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At least 379 records · Page 21

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DOE OSTI2021

High performance, rapid thermal/UV curing epoxy resin for additive manufacturing of short and continuous carbon fiber epoxy composites

An additive manufacturing resin system includes a container; a build platform in the container; a build platform drive; an additive manufacturing resin that forms an additive manufacturing resin bath; an additive manufacturing print head; a build material supply connected to the additive manufacturing print head; an infill resin in the container, wherein the infill resin is supported by the additive manufacturing resin bath; a computer controller; and an extruded material that forms the product, wherein the infill resin at least partially surrounds the extruded material that forms the product. An infill resin supply provides the infill resin into the container and a control valve is connected to the infill resin supply. An IR light sensor is connected to the control valve and operatively connected to the infill resin in the container.

Lewicki, James↗

DOE OSTI2021

Design and Experimental Demonstration of an Additive Manufactured Smart Oxy-Methane Burner for High Pressure and Supercritical Combustion

Pressurized oxy combustion-based systems can improve efficiency by recovering latent heat of the steam in the Flue Gas and achieving 90% CO2 capture. In addition, the novel Directly Heated Supercritical Carbon Dioxide (DH-SCO2) power cycles can achieve high thermal efficiencies and provide nearly full carbon capture. Additionally, due to the reduction of flue gas at higher pressure, smaller system size and capital cost reductions are also possible. Recent thermodynamic analysis of the DH-SCO2 cycle performed by the UTEP research team shows that combustion conditions in the vicinity of 300 bar pressure and 1000-1400 K temperature allow for relatively high system efficiencies while operating within the limit of available combustor materials. However, the realization of a directly heated supercritical power cycle requires combustion systems to operate in supercritical conditions and at temperature far below the blowout limit of conventional flames (above 1500 K). The thermodynamic properties along with the combustion properties and kinetics are unexplored at such conditions. Additionally, the interaction of the supercritical environment with energy components is also unknown. High-pressure combustion tests are performed using a smart burner at some intermediate pressure ranges (<20 bar) to help minimize these knowledge gaps. The knowledge obtained from the high-pressure test will assist in understanding the combustion chamber pressurization mechanism, ignition and flame behavior at the elevated pressure. The obtained data will act as a systematic first step in testing at higher pressures of 100 and 300 bar pressures.The primary purpose of this Dissertation is to demonstrate the operability of a low NOx smart burner for oxy-methane combustion at high pressure (< 20 bar) and scalable up to supercritical conditions. A shear co-axial smart burner is designed with a real-time temperature monitoring capability to understand the burner face interaction at high-pressure conditions. In addition, the burner has four independent injection ports to allow the independent injection of fuel and dilution gases in the combustor. The maximum operating capability of the burner is 575 kWth. The burner was fabricated using a Laser Powder Bed Fusion process with Nickel Alloy 718. A powder removal technology was invented comprising ultrasonic vibration, liquid nitrogen exposure and media blasting to remove powders from internal channels of the burner. The burner operability tests are performed in the high-pressure combustor and the swirl combustor. The high-pressure combustor was used to investigate the burner operability and thermal soak back at different pressurized conditions. The experimental tests in high-pressure combustor up to 275 kWth input resulted in 16.5 bar chamber pressure and 198°C thermal soaks back to the burner. The burner was capable of providing the required thermal input within a 3% deviation range. In addition, soot formation occurred at high-pressure tests. The swirl combustor was used to observe the flame stability of the burner. Flame lift-off was observed for jet velocities above 450 m/s. Additionally, lift-off decreased for low co-flow velocities. CO2 dilution experiments showed increased flame instabilities for all conditions above 50% dilution ratios. At lower thermal inputs, partial flame blow-offs occurred for dilution ratios above 50%. All conditions significantly reduced the flame temperature and increased the flame lift-off height. Finally, a 2nd generation AM smart burner was designed using the knowledge from the 1st generation burner experiments. The 2nd generation burner incorporated two sets of swirlers with 0.9 swirl no. A cooling system was also designed for long-duration tests at higher pressures. The thermal input and division of the burner's power are kept the same as the 1st generation burner. The burner is to be fabricated using nickel-alloy 718 for high-pressure handling capability. The design can sustain at high-pressure conditions up to 100 bar.

