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At least 415 records · Page 23

All sources NASA NTRS DOE OSTI

DOE OSTI2014

The development of poly(vinyl chloride) [PVC] extrusions for a 14,000-ton self-supporting structure for the detection of neutrinos

The NOvA Neutrino Experiment has built a one of a kind self-supporting plastic structure, potentially the largest ever built. The PVC structure serves as a neutrino detector and is composed of 28 individual blocks that measure 15.5 m (51 feet) high by 15.5 m (51 feet) wide by 2.1 m (7 feet) deep. The primary parts in the detector construction are 15.5m (51 foot), 15-cell PVC extrusions. These extrusions from the basis of the detector modules which are laminated together in a crossed pattern to form the individual blocks and then filled with mineral oil based liquid scintillator. The self-supporting nature of the detector places important structural requirements on both the PVC formulation and the extrusions. Block assembly requirements impose narrow geometric tolerances. Due to the method of detecting neutrinos, the extrusions must possess exceptionally high reflectivity over a particular wavelength range. The requirement places additional restrictions on the components of the PVC formulation. Altogether, the PVC extrusions have to maintain important reflectivity characteristics, provide structural support to the detector, and meet relatively tight geometric requirements for assembly. In order to meet these constraints, a custom PVC formulation had to be created and extruded. Here, we describe the purpose and requirements of the NOvA detector leading to the production of our unique PVC extrusion, summarize the R&D process, and discuss the lessons learned.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Influence of Fiber Orientation on Deformation of Additive Manufactured Composites

Anisotropy caused by flow-induced fiber orientation of discontinuous fibers within the extrudate in the Extrusion Deposition Additive Manufacturing (EDAM) process gives rise to anisotropic shrinkage in printed parts and thereby, final part deformations. Three fiber orientation states, described by the second-order orientation tensor, were investigated to determine their influence upon final geometry. Two material systems were investigated including a short glass fiber-reinforced polyamide and a short carbon fiber-reinforced polyamide. A curvilinear geometry was modeled and printed virtually in the thermo-mechanical simulation, ADDITIVE3D©. The scale of the printed geometry was in the range of 300–400 mm and contained three semicircular geometry regions connected to linear regions, thereby inducing significant magnification of the spring-in deformation. The predicted deformation of the printed geometry for the three fiber orientation states and two material systems were compared. The deformation predicted for glass fiber-filled polyamide and carbon fiber-filled polyamide of the same fiber orientation states showed comparable deformations. In conclusion, the largest residual deformation was shown to correspond to the orientation tensor with the greatest degree of anisotropy.

36 MATERIALS SCIENCE↗

DOE OSTI2022

No ball milling needed: Alternative ODS steel manufacturing with gas atomization reaction synthesis (GARS) and friction-based processing

Oxide dispersion strengthened (ODS) steels are promising structural materials for future fusion reactors. The high-density (~10 23 /m 3 ) of highly stable Y-(Ti)-O nano-oxides provide high sink strength for radiation resistance and high-temperature (> 650 °C) creep strength. Concomitantly, helium management is enabled by trapping high density (~10 23 /m 3 ) of small (< 3 nm) helium bubbles in the vicinity of nano-oxides. However, conventional route of making ODS steels involves prolonged ball milling, canning, degassing, and laborious thermo-mechanical processing (TMP). Such route, especially the batch-by-batch ball milling step, faces persistent challenge with scalability and high costs. Gas atomization reaction synthesis (GARS) method has demonstrated the potential of making precursor ODS steel powders without ball milling, but the nano-oxide density was around 10 21 /m 3 in the final consolidated form by conventional TMP. Taking advantage of GARS precursor powder, we use friction-based processing, including friction consolidation and extrusion, to manufacture ODS steel with further improved nano-oxide characteristics. Here, preliminary results showed that Y/Ti/O species were intimately mixed and rapidly reacted to form nano-oxides with a number density of ~10 22 /m 3 .

