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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Neural Networks to Find the Optimal Forcing for Offsetting the Anthropogenic Climate Change Effects

Abstract Of great relevance to climate engineering is the systematic relationship between the radiative forcing to the climate system and the response of the system, a relationship often represented by the linear response function (LRF) of the system. However, estimating the LRF often becomes an ill-posed inverse problem due to high-dimensionality and nonunique relationships between the forcing and response. Recent advances in machine learning make it possible to address the ill-posed inverse problem through regularization and sparse system fitting. Here, we develop a convolutional neural network (CNN) for regularized inversion. The CNN is trained using the surface temperature responses from a set of Green’s function perturbation experiments as imagery input data together with data sample densification. The resulting CNN model can infer the forcing pattern responsible for the temperature response from out-of-sample forcing scenarios. This promising proof of concept suggests a possible strategy for estimating the optimal forcing to negate certain undesirable effects of climate change. The limited success of this effort underscores the challenges of solving an inverse problem for a climate system with inherent nonlinearity. Significance Statement Predicting the climate response for a given climate forcing is a direct problem, while inferring the forcing for a given desired climate response is often an inverse, ill-posed, problem, posing a new challenge to the climate community. This study makes the first attempt to infer the radiative forcing for a given target pattern of global surface temperature response using a deep learning approach. The resulting deeply trained convolutional neural network inversion model shows promise in capturing the forcing pattern corresponding to a given surface temperature response, with a significant implication on the design of an optimal solar radiation management strategy for curbing global warming. This study also highlights the technical challenges that future research should prioritize in seeking feasible solutions to the inverse climate problem.

Ren, Huiying↗
DOE OSTI2018

A Comparative Life-Cycle Assessment of Briquetting Logging Residues and Lumber Manufacturing Coproducts in Western United States

Abstract. Timber harvest activities in the western United States have resulted in large volumes of low- to no-value logging (forest) residues. Alternatives to pile-and-burning are needed to best utilize this material and to mitigate the resultant environmental impacts. Briquetting (densifying) forest residues near-woods is one such option and is the focus of this study. This