Islam, Md Nawshad Arslan↗

DOE OSTI2022

ADDITIVELY MANUFACTURED SURFACE HEAT TRANSFER ENHANCEMENTS FOR THE TRANSFORMATIONAL CHALLENGE REACTOR

The Transformational Challenge Reactor (TCR) is a high-temperature gas-cooled reactor design that uses additively manufactured fuel elements. TCR fuel elements have walls made of silicon carbide and are filled with tristructural-isotropic fuel particles. These fuel elements can have radically different shapes and integrated features than existing designs due to the reduced cost for complex structures in binder jet additive manufacturing. As such, binder jet additive manufacturing enables wall surface features to be embedded that can deliver superior heat transfer performance than smooth wall designs. In this work, the authors conducted a computational fluid dynamics study to evaluate selected wall features integrated into TCR fuel elements. Results show that surface features can outperform smooth wall designs; however, there are unique challenges for gas-cooled reactor core designs that have not been fully explored by previous research. For example, the rough surface finish and process variability of ceramics additive manufacturing make it challenging to predict surface roughness effects before fabrication. Additionally, the small hydraulic diameters of coolant channels in reactor cores make it difficult to engineer surface features that do not significantly increase the pressure drop. Engineers must carefully size surface features for heat transfer enhancement in additive fuel elements to operate above the base material's surface roughness effects and below the coolant channel size.

Weinmeister, Justin↗

DOE OSTI2022

3D printing of additive structures for nuclear fuels

A method for manufacturing a nuclear fuel compact is provided. The method includes forming an additive structure, consolidating a fuel matrix around the additive structure, and thermally processing the fuel matrix to form a fuel compact in which the additive structure is encapsulated therein. The additive structure optionally includes a vertical segment and a plurality of arm segments that extend generally radially from the vertical segment for conducting heat outwardly toward an exterior of the fuel compact. In addition to improving heat transfer, the additive structure may function as burnable absorbers, and may provide fission product trapping.

Terrani, Kurt A.↗

DOE OSTI2023

3D printing of additive structures for nuclear fuels

Terrani, Kurt A.↗

DOE OSTI2015

Impacts of an additional exhaust shaft on WIPP performance - 15170

The Waste Isolation Pilot Plant (WIPP), located in southeastern New Mexico, has been developed by the U.S. Department of Energy (DOE) for the geologic (deep underground) disposal of transuranic (TRU) waste. WIPP performance assessment (PA) demonstrates repository performance from facility closure to 10,000 years after closure. The recent radiological release event at the WIPP site has temporarily halted waste emplacement activities at the facility. A modified ventilation system is envisioned that will provide sufficient airflow necessary for the resumption of full-rate disposal operations in the future. A primary component of the modified ventilation system is an additional exhaust shaft in the north end of the repository. There are four shafts currently in the repository north end, namely a salt handling shaft, an exhaust shaft, a waste shaft, and an air intake shaft. These shafts are combined into a single composite shaft in WIPP PA that captures the combined impacts of all of them. The proposed additional exhaust shaft is combined with the four existing shafts in the repository model to determine its impacts on long-term repository performance. Moreover, mined volume in the repository north end is modified in the repository representation so as to include additional drifts created to access the new shaft. Computed gas and brine flow behaviors corresponding to the repository with the additional exhaust shaft are compared to those obtained in the PA executed for the 2014 Compliance Re-certification Application (the CRA-2014 PA). Results show that the repository with an additional exhaust shaft and drifts yields brine and gas flow behaviors similar to the current repository configuration. It is concluded that WIPP continues to satisfy regulatory compliance limits with the addition of an exhaust shaft and its access drifts, with compliance curves like those found in the CRA-2014 PA for total normalized releases. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Methods and apparatus for embedding heating circuits into articles made by additive manufacturing and articles made therefrom

Methods of embedding a heating circuit in an article fabricated by additive manufacturing. The methods describe techniques such as co-extruding a wire, capable of being heated, along with print material in additive manufacturing of the article, and placing a pre-shaped wire capable of being heated between adjacent layers of the article. A third method includes dispensing a wire, capable of being heated, during the additive manufacturing of the article, and compacting the wire into the printed material. An apparatus for embedding a heating circuit in an article fabricated by additive manufacturing. The apparatus contains a wire dispenser, a cutter to control the length of the wire dispensed, and a compactor capable of embedding the wire capable of being heated into the printed material. An article made by additive manufacturing is disclosed. The article contains at least one heating element embedded in the article during the additive manufacturing process.

Barocio, Eduardo↗

DOE OSTI2025

DEVELOPMENT OF INEXPENSIVE HIGH TEMPERATURE NITI-BASED SHAPE MEMORY ALLOYS FOR POWDER BED ADDITIVE MANUFACTURING

NiTi and NiTi-based Shape Memory Alloys (SMA) exhibit a reversible solid-state phase transformation from martensite to austenite driven by thermal energy. High temperature (Mf>100°C) SMAs are martensite at room temperature and can be fabricated into solid-state actuators that return to a pre-programmed shape against a designed load after heating to transformation threshold. Reactive as-fabricated additively manufactured parts (4-D printing) is the current state of the art in manufacturing of SMAs but requires compositions compliant to rapid solidification. Existing actuator designs are developed from commercially available, highly investigated material compositions. However, existing high temperature high performance (high actuation strain, low thermal hysteresis) shape memory alloys contain significant (>10% at.) portions of high-cost Platinum Group Metals (PGMs). It is of significant scientific interest to investigate material compositions that are peer performing or superior to PGMs whose constituent elements represent a significant cost savings. Shape memory alloy properties vary significantly with small (0.1% at.) compositional changes making robust investigative sample sets very large. Computational material design can be deployed to shrink the compositional space of possible alloy combinations and reduce the experimental load in material discovery. Investigating shape memory effect (SME) and validating process additive process parameters for a single novel composition is cost intensive in both time and consumed materials. Additionally, sub-optimal processing, oxygen, or solidification rate sensitivity could render additively manufacturing specimens without micro, macro cracks, or significant chemical variance impossible. Unfortunately, such failure susceptibility cannot be simulated. Therefore, a research pathway to validate novel shape memory alloy compositions for powder bed fusion additive manufacturing without the need for powdered feedstock is also proposed. This research investigates novel high temperature shape memory alloys for actuators without platinum group alloying elements to discover one that could be commercially viable as an additive manufacturing feedstock.

Sundermann, Tayler↗

DOE OSTI2025

Dimolybdenum Paddlewheel Complexes with Cation Binding Sites as Electrolyte Additives to Manipulate the Solid-Electrolyte Interphase at Lithium Metal Anodes

The use of electrolyte additives at millimolar loadings to control the surface chemistry of lithium metal anodes (LMAs) is a leading strategy to improve lithium metal batteries and promote electrosynthetic reactions. Whereas previous studies employed either inorganic or organic additives, in this study, we report the first organometallic additive, Mo 2 (mea) 4 [1, mea = 2-(2-methoxyethoxy)acetate], a dimolybdenum paddlewheel complex that is stable under Li plating conditions and features cation binding sites in the second coordination sphere that promote reversible Li + coordination. Binding of Li + ions to 1 induces immobilization of cationically charged aggregates (or products thereof) into the solid electrolyte interphase (SEI), imparting multiple beneficial functions. The modified SEI was found to protect the LMA against parasitic side reactions, produce modest but measurable improvements to Li plating properties (e.g., overpotential, surface structure, and Coulombic efficiency), and improve interfacial charge transport properties. Furthermore, the most notable benefit to battery cycling performance appears in calendar aging tests, which show that the presence of the additive protects the LMA from parasitic side reactions that would otherwise decrease overall cell cycling efficiency over time. Collectively, these data disclose a tactic for designing electrolyte additives using principles of organometallic synthesis.

Additives↗

DOE OSTI2018

Influence of dual nitrogen and phosphorus additions on nutrient uptake and saturation kinetics in a forested headwater stream

Nitrogen (N) and phosphorus (P) can limit autotrophic and heterotrophic metabolism in lotic ecosystems, yet most studies that evaluate biotic responses to colimitation focus on patch-scale (e.g., nutrient diffusing substrata) rather than stream-scale responses. In this study, we evaluated the effects of single and dual N and P additions on ambient nutrient uptake rates and saturation kinetics during two biologically contrasting seasons (spring, autumn) in Walker Branch, a temperate forested headwater stream in Tennessee, USA. In each season, we used separate instantaneous pulse additions to quantify nutrient uptake rates and saturation kinetics of N (nitrate) and P (phosphate). We then used steady-state injections to elevate background stream water concentrations (to low and then high background concentrations) of one nutrient (e.g., N) and released instantaneous pulses of the other nutrient (e.g., P). We predicted that elevating the background concentration of one nutrient would result in a lower ambient uptake length and a higher maximum areal uptake rate of the other nutrient in this colimited stream. Our prediction held true in spring, as maximum areal uptake rate of N increased with elevated P concentrations from 185 µg m –2 min –1 (no added P) to 354 µg m –2 min –1 (high P). This pattern was not observed in autumn, as uptake rates of N were not measurable when P was elevated. Further, elevating background N concentration in either season did not significantly increase P uptake rates, likely because adsorption rather than biotic uptake dominated P dynamics. Laboratory P sorption assays demonstrated that Walker Branch sediments had a high adsorption capacity and were likely a sink for P during most pulse nutrient additions. Furthermore, it may be difficult to use coupled pulse nutrient additions to evaluate biotic uptake of N and P in streams with strong P adsorption potential. Future efforts should use dual nutrient addition techniques to investigate reach-scale coupled biogeochemical cycles (C–N–P, and other elemental cycles [e.g., Fe, Mo]) across seasons, biomes, and land-use types and over longer time periods.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2019

LDRD 19A42-015, Multi-Wire Arc Additive Manufacturing

Additive manufacturing (AM) techniques can efficiently and cost-effectively fabricate components with both geometrical and compositional complexities, where functionally-graded compositions in a component allow multiple service requirements to be simultaneously addressed, such as corrosion and high temperature structural requirements. High cost alloy compositions need only be deposited in local areas where they are needed. A multi-wire arc additive manufacturing (m-WAAM) system was developed to enable functionally-graded, additively manufactured complex structures. The m-WAAM system utilizes multiple filler wire alloys, allowing control of composition and composition gradients in the component during additive fabrication. Ultimately, this project successfully developed a high deposition rate, arc-based, additive manufacturing process with the truly novel capability of enabling spatial composition tailoring during the build of the component. System capabilities and process science will be studied in a follow-on LDRD starting next year.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Additive Engineering for Efficient and Stable Perovskite Solar Cells

Perovskite solar cells (PSCs) have reached a certified 25.2% efficiency in 2019 due to their high absorption coefficient, high carrier mobility, long diffusion length, and tunable direct bandgap. However, due to the nature of solution processing and rapid crystal growth of perovskite thin films, a variety of defects can form as a result of the precursor compositions and processing conditions. The use of additives can affect perovskite crystallization and film formation, defect passivation in the bulk and/or at the surface, as well as influence the interface tuning of structure and energetics. Here, recent progress in additive engineering during perovskite film formation is discussed according to the following common categories: Lewis acid (e.g., metal cations, fullerene derivatives), Lewis base based on the donor type (e.g., O-donor, S-donor, and N-donor), ammonium salts, low-dimensional perovskites, and ionic liquid. Various additive-assisted strategies for interface optimization are then summarized; additives include modifiers to improve electron- and hole-transport layers as well as those to modify perovskite surface properties. To conclude, an outlook is provided on research trends with respect to additive engineering in PSC development.

14 SOLAR ENERGY↗

DOE OSTI2018

Clinical Indication for Computed Tomography During Hepatic Arteriography (CTHA) in Addition to Dynamic CT Studies to Identify Hypervascularity of Hepatocellular Carcinoma

PurposeTo identify factors benefiting from computed tomography during hepatic arteriography (CTHA) in addition to dynamic CT studies at the preoperative evaluation of the hypervascularity of hepatocellular carcinoma (HCC).Materials and MethodsWe retrospectively divided 45 patients with HCC, who underwent both dynamic CT (dCT) and CTHA, into two groups based on the number of hypervascular HCCs identified on dCT and CTHA studies. In group A, the number of HCCs identified by dCT and CTHA was the same and additive CTHA had not been indicated. In group B, fewer HCCs were counted on dCT than on CTHA images, indicating that additive CTHA studies had been appropriate. We compared the patient characteristics, the serum alpha-fetoprotein level, and the tumor-liver contrast (TLC) of the main tumor on dCT scans of both groups. To identify factors alerting to the benefit of additional CTHA studies, we performed univariate logistic regression analysis. Statistically significant parameters were subjected to receiver operating characteristic analysis for obtaining the optimal cutoff value indicative of the benefit of CTHA.ResultsUnivariate analysis identified only the TLC of the main tumor on dCT images as a significant factor for the benefit of CTHA images (P < 0.01). At the optimal cutoff value for the TLC of the main tumor on dCT images (15.9 Hounsfield units), the sensitivity and specificity for the benefit of CTHA were 85.0 and 92.0%, respectively.ConclusionEvaluation of the TLC of the main tumor on dCT scans identifies patients in whom additive CTHA studies are beneficial.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

DOE OSTI2018

The Effects of Low Frequency on the Microstructure and Mechanical Properties of High-Strength Al-Mg Aluminum Alloys by Wire and Double-Pulsed Arc Additive Manufacturing

An innovative and high deposition efficiency process, the double-pulsed arc additive manufacturing process, is used to produce high-strength Al-Mg wall components. This dissertation investigates the electrical parameter acquisition, bead appearance, porosity morphology, microstructure and mechanical properties of additively manufactured high-strength Al-Mg wall components and how these are affected by the low frequency of the double-pulsed arc additive manufacturing process. Then, using this process at different low frequencies of 0, 1, 3, 5, 7 and 9 Hz, multilayer deposition experiments were performed. It can be observed that the deposit porosity is obviously eliminated compared with cold metal transfer (CMT) process. The bead appearance of the deposited aluminum wall varies clearly with low frequencies, and at a low frequency of 3 Hz, its appearance is the best of all. The optical observation of microstructure proves that the average grain size varies significantly with low frequency, and at a low frequency of 1 Hz, it is the smallest. In addition, the deposited wall showed maximum mean microhardness and maximum ultimate tensile strength at a low frequency of 3 Hz. Considering the deposited porosity and mechanical priorities, double-pulsed arc additive manufacturing with a frequency of 3 Hz is more suitable for making high-strength Al-Mg wall components than at other low frequencies.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Additively Manufactured Single-Use Molds and Reusable Patterns for Large Automotive and Hydroelectric Components

Additive manufacturing (AM) has the potential to reduce costs in the casting industry, particularly for large parts (i.e., components with any dimension > 12 in.). In this study, pilot-scale production case studies of hydroelectric and automotive parts were used to evaluate two AM-enabled casting methods: the direct printing of sand molds by binder jet and printing of reusable cope and drag patterns for sand casting. An additional benefit was found when additively manufactured patterns were used in combination with heat-treat free aluminum alloys, to produce castings of complex hydrodynamic surfaces. These parts previously required production via subtractive machining due to part distortion induced by the quench step of heat treatments. The machine types used for the three case studies are sand-binder jet, high-resolution polymer fused deposition modeling (FDM), and big area additive manufacturing (BAAM) FDM in combination with CNC machining. Each method demonstrated distinct advantages over traditional casting practices in particular use cases. Single-use molds show great reductions in start-up cost to produce one-off or legacy parts, and additively manufactured impression patterns show promise for innovating the tooling design process for complex geometry and large castings.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Geometrical effects on the measured neutron residual stress in additively manufactured cold spray AA6061

Aluminum cold spray additive builds were made with varying wall widths and geometries to explore the effects of build geometry on residual stress development in the additively sprayed material. Deposition rates of over 750 g/hr were achieved without any cracking or delamination of the additively manufactured components. Neutron residual stress measurements revealed a maximum tensile residual stress of 41 MPa at the interface of the substrate and a maximum compressive residual stress of −35 MPa in the cold sprayed material. While there was not found to be significant residual stress changes between the cold sprayed walls, the cold sprayed cylinder had varying residual stress throughout the diameter with the outer diameter having a higher tensile residual stress than the interior. The low residual stress and minimal geometrical dependency demonstrate further part size is possible without concerns for component failure in AA6061. The application of common coating residual stress models to full scale additive builds is evaluated and discussed. The lack of residual stress evolution was studied by in-situ coating property measurement that revealed that the deposition stress of the AA6061 sprays reduced with increased layer thickness. In conclusion, this study provides insight into the evolution of residual stress in cold spray additive components and how both the mechanics and material responses differ from coatings.

Additive manufacturing↗

DOE OSTI2022

Unique W-Shape Y6 isomer as effective solid additive for High-Performance PM6:Y6 polymer solar cells

The current top-performing polymer solar cell (PSC) systems are mostly based on PM6:Y6 host blend. To date, numerous materials have been explored as the third component for these systems to form ternary blends or as additives. Vitrification agents are a group of additives proved to be useful in affecting the morphology of organic semiconductors. Here to design a suitable vitrification agent for non-fullerene electron acceptor Y6, an isomer strategy was explored where the thienothiophene wings of the Y6 molecule were inversed to form a W-shaped Y6 isomer of i-Y6. It was found that i-Y6 crystallized poorly with a different packing style than Y6 and could blend well in amorphous phase of Y6. These properties enabled i-Y6 to finely tune the morphology of PM6:Y6 blend at low additive dosages. The power conversion efficiency (PCE) of PM6:Y6 based PSC was raised from 16.827% to 17.433% at a dosage of Y6:i-Y6 ratio of 24:1. This work demonstrated isomerization as a viable strategy for developing solid additives for high performance PSC blends and vitrification agents as effective additives for tuning morphology and improving performances of PSCs.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Phase stability and mechanical properties of wire + arc additively manufactured H13 tool steel at elevated temperatures

Wire + arc additive manufacturing (WAAM) is considered an innovative technology that can change the manufacturing landscape in the near future. WAAM offers the benefits of inexpensive initial system setup and a high deposition rate for fabricating medium- and large-sized parts such as die-casting tools. Here, AISI H13 tool steel, a popular die-casting tool metal, is manufactured by cold metal transfer (CMT)-based WAAM and is then comprehensively analyzed for its microstructural and mechanical properties. Location-dependent phase combinations are observed, which could be explained by nonequilibrium thermal cycles that resulted from the layer-by-layer stacking mechanism used in WAAM. In addition, remelting and reheating of the layers reduces welding anomalies (e.g., pores and voids). The metallurgical characteristics of the H13 strongly correlate with the mechanical properties. The combinations of phases at different locations of the additively manufactured part exhibit a periodic microhardness profile. Martensite, Retained Austenite, Ferrite, and Carbide phases are found in combination at different locations of the part based on the part’s temperature distribution during additive deposition. Moreover, the tensile properties at elevated temperatures (23 °C, 300 °C, and 600 °C) are comparable to those from other WAAM and additive manufacturing (AM) processes. The X-ray diffraction results verify that the microstructural stability of the fabricated parts at high temperatures would allow them to be used in high temperatures.

36 MATERIALS SCIENCE↗