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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

A Facile Degumming Method of Kenaf Fibers Using Deep Eutectic Solution

An eco-friendly and effective degumming method needed to be developed for producing kenaf bast fibers. As such, this study devised a novel deep eutectic solvent (DES) method coupled with microwave and alkaline-ultrasonic treatment. The novel method could effectively remove the gummy matters, providing a smooth and clean fiber surface. The properties of the fibers were assessed including chemical compositions, surface structure, crystallinity index (66.68%) and thermal properties. The residual gum content (9.419%), fiber fineness (4.125tex), breaking tenacity (13.650 cn/tex) of the refined dry fibers produced by the novel treatment were comparable with the fibers produced by the traditional two-step alkali boiling method. Besides, the novel method could reduce the usage of chemical, water and time by 48.9%, by 66.7% and 66.8%, respectively. These results revealed that the novel combined DES pretreatment is a practical and feasible pretreatment method for kenaf bast degumming, demonstrating its facile, green energy-saving and fast properties in the degumming process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Spatially Resolved Raman Spectroscopy of Thin Carbon Interphase in SiC Ceramic Matrix Composites

A dedicated analysis method is presented to extract the Raman spectrum of an interphase layer thinner than the laser spot size. We focused on spatial correlations between the contrast of optical micrographs and Raman hyperspectral data to predict the constituents of the mixed spectra measured near the interphase. By employing a mapping step size of 0.1 μm, the Raman spectrum of approximately 0.3-μm-thick carbon interphase in a SiC fiber-reinforced SiC matrix composite was extracted from data acquired with a theoretical spot size of about 0.7 μm. Notably, conventional chemometrics procedures were unable to isolate the interphase signal, instead producing a spectrum representing a mixture of interphase and matrix. This study used another composite with approximately 0.9-μm-thick interphase to validate the analysis method, enabling direct measurement of the interphase spectrum. The proposed Raman analysis method has advantages in specimen volume and turnaround time compared to traditional characterization methods, such as transmission electron microscopy. In conclusion, this study also evaluates the applicability of the analysis method to different composite materials and identifies key requirements of the measurements, including the ratio of interphase thickness to spot size and the homogeneity of the surrounding matrix.

ceramic matrix composite↗
DOE OSTI2020

Analyzing Next-Generation Supply Chains Using the Materials Flows through Industry Tool

The Materials Flows through Industry (MFI) tool is a supply chain modeling tool developed at the National Renewable Energy Laboratory (NREL) with funding from the Department of Energy's Advanced Manufacturing Office. MFI was created to identify and analyze opportunities to reduce the energy and carbon intensities of the U.S. industrial sector (Hanes and Carpenter 2017). In this work, we present an overview of the MFI tool's structure and capabilities, as well as the results of using MFI to analyze a novel NREL-developed process to 'upcycle' PET plastic into higher-value composite materials (Rorrer et al. 2019). This process combines recycled PET (rPET) plastic with inputs that can be derived from biomass, including muconic acid, acrylic acid, and ethylene glycol, to chemically break down the plastic back to its monomers in a process called glycolization. Then, repolymerization and the application of fiberglass yields the valuable glass fiber reinforced plastic (GFRP) composite, a performance material used in the manufacture of wind turbine blades, boat hulls, and other applications. This rPET-derived GFRP was found to have superior strength and fiberglass adhesion compared to conventional GFRP formulations. Our findings indicate that this GFRP production process, were it to be widely commercialized beyond its current lab-scale, could potentially reduce the fossil energy intensity of the GFRP supply chain by between 37% and 58% compared to the conventional method of GFRP manufacture from fossil-derived inputs. We also estimate potential supply chain greenhouse gas (GHG) emissions reductions between 30% and 40% from this process. Scaling these GHG offset estimates up to annual GFRP production in the U.S. would be roughly equivalent to removing between 150,000 and 200,000 vehicles from U.S. roads. These ranges of impact estimates represent the range of differences associated with the various economic allocation methods we have assumed for the intensity contributions from the first life of the PET plastic. Following Shen et al. (2010), we derive economic allocation factors from the current price ratios of clear- and green-colored recycled PET plastic to virgin PET resin ('waste-valuation' approach) or assume them to be zero in a more simplistic allocation ('cutoff' approach). Future work involving the MFI modeling tool will also be discussed, including preliminary results comparing the energy intensity of conventional and bio-based nylons manufacturing. Attendees will also be encouraged to conduct MFI supply chain modeling of their own by requesting a user account on the MFI web application, which is freely available to the public at the following address: https://mfitool.nrel.gov.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Closed‐Loop Recyclable Vitrimer Plastics from PET Waste: A Design for Circularity

