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At least 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Coal Enhanced PEEK Filament Production for Additive Manufacturing in Industrial Services

The project (Award DE-FE0032146), led by Baker Hughes in collaboration with the University of Wyoming, aims to develop composite PEEK (Polyether-ether-ketone) materials enhanced using coal-derived graphene-based additives suitable for additive manufacturing (3D printing). Coal char (CC), graphene oxide (GO), and reduced graphene oxide (rGO), derived from Powder River Basin (PRB) coal, were successfully integrated into commercial PEEK feedstock. The composite PEEK materials demonstrated tensile and flexural strengths and modulus, Shore hardness, and thermal properties similar to unfilled PEEK. Dielectric strength of 0.5% GO/PEEK is twice that of unfilled PEEK. However, tensile elongation and Izod impact toughness of the composite materials are lower than unfilled PEEK. The 10% CC/PEEK material also shows good recyclability albeit with slightly increased glass transition and cold crystallization temperatures. Filaments of the composite PEEK materials were fabricated using a Filabot system. 3D printing of the composite PEEK initially encountered feeding stoppage caused by the non-uniform diameter of the filament, which was resolved by reducing the nominal diameter from 1.75 to 1.65 mm. The printability of the composite PEEK filaments is limited in geometry and build time, driven by differences in base PEEK feedstock from the commercial PEEK filament at printing conditions. Prototype part printed using the composite filaments shows inconsistent bead width and bead interruption resulting in porosity. Preliminary process and economic evaluation using PRB coal char estimates the cost of GO to be $0.5/lb. Considering the small fraction expected in the composite PEEK, the GO cost is several orders of magnitude lower than the commercial PEEK filament. It is recommended that the printability of composite PEEK filaments to be improved by optimizing the composite PEEK material at the printing conditions and reducing the variations in filament extrusion. Also important is to identify the mechanisms of how coal-derived additives affect the composite PEEK performance and printing characteristics to allow customized material design and processing for target performance.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2017

Nondestructive Evaluation of Alkali-Silica Reaction in High-Strength Concrete for Aging Structures Sustainability

Concrete is a multiphase geo-material, which is utilized extensively in passive supporting and shielding structures at nuclear facilities. Chemo-mechanical degradation of concrete in old structures is a challenge to sustainability of aging commercial light water reactors. Alkali-silica reaction (ASR) is a common slowly evolving chemo-mechanical damage mechanism of concrete, which could take tens of years to reach the threshold stage when visible cracks appear in a concrete structure. In ASR, concrete constituents react with each other, namely the alkalis in the pore solution of hydrated cement paste (mostly K{sup +}OH{sup -} and Na{sup +}OH{sup -}) react with non-crystalline silica (SiO{sub 2}) of the aggregates to form highly hydrophilic gel. At sufficient levels of ambient relative humidity (typically above 85%), imbibition of water causes expansion of the ASR gel, which results in cracking of constrained reinforced concrete and ultimate structural weakening below safety margin levels. Stability and functional performance of concrete structures potentially suffering from chemo-mechanical deterioration due to ASR is evaluated in a multi-stage process involving material evaluation and structural engineering analysis. Existing methods used by industry for concrete material evaluation are based on extrusion of cores from multiple locations in a structure, and destructive laboratory tests on cores. Because each destructive test requires separate core extrusion, the total number of cores taken from the structure at once could be numbering in hundreds. Laboratory tests include petrography (high resolution optical microscopy of core sections) to develop damage rating index (DRI) score of concrete cores. Another test may involve chemical pore solution extraction from cores, and solution speciation analysis using inductively coupled plasma and mass spectroscopy (ICP/MS). Other tests may consist of mechanical evaluation of cores strength and fracture toughness. The DRI score of concrete material as well as other information obtained from the laboratory tests is subsequently used in structural engineering calculations, where stresses in the entire structure are modeled to evaluate its safety and mechanical stability. Extrusion of a large number of cores is highly undesirable for evaluation of nuclear facility concrete structures. The amount of destructive material testing could be minimized by developing methods for in-situ NDE of ASR to quantify the amount of deterioration that is occurring in the structure, and to identify areas in the structure where more deterioration may be occurring.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The Prediction of Microstructure Evolution of 6005A Aluminum Alloy in a P-ECAP Extrusion Study

