and then the improved ALO algorithm is used to optimize the parameters of the ELM. Finally, the proposed GWO‐ALO‐ELM algorithm is used to correct the illumination of the dyed fabric, and restore the graphics to the effect display under standard illumination through the diagonal reduction model. Compared with the experimental results of GWO‐ELM, ALO‐ELM, backpropagation (BP), ELM, random vector function link (RVFL), and other algorithms, it can be seen that the GWO‐ALO‐ELM algorithm proposed in this paper has good predictive value and quasi‐bias effect, and good stability.

Zhou, Zhiyu↗

DOE OSTI2018

An Improved Design and Versatile New Lamination Fabrication Method for Twin Electrode Thin Layer Cells Utilizing Track‐etch Membranes

Abstract Reported here are laminated membrane electrodes, an improved design and more advantageous method of fabrication for previously reported thin layer cell electrode systems developed on track‐etch membranes. The laminated membrane approach potentially further improves flow resistance by dramatically reducing the surface area to volume ratio, but also produces a cohesive device that can be more readily applied to a broad range of applications. In addition, this new fabrication method was implemented in a scalable, commercial process and resulting product demonstrations indicate that volume manufacturing is feasible. Characterization of laminated membrane electrodes reveal redox cycling amplification factors as high as 30 with linear responses to variable concentrations of redox couple. These performance characteristics are shown to be comparable to similar generator‐collector systems fabricated through much more laborious laboratory methods. This combination of added versatility, cost‐reduced fabrication and exceptional performance clearly reveals unrealized potential of track‐etch membrane approaches and boosts their candidacy as powerful new options for generator‐collector electrode systems.

Hauke, Adam↗

DOE OSTI2019

Developing AlMn Films for Argonne TES Fabrication

The reference design for the next-generation cosmic microwave background (CMB) experiment, CMB-S4, relies on large arrays of transition-edge sensor (TES) bolometers coupled to Superconducting Quantum Interference Device (SQUID)-based readout systems. Mapping the CMB to near cosmic variance limits will enable the search for signatures of inflation and constrain dark energy and neutrino physics. AlMn TESes provide simple film manufacturing and highly uniform arrays over large areas to meet the requirements of the CMB-S 4 experiment. TES parameters such as critical temperature and normal resistance must be tuned to experiment specifications and can be varied based on geometry and steps in the fabrication process such as deposition layering, geometry, and baking time and temperature. Using four-terminal sensing, we measured T C and R N of AlMn 2000 ppm films and devices of varying thicknesses fabricated at Argonne National Laboratory to motivate device geometries and fabrication processes to tune T C to 150–200 mK and R N to ~10 mΩ. Furthermore, measurements of IV curves and time constants for the resulting devices of varying leg length were made using time-division SQUID multiplexing and determined TC, G, k, f 3db , and RN. We present the results of these tests along with the geometries and fabrication steps used to tune the device parameters to the desired limits.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2019

The Development of Eco-Friendly Dye Microcapsules for Wool Fabric Dyeing Application

There is an urgent need to reduce the environmental impacts of wool fabrics dyeing process while maintain its dyeing effects. Microcapsule technology is a potential option which could be used to move towards cleaner production process and to cope with ever-increasing demands for wool fiber dyeing efficiency. Reactive dyestuff microcapsules were prepared via reverse-phase evaporation methods and then auxiliary-free dye microcapsules were used to dye the wool fabrics. Transmission electron microscope images and fourier transform infrared showed that dye microcapsules possessed a spherical core–shell structure with a diameter of about 500 ± 5 nm. The processing factors were analyzed and optimized by using response surface methodology to improve the encapsulation rate. Higher fixation rate (80.13% vs. 72.03%) of dyed wool fabric, while lower absorbance of dyestuff (0.071 vs. 0.96), chemical oxygen demand (COD, 190 mg/L vs. 1395 mg/L) and biological oxygen demand (BOD{sub 5}, 83.5 mg/L vs. 649.3 mg/L) of residual wastewater were observed by using microcapsule dyeing, compared with conventional dyeing process. In addition, the results also demonstrated that the filtrated wastewater of microcapsule dyeing can be recycled as dyebath to replace distill water. Thus, we innovatively produced a novel dye microcapsule for wool fabric dyeing application, advancing greatly in reducing the discharge of contaminants to environment, but also in economizing water and energy resources.

