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At least 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

3D Printing of Cement-Based Materials Using Seawater for Simulated Marine Environments

Global demand for adaptable and rapidly deployable construction solutions in offshore, coastal, and fluvial environments continues to rise, driven by pressing needs to develop energy platforms, improve coastal resilience, and support emergency response in the face of natural disasters. Increased investment in human-made coastal infrastructure, such as piers, support structures for power lines, offshore wind farms, and seawall protection systems, further underscores this trend. This study investigates the development of printable concrete mixtures for underwater environments using seawater as a replacement for freshwater, using a 3D printing syringe-based extrusion system. The effect of seawater addition and the printing medium (in air vs. underwater) was assessed via rheological and mechanical performance characterization. The results indicate rheological properties are favorable for seawater adoption by producing mixtures with higher yield stress and viscosity with the same levels of admixtures used for freshwater. Seawater-based mixtures demonstrated superior dimensional stability compared to freshwater counterparts, maintaining cross-sectional geometry, while compressive strength results showed no statistical differences between in-air and underwater samples. However, flexural strength was significantly influenced by geometry and printing medium. These findings establish critical rheological parameters for printable underwater mixtures and highlight the need for optimized curing strategies and layer bonding techniques to improve interfacial strength in underwater 3D printing applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A very high energy hadron collider on the Moon

Abstract The long-term prospect of building a hadron collider around the circumference of a great circle of the Moon is sketched. A circular collider on the Moon (CCM) of ∼11 000 km in circumference could reach a proton–proton center-of-mass collision energy of 14 PeV—a thousand times higher than the Large Hadron Collider at CERN—optimistically assuming a dipole magnetic field of 20 T. Several aspects of such a project are presented, including siting, construction, availability of necessary materials on the Moon, and powering, as well as a discussion of future studies and further information needed to determine the more concrete feasibility of each. Machine parameters and vacuum requirements are explored, and an injection scheme is delineated. Other unknowns are set down. Due to the strong interest from multiple organizations in establishing a permanent Moon presence, a CCM could be the (next-to-) next-to-next-generation discovery machine for high-energy particle physics and a natural successor to next-generation machines, such as the proposed future circular collider at CERN or a super proton–proton collider in China, and other future machines, such as a collider in the Sea, in the Gulf of Mexico. A CCM would serve as an important stepping stone toward a Planck-scale collider sited in our Solar System.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

Unraveling disadhesion mechanism of epoxy/CSH interface under aggressive conditions

Almost all FRP-reinforced concrete exposed to the marine environment are susceptible to durability deficiencies due to failure of the FRP/epoxy/concrete interface, especially the vulnerable epoxy/concrete interface, which is frequently attacked by water and ions. Herein, molecular dynamics simulations of epoxy/CSH interface under different environmental exposures are utilized to specifically elucidate the degradation principles of water and ions on the bonding properties and mechanical responses of the epoxy/concrete interface. The environmental sequences associated with the interfacial bonding degradation are arranged as Na{sub 2}SO{sub 4} + NaCl>NaCl>Na{sub 2}SO{sub 4} > Water>Dry. Remarkably, water molecules weaken the interaction between the epoxy and CSH by robbing interfacial H- and Ca-O bonds, thereby reducing the energy barrier to interfacial peel and shear failure. The weakening effects are exacerbated by the presence of aggressive ions, as Na{sup +} ions attracted to the CSH surface accumulate more water molecules in the interfacial region by forming hydrated ions clusters, which ultimately accelerates the epoxy/CSH interfacial degradation.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Effects of organic additives on calcium hydroxide crystallisation during lime slaking

Highlights: • Sucrose and lignosulfonate reduce the crystallite size of Ca(OH){sub 2}. • Lime slaking in sucrose solutions leads to Ca(OH)2 with irregular shape. • Lime slaking in presence of lignosulfonate leads to plate-like Ca(OH){sub 2} crystals. • Effects of additives are enhanced when introduced before slaking. • Additives stabilise the unstable edge faces of Ca(OH){sub 2} during ageing. Organic compounds, often used in cement systems as admixtures, may affect the crystallisation and carbonation kinetics of Ca(OH){sub 2}, an important phase of hydrated cement. Here, we investigated changes in Ca(OH){sub 2} morphology in the presence of 3 organic compounds, commonly encountered in cement and lime-based materials: sucrose, pectin and calcium lignosulfonate. The additives were introduced either before or after lime slaking to determine the influence of temperature. Ca(OH){sub 2} crystals and supernatant solutions were characterised at time of slaking and after 6 months of ageing using scanning electron microscopy, X-ray diffraction and optical emission spectroscopy. Our results indicate that the morphology of Ca(OH){sub 2} crystals is modified by the characteristics of the organic molecules which promote formation of Ca(OH){sub 2} with habits that can result in faster carbonation, an effect that is detrimental to cement used in reinforced concrete. These effects are enhanced when the additives are introduced before slaking, likely as a result of thermal degradation.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Hydro-chemo-mechanical phase field formulation for corrosion induced cracking in reinforced concrete

Steel corrosion induced cracking in reinforced concrete structures is often caused by volumetric straining at the steel-concrete interface. This volumetric strain is mainly controlled by the rate of generation of corrosion product, which depends on the diffusion of Cl{sup −} and dissolved O{sub 2} as well as the chemical reaction at the steel-concrete interface. While many numerical modeling techniques have been proposed to tackle this complex phenomenon, most have been limited to using staggered solution schemes, where the diffusion, chemical reaction, mechanical strain, and crack fields are solved for separately. Unfortunately, such approaches introduce numerical errors that can lead to unrealistic predictions. Therefore, a coupled solution, is needed to remove the formulation induced errors and understand this complex phenomenon. To provide a unifying solution framework for corrosion induced cracking in reinforced concrete, a phase field formulation is presented and implemented with FEM algorithms. The governing equations are derived from the system's free energy and Fick's law of diffusion. The proposed formulation was first validated in 1D by comparing the modeling results with the semi-analytical solution approximated via Laurent series to avoid singularities in the complex domain. 2D plane strain solutions to the embedded rebar undergoing corrosion induced cracking with pre-cracks are also presented and compared with the approximated solutions from linear elastic fracture mechanics theory (LEFM). The modeling of crack propagation enabled by the proposed formulation is also presented along with parametric studies to reveal the roles of the fracture toughness and permeability of the concrete on the corrosion induced cracking. A case study was also conducted on H-pile steel with concrete jackets to demonstrate the feasibility of modeling corrosion induced fracture in reinforced concrete structures with complex steel-concrete interfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Experimental evidence for the acceleration of slag hydration in blended cements by the addition of CaCl2

Cements with high substitution rates of ground granulated blast furnace slags (GGBS) have the potential to significantly lower CO{sub 2} emissions of concrete, but their early age strength is often below those of traditional OPC cements. One way of mitigating this drawback is to use accelerating admixtures. In this study, the effect of CaCl{sub 2} additions on the hydration of blended cements was investigated by measuring compressive strength, porosity, heat release and propagation of ultrasound in blends containing 70 wt% of GGBS. The onset of formation of aluminate phases was monitored using in-situ XRD. The effect of CaCl{sub 2} on slag hydration was isolated by replacing GGBS by an inert quartz filler. Results showed that compressive strength values at one, two and seven days were increased by 50% by the CaCl{sub 2} addition. The increases in compressive strength corresponded to a reduction in pore space. GGBS hydration contributed to the heat development, structuration and compressive strength of the blended cements from 15 h. The addition of CaCl{sub 2} led to an earlier onset of the GGBS reaction, at around 10 h, and increased the rate of GGBS hydration during the first seven days. The time of onset of the GGBS contribution was also the moment when AFm precipitation started. In CaCl{sub 2}-containing blends, Cl was incorporated in AFm.

36 MATERIALS SCIENCE↗
NASA NTRS2014

Evaluation of Geopolymer Concrete for Rocket Test Facility Flame Deflectors

The current paper presents results from a combined research effort by Louisiana Tech University (LTU) and NASA Stennis Space Center (SSC) to develop a new alumina-silicate based cementitious binder capable of acting as a high performance refractory material with low heat ablation rate and high early mechanical strength. Such a binder would represent a significant contribution to NASA's efforts to develop a new generation of refractory 'hot face' liners for liquid or solid rocket plume environments. This project was developed as a continuation of on-going collaborations between LTU and SSC, where test sections of a formulation of high temperature geopolymer binder were cast in the floor and walls of Test Stand E-1 Cell 3, an active rocket engine test stand flame trench. Additionally, geopolymer concrete panels were tested using the NASA-SSC Diagnostic Test Facility (DTF) thruster, where supersonic plume environments were generated on a 1ft wide x 2ft long x 6 inch deep refractory panel. The DTF operates on LOX/GH2 propellants producing a nominal thrust of 1,200 lbf and the combustion chamber conditions are Pc=625psig, O/F=6.0. Data collected included high speed video of plume/panel area and surface profiles (depth) of the test panels measured on a 1-inch by 1-inch giving localized erosion rates during the test. Louisiana Tech conducted a microstructure analysis of the geopolymer binder after the testing program to identify phase changes in the material.

Allgood, Daniel C.↗
NASA NTRS2006

Platform for Testing Robotic Vehicles on Simulated Terrain

The variable terrain tilt platform (VTTP) is a means of providing simulated terrain for mobility testing of engineering models of the Mars Exploration Rovers. The VTTP could also be used for testing the ability of other robotic land vehicles (and small vehicles in general) to move across terrain under diverse conditions of slope and surface texture, and in the presence of obstacles of various sizes and shapes. The VTTP consists mostly of a 16-ft-(4.88-m)-square tilt table. The tilt can be adjusted to any angle between 0 (horizontal) and 25 . The test surface of the table can be left bare; can be covered with hard, high-friction material; or can be covered with sand, gravel, and/or other ground-simulating material or combination of materials to a thickness of as much as 6 in. (approx. 15 cm). Models of rocks, trenches, and other obstacles can be placed on the simulated terrain. For example, for one of the Mars- Rover tests, a high-friction mat was attached to the platform, then a 6-in.- ( 15 cm) deep layer of dry, loose beach sand was deposited on the mat. The choice of these two driving surface materials was meant to bound the range of variability of terrain that the rover was expected to encounter on the Martian surface. At each of the different angles at which tests were performed, for some of the tests, rocklike concrete obstacles ranging in height from 10 to 25 cm were placed in the path of the rover (see figure). The development of the VTTP was accompanied by development of a methodology of testing to characterize the performance and modes of failure of a vehicle under test. In addition to variations in slope, ground material, and obstacles, testing typically includes driving up-slope, down-slope, cross-slope, and at intermediate angles relative to slope. Testing includes recording of drive-motor currents, wheel speeds, articulation of suspension mechanisms, and the actual path of the vehicle over the simulated terrain. The collected data can be used to compute curves that summarize torque, speed, power-demand, and slip characteristics of wheels during the traverse.

Lindemann, Randel↗
DOE OSTI2021

Grizzly Development for Light Water Reactor and Advanced Reactor Applications in Fiscal Year 2021

This report summarizes work performed during Fiscal Year (FY) 2021 at Idaho National Laboratory (INL) for the U.S. Department of Energy’s Nuclear Engineering Advanced Modeling and Simulation (NEAMS) program for the Structural Materials and Chemistry Technical Area in the work package entitled “MS-21IN050106 - Structural Materials - INL.” This effort mainly focused on development and application of capabilities for engineering-scale analysis of nuclear reactor structural components in the Grizzly and BlackBear codes. These efforts include performance improvements and application of models for high-temperature component response, cluster dynamics modeling of precipitation in light water reactor pressure vessel steel, engineering-scale capability development in the areas of concrete simulation and reactor pressure vessel analysis, and preparation for and conducting an independent assessment of the adherence of these codes to software quality standards.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Reinventing CEMENT: Carbonation-Enabled Mineralization to Engender Novel Technology

Cement is the most important building material used in civil infrastructure but it is extremely energy intensive to produce. We developed novel ways to make cements at low temperatures by mimicking the chemistry of the calcium silicate mineral pseudowollastonite. Pseudowollastonite is interesting because when it is exposed to hot (90-150oC), alkaline conditions with CO2 and water it reacts to form mineral phases that are much stronger than commercial cements. The resulting phases are also much more resistant to acid attack and have lower permeability, which will make them last longer. Many of the mineral phases in our cements are similar to those that exist in ancient Roman cements that have lasted thousands of years. Our objective was to understand how waste materials from industrial processes (such as power production, municipal solid waste treatment, or power plants) can be used to replicate the conditions that give pseudowollastonite cement its remarkable properties. We worked to optimize our formulations and incorporate the cements into concrete blends that the industry can test and consider using in different applications. Our cements could be used in pre-cast cement structural elements, which makes up nearly 20% of the total cement market and is growing rapidly. This work supports ARPA-E program objectives to significantly improve the industrial efficiency of materials production.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Environmentally Friendly Use of Carbon Ore for Advanced Building Materials for Homes and Commercial Buildings

Through this effort, X-MAT CCC sought to confirm the utility and commercialization potential of carbon-derived building materials (CDBM) technology licensed from our partner, Semplastics. These CDBM products contain at least 52% coal-derived carbon by mass. Including the binders within the resin, the products contain at least 71% carbon by mass overall, meeting a key criterion for DE-FOA-0002185 – Area of Interest (AOI) 5 – Design Research and Development, Validation, and Fabrication of a Prototype Carbon-Based Building. The Phase II project has resulted in a technology demonstrator prototype structure, a detailed design for a carbon-based building, and updated techno-economic analysis (TEA) including detailed market surveys to show the commercial viability of CDBM products. We pursued the following objectives in Phase II: (1) construction of a partial building shell as a technology demonstrator, (2) testing of CDBM products, individually and in assemblies, (3) demonstration of bonding of CDBM and traditional building materials (TBM) in structural applications, (4) production of a detailed design for a carbon-based building, and (5) an update of the TEA that was performed in Phase I. In Phase II, X-MAT CCC and our industry team performed the development and testing needed to improve the maturity of the technology from a Technology Readiness Level (TRL) of 5 to TRL 6. CDBM have been shown by our partner Semplastics to exhibit a number of high-performance characteristics, including high strength (five times the flexure strength of the best commercial brick, and more than twice the compressive strength of construction-grade concrete block), lower density, improved mechanical durability and abrasion resistance, very high temperature stability, and resistance to chemicals, acids, salts, and water. These properties offer significant improvements over conventional building materials. Phase II built upon the work accomplished in Phase I by performing technical and economic research and development to confirm the viability of CDBM as commercial products in various markets. Acknowledgment: This material is based upon work supported by the Department of Energy under Award Number DE-FE0031985.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Calcium Carbonate Cement: A Carbon Capture, Utilization, and Storage (CCUS) Technique

A novel calcium carbonate cement system that mimics the naturally occurring mineralization process of carbon dioxide to biogenic or geologic calcium carbonate deposits was developed utilizing carbon dioxide-containing flue gas and high-calcium industrial solid waste as raw materials. The calcium carbonate cement reaction is based on the polymorphic transformation from metastable vaterite to aragonite and can achieve >40 MPa compressive strength. Due to its unique properties, the calcium carbonate cement is well suited for building materials applications with controlled factory manufacturing processes that can take advantage of its rapid curing at elevated temperatures and lower density for competitive advantages. Examples of suitable applications are lightweight fiber cement board and aerated concrete. The new cement system described is an environmentally sustainable alternative cement that can be carbon negative, meaning more carbon dioxide is captured during its manufacture than is emitted.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Corrosion of rebar in concrete. Part IV. On the theoretical basis of the chloride threshold

A theory is developed for calculating the chloride threshold (CT) from the Point Defect Model (PDM). CT is defined as the ratio [Cl - ]/[OH - ] at which the passivity breakdown voltage (E b ) equals the corrosion potential, ECP. CT is sensitive to the T, ECP, pH, and E b , because all four appear in the exponent X in CT = 10 X . Small uncertainties in these parameters translate into a large uncertainty in CT, emphasizing the need for accurate T, ECP, pH, and E b data. We demonstrate the theory by successfully calculating CT using data for selected systems.

36 MATERIALS SCIENCE↗
NASA NTRS2005

Hematite on the Surface of Meridiani Planum and Gusev Crater

Meridiani Planum was selected as a landing side for the Rover Opportunity because of an indication of hematite observed from orbit. Meridiani Planum consists of sorted sands with aeolian features like ripples and desert pavements. In impact craters, a high-albedo layered bedrock is exposed. The soil is a mixture of: (i) fine sand material in the size ranges of 50 to 150 m, (ii) sub-angular, irregular particles of 0.5 to 5 mm size with submillimeter circular voids that are most likely vesicular basaltic fragments, and (iii) spherules with a restricted grain size between 4 and 6 mm. The Mini-TES on board the rover Opportunity identified a hematite signature at distance resulting from mm-sized spherules as determined by the Moussbauer Spectrometer. Small quantities of similar spherules (2 vol. %) were found in rock exposures in Eagle crater and were interpreted as concretions that formed by precipitation from aqueous fluids inside sedimentary rocks. At Gusev crater no hematite was observed until sol 90 except for layering on a rock. Our investigations of hematite bearing materials, measured by the Alpha Particle X-ray Spectrometer (APXS), Moussbauer Spectrometer (MB), and Microscopic Imager (MI), provide a more integrated view of different occurrences of hematite on the martian surface. Chemistry of soils and rocks: Chemical compositions

Brueckner, J.↗
DOE OSTI2021

Facility Safety Plan – Building 225

B225 is operated by the Weapons and Complex Integration (WCI) Directorate and is classified as a Low Hazard facility for radiological hazards and Light Science Industry (LSI) for chemical, radiation generating devices (RGDs) and industrial hazards. Explosives and biological hazards are not authorized for B225. B225 is located in the southwest quadrant of Lawrence Livermore National Laboratory (LLNL) less than 600 meters from the nearest site boundary. B225 is a single-story concrete tilt-up building with a steel deck roof. The primary mission of this facility is to apply nondestructive evaluation (NDE) methods to materials, components, and assemblies. B225 also contains the polymer additive manufacturing laboratories. The floor plans for B225 are provided in Appendix A.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Void-Engineered Metamaterial Delay Line with Built-In Impedance Matching for Ultrasonic Applications

Metamaterials exhibit unique ultrasonic properties that are not always achievable with traditional materials. However, the structures and geometries needed to achieve such properties are often complex and difficult to obtain using common fabrication techniques. In the present research work, we report a novel metamaterial acoustic delay line with built-in impedance matching that is fabricated using a common 3D printer. Delay lines are commonly used in ultrasonic inspection when signals need to be separated in time for improved sensitivity. However, if the impedance of the delay line is not perfectly matched with those of both the sensor and the target medium, a strong standing wave develops in the delay line, leading to a lower energy transmission. The presented metamaterial delay line was designed to match the acoustic impedance at both the sensor and target medium interfaces. This was achieved by introducing graded engineered voids with different densities at both ends of the delay line. The measured impedances of the designed metamaterial samples show a good match with the theoretical predictions. The experimental test results with concrete samples show that the acoustic energy transmission is increased by 120% and the standing wave in the delay line is reduced by over a factor of 2 compared to a commercial delay line.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A machine learning approach for clinker quality prediction and nonlinear model predictive control design for a rotary cement kiln

Abstract Cement manufacturing is energy‐intensive (5Gj/t) and comprises a significant portion of the energy footprint of concrete systems. Incorporating modern monitoring, simulation and control systems will allow lower energy use, lower environmental impact, and lower costs of this widely used construction material. One of the goals of the CESMII roadmap project on the Smart Manufacturing of Cement included developing an analytical process model for clinker quality that includes the chemistry of the kiln feed and accounts for critical process variables. This predictive model will be used in nonlinear model predictive control system designed to significantly reduce process energy use while maintaining or improving product quality. In the cement manufacturing plant used in this study, the kiln feed (meal) is tested every 12 h and used to estimate the mineral composition of the cement kiln output (clinker) using the stoichiometry‐based Bogue's model and the expertise of the plant operators. During kiln operation, kiln output (clinker) is sampled and tested every 2 h to measure its chemical and mineral composition. The predicted and measured values of the clinker composition are used by the plant operators to adjust the kiln input stream and the production process characteristics to maintain stable operation and uniform product quality. However, the time delay between prediction and testing, along with inaccuracies inherent in the Bogue's model have made any process changes designed to minimize energy use problematic, especially in‐light of potential clinker quality issues that process changes often pose. A new analytical model that integrates quality information and process operation information has been developed from data collected from 2 years of production from an operating cement facility. To make the model fuel‐type‐independent, consumed heat energy was computed in the model instead of fuel type and amount. A Feedforward Network was trained and tailored from collected data. Many data‐based simulations were conducted to quantitatively evaluate the proposed model and the 5‐fold cross‐validation procedure was used to test the models. The resulting predictive model was shown to have a low root mean square error (MSE) with respect to the estimated clinker mineral composition compared to that using the industry standard “Bogue’ model”. The end goal of this work was to develop a single machine learning tool that allows the use of quality control data and process control variables to improve energy efficiency of the process in a continuous fashion. The proposed nonlinear model predictive control system (NMPC) can generate predicted kiln production characteristics based on manipulated variables in manner that accurately follows the target product quality values. Simulation results also show that the proposed model produced accurate predictions of kiln outputs that fell within the required constraints, while manipulating control variables within typical operational ranges.

Ali, Asem M.↗