Finite element modeling (FEM) was applied for predicting the recrystallized structure in extruded 6005 aluminum alloy, and simulated results were experimentally validated. First, microstructure evolution of 6005 aluminum alloy during deformation was studied by means of isothermal compression test, where the processing parameters were chosen to reproduce the typical industrial conditions. Second, microstructure evolution was analyzed, and the obtained information was used to fit a dynamic recrystallization model implementing inside the DEFORM-3D FEM code environment. FEM of deformation of 6005 aluminum has been established and validated by microstructure comparison. Finally, the obtained dynamic recrystallization model was applied to tube extrusion by using a portholes-equal channel angular pressing die. The finite element analysis results showed that coarse DRX grains occur in the extruded tube at higher temperature and in the extruded tube at the faster speed of the stem. The test results showed material from the front end of the extruded tube has coarse grains (60 μm) and other extruded tube has finer grains (20 μm).

36 MATERIALS SCIENCE↗
DOE OSTI2015

Effect of cooling rate on the properties of high density polyethylene/multi-walled carbon nanotube composites

High density polyethylene (HDPE)/multi-walled carbon nanotube (MWCNT) nanocomposites were prepared by melt mixing using twin-screw extrusion. The extruded pellets were compression moulded at 200°C for 5min followed by cooling at different cooling rates (20°C/min and 300°C/min respectively) to produce sheets for characterization. Scanning electron microscopy (SEM) shows that the MWCNTs are uniformly dispersed in the HDPE. At 4 wt% addition of MWCNTs composite modulus increased by over 110% compared with the unfilled HDPE (regardless of the cooling rate). The yield strength of both unfilled and filled HDPE decreased after rapid cooling by about 10% due to a lower crystallinity and imperfect crystallites. The electrical percolation threshold of composites, irrespective of the cooling rate, is between a MWCNT concentration of 1∼2 wt%. Interestingly, the electrical resistivity of the rapidly cooled composite with 2 wt% MWCNTs is lower than that of the slowly cooled composites with the same MWCNT loading. This may be due to the lower crystallinity and smaller crystallites facilitating the formation of conductive pathways. This result may have significant implications for both process control and the tailoring of electrical conductivity in the manufacture of conductive HDPE/MWCNT nanocomposites.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Path Optimization Along Lattices in Additive Manufacturing Using the Chinese Postman Problem

Here, we develop a method for programming minimal time tool paths for single-bead-wide extrusions in additive manufacturing (AM) along an arbitrary lattice. We present a graphical model of the three-dimensional (3D) printing process and use the solution to the Chinese Postman Problem (CPP) to optimize the motion of an extruder on a given mesh. We present some graph theory background and explain how to solve the CPP. We then present experimental results, in which we demonstrate the implementation of the CPP in 3D printing. Last, we explain how our graphical understanding of AM can be further utilized to achieve greater optimization in additive research.

3D printing↗
DOE OSTI2024

Crafting Multifunctional Materials with Tailored Mechanical and Magnetic Properties by Solid-State Non-equilibrium Processing

Aluminum matrix composites hold promise for creating lightweight structural components with multifunctional properties. Nonetheless, achieving desired magnetic or electrical characteristics without compromising their fundamental mechanical properties presents a significant challenge. Here, in this study, we explore mechanical stir-based extrusion as a solid-state metalworking technique to develop fine-grained microstructures and highly refined metallic composites. Our study focuses on creating a SmCo 5 -reinforced aluminum matrix composite using solid stir extrusion (SSE) and assessing its microstructure, mechanical, and magnetic properties through a comprehensive suite of characterization tools, including x-ray diffraction, electron microscopy, and magnetometry. Our findings reveal that incorporating a small amount (3.76 wt.%) of SmCo 5 phase in a non-heat-treatable, non-magnetic aluminum alloy via SSE yields a composite that exhibits good hard magnetic characteristics with a large coercivity (H ci = 13.5 kOe) and improved mechanical properties. This study underscores non-equilibrium processing via solid-state high-speed stirring as a compelling method for crafting multifunctional materials with tailored mechanical and magnetic properties.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Real-time process monitoring for direct ink write additive manufacturing

Direct ink write (DIW) printing of reactive resins presents a unique challenge due to the time-dependent nature of the rheological and chemical properties of the ink. As a result, careful print optimization or process control is important to obtain consistent, high quality prints. The present invention uses a flow-through characterization cell for in situ chemical monitoring of a resin ink during DIW printing. Additionally, in-line extrusion force monitoring can be combined with off-line post inspection using machine vision. By combining in-line spectroscopy and force monitoring, it is possible to follow reaction kinetics (for example, curing of a reactive resin) and viscosity changes during printing, which can be used for a closed-loop process control. Additionally, the capability of machine vision to automatically identify and quantify print artifacts can be incorporated on the printing line to enable real-time, AI-assisted quality control of the printed products. Together, these techniques can form the building blocks of an optimized process control strategy when complex reactive ink must be used to produce printed hardware.