Plastics are essential to modern society, but their low recycling rates and inefficient end-of-life management pose a significant environmental challenge. Herein, the efficient strategy for upcycling postconsumer poly(ethylene terephthalate) (PET) waste into robust, closed-loop recyclable vitrimer plastics and composites is presented to address this issue. The catalyst-free aminolysis utilizes readily available amines to deconstruct diverse PET wastes into macromonomers, which are upcycled into vitrimers, exhibiting superior mechanical properties and exceeding the ultimate tensile stress and Young's Modulus of virgin PET by 80% and 150% respectively. These vitrimers exhibit excellent healability, shape memory, thermal reprocessability, and closed-loop chemical recyclability, enabling quantitative macromonomer recovery even from mixed plastic waste streams and glass/carbon fiber reinforced vitrimer (G/CFRV) composites. Furthermore, the vitrimer resin yields robust GFRV and CFRV composites with tensile strengths exceeding those of traditional epoxy composites by 100% and 80%, respectively, while maintaining complete chemical recyclability of both constituent materials. A preliminary technoeconomic analysis confirms the costeffectiveness and competitiveness of the facile PET deconstruction approach, which is potentially adaptable to other condensation polymers. Further, this study presents a facile approach to upcycling plastic waste into circular plastics and composites, offering a sustainable solution to global plastic waste management and fostering a circular economy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Scalable, Infiltration-Free Ceramic Matrix Composite Manufacturing

Manufacturing of ceramic matrix composites (CMCs) with carbon fiber and carbon matrix includes a time- and labor-intensive ceramic infiltration step that is responsible for more than half of the total manufacturing cost. To make CMCs cost-competitive in price-sensitive markets, like concentrated solar power, it is essential to develop a CMC manufacturing process that skips the ceramic infiltration process. In this work, we will show how a high-char-yield preceramic resin can eliminate the infiltration step while maintaining material density and evaluate the technoeconomic impact of our CMC manufacturing process. We monitor both morphology and porosity to determine the quality of CMCs made with different preceramic resins and evaluate the impact of polymer infiltration and pyrolyzing cycles.

matrix composite, polymer infiltration and pyrolys↗
DOE OSTI2024

Simplified, Infiltration-free Ceramic Matrix Composite Manufacturing

Manufacturing of ceramic matrix composites (CMCs) with carbon fiber and carbon matrix includes a time- and labor-intensive ceramic infiltration step that is responsible for more than half of the total manufacturing cost. To make CMCs cost-competitive in price-sensitive markets, like concentrated solar power, it is essential to develop a CMC manufacturing process that skips the ceramic infiltration process. In this work, we will show how a high-char-yield preceramic resin can eliminate the infiltration step while maintaining material density and evaluate the technoeconomic impact of our CMC manufacturing process. Here, we monitor both morphology and porosity to determine the quality of CMCs made with different preceramic resins and evaluate the impact of polymer infiltration and pyrolyzing cycles.

36 MATERIALS SCIENCE↗
DOE OSTI2021

RapidClave® Technology Demonstrations – II Hat Stiffener

This project sought to evaluate the cost and performance of both polymeric and metallic tooling for use with the RapidClave® composite process. Teijin’s rapid cure carbon/epoxy prepreg, Q183, was selected to fabricate demonstration components, of aerospace design, which currently are fabricated via compression molding using matched steel tooling. The ability to fabricate components using this prepreg in the RapidClave®, and using low cost single sided tooling, could significantly reduce the cost of part manufacture and shorten production lead times for tooling fabrication. The component demonstration article was a “hat stiffener” geometry typically used to reinforce fuselage or wing skins of an aircraft. A rapid preforming process was demonstrated and rapid process cycle times similar to compression molding were achieved by placing the preform on hot tooling, thus avoiding the time and energy associated with typical thermal cycling. A 90% reduction in tooling cost was achieved through the use of single sided aluminum or polymeric additive tooling when compared to compression molding matched steel tooling. In addition to rapid cycle times, RapidClave® offers the ability to change out tooling in minutes such that multiple part geometries can be fabricated in one shift.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A reusable neural network pipeline for unidirectional fiber segmentation

Abstract Fiber-reinforced ceramic-matrix composites are advanced, temperature resistant materials with applications in aerospace engineering. Their analysis involves the detection and separation of fibers, embedded in a fiber bed, from an imaged sample. Currently, this is mostly done using semi-supervised techniques. Here, we present an open, automated computational pipeline to detect fibers from a tomographically reconstructed X-ray volume. We apply our pipeline to a non-trivial dataset by Larson et al . To separate the fibers in these samples, we tested four different architectures of convolutional neural networks. When comparing our neural network approach to a semi-supervised one, we obtained Dice and Matthews coefficients reaching up to 98%, showing that these automated approaches can match human-supervised methods, in some cases separating fibers that human-curated algorithms could not find. The software written for this project is open source, released under a permissive license, and can be freely adapted and re-used in other domains.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Mechanisms of stored energy release in silicon carbide materials neutron-irradiated at elevated temperatures

