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At least 397 records · Page 22

Correction of crosstalk effect in the Low Energy RHIC electron Cooler Booster Cavity

we report that the Low Energy Relativistic Heavy Ion Collider (RHIC) electron Cooler (LEReC) is designed to deliver a 1.6 MeV to 2.6 MeV electron beam, with rms dp/p less than 5e-4. The superconducting radiofrequency (SRF) Booster Cavity is the major accelerating component in LEReC. It is a 0.4 cell cavity operating at 2 K, providing a maximum energy gain of 2.2 MeV. It is modified from an experimental Energy Recovery Linac (ERL) photocathode gun, and thus has fundamental power couplers (FPCs), pickup (PU) couplers (field probes) and HOM coupler close to each other on the same side of the cavity. Direct capacitive coupling between the FPC and PU, called the crosstalk effect, combined with microphonic detuning, can induce closed loop voltage fluctuations that exceed the total energy spread requirement of LEReC. The crosstalk effect in this cavity is modelled, simulated, and measured, and a correction method is proposed and demonstrated to suppress the voltage fluctuation so that energy spread requirement can be met.

43 PARTICLE ACCELERATORS↗

LDRD for a high-current polarized-beam photogun

The electron accelerator driving the Ce+BAF conversion target requires a spin-polarized photogun capable of delivering a CW beam current of at least 1 mA. As the high beam current limits the useful operating time of the gun between photocathode reactivations due to ion back-bombardment, it is critical to increase the charge lifetime. A Jefferson Lab LDRD project aims to calibrate the simulation models needed to predict photocathode lifetime as a function of electrostatic optics and drive laser parameters in order to design a gun providing at least 1000 C charge lifetime. A prototype gun demonstrating the validity of the scaling predictions will be built and tested at the Gun Test Stand. I will describe the background and progress of this project and give an outlook on the expected performance.

Bruker, Max [Thomas Jefferson National Accelerator↗

Onorbit electron beam welding experiment definition

The proposed experiment design calls for six panels to be welded, each having unique characteristics selected to yield specific results and information. The experiment is completely automated and the concept necessitated the design of a new, miniaturized, self-contained electron beam (EB) welding system, for which purpose a separate IR and D was funded by the contractor, Martin Marietta Corporation. Since future tasks beyond the proposed experiment might call for astronauts to perform hand-held EB gun repairs or for the gun to be interfaced with a dexterous robot such as the planned flight telerobotic servicer (FTS), the EB gun is designed to be dismountable from the automated system. In the experiment design, two separate, identical sets of weld panels will be welded, one on earth in a vacuum chamber and the other onorbit in the aft cargo bay of an orbiter. Since the main objective of the experiment is to demonstrate that high quality welds can be achieved under onorbit conditions, the welds produced will be subjected to a wide range of discriminating non-destructive Q.C. procedures and destructive physical tests. However, advantage will be taken of the availability of a fairly large quantity of welded material in the two series of welded specimens to widen the circle of investigative talent by providing material to academic and scientific institutions for examination.

William H. Hooper↗

Production of Mg and Al Auger electrons by noble gas ion bombardment of Mg and Al surfaces

Relative production efficiencies of Mg and Al Auger electrons by He, Ne, Ar, Kr, and Xe ion bombardment are reported as a function of ion energy for energies not exceeding 3 keV. The experimental apparatus employed consisted of a LEED-Auger system equipped with an ion gun and a four-grid retarding-potential analyzer. It is found that: (1) the shape of the ion-excited Auger signal was independent of the rare gas and quite symmetric; (2) the Al signal was about an order of magnitude smaller than the Mg signal for a given bombarding species and ion-gun voltage; (3) no signal was observed for He(+) bombardment under any of the experimental conditions; (4) signal strengths were independent of temperature and ion dose; (5) the Auger production efficiencies differed by no more than a factor of two among the different gases - except for He(+) - on a given metal; (6) all the signal strengths increased with increasing ion-gun voltage, with no maximum exhibited; and (7) the apparent threshold energy for the Al signal was higher than that for the Mg signal. The differences between the results for the two metals are attributed to the fact that the Al 2p orbital lies deeper in energy and closer to the nucleus than the corresponding Mg orbital.