Cook, Adam W.↗
DOE OSTI2017

Structures and transport dynamics of a Campylobacter jejuni multidrug efflux pump

Resistance-nodulation-cell division efflux pumps are integral membrane proteins that catalyze the export of substrates across cell membranes. Within the hydrophobe-amphiphile efflux subfamily, these resistance-nodulation-cell division proteins largely form trimeric efflux pumps. The drug efflux process has been proposed to entail a synchronized motion between subunits of the trimer to advance the transport cycle, leading to the extrusion of drug molecules. Here we use X-ray crystallography and single-molecule fluorescence resonance energy transfer imaging to elucidate the structures and functional dynamics of the Campylobacter jejuni CmeB multidrug efflux pump. We find that the CmeB trimer displays a very unique conformation. A direct observation of transport dynamics in individual CmeB trimers embedded in membrane vesicles indicates that each CmeB subunit undergoes conformational transitions uncoordinated and independent of each other. On the basis of our findings and analyses, we propose a model for transport mechanism where CmeB protomers function independently within the trimer.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Coal-based Bricks & Blocks (CBBs): Process Development to Prototype Fabrication Coupled with Techno-Economic Analysis and Market Survey

Coal-based bricks and blocks (CBBs) were formulated using anthracite and thermoplastic binder. Lab scale test composites were formed by hot-press molding and commercial extrusion for test articles and for a full-scale prototype. Formulations and test matrices followed a systematic experimental design to examine the effects of and interactions among three primary independent variables: a) thermoplastic type, b) weight fractions of binder relative to the total anthracite weight, and c) relative proportions of large versus small (milled) anthracite size fractions. Technical performance metrics include compressive strength, modulus, porosity/permeability and density. These DoE studies establish composition-property relations and identify the best combination for any desired property of interest – in particular, strength. Based on CBB composition and fabrication process, validated against technical performance metrics, a techno-economic analysis was constructed which incorporated a process flow model, engineering design (with scaling), and calculated capital plus operating costs. Based on measured property metrics and estimated process economics and a projected price by TEA (techno-economic analysis), building and construction target markets were identified by a market survey assessment. With known cost, price, performance metrics and competitive advantages for CBBs matched with commercial applications/uses, a technical gap analysis was performed to identify further development required for scale-up and commercialization.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Structural uniformity and compositional homogeneity of solid-phase alloyed rod

Solid-phase processes have emerged as an alternative to fusion-based alloying to avoid coarse microstructures, undesirable phase formation, and high energy consumption. However, achieving uniform distribution of alloying elements during friction-based processing remains challenging due to highly heterogeneous thermomechanical conditions. This work evaluates the structural uniformity and compositional homogeneity of Al–Cu–Zn alloyed rods produced by friction extrusion (FE) and establishes the role of the rotational speed to feed rate ratio (N/V) on alloying effectiveness. A systematic matrix of FE experiments was conducted at constant extrusion ratio with N/V values ranging from 3.7 to 300. Compositional uniformity was assessed along the rod length (ICP-OES), in three dimensions (X-ray computed tomography), and at the microscale (SEM–EDS), supported by a gray-level co-occurrence matrix (GLCM)–based homogeneity metric. Smoothed particle hydrodynamics (SPH) simulations were used to reveal material flow and thermomechanical fields. Results show that N/V = 100 produces a high-shear mixing zone that eliminates the unmixed core and enables near-full dissolution and dispersion of Cu and Zn. At lower N/V, a laminar flow region persists at the rod center, causing segregation and large composition gradients. The combined experimental–computational analysis provides mechanistic insight into the transition from fragmented particle dispersion to thermomechanically assisted metallurgical mixing. This study establishes processing–structure relationships for solid-phase alloying and provides guidance for achieving homogenized compositions comparable to wrought alloys via rapid, scalable FE processing.