Understanding the stored energy release behavior of SiC is crucial for the design of SiC-based fuel cladding for light water reactors because stored energy release affects response during accident conditions. Differential scanning calorimetry was used to evaluate the stored energy of monolithic SiC and SiC fiber–reinforced SiC matrix composite variants following neutron irradiation under light water reactor–relevant dose and temperature conditions. The tests were performed at heating rates of 0.5, 3, and 20 K/min up to 1,273 K. The onset temperature of the energy release roughly corresponded to the irradiation temperature, and energy release was delayed as the heating rate increased. The monolithic and composite specimens exhibited similar stored energy release behavior up to ~1,000 K, and above that temperature, the energy release depended more on material type. The energy release measured in this study is below the material-specific heat capacity at temperatures below ~1,000 K but exceeds it under certain material and annealing conditions at temperatures above ~1,000 K. The amount of irradiation-induced volumetric swelling of the specimens was an indication of the total stored energy. Based on this observation, the energy release behavior was described by a swelling recovery model.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Assessment of CASL VERA for BWR analysis and application to accident tolerant SiC/SiC channel box

Application of the Virtual Environment for Reactor Applications (VERA) to BWR analysis is assessed in this paper by comparing results to those calculated using other widely-used modeling tools, namely the U.S. Nuclear Regulatory Commission’s PARCS/PATHS and the Serpent Monte Carlo particle transport code. Additionally, VERA is used to calculate 3-D temperature and fast neutron flux distributions in silicon carbide (SiC) fiber-reinforced, SiC matrix composite (SiC/SiC) BWR channel boxes, which are being studied as an Accident Tolerant Fuel core structural material concept. We found that the code-to-code comparisons were favorable, and the SiC/SiC channel box evaluation demonstrates the many advanced modeling features VERA provides while also highlighting the non-uniformity in fast neutron flux distributions that can play a role in potential SiC/SiC channel box deformation. Traditional BWR analysis tools do not have the calculation fidelity necessary for coupled assessment of flux and temperature gradients in a SiC/SiC channel box. VERA is a state-of-the-art modeling environment that was developed to increase the safety and economic competitiveness of nuclear power through improved modeling accuracy. While VERA has already been deployed in the nuclear industry for PWR applications, the current study is a vital initial step in the extensive development, validation, and verification that VERA must go through to be useful for BWR applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Microstructural and nanomechanical studies of PVD Cr coatings on SiC for LWR fuel cladding applications

The microstructure and nanomechanical properties of pure Cr coatings deposited on SiC with various physical vapor deposition (PVD) methods have been investigated for the mitigation of hydrothermal corrosion of SiC-SiC f (SiC fiber-reinforced SiC matrix) composite fuel cladding in light water reactors (LWR). Cr coatings (4–7 μm thick) were deposited on unbiased SiC substrates using six variants of magnetron sputtering processes: (i) standard (S-DCMS), (ii) pulsed (P-DCMS), (iii) ion-assisted (I-DCMS), and (iv) pulsed ion-assisted direct current magnetron sputtering (PI-DCMS), (v) high-power impulse magnetron sputtering (HiPIMS), and (vi) bipolar HiPIMS (B-HiPIMS). Microstructural characterization and nanoindentation testing were used to evaluate effects of deposition technique on coating microstructure and nanomechanical properties. The application of positive reverse pulses to the sputter target induced coarsening of the columnar grain structure, while ion bombardment of substrates during deposition promoted densification of the coating microstructure. Both effects are exemplified in B-HiPIMS deposition, resulting in a high-density microstructure with compressive residual stress. Material pile-up around nano-indents and plastic work during nanoindentation were analyzed to understand deformation behavior of the coatings. Finally, the results suggest the B-HiPIMS process to be among the promising methods for the deposition of Cr coatings on SiC-SiC f for LWR cladding application.

36 MATERIALS SCIENCE↗
DOE OSTI2021

RapidClave® Technology Demonstrations - I

This demonstration sought to show a dramatic reduction in tool cost for RapidClave® tooling, taking advantage of recent modifications made on the RapidClave® system. Instead of building tools with complex internal heating, simple aluminum tools would be produced and heated externally through the recently added hot plate and air blower inside the RapidClave® system. Baselining against this tooling is the legacy RapidClave® tooling, as well as compression tooling, which would be the incumbent processing technique that the RapidClave® is displacing. Both an automotive and aerospace application were used to evaluate the tooling and process. Specifically, a four-piece Volkswagen hood structure was selected as an appropriate automotive geometry, while a wing structure representative of a current wing entering limited production was provided by Cornerstone Research Group for evaluating aerospace applications. In total, six tools were fabricated, and costs were compared against compression tooling quotes of the same tool geometry. A cost savings of over 80% was shown on all the tools. This demonstration also produced parts in the RapidClave® using the abovementioned tools to validate the low-cost tooling and the machine modifications. Solvay recommended two prepreg systems, CYCOM® EP2750 and SolvaLite™ 712, as appropriate for aerospace and automotive applications, respectively. Flat panels of each material were fabricated to verify cure parameters before proceeding with actual part fabrication. On-tool cycle times of approximately 30 minutes was achieved, with modifications identified to lower the time further.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Tunable PA6 Polymer System for Thermoplastic Reinforced Body Panels