36 MATERIALS SCIENCE↗

DOE OSTI2018

A Low-Cost Fabrication Technique for the Growth of Single-Domain GdBCO Bulk Superconductor from Raw Metal Oxides

A single-domain GdBCO bulk superconductor is usually fabricated using a mixture of pre-reacted precursor powders (including GdBa{sub 2}Cu{sub 3}O{sub 7−δ} and Gd{sub 2}BaCuO{sub 5}) by the top-seeded melt texture growth (TSMTG) process. However, the synthesis of pure-phase precursor powder by the solid-state sintering reaction can not only consume time for weeks but also prolong the fabrication process and can lead to a low-efficiency and high-cost process. In this paper, we reported the successful growth of single-domain GdBCO bulk superconductors by the top-seeded metallic oxide melt growth (TS-MOMG) process in which the raw materials of Gd{sub 2}O{sub 3}, BaO, and CuO, the three different metallic oxides, are just involved to fabricate the single-domain GdBCO bulk superconductors. After detailed investigations in the morphology, levitation force, trapped magnetic field, and critical temperature of the grown samples with different ratios, it was found that the simplified precursor-phase source can be used to fabricate the single-domain GdBCO bulk superconductors more efficiently, which can combine the crystal growth procedure and greatly economize the preparation cost and the time to the most extent.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2018

Performance of Dye-Sensitized Solar Cells (DSSCs) Fabricated with Zinc Oxide (ZnO) Nanpowders and Nanorods

Due to their high efficiencies, along with lower production costs, many researchers are working on dye-sensitized solar cells (DSSCs) over last few decades as a substitute technology for nonconventional energy. Nanostructured ZnO has got many interesting properties such as wide band gap, large exciton binding energy, good exciton stability, and high breakdown strength, which are applicable as DSSC electrodes. This present work compares the device properties of DSSC fabricated using ZnO nanorods on a ZnO film and ZnO nanopowders. Different types of ZnO photoanode and dye combinations are used to study the stability and photovoltaic properties of the DSSC cell. The photovoltaic properties of the ZnO-based DSSC samples were systematically investigated. The photovoltaic properties of fabricated cell obtained are discussed in the light of band structure and density of states of different types of ZnO nanolayers. The ZnO nanorods fabricated through the sol–gel route have more uniform thickness resulting in enhanced photovoltaic properties of the fabricated device.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2020

The microstructure of a selective laser melting (SLM)-fabricated NiTi shape memory alloy with superior tensile property and shape memory recoverability

A selective laser melting (SLM)-fabricated NiTi with superior tensile property and shape memory recoverability was obtained by using a unique stripe rotation scanning strategy. Here, the alloy characteristics, formation mechanisms and evolution in terms of twins, dislocations and precipitations of the alloy were systematically studied. Compared to the conventional smelting-followed-by-machining, the SLM fabrication process involves rapid solidification and repeated heating, which confer distinctive characteristics to the microstructures of SLM-fabricated NiTi alloys. Rapid solidification promotes the formation of a supersaturation solid solution matrix containing a high concentration vacancies, which in turn aggregate to generate a high density of dislocations. During subsequent repeated heating stages, these dislocations occur thermal motion along three directions of <001 > , <111> and <110 >, leading to the formation of thermal kinks, helical dislocations and wave morphology. Simultaneously, precipitated particles Ti 3 Ni 4 repeatedly nucleate and heterogeneous grow with the movement of dislocation. Such precipitation behavior, termed repeated precipitation, has not been previously reported in the conventional NiTi alloys, suggesting that it could be a unique characteristic of such alloy. After martensitic transformation, only two twins, {1 1¯ 1} type I twin and compound twin, are detected. The twinning lamellae of these two twins, where precipitation and dislocation pile-ups exist, often have uneven thickness and chaotic arrangement. Besides, the unique self-accommodated microstructures, such as secondary {1 1¯ 1} type I twin and compound twin with “herring-bone’’ lamellae, which often appear in the deformed or nanocrystalline NiTi, can also be observed. These unique microstructures may confer the distinctive properties to the SLM-fabricated NiTi.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Scalable electric-field-assisted fabrication of vertically aligned carbon nanotube membranes with flow enhancement

In this work, we report a solution-based approach for fabricating vertically aligned carbon-nanotube (VACNT) membranes, which improves on the unaligned nature of CNT mixed-matrix membranes. This approach addresses important challenges regarding scalability and incorporation of different types and sizes of nanotube as pores in a membrane. In a new, solvent-deposition approach, CNTs are dispersed and then aligned and concentrated via electro-deposition from an organic solvent, using a composite AC + DC electric field to form aligned CNT arrays. This enables VACNT number densities that are two orders-of-magnitude higher than possible from direct suspension of CNTs in the liquid oligomer. The solvent is then replaced by a UV-curable oligomer, which is selectively cured to form macroscopic membranes of highly controlled thickness. After plasma etching to open pores, the VACNT membranes are shown to be permeable, and to have pore sizes consistent with flow through internal channels of the CNTs. In a first for field-aligned, solution-fabricated VACNT membranes, the pores show substantial, 100–300 × , gas-flow enhancement compared to theory, similar to membranes fabricated via less scalable methods (i.e., by CVD growth of already aligned CNT forests). The solution-based, electric-field-assisted approach aligns nanotubes of different sizes and types grown by any means, and is scalable to the efficient fabrication of large-area VACNT membranes for a variety of important applications.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Design, fabrication, and testing of a water-cooled tungsten-foam high-heat flux plasma-facing module