Aluminum↗
DOE OSTI2023

Enabling Recycling of Composites: Understanding the Impacts of Multiple Thermal Processing Cycles

When considering the utilization of recycled short carbon fiber feedstock materials for advanced manufacturing, understanding the material degradation behavior is essential in determining how many times a composite material can be effectively reprocessed and remanufactured. This study characterizes the degradation behavior of short carbon fiber acrylonitrile butadiene (CF-ABS) that has been reprocessed five times with twin screw extrusion. Parallel plate rheology was completed to observe the degradation in complex viscosity of the recycled feedstock materials. Gel permeation chromatography (GPC) was utilized to characterize the changes in molecular weight distribution of the recycled materials as a result of thermal and mechanical degradation during the re-processing steps. Rheological characterization, GPC, and twin-screw processing data help inform the process optimizations required to process the recycled feedstock material. Successful characterization of the degradation behavior of short fiber composite feedstock materials aids in increased understanding of the lifespan of high value carbon fiber composite materials and aids in process optimization of recycled composite materials.

Walker, Roo↗
DOE OSTI2019

Characterization of Covetic Materials for Process Control. Final CRADA report

GDC Industries LLC has been performing process research on covetic materials since its formation in February 2015. With assistance from DOE and the Air Force via SBIR projects, GDC focused on the enhancement of aluminum alloys to covetics to replicate a previously reported electrical conductivity of about 67% IACS (International Annealed Copper Standard). GDC has established a joint development agreement with General Cable Corporation, wherein General Cable agreed to perform numerous extrusions of as cast covetics and subsequent tensile and electrical conductivity tests on the resultant wire. Covetics conversion was proven but the significant improvement is yet to be replicated. To control the experiments towards enhanced process control, a series of designed experiments was created by an expert in process control from the automotive industry. Six process variables were identified and a designed experiment matrix requiring 18 independent conversions was created at GDC. The result of those designed experiments has now allowed GDC to focus on two process variables, namely, residence time and DC current in the conversions with the other four variable held constant. While this work is useful in replicating the earlier enhancements, GDC feels it will not be sufficient for the necessary process knowhow for scale up required by industry as GDC still does not have a direct correlation of the process variables to the actual carbon in the finished covetics. Since 2015, GDC has been aware of the capabilities existing at Argonne National Laboratory for performing carbon analysis that exceeds the precision commonly available to Industry. GDC and ANL submitted a proposal in response to the DOE-EERE – Small Business Vouchers Pliot Program announcement and the proposal was selected for funding. GDC will melt-process covetic aluminum samples following their design of experiment criteria and have the as-casted samples extruded by their partner, General Cable. Argonne will measure the conductivity, analyze carbon content, perform X-ray diffraction, and examine the microstructural features of the samples. Careful process variable measurements will be recorded by each party such that correlations can be developed indicating process parameters that yield the best carbon concentration in covetics.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Thermal Conductivity Measurement of Extrusion-Printed Silver Using Modulated Photothermal Radiometry

Flexible printed electronics is a rapidly growing field with applications in conformal and flexible devices. However, the physical properties of the films created by many state-of-the-art printing methods become highly dependent on printing parameters, resulting in varying thermal properties often differing significantly from their bulk ink components. To understand the influence of the printing process, we build upon our previous work, where a noncontact optical technique, known as modulated photothermal radiometry (MPTR), was used to measure the thermal conductivity of aerosol-jet-printed thin films. In this work, we use the method to study the thermal properties of extrusion-printed silver on glass and alumina substrates. A noise-resistant data analysis fitting technique is applied using a 2-D heat transfer model. Here, the thermal conductivity measurement is validated using the Weidemann-Franz (WF) relationship from measured electrical conductivity values.

42 ENGINEERING↗
DOE OSTI2025

Defect Detection Model Development for Large Scale Thermoplastic Printing

Large-format additive manufacturing (LFAM) offers several advantages, including high throughput, cost-effective pellet-fed extrusion, and the capability to produce large-scale structures. The main pain points of LFAM include start and stops during the printing process, warpage, long layer times that lead to bead freezing, and bead separation due to shrinkage. These issues can lead to overfill, underfill and buildup of material in different sections of a print. This can lead to hidden defects embedded within the printed layers, or even ultimate failure of the printed structure. This ensures these defects can only be identified through nondestructive testing (NDT) inspection methods after printing, which can be timely and costly. Aligned Vision work specializes in 2D projectors with visual inspection systems and machine learning. Traditionally system is used for composite layup and layup inspections. In this work we used the LFAM system at Oak Ridge National Laboratory to create defect rich samples. The Aligned Vision inspection system then performed in-situ monitoring of the print process after each part was printed. This in-situ vision inspection system was used to develop a layer-by-layer inspection model that looks for overfill, underfill, and the buildup of defects using only a camera-based vision system. This leads to the assurance of high-quality production components.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Lansoprazole induces apoptosis of breast cancer cells through inhibition of intracellular proton extrusion

Highlights: • Lansoprazole (LPZ) induces cell apoptosis in breast cancer cells. • LPZ markedly inhibits intracellular proton extrusion. • LPZ induces an increase in intracellular ATP level, lysosomal alkalinization and ROS accumulation. - Abstract: The increased glycolysis and proton secretion in tumors is proposed to contribute to the proliferation and invasion of cancer cells during the process of tumorigenesis and metastasis. Here, treatment of human breast cancer cells with proton pump inhibitor (PPI) lansoprazole (LPZ) induces cell apoptosis in a dose-dependent manner. In the implantation of the MDA-MB-231 xenografts in nude mice, administration of LPZ significantly inhibits tumorigenesis and induces large-scale apopotosis of tumor cells. LPZ markedly inhibits intracellular proton extrusion, induces an increase in intracellular ATP level, lysosomal alkalinization and accumulation of reactive oxygen species (ROS) in breast cancer cells. The ROS scavenger N-acetyl-L-cysteine (NAC) and diphenyleneiodonium (DPI), a specific pharmacological inhibitor of NADPH oxidases (NOX), significantly abolish LPZ-induced ROS accumulation in breast cancer cells. Our results suggested that LPZ may be used as a new therapeutic drug for breast tumor.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2018

Design and Modeling of Vacuum Pumping for Steady-State Pellet Fueling Systems

We report that future long-pulse magnetic confinement fusion reactors will require density and isotopic mixture control using steady-state repeating pellet injectors. For high-energy density burning plasmas, pellet velocities of 1 km/s and above will be required for sufficient plasma penetration to achieve high fueling efficiency. Currently, steady-state repeating injection systems utilize cryogenic extruder systems to produce an extrusion of solid deuterium or deuterium-tritium. In repeating light gas gun injectors, the solid extrusion is cut and simultaneously loaded into a barrel. Once loaded, a fast operating gas valve delivers a high pressure burst of gas to accelerate the pellet down the barrel and into the machine. This process takes ~10 ms to achieve. Adequate gas pumping of the extruder exhaust and injection line propellant gas collection chambers is necessary for optimal operation of the pellet fueling system. Excess solid from the extruder sublimates in an exhaust chamber. The gas pressure in the extruder exhaust chamber must remain low to maintain low heating loads on the cooling mechanism (cryorefrigerators or liquid helium flow) and to reduce thermal conduction to the extrusion. Pumping the injection line chambers is necessary to limit propellant gas flow into the machine. A numerical simulation code was created to predict temporal pumping performance for these repeating pellet injection systems. Lastly, this paper outlines the methods and assumptions used to create this model and compares results to the pellet injection system currently employed on DIII-D, the steady-state pellet injection system planned for the Wendelstein 7-X, and a brief analysis of the ITER conceptual pellet fueling system.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Copper-Tantalum Metal Matrix Composites Consolidated from Powder Blends by Severe Plastic Deformation

We investigated the effectiveness of severe plastic deformation by equal channel angular extrusion (ECAE) for consolidation of metal powders into metal matrix composites. Equal volumes of copper (Cu) and tantalum (Ta) powders were consolidated at ambient temperature via different ECAE routes. Composites processed by ECAE routes 4E and 4Bc were also processed at 300 °C. The resulting materials were characterized by scanning electron microscopy (SEM) and compression testing. Processing by route 4Bc at 300 °C resulted in the highest compressive strength, lowest anisotropy, and least strain rate sensitivity. We conclude that the superior properties achieved by this route arise from mechanical bonding due to interlocking Cu and Ta phases as well as enhanced metallurgical bonds from contact of pristine metal surfaces when the material is sheared along orthogonal planes.

36 MATERIALS SCIENCE↗