Project Goal: Overall, a redesigned polyamide system will combine the ductility and processing of a PA6 matrix, the strength and modulus of CF, and the facile recyclability of esters. Approach: PEA can be synthesized under conventional, industrially relevant pathways. Material properties and processing will be analyzed and compared to commercial PA6 material. Results: Polycondensation, traditional for polyesters, was successful in synthesized a PEA. PEA exhibited fast crystallization and bimodal melting behavior suggesting beneficial crystallization kinetics. PEA exhibit reduced melting temperatures owed to the incorporation of ester units in the polymer structure.

42 ENGINEERING↗
DOE OSTI2021

Tuning Thermal and Mechanical Properties of Polydimethylsiloxane with Carbon Fibers

In order to meet the needs of constantly advancing technologies, fabricating materials with improved properties and predictable behavior has become vital. To that end, we have prepared polydimethylsiloxane (PDMS) polymer samples filled with carbon nanofibers (CFs) at 0, 0.5, 1.0, 2.0, and 4.0 CF loadings (w/w) to investigate and optimize the amount of filler needed for fabrication with improved mechanical properties. Samples were prepared using easy, cost-efficient mechanical mixing to combine the PDMS and CF filler and were then characterized by chemical (FTIR), mechanical (hardness and tension), and physical (swelling, thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and coefficient of thermal expansion) analyses to determine the material properties. We found that hardness and thermal stability increased predictably, while the ultimate strength and toughness both decreased. Repeated tension caused the CF-filled PDMS samples to lose significant toughness with increasing CF loadings. The hardness and thermal degradation temperature with 4 wt.% CF loading in PDMS increased more than 40% and 25 °C, respectively, compared with the pristine PDMS sample. Additionally, dilatometer measurements showed a 20% decrease in the coefficient of thermal expansion (CTE) with a small amount of CF filler in PDMS. In this study, we were able to show the mechanical and thermal properties of PDMS can be tuned with good confidence using CFs.

degradation temperature↗
DOE OSTI2023

MEASURING THERMALLY-INDUCED DISTORTION OF LARGE-SCALE COMPOSITE PRINTED STRUCTURES USING DIGITAL IMAGE CORRELATION

Additive manufacturing (AM) gives designers the ability to create complex part geometries without several of the limitations of traditional manufacturing. Large-Scale AM (LSAM) allows the creation of large composite structures and is a popular area of composite tooling research. Fiber-reinforced polymers are common feedstock for LSAM tooling but introduce anisotropic thermomechanical properties that can lead to the warpage of tools at autoclave conditions. Digital image correlation (DIC) has been used to measure the coefficient of thermal expansion (CTE) of LSAM parts using a novel DIC Oven design. This method was utilized to measure the CTE of LSAM structures printed using different fiber-reinforced materials and multiple geometries. Specifically, glass fiber ABS (GF-ABS) and carbon fiber ABS (CF-ABS) samples were compared as well as cube and plate geometries for each material. The temperature profile over time was also evaluated to determine how rapidly the strain of the sample increased as temperature of the DIC Oven was increased. A thermal model was developed to predict temperature profiles for various samples and identify when the samples had reached thermal equilibrium.

Corum, Tyler↗
DOE OSTI2022

Uncertainty quantification in elastic constants of SiC f /SiC m tubular composites using global sensitivity analysis

Silicon carbide fiber and silicon carbide matrix (SiC f /SiC m ) tubes produced through the chemical vapor infiltration process have become a candidate cladding material in nuclear applications. The performance of this composite is influenced by many variables such as braiding angle, porosity, material properties, etc., which vary over a range of values due to the inherent fluctuations in the manufacturing process. In this study, the variability in elastic constants of SiC f /SiC m composite has been quantified through multiscale finite element (FE) simulations, variable screening, and high-fidelity surrogate modeling. The key variables dominantly affecting the elastic constants of SiC f /SiC m tubes were identified using global sensitivity analysis. A surrogate to the high-fidelity FE-based model was used in Monte Carlo simulations to generate a hundred thousand samples from which the uncertainty in elastic constants was assessed. It turned out that the coefficient of variation was less than 10%.

Materials Science↗