36 MATERIALS SCIENCE↗

DOE OSTI2014

Letter Report Documenting Progress of Second Generation ATF FeCrAl Alloy Fabrication

Development of the 2 nd generation ATF FeCrAl alloy has been initiated, and a candidate alloy was selected for trial tube fabrication through hot-extrusion and gun-drilling processes. Four alloys based on Fe-13Cr-4.5Al-0.15Y in weight percent were newly cast with minor alloying additions of Mo, Si, Nb, and C to promote solid-solution and second-phase precipitate strengthening. The alloy compositions were selected with guidance from computational thermodynamic tools. The lab-scale heats of ~ 600g were arc-melted and drop-cast, homogenized, hot-forged and -rolled, and then annealed producing plate shape samples. An alloy with Mo and Nb additions (C35MN) processed at 800°C exhibits very fine sub-grain structure with the sub-grain size of 1-3μm which exhibited more than 25% better yield and tensile strengths together with decent ductility compared to the other FeCrAl alloys at room temperature. It was found that the Nb addition was key to improving thermal stability of the fine sub-grain structure. Optimally, grains of less than 30 microns are desired, with grains up to and order of magnitude in desired produced through Nb addition. Scale-up effort of the C35MN alloy was made in collaboration with a commercial cast company who has a capability of vacuum induction melting. A 39lb columnar ingot with ~81mm diameter and ~305mm height (with hot-top) was commercially cast, homogenized, hot-extruded, and annealed providing 10mm-diameter bar-shape samples with the fine sub-grain structure. This commercial heat proved consistent with materials produced at ORNL at the lab-scale. Tubes and end caps were machined from the bar sample and provided to another work package for the ATF-1 irradiation campaign in the milestone M3FT-14OR0202251.

2nd generation ATF FeCrAl alloy↗

DOE OSTI2018

Sandia National Laboratories

Sandia National Laboratories is a multimission laboratory managed by National Technology & Engineering Solutions of Sandia, LLC a wholly owned subsidiary of Honeywell International, Inc., for the U.S. Department of Energy's National Nuclear Security Administration. Sandia has a long history of pioneering AM technology development. In the mid 1990s, Sandia developed laser-engineered net shaping (LENS), one of the first direct metal AM technologies, which was commercialized by Optomec. Robocast, an extrusion-based direct-write process for 3D ceramic parts, is another technology developed at Sandia. It was commercialized by Robocast Enterprises, LLC. As of January, 2019, Sandia was conducting AM R&D projects valued at about $25 million, with an emphasis on: 1) analysis-driven design, 2) materials reliability, and 3) multi-material AM.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Testing Protocol Development for the Fracture Toughness of Parts Built with Big Area Additive Manufacturing

The mechanical testing of additively manufactured parts has largely relied on the existing standards developed for traditional manufacturing. While this approach leverages the investment made in current standards development, it inaccurately assumes that the mechanical response of additive manufacturing (AM) parts is identical to that of parts manufactured through traditional processes. When considering thermoplastic, material extrusion AM, the differences in response can be attributed to an AM part’s inherent inhomogeneity caused by porosity, interlayer zones, and surface texture. Additionally, the interlayer bonding of parts printed with large-scale AM is difficult to adequately assess, as much testing is performed such that stress is distributed across many layer interfaces; therefore, the lack of AM-specific standards to assess interlayer bonding is a significant research gap. To quantify interlayer bonding via fracture toughness, double cantilever beam (DCB) testing has been used for some AM materials, and DCB has been generally used for a variety of materials including metal, wood, and laminates. Mode I DCB testing was performed on thermoplastic matrix composites printed with Big Area Additive Manufacturing (BAAM). Of particular interest was the notch shape and deflection speed during testing. The results examine the differences when using two notch types and three deflection speeds. The testing method introduced by the following paper differentiates itself from the ones described in the standards used by modernizing the methodology. This was conducted with the introduction of Digital Image Correlation (DIC) to gather displacement and load data simultaneously without human intervention.

Polymer Science↗

NASA NTRS1972

The Alhazen to Abul Wafa swirl belt: An extensive field of light colored, sinuous markings, part T

Problematic causes and characteristics of light colored sinuous markings on the lunar surface are explored. Two processes, exogenetic and endogenetic, are examined in detailed. During the endogenetic process it is suggested that impact ejecta deposition and surface disturbances cause the markings. During the endogenetic process, it is suggested that extrusive volcanism and sublimation and/or alteration cause the markings.