Here, we present a comprehensive study detailing the design, fabrication and testing a new modular “finger” component, featuring a hexagonal tungsten foam armor tile bonded to the top surface of the water-cooled finger unit. The mechanical, thermal, and particle transport properties of the tungsten foam armor were determined for a wide range of porosity and cell size, and then combined in an equivalent solid material with “effective” properties suitable for large-scale simulations. A series of 3-D multiphysics simulations for coupled thermal and mechanical behavior of the “finger” module are used to optimize the design before fabrication. The simulation results show that, for the expected experimental conditions, a safe range of heat flux and foam porosity is possible for both water-cooling and helium-cooling. Based on these multiphysics simulations, an optimum finger cooling module has been fabricated at Ultramet, Inc. A series of experiments were designed to study the thermomechanical performance of the “finger” unit under steady-state and transient thermal loading at surface heat flux up to 16 MW/m 2 in the High Energy Flux Test facility (HEFTY) at UCLA. Testing conditions included low-power, steady-state plasma exposure at 6 MW/m 2 , followed by severe high heat flux cycles at 16 MW/m 2 . Results of these tests are explained through comparisons with multiphysics simulations. To eliminate the effects of thermomechanical damage carried out on a module on its thermo-mechanical response on a subsequent test, three different yet identically designed and fabricated finger modules were tested. The results show that the current design is capable of cooling the walls of fusion devices at surface heat flux up to 6 MW/m 2 without failure, and that the failure heat flux limit is below 16 MW/m 2 .

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2018

A review on the fatigue behavior of Ti-6Al-4V fabricated by electron beam melting additive manufacturing

Electron beam melting (EBM) is a swiftyly-developing metal additive manufacturing process that holds significant interest in the aerospace and biomedical industries for the high-strength titanium alloy, Ti-6Al-4V. These industries have fatigue-limited applications, yet a lack of understanding of the EBM process-microstructure-fatigue relationships limit widespread use and presents challenges for certification. In this review, uniaxial fatigue data was collected and the effects of build orientation, surface roughness, and hot-isostatic pressing are linked to the fatigue properties highlighting microstructure, defects, and failure mechanisms. The observations and conclusions are supported by statistical analysis using the mean fatigue life obtained by the Statistical Fatigue-Limit Model. Both EBM-process and post-process structure relationships are discussed in order to identify the best-practice for fatigue-resistant design. The performance of the EBM material is compared to conventionally manufactured Ti-6Al-4V and possible methods to increase the fatigue resistance are discussed. Anisotropic fatigue behavior was observed in as-fabricated parts and no statistical distinction was found in the fatigue performance of HIPed and as-fabricated material provided the same as-fabricated rough surface condition. However, comparable fatigue life to traditionally manufactured lamellar Ti-6Al-4V is achieved when both post-process HIP and machining are applied to EBM-fabricated parts.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Fabrication and testing of U–7Mo monolithic plate fuel with Zircaloy cladding

The Materials Management and Minimization program is developing fuel designs to replace highly enriched fuel with fuels of low enrichment. In the most challenging cases, U–(7–10wt%)Mo monolithic plate fuel are proposed. The chosen design includes aluminum-alloy cladding, which provides some challenges in fabrication and fuel/cladding interaction in service. We investigated zircaloy cladding, specifically Zry–4as an alternative cladding, and development of a fabrication method was performed by researchers with the Comisión Nacionalde Energia Atómica (CNEA) in Argentina, resulting in test fuel plates (Zry–4 clad U–7Mo) which were subsequently tested in the Advanced Test Reactor in Idaho. Because Zry–4 and U–(7–10)Mo have similar high-temperature mechanical properties, fabrication was simplified in that the fuel foil and cladding could be co-rolled and bonded. The challenge was to prevent a thermal-expansion mismatch which could destroy the fuel/cladding bond before complete bonding was achieved; the solution was to prevent the composites from cooling significantly between roll passes. Our final product performed very well in-reactor, showing good bonding, very little fuel/cladding interaction, either from fabrication or in-reactor testing, and little swelling, especially no detectable heterogeneous bubble formation at the fuel/cladding interface tested to a fission density of up to 2.54E+21

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