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Two figures are shown: Pressure dependence of the shear modulus of Ta for two fundamental curves: the 300 K isotherm and the Hugoniot; and, Scaling of the high pressure strength (Y) of Ta with shear modulus (G). The dashed curve represents a hypothetical G which is fit such that the linear scaling approximation matches the data.
Carbon fiber (CF) is central to produce lightweight, high pressure, composite overwrapped pressure vessels (COPVs), which are used for on-board storage of hydrogen for fuel cell vehicles. In 2015, carbon fiber cost accounted for 62% of the cost of a hydrogen storage system, as COPVs were manufactured with T700S CF at $\$ $29.40/kg CF. The high cost of hydrogen storage, largely attributed to the carbon fiber cost, limits the application of fuel cells in vehicles. Therefore, our team endeavored to develop fiber processing to demonstrate carbon fiber tensile properties similar to T700S with a production cost potential of $\$ $12.60/kg or less. Here, the overarching goal of the project was the development of low cost, high strength carbon fiber for composite overwrapped pressure vessels. Within the project, our team investigated a new low-cost, high-volume, high quality polyacrylonitrile (PAN)-based precursor terpolymer for the production of carbon fiber precursors, methods for increasing water and energy use efficiency in wash-water/solvent separation, and ultimately developed a multifilament spinning and conversion process for the production of hollow carbon fibers from a segmented arc spinneret utilizing a solution spinning method.
The Advanced Fuels Campaign is currently focusing on development of accident-tolerant fuels that possess a range of property modifications intended to improve fuel performance during accident and transient conditions as well as extend license limits to burnups beyond 62 MWd/kgU. Both of these drivers have identified understanding and mitigating fuel cracking as a key performance criterion. Small-scale cantilever beam testing has been identified as a plausible method by which to collect fracture data for UO 2 as a function of chemical and structural evolutions introduced either during fabrication or irradiation. While this method has been found to be capable of providing data that are in reasonable agreement with literature for unirradiated UO 2 , the inherently small sample volumes that can be sampled limit its ability to capture the statistical nature of mechanisms that govern the fracture of brittle ceramics. A biaxial flexure strength test was developed to be used for unirradiated UO 2 . This method is standard in the community, but no systems presently in use at national laboratories, universities, or private companies are available to be used for nuclear fuel materials. This report describes the operation and benchmarking of this system, which has been validated for a number of common oxides. Future work will extend this system to characterization of both doped UO 2 and other relevant microstructural modifications that can also be measured using small-scale cantilever beam testing. Comparison of datasets collected using both methods will allow the overall applicability of small-scale techniques to be assessed and provide confidence or bounds on their use for irradiated fuels.
The proposed simple common model for multiphase strength and EoS (CMMP) is meant to be sufficiently simple that each of the collaborating labs can share in a common starting point. Another objective is to start with relatively simple assumptions, which will not necessarily capture details of the physical processes, and incrementally add complexity in order to identify the minimal-needed technical detail. Through this co-evolution of model and experiment, we will better learn the importance of various theoretical approximations and where to invest future resources in experiment and model development. This simple framework is based on pressure and temperature equilibrium of all co-existing phases combined with deviatoric stress averaging through a volume fraction weighted ow stress and a volume fraction weighted shear modulus. Implementations of the framework based on equilibrium phase fractions (i.e. instantaneous kinetic rate) and for finite rate transition kinetics are proposed.
The constitutive model parameters for molybdenum obtained from the Plansee supplier have been constrained via Strength-Stabilized Rayleigh-Taylor experiments performed at the Los Alamos Neutron Science Center. Previous Hopkinson-bar measurements have produced a degenerate family of constitutive model parameters proven in the low strain rate regime. The experiments presented here provide a constraint at strain rates from 10 4 –10 6 s -1 which is used to select a preferred set of parameters for high strain-rate applications. Further analysis is warranted including determining a global fit in parameter space using all available high and low strain-rate data available.
During the first phase of this project, small and large Strangpresse extruders were assessed at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility (MDF). This phase resulted in Strangpresse exclusively licensing some of ORNL’s previously developed extruder technology for high-volume thermoplastic additive manufacturing (AM). Phase II of this project will focus on further development and optimization of Strangpresse extruders for increased efficiency and increased throughput. The objective of this project is to develop a new extruder with a higher output and less energy usage than current AM thermoplastic extruders and to develop and evaluate a new tamper mechanism for increasing Z-strength resulting in an advanced and optimized extruder and tamper system.