El-Baz, F.↗

NASA NTRS1990

Quantitative characterization of spatial distribution of particles in materials: Application to materials processing

Most engineering materials contain second phase particles or fibers which serve to reinforce the matrix phase. The effect of reinforcements on material properties is usually analyzed in terms of the average volume fraction and spacing of reinforcements, quantities which are global microstructural characteristics. However, material properties can also depend on local microstructural characteristics; for example, on how uniformly the reinforcing phase is distributed in the material. The analysis method will then be applied to a materials processing problem to discover how processing parameters can be selected to maximize redistribution of the reinforcing phase during processing. Several mathematical analysis methods could be adapted to the problem of characterizing the distribution of particles in materials. A tessellation-based method was selected. In the first phase of the investigation, a software package was written to automate the analysis. Typical results are shown. The analysis technique allows the degree to which particles are clustered together, the size and spacing of particle clusters, and the particle density in clusters to be found. The analysis methods were applied to computer-generated distributions and to a few real particle-containing materials. Methods for analyzing a nonuniform particle distribution in a material can be applied to two broad classes of materials science problems: understanding how the resulting particle distribution affects properties. The analysis method described is applied to a materials processing problem: how to select extrusion conditions to maximize the redistribution of reinforcing particles that are initially nonuniformly distributed. In addition, the tessellation-based method to analyze star distributions in spiral galaxies was adapted, illustrating the diverse types of problems to which the analysis method can be applied.

Parse, J. B.↗

NASA NTRS2018

Igneous Rocks Formed by Hypervelocity Impact

Igneous rocks are the primary building blocks of planetary crusts. Most igneous rocks originate via decompression melting and/or wet melting of protolith lithologies within planetary interiors and their classification and compositional, petrographic, and textural characteristics, arewell-studied. As our exploration of the Solar System continues, so too does the inventory of intrusive and extrusive igneous rocks, settings, and processes. The results of planetary exploration have also clearly demonstrated that impact cratering is a ubiquitous geological process that has affected, andwill continue to affect, all planetary objectswith a solid surface,whether that be rock or ice. It is nowrecognized that the production of igneous rocks is a fundamental outcome of hypervelocity impact. The goal of this review is to provide an up-to-date synthesis of our knowledge and understanding of igneous rocks formed by hypervelocity impact. Following a brief overview of the basics of the impact process, we describe howand whymelts are generated during impact events and howimpactmelting differs fromendogenic igneous processes.While the processmay differ,we showthat the products of hypervelocity impact can share close similarities with volcanic and shallow intrusive igneous rocks of endogenic origin. Such impact melt rocks, as they are termed, can display lobate margins and cooling cracks, columnar joints and at the hand specimen andmicroscopic scale, such rocks can displaymineral textures that are typical of volcanic rocks, such as quench crystallites, ophitic, porphyritic, aswell as features such as vesicles, flowtextures, and so on.Historically, these similarities led to themisidentification of some igneous rocks now known to be impact melt rocks as being of endogenic origin. This raises the question as to how to distinguish between an impact versus an endogenic origin for igneous-like rocks on other planetary bodies where fieldwork and sample analysis may not be possible and all that may be available is remote sensing data.While the interpretation of some impact melt rocks may be relatively straightforward (e.g., for clast-rich varieties and those with clear projectile contamination) we conclude that distinguishing between impact and endogenic igneous rocks is a non-trivial task that ultimately may require sample investigation and analysis to be conducted. Caution is, therefore, urged in the interpretation of igneous rocks on planetary surfaces.

Osinski, Gordon R.↗

DOE OSTI2019

Effect of the Processing-Induced Morphology on the Mechanical Properties of Biodegradable Extruded Films Based on Poly(lactic acid) (PLA) Blends

Biodegradable films based on poly(lactic acid) blends were obtained by cast extrusion. Their tensile and fracture behavior was investigated and the effect of the processing conditions through the extrusion rolling speed on this behavior was analyzed. In uniaxial tensile tests, all films presented completely ductile behavior exhibiting a defined yield point, strain softening after this point and a plateau before fracture. Fracture behavior was determined through quasi-static fracture tests on deeply double edge notched tensile specimens. The film obtained at the lowest rolling speed exhibited completely ductile behavior hence, the Essential Work of Fracture methodology was applied to characterize its fracture. The film processed at intermediate rolling speed, on the other hand, presented ductile fracture or ductile instability depending on the ligament length and the film obtained with the highest rolling speed exhibited a transition regime fracture. In order to compare the fracture behavior of the different films, the J-integral at maximum load J{sub max} was adopted. Differences in the films fracture behavior were correlated to the processing-induced morphology.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Automated Manufacturing of Grid Stiffened Panels with Radically Reduced Tooling

Grid stiffened continuous fiber reinforced composite panels are an attractive option for creating lightweight structures due to the tailorability for various applications and the resulting high specific properties. However, the panel stiffeners and stiffener intersections result in high tooling complexity and correspondingly high cost of implementation. These factors have limited the impact of such structures in the composites industry. Previous research has demonstrated the ability to produce high quality, high aspect ratio beams, representative of individual grid stiffeners, using E-glass/PET comingled tow via direct digital manufacturing. Further, prior preliminary efforts have demonstrated the potential to use the same approach to manufacture grid intersections that have continuous fiber in both directions. To expand on the previous efforts in grid stiffeners produced by direct digital manufacture with radically reduced tooling requirements, this effort compares two methods of providing positioning and consolidation, nozzle vs. roller. Both processes are based on a commingled yarn feedstock. The extrusion through a nozzle has been shown to enable grid intersection control through local variations in applied consolidation and serves as the baseline process. However, this approach requires a continuous placement path to create the complete grid stiffened panel as no mechanism for cutting and restarting has been implemented. Alternatively, a newly developed placement head incorporating cut and refeed, mounted to a 6-axis robot, offers the potential of improved path placement efficiency. The two techniques are used to produce similar grid composite stiffeners to evaluate the effectiveness of producing the grid intersections. Rate of deposition of the two end effectors are compared and the quality of the associated grid stiffeners, and intersections, are determined through measurement of geometry, fiber volume fraction and void fraction.

Engineering↗

NASA NTRS1974

Liquid-metal atomization for hot working preforms

Rapid quenching of a liquid metal by atomization or splat cooling overcomes the major limitation of most solidification processes, namely, the segregation of alloying elements, impurities, and constituent phases. The cooling rates of different atomizing processes are related to the dendrite arm spacings and to the microstructure of the atomized powders. The increased solubility limits and the formation of metastable compounds in splat-cooled alloys are discussed. Consolidation of the powders by hot isostatic compaction, hot extrusion, or hot forging and rolling processes yields billets with properties equivalent to or better than those of the wrought alloys. The application of this powder processing technology to high-performance alloys is reviewed.

Grant, N. J.↗

DOE OSTI2024

Reactive extrusion of frontally polymerizing continuous carbon fiber reinforced polymer composites

The manufacturing of carbon fiber-reinforced polymer (CFRP) composites demands rapid and energy-efficient strategies. Frontal polymerization (FP) enables the manufacturing of CFRP using dicyclopentadiene (DCPD) thermoset polymer which meets these requirements. In this work, we introduce reactive extrusion of CFRP (RE-CFRP), where two rollers provide localized heat and pressure to sustain the curing reaction and the consolidation of a continuous carbon fiber tow pre-impregnated with DCPD. We study the effect of the extrusion speed, temperature, and compaction force on the properties of the produced CFRP. Mechanical testing confirms that the resulting fiber volume fraction and the elastic modulus are similar to bulk cured tows. A homogenized thermo-chemical model is developed to study the effect of the process parameters on the polymerization reaction. The process produces hollow woven composite tubes directly via extrusion and in situ curing. Overall, this process offers advantages in curing, tooling, speed, and energy.

36 MATERIALS SCIENCE↗

DOE OSTI2023

1. Introduction to Additive Manufacturing

Additive manufacturing (AM) is the process of constructing an object by adding layer upon layer of material in specific locations, to build the object into its final shape. There are many different AM processes that can be used to add layers of material, such as extrusion, material jetting, and sheet lamination. All of the AM processes are a form of digital fabrication because the object to be constructed must first be modeled with a computer. The modeled object must be converted into machine instructions that an AM system can use to construct the object. This chapter serves as an introduction to the many different AM processes. Subsequent chapters will explore the intricacies of creating machine instructions for the AM processes introduced here.

Macdonald, Eric↗

DOE OSTI2026

Additive Manufacturing of Cryogenic Austenitic Steel JK2LB via Wire-Fed Directed Energy Deposition (DED) for Fusion Energy Applications

This study explores the feasibility of fabricating cryogenic austenitic steel JK2LB via both laser-based directed energy deposition (laser-DED) and arc-based directed energy deposition (arc-DED) additive manufacturing processes for potential application in fusion reactors. JK2LB, a low-nickel, high-manganese stainless steel developed for ITER, offers excellent cryogenic toughness, radiation resistance, and decay-to-clearance characteristics. Although JK2LB was originally designed to endure cyclic stresses at cryogenic temperatures in tokamaks, its low-temperature mechanical integrity and radiation tolerance also make it a promising candidate for structural components, such as the coil case/support structure in nonplanar high-temperature superconducting magnet assemblies in stellarators. Directed energy deposition (DED) additive manufacturing was selected for this study due to its capability to fabricate large structures with complex geometries. Here, to address the long lead time and high cost associated with acquiring conventional JK2LB solid wire, JK2LB powder-cored wire was developed as the feedstock material. Testing blocks were then fabricated using both wire-fed laser-DED and arc-DED processes. Microstructural and compositional analyses revealed that both DED approaches yield fully austenitic phase and columnar grain structures. Mechanical testing at room temperature revealed that both DED routes achieved yield strength and elongation comparable to those of conventionally processed JK2LB via vacuum melting, electroslag remelting, extrusion, and drawing, though ultimate tensile strength was reduced due to Mn loss and large columnar grains. As a study mainly focusing on the additive manufacturing process, this work demonstrates the potential of additive manufacturing for fusion energy applications and provides a basis for optimization and future cryogenic mechanical evaluation.

Cryogenic steel↗

NASA NTRS2000

Analysis of edible oil processing options for the BIO-Plex advanced life support system

Edible oil is a critical component of the proposed plant-based Advanced Life Support (ALS) diet. Soybean, peanut, and single-cell oil are the oil source options to date. In terrestrial manufacture, oil is ordinarily extracted with hexane, an organic solvent. However, exposed solvents are not permitted in the spacecraft environment or in enclosed human tests by National Aeronautics and Space Administration due to their potential danger and handling difficulty. As a result, alternative oil-processing methods will need to be utilized. Preparation and recovery options include traditional dehulling, crushing, conditioning, and flaking, extrusion, pressing, water extraction, and supercritical extraction. These processing options were evaluated on criteria appropriate to the Advanced Life Support System and BIO-Plex application including: product quality, product stability, waste production, risk, energy needs, labor requirements, utilization of nonrenewable resources, usefulness of by-products, and versatility and mass of equipment to determine the most appropriate ALS edible oil-processing operation.

NASA Discipline Life Support Systems↗

DOE OSTI2010

Analysis of Material Flow in Screw Extrusion of Aluminum

Screw extrusion of aluminum is a new process for production of aluminum profiles. The commercial potential could be large. Little experimental and numerical work has been done with respect to this process.The material flow of hot aluminum in a screw extruder has been analyzed using finite element formulations for the non-Newtonian Navier-Stokes equations. Aluminum material properties are modeled using the Zener-Holloman material model. Effects of stick-slip conditions are investigated with respect to pressure build up and mixing quality of the extrusion process.The numerical results are compared with physical experiments using an experimental screw extruder.

36 MATERIALS SCIENCE↗

NASA NTRS2012

Friction modifier using adherent metallic multilayered or mixed element layer conversion coatings

A process for creating conversion coatings and spin, drawing, and extrusion finishes for surfaces, wherein the conversion coatings and spin, drawing, and extrusion finishes contain potassium, phosphorus, nitrogen, silicon, and one or more non-alkaline metals. The process comprises forming a first aqueous solution of silicate, potassium hydroxide, and ammonium hydroxide; forming a second aqueous solution of water, phosphoric acid, ammonium hydroxide, an alkali metal hydroxide, and one or more non-alkaline metals, and then combining the first solution with the second solution to form a final solution. This final solution forms an anti-friction multi-layer conversion coating or a spin, drawing, and extrusion finish on a surface when applied to the surface, either directly or as an additive in lubricating fluids.

Schramm, Harry F.↗