Ferrante, J.↗

Scanning-electron-microscope study of normal-impingement erosion of ductile metals

Scanning electron microscopy was used to characterize the erosion of annealed copper and aluminum surfaces produced by both single- and multiple-particle impacts. Macroscopic 3.2 mm diameter steel balls and microscopic, brittle erodant particles were projected by a gas gun system so as to impact at normal incidence at speeds up to 140 m/sec. During the impacts by the brittle erodant particles, at lower speeds the erosion behavior was similar to that observed for the larger steel balls. At higher velocities, particle fragmentation and the subsequent cutting by the radial wash of debris created a marked change in the erosion mechanism.

Brainard, W. A.↗

Coaxial carbon plasma gun deposition of amorphous carbon films

A unique plasma gun employing coaxial carbon electrodes was used in an attempt to deposit thin films of amorphous diamond-like carbon. A number of different structural, compositional, and electrical characterization techniques were used to characterize these films. These included scanning electron microscopy, scanning transmission electron microscopy, X ray diffraction and absorption, spectrographic analysis, energy dispersive spectroscopy, and selected area electron diffraction. Optical absorption and electrical resistivity measurements were also performed. The films were determined to be primarily amorphous, with poor adhesion to fused silica substrates. Many inclusions of particulates were found to be present as well. Analysis of these particulates revealed the presence of trace impurities, such as Fe and Cu, which were also found in the graphite electrode material. The electrodes were the source of these impurities. No evidence of diamond-like crystallite structure was found in any of the film samples. Details of the apparatus, experimental procedure, and film characteristics are presented.

Sater, D. M.↗

Compensating slice emittance growth in high brightness photoinjectors using sacrificial charge

Achieving maximum electron beam brightness in photoinjectors requires detailed control of the 3D bunch shape and precise tuning of the beam focusing. Even in state-of-the-art designs, slice emittance growth due to nonlinear space charge forces and partial nonlaminarity often remains non-negligible. In this work, we introduce a new means to linearize the transverse slice phase space: a sacrificial portion of the bunch’s own charge distribution, formed into a wavebroken shock front by highly nonlinear space charge forces within the gun, whose downstream purpose is to dynamically linearize the desired bunch core. We show that linearization of an appropriately prepared bunch can be achieved via strongly nonlaminar focusing of the sacrificial shock front, while the inner core focuses laminarly. This leads to a natural spatial separation of the two distributions: a dense core surrounded by a diffuse halo of sacrificial charge that can be collimated. Multiobjective genetic algorithm optimizations of the ultracompact x-ray free electron laser injector employ this concept, and we interpret it with an analytic model that agrees well with the simulations. In simulation, we demonstrate a final bunch charge of 100 pC, peak current ∼ 30 A, and a sacrificial charge of 150 pC (250 pC total emitted from cathode) with normalized emittance growth of < 20 nm rad due to space charge. This implies a maximum achievable brightness approximately an order of magnitude greater than existing free electron laser injector designs. Published by the American Physical Society 2024

43 PARTICLE ACCELERATORS↗

Pressure Response Optimization of an Eddy Current-Driven Flyer Plate Valve for the ITER Shattered Pellet Injection System

One technique for mitigating disruptions in a tokamak is shattered pellet injection (SPI). SPI is a process in which a large solid pellet consisting of deuterium, neon, or argon is desublimated in a pipe gun barsrel and launched downstream. Pellets are shattered just before entering the plasma by an impact with an angled tube. Injection of these materials into the plasma radiates stored thermal energy, limits current decay rates, suppresses the generation of runaway electrons, and dissipates runaway electrons if necessary. A critical element of the SPI system is a fast-acting valve that releases high-pressure gas to dislodge and accelerate pellets directly, or indirectly via a mechanical punch. A prototype valve sized for the ITER SPI system has been designed and fabricated. A pulsed high-voltage power supply energizes the valve’s internal magnetic coil, which induces eddy currents in the adjacent flyer plate resulting in a repulsive force between the flyer plate and the coil. The flyer plate action lifts a valve seat, allowing high-pressure gas to flow from the valve plenum to the downstream (breech) location of the pellet or mechanical punch. All of the valve’s internal components are designed to operate in ITER-level static background magnetic fields. Here, a study was conducted to optimize the downstream pressure response for a range of valve sizes and operating pressures. In particular, the study analyzes the breech pressure response associated with varying plenum pressures as well as varying breech volumes. A computational fluid dynamics simulation was built in STAR-CCM+ and validated against data from laboratory experiments. The resulting simulation outputs, in the form of downstream responses for a variety of initial plenum pressures and breech volumes, will be used as a complement to experimental data to ensure the pressure pulse is suitable for pellet survivability. These data, combined with studies on pellet shear strength and shock response, will be applied to optimization of overall operating parameters of the ITER SPI system.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

In situ characterization of foreign object damage (FOD) in environmental-barrier-coated silicon carbide (SiC) ceramic

Environmental barrier coatings (EBCs) protect advanced ceramics and ceramic matrix composites (CMCs) from oxidation and corrosion in gas turbine engine environments. Foreign object damage (FOD), where debris impact the protective coatings, is a critical hazard which limits the turbine durability. Despite previous efforts to understand FOD in EBCs, a detailed understanding of the fundamental transient damage mechanisms is still lacking. In the current work, the real-time FOD behavior of a Mullite / Silicon EBC was visualized via a dynamic synchrotron X-ray source in phase contrast imaging (PCI) configuration. Prior to the in situ FOD experiments, the microstructure and composition of the coating were respectively characterized using a scanning electron microscope (SEM) and X-ray diffraction (XRD). The variation in the properties of the debris was modeled by ~ 1.5 mm diameter Partially Stabilized Zirconia (PSZ) and Silicon Nitride (Si 3 N 4 ) spheres. A modified light-gas gun setup, synchronized with the X-ray beam, was used to propel the projectiles at velocities ranging between 300 and 355 m·s -1 . Coated samples were impacted under a fully backed support configuration and at normal incidence. Coating penetration and delamination, as well as projectile deformation at the bond coat resulted for FOD by PSZ spheres. Comparatively, projectile fracture, with subsequent rebound of fragments, as well as complete coating penetration and delamination at the substrate interface occurred for FOD by Si 3 N 4 spheres. It should be noted that only cone cracking was observed for FOD by PSZ spheres while back surface cracking was present for both projectile types. Qualitative understanding of the driving forces for the observed damage mechanisms were provided.

36 MATERIALS SCIENCE↗

New Simulations for Ion-Production and Back-Bombardment in GaAs Photo-guns

GaAs-based DC high voltage photo-guns used at accelerators with extensive user programs must exhibit long photocathode operating lifetime. Achieving this goal represents a significant challenge for proposed high average current facilities that must operate at tens of milliamperes or more. Specifically, the operating lifetime is dominated by ion back-bombardment of the photocathode from ionized residual gas. While numerous experiments have been performed to characterize the operating lifetime under various conditions, detailed simulations of the ion back-bombardment mechanism that explains these experiments are lacking. Recently, a new user routine was implemented using the code General Particle Tracer (GPT) to simulate electron impact ionization of residual beam line gas and simultaneously track the incident electron, the ejected electron, and the newly formed ion. This new routine was benchmarked against analytical calculations and then applied to experiments performed at the CEBAF injector at the Thomas Jefferson National Accelerator Facility to study the effectiveness of limiting ions from entering the cathode-anode gap using a positively biased anode. These simulations were performed using detailed 3D field maps produced with CST Microwave Studio describing the photo-gun electrostatics. Discussion of the experiment and the application of this new GPT routine to model the experiments will be presented at the workshop.

Yoskowitz, Joshua↗

Advanced ion thruster and electrochemical launcher research

The theoretical model of orificed hollow cathode operation predicted experimentally observed cathode performance with reasonable accuracy. The deflection and divergence characteristics of ion beamlets emanating from a two grid optics system as a function of the relative offset of screen and accel grids hole axes were described. Ion currents associated with discharge chamber operation were controlled to improve ion thruster performance markedly. Limitations imposed by basic physical laws on reductions in screen grid hole size and grid spacing for ion optics systems were described. The influence of stray magnetic fields in the vicinity of a neutralizer on the performance of that neutralizer was demonstrated. The ion current density extracted from a thruster was enhanced by injecting electrons into the region between its ion accelerating grids. Theoretical analysis of the electrothermal ramjet concept of launching space bound payloads at high acceleration levels is described. The operation of this system is broken down into two phases. In the light gas gun phase the payload is accelerated to the velocity at which the ramjet phase can commence. Preliminary models of operation are examined and shown to yield overall energy efficiences for a typical Earth escape launch of 60 to 70%. When shock losses are incorporated these efficiencies are still observed to remain at the relatively high values of 40 to 50%.

Wilbur, P. J.↗

Simulations of active ion injection experiments on ARCS 3

The ARCS 3 sounding rocket experiment used two argon guns oriented parallel and perpendicular to the geomagnetic field. The parameters of this experiment have been used in a series of particle simulations in order to interpret ion beam interaction with the multispecies ionospheric plasma. Along with the lower hybrid mode between the electron and the hydrogen gyrofrequencies, ion-ion hybrid modes between the hydrogen and helium gyrofrequencies and between the helium and oxygen gyrofrequencies are identified in the simulations. Besides these cold plasma modes, warm Bernstein modes of the respective ion species are identified. The parallel argon beam injections excite lower hybrid waves perpendicular to the magnetic field because of the finite thermal spread of the parallel beam. Perpendicular ion heating of background hydrogen, helium, and oxygen is comparable in the simulations. Comparisons are made with the wave and particle data from the ARCS 3 rocket experiment.

Hudson, M. K.↗

Correlations Among Microstructure, Morphology, Chemistry, and Isotopic Systematics of Hibonite in CM Chondrites

Introduction: Hibonite is a primary refractory phase occurring in many CAIs, typically with spinel and perovskite. Our microstructural studies of CAIs from carbonaceous chondrites reveal a range of stacking defect densities and correlated non-stoichiometry in hibonite. We also conducted a series of annealing experiments, demonstrating that the Mg-Al substitution stabilized the formation of defect-structured hibonite. Here, we continue a detailed TEM analysis of hibonite-bearing inclusions from CM chondrites that have been well-characterized isotopically. We examine possible correlations of microstructure, morphology, mineralogy, and chemical and isotopic systematics of CM hibonites in order to better understand the formation history of hibonite in the early solar nebula. Methods: Fifteen hibonite-bearing inclusions from the Paris CM chondrite were analyzed using a JEOL 7600F SEM and a JEOL 8530F electron microprobe. In addition to three hibonite-bearing inclusions from the Murchison CM chondrite previously reported, we selected three inclusions from Paris, Pmt1-6, 1-9, and 1-10, representing a range of 26Al/27Al ratios and minor element concentrations for a detailed TEM study. We extracted TEM sections from hibonite grains using a FEI Quanta 3D field emission gun SEM/FIB. The sections were then examined using a JEOL 2500SE field-emission scanning TEM equipped with a Thermo-Noran thin window EDX spectrometer. Results and Discussion: A total of six hibonite-bearing inclusions, including two platy hibonite crystals (PLACs) and four spinel-hibonite inclusions (SHIBs), were studied. There are notable differences in chemical and isotopic compositions between the inclusions (Table 1), indicative of their different formation environment or timing. Our TEM observations show perfectly-ordered, stoichiometric hibonite crystals without stacking defects in two PLACs, 2-7-1 and 2-8-2, and in three SHIBs, Pmt1-6, 1-9, and 1-10. In contrast, SHIB 1-9-5 hibonite grains contain a low density of stacking defects linked to an increase in MgO contents, indicating complex, disordered intergrowths of stoichiometric and MgO-enriched hibonites. From the data collected to date, we find no clear correlation between the microstructures of hibonite and its morphological and mineralogical types that reflect distinct chemical and isotopic systematics [6-8,10]. Interestingly, the presence of no or few stacking defects in hibonite from the PLACs and SHIBs are in contrast to our experimental studies that produced very high densities of stacking defects in hibonite [3-5]. Unlike our experi-ments, electron microprobe data from the PLACs and SHIBs hibonite grains show a strong correlation between (Ti4++Si4+) and Mg2+ cations, suggesting that coupled substitutions of (Ti4++Mg2+) and (Si4++Mg2+) for 2Al3+ inhibit the formation of defect-structured hibonite. However, our experimental studies suggest that kinetics (e.g., cooling rate) or other thermal effects also exert a strong control on the microstructures and chemical compositions of hibonite. In Pmt1-6, elongated perovskite grains present at the hibonite grain boundaries display (121) twinning, indicative of a fast cooling (>50degC/min) after high-temperature events. Therefore, the nebular microstructural characteristics of hibonite, at least in this inclusion, would not have destroyed by subsequent high-temperature annealing. Conclusions: Our TEM observations thus far show no clear correlation in microstructures, morphological and mineralogical characteristics, and chemical and isotopic systematics of hibonites from CM chondrites. The observed variation in stacking defect densities in the hibonites may be controlled by thermal processes in the early solar nebula. A detailed TEM analysis of additional CM hibonite samples is underway to evaluate this hypothesis.

Han, J.↗

SPACE CHARGE EFFECT IN LOW ENERGY MAGNETIZED ELECTRON BEAM

Magnetized electron cooling is one of the major approaches towards obtaining the required high luminosity in the proposed Electron-Ion Collider (EIC). In order to increase the cooling efficiency, a bunched electron beam with a high bunch charge and high repetition rate is required. At Jefferson Lab, we generated magnetized electron beams with high bunch charge using a new compact DC high voltage photogun biased at -300 kV with bialkali-antimonide photocathode and a commercial ultra-fast laser. This contribution discusses how magnetization affects space charge dominated beams as a function of magnetic field strength, gun high voltage, and laser pulse width, and spot size in comparison with simulations performed using General Particle Tracer.

Wijethunga, S.A.K.↗

X-Ray Photoelectron Spectroscopy

The interaction of photon and the electron goes back to the early part of 19th century emanating from the photo-electric effect depicted by none other than Albert Einstein (Ref 1) described in 1905, and the redistribution of kinetic energy resulting from the interaction of x-ray and solids reported during early part of the century (Ref.2). The spectrum resolutions obtained at that time was not sufficient to observe distinct peaks in spectra for materials. Thus, these phenomena hardly attracted any attention for many years following these discoveries. The modern X-ray Photoelectron Spectroscopy (XPS) has been possible by the extensive and significant contribution from Kai Siegbahn and others (Ref.3, 4) of Uppsala University. Siegbahn developed and employed a high-resolution electron spectrometer that revealed electron peaks in a spectrum emerging from the interaction of x-rays and solids. Eventually, Kai Siegbahn received Nobel Prize in 1981 for his contributions to XPS. Around 1958, shifts in elemental peaks were realized in compounds when the same elements are bound to other but different elements. This discovery resulted in the chemical state identification in various chemicals as well as the oxidation states of atoms in compounds. Because of these useful physical effects, the Uppsala group named XPS with a synonymous name of ESCA (Electron Spectroscopy for Chemical Analysis) used widely today and will be used here alternatively. Therefore, XPS or ESCA not only identifies the element, but also the compound these elements form, from their chemical shifts. Compared to other micro-analytical techniques such as Energy Dispersive (EDS) or Wavelength Dispersive (WDS) techniques, XPS analyzes only few atomic layers present on the surface. This was discovered early in 1966 (Ref. 5). While this has awarded a merit to the analytical technique to analyze very thin layers such as films and coatings, it often analyzes the adsorbed superficial gases and contaminations on a sample introduced to its analytical chamber. This necessitates the surface is cleaned and the underlying material, material of interest, is exposed in a clean environment such that the material of interest is analyzed. The cleaning is accomplished by a scanning ion gun within the analytical chamber of the instrument. Ion gun uses an argon gas and is commonly attached in most modern machines. Reliable and efficient vacuum systems employed in modern machines does not allow adsorbed layers to rebuild after the surface is cleaned. Development of efficient and reliable vacuum pumps over these developmental years is yet another important step in the commercialization of XPS machines. Vacuum levels of better than 10-7 torr are essential to increase the mean free path of electrons released from the sample surface. Thus, modern machines are equipped with high capacity ion, turbo or cryogenic pumps in their analytical chambers. Today, XPS has advanced from an applied physics laboratory to industry for use in quality control as well as analysis of contaminants and has taken a dominant role in microanalysis. Its uniqueness arises from the fact that it is considered non-destructive compared to other common micro-analytical techniques using the electron and ion excitation sources. Polymers and plastics could be analyzed since the binding energies of saturated and unsaturated bonds in atoms could be separated. Extremely thin layers could be analyzed including materials with layered structures. The technique, though did not advance for many years, has now opened a new window for research as well as applications in industry due to its ability to separate and measure the chemical shifts in bound elements. Principles

Panda, Binayak↗

Nucleation and growth of voids in shock loaded copper bicrystals

Understanding the evolution of damage and deformation due to spall at grain boundaries can provide a basis for connecting micro- to macroscale failure behavior in metals under extreme conditions. Copper bicrystal samples were shock loaded using flyer-plate impacts in a light gas gun with shock stresses ranging from 3 to 6 GPa. Pulse duration as well as crystal orientation along the shock direction were varied for a fixed boundary misorientation to determine their effects on void nucleation and coalescence. Samples were soft recovered and cross-sectioned to characterize damage using electron backscattering diffraction and scanning electron microscopy to gather information on damage characteristics at and around the GB, with emphasis on growth of boundary and bulk voids. Chemistry and composition analysis were also performed on samples to determine if trace elements present in a sample affected the threshold for void nucleation. Results show that the kinetics of damage growth at the boundary are strongly affected by stress level and impurities. It was found that the boundary selected had a similar or even lower tendency to show damage than the bulk at low pulse durations and amplitudes. As pulse duration and amplitude increased damage localized at the boundary, which was found to consist of many small voids, indicating that the boundary experienced rapid void nucleation and coalescence. Furthermore, the presence of impurities correlated strongly with scatter on damage evolution.

36 MATERIALS SCIENCE↗

Observation of Polarization-Dependent Changes in Higher-Order Mode Responses as a Function of Transverse Beam Position in Tesla-Type Cavities at FAST

Higher-order modes (HOMs) in superconducting rf cavities present problems for an electron bunch traversing the cavity in the form of long-range wakefields from previous bunches. These may dilute the emittance of the macropulse average, especially with low emittance beams at facilities such as the European X-ray Free-electron Laser (XFEL) and the upgraded Linac Coherent Light Source (LCLS-II). Here we present observations of HOMs driven by the beam at the Fermilab Accelerator Science and Technology (FAST) facility. The FAST facility features two independent TESLA-type cavities (CC1 and CC2) after a photocathode rf gun followed by an 8-cavity cryomodule. The HOM signals were acquired from cavities using bandpass filters of 1.75 ± 0.15 GHz, 2.5 ± 0.2 GHz, and 3.25 ± 0.2 GHz and recorded using an 8-GHz, 20 GSa/s oscilloscope. The frequency resolution obtained is sufficient to separate polarization components of many of the HOMs. These HOM signals were captured from CC1 and cavities 1 and 8 of the cryomodule for various initial trajectories through the cavities, and we observe correlations between trajectory, HOM signals, and which polarization component of a mode is affected.

Thurman-Keup, Randy Michael↗

Reducing Mass of Steel Auto Bodies using Thin Advanced High Strength Steel with Carbon-Fiber Reinforced Epoxy

Diversitak, a company based in Detroit, MI, has developed a proprietary, low specific gravity, carbon fiber-reinforced epoxy (CFRE) under U.S. patent number 9,963,58832. Preliminary testing on this new material conducted in collaboration with ArcelorMittal Steel Company proved out the CFRE concept. A thin layer of this CFRE was applied to a stamped sheet of steel with residual stamping oils from a mill, in a time corresponding to automotive processing (e.g., ~15 seconds), and processed following automotive e-coat procedures (phosphating + 175–200°C heating), to complete the curing. No problems with adherence or performance were noted. While the CFRE does add weight to a thin gauge steel panel, it weighs much less than what is displaced by using thicker conventional mild steel gauges. The application of the coating showed a significant increased dent resistance, oil canning resistance, and part stiffness.This current two-year project was designed to mature this new technology to near manufacturing readiness to reduce the weight of a vehicle and lower the cost of weight reduction. The process involves the use of thinner gauge steels than are currently used. The collaborative development team included two industrial manufacturers: Diversitak and ArcelorMittal Steel Company; LightMAT; and two National Laboratories: Oak Ridge National Laboratory (ORNL) and Idaho National Laboratory (INL). The team developed a new manufacturing process to reduce the weight of a vehicle and lower the cost of weight reduction, as well as a better understanding of how to apply the coating so that it will perform to a high standard in-service. The team also performed an in-depth study to determine the long-term durability of the materials manufactured using this technology and well-known automotive industry standard tests.The overall process involved stiffening the thinner gauge steel by applying the CFRE on only one side. To accomplish this goal, the optimal reinforcement fiber length and fiber concentration was first determined. This was followed by measuring the coefficient of thermal expansion (CTE) in all three directions, so it could be fed into manufacturing models and methods for rapidly and inexpensively applying the coating. This was followed by panel level evaluations of the coating and steel combination, and then by full part demonstration of the technology on door panels. The final step was corrosion testing of the parts.ArcelorMittal characterized the advanced high strength steel (AHSS) (e.g., metallurgy-heat treatment for required AHSS properties as a function of the sheet thickness, state of internal stress) and quantified CFRE adhesion to the steel as a function of sheet preparation (e.g., rolling and stamping).ORNL optimized the fiber length, fiber concentration, and coating thickness for best vehicle function and performance at the least cost. Along with the suppliers, ORNL developed a durable CFRE application process (e.g., gun material, design, robotic dispensing process) and identified the adhesion stability of the CFRE during process holding. An approach to ensure that application/curing timing conforms to conventional assembly line speed and plant cycle times was determined. ORNL also determined the CTE of the material in all three directions and performed material scanning electron microscopy (SEM) analyses.INL characterized the corrosion properties of the steel panels coated with CFRE. The panels were investigated for corrosion resistance and stability as replacement materials used in automotive body panels to reduce mass. The coupons tested at INL were supplied by Diversitak after an optimized CFRE formulation was achieved in the already coated form for corrosion testing.

99 GENERAL AND MISCELLANEOUS↗