This project was a pioneering study of the effect of nanochitin additives on setting time, rheological, and mechanical properties of cementitious materials. Chitin is the second most abundant biopolymer in nature after cellulose and is readily available from byproducts of the growing seafood industry. In this study, chitin powder from shrimp shells was processed into chitin nanocrystals (ChNCs) and chitin nanofibers (ChNFs). Ch-Cs delayed initial and final set times with their high ionic surface charges likely by electrostatic repulsion. The viscosity of fresh cement paste increased with Ch-NFs, while Ch-NCs did not significantly affect rheological properties. The distinct effects of the two nanochitin forms are attributed to the mobility of the different morphologies of the rod-like ChNCs vs. the entangled and restrained network of the ChNFs. Nanochitin forms showed encouraging results by significantly increasing flexural strength by ~40% at the optimum concentration of 0.05 wt% and significant increases in fracture energy. These bio-additives were found promising and future studies should continue to evaluate their use in concrete.
Multi-phase problems have so many more unknowns, we’d like to have a tool to constrain some open questions related to microstructure and twin & dislocation behavior. We want an atomistic scale perspective on aspects of strength. Some multi-scale questions accessible to atomistic study: What lattice-specific behavior influences dislocation production/mobility and/or twinning? Do the phase transformations wipe-out, modify or preserve grain size and orientation? Does plastic strain reset at phase transition? If so under what conditions? Tin is the material chosen for the effort because it is non-hazardous and has multiple accessible solid phases at relatively low pressures.
Three different microstructures of the same steel alloy were investigated to study the influence of microstructure on spall strength and damage. Microstructure influences spall behavior within the explored dynamic regime. Second phase morphology, interphase interface characteristics, and grain boundary character shown to influence spall behavior. Continued understanding of microstructure’s influence on spall and damage needed for targeted material design.
This project has developed and demonstrated two high-volume applications for Coal Combustion Residuals (CCR) with annual usage on the order of billions of pounds. The CCR is encapsulated in a recently developed water-impervious inorganic resin coating to reduce leaching of toxic elements from CCR by more than 80% as a first step. Target commercial applications demonstrated for the encapsulated CCR were as reinforcement for high-strength structural columns composed of CCR embedded in a ceramic matrix and as filler in high-volume plastics such as polypropylene. The encapsulated particles produced columns with properties superior to concrete, and a 30% to 50% improvement in stiffness over current fillers in plastics. CCR from bituminous and lignite coal was evaluated and shown to provide high performance, with the bituminous CCR producing the strongest columns and the lignite-based CCR provided the best performance as coated filler in polypropylene. The two-year project advanced both material systems from a Technology Readiness Level (TRL) of 2 to TRL 4.
Development of high strength, corrosion resistant, aluminum alloys is important to a number of industries, including automotive, aerospace, power, etc. Understanding how processing methods such as casting, chemistry, additives and recycle content affect an alloy’s microstructure and performance in real world environments is crucial to their implementation. One major concern is how the repeated exposure to saline solutions can be detrimental to the structural integrity of aluminum alloy components. This study was undertaken as a collaboration between Eck Industries and PNNL to investigate the stress corrosion cracking (SCC) and corrosion behavior of aluminum alloys. This work examines the SCC response of three different materials set. First is cast A206 Al alloy produced by three different casting techniques (i.e., permanent mold, and sand casting with and without chill) and with or without nano forming additives as potential grain refiners. The second materials set comprises Al alloy tubes extruded by PNNL’s ShAPE process and produced using raw material with three different ratios of twitch and pre-consumer Al 6061 scrap. Finally, the third materials set comprises two Al-Si-Mg-Fe alloys with controlled Si% and Fe% to mimic recycle grade Al alloys. The corrosion behavior of these materials was characterized using SCC testing and scanning electrochemical cell microscopy (SECCM) technique; mechanical behavior was characterized using tensile testing, and microstructure was characterized using optical and electron microscopy techniques. Of the A206 Al alloys, the samples with nano forming additives performed poorly compared to those without. The best SCC performance (i.e. least degradation in mechanical properties) was demonstrated by A206 alloy sand cast with chill while the permanent mold sample showed the worst SCC performance. The SECCM was performed on A206 alloy sand cast with chill to understand the effect of microstructure and determine the location-dependent corrosion properties on grain boundaries (GB) and inside grains (IG) on the sample. The corrosion potential and current measured on GB and IG at various points on the sample established that the GB locations are more cathodic and corrosive than the IG locations. Further work needs to be conducted to investigate the mechanisms behind the observed dependence of SCC on casting technique and nano forming additives. Among the ShAPE extruded tubes, SECCM data suggests the decreasing order of tendency to corrode as follows: 100% twitch > 75% twitch > 50% twitch. Finally, both variants of the Al-Si-Mg-Fe alloys showed a large volume fraction of Fe- and Si-containing intermetallics and additional work is needed to discern differences in their respective corrosion responses. In summary, correlating local electrochemical behavior (e.g. via SECCM) with micro/nanostructure, in conjunction with bulk mechanical behavior, can help identify the right fabrication method and alloy chemistry to minimize SCC issues in Al alloys.
This presentation showcases the Real-Time Phasor Analytics (RTPA) framework for monitoring inertia and assessing system strength in power grids. RTPA is an open-source tool designed to standardize access to data from Power Management Units (PMUs) and Phasor Data Concentrators (PDCs). It facilitates real-time connectivity to multiple PDCs in accordance with the IEEE C37.118-2 standard and supports asynchronous data stream integration. Additionally, RTPA can simulate a PDC server streaming C37.118-2 data and provides Python bindings for seamless interaction with the framework, eliminating the need for direct Rust programming.
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.
The dynamic strength and equation of state of an epoxy (Epon 828 cured with diethanolamine) is characterized through combined experimental and numerical analysis.
The pressure-dependent and initial-density-dependent dynamic strengths of three brittle powders, SiC, B4C, and CaF2, are determined via the Tamped Richtmeyer-Meshkov instability (RMI) method.
We report exciton-polaritons formed from core-only, core-crown, and core-shell NPLs, which, alongside finite-difference time-domain (FDTD) simulations of Fabry-Pérot cavity mode volume, allow for the verification of core-only and determination of core-crown and core-shell oscillator strengths. Additionally, we show that polaritons can be used not only as a means of altering the properties of coupled emitters, but as an analytical tool to better understand the properties of coupled emitters.
A compositional modification has been proposed to validate an alloy design which potentially eliminates the requirement of post-weld heat treatment (PWHT) while preserving the advantage of mechanical properties in a reduced activation bainitic ferritic steel based on Fe-3Cr-3W-0.2V- 0.1Ta-Mn-Si-C, in weight percent, developed at Oak Ridge National Laboratory in 2007. The alloy design includes reducing the hardness in the as-welded condition for improving toughness, while increasing the hardenability for preserving the high-temperature mechanical performance such as creep-rupture resistance in the original steel. To achieve such a design, a composition range with a reduced C content combining with an increased Mn content has been proposed and investigated. Newly proposed “modified” steel successfully achieved an improved impact toughness in the as- welded condition, while the creep-rupture performance across the weldments without PWHT demonstrated ~50% improvement of the creep strength compared to that of the original steel weldment after PWHT. The obtained results strongly support the validity of the proposed alloy design.
The crack tip opening angle (CTOA) is one of fracture toughness parameters that has been used for decades in describing large stable crack growth in thin-walled aerospace structures under the low-constraint conditions. Recently, the pipeline industry has developed a growing interest in using the CTOA parameter to serve as the minimum required fracture toughness to arrest dynamic crack propagation in modern gas transmission pipelines made of high-strength ductile steel. To meet this industrial need, the CTOA test standard ASTM E3039 was therefore developed for measuring the constant critical CTOA. ASTM E3039 recommends a drop weight tearing test (DWTT) specimen with a shallow crack for standard CTOA testing, but its CTOA may depend on the low constraint condition of the DWTT specimen at the crack tip. Verifying the constraint independence of the DWTT-measured CTOA thus becomes indispensable for applying CTOA toughness to the running fracture control in the pipeline design. For this purpose, the present paper evaluates critical CTOA values in a set of fracture toughness tests on single-edge notched bend (SENB) specimens with shallow and deep cracks, based on four CTOA estimation models. Among these, the Ln(P)-LLD linear fit model is similar to that recommended by ASTM E3039 for CTOA calculation. Fracture test data for X80 pipeline steel and HY80 structural steel were considered in the CTOA evaluation. The results showed that the four CTOA models were able to determine a constraint independent CTOA value for stable crack growth in the SENB specimens. As a result, a single, reliable, constant CTOA value could be determined regardless of the specimen geometry or the crack-tip constraint conditions. Therefore, the CTOA measured using ASTM E3039 is constraint-independent and transferable to use in cases of actual cracks propagating in gas transmission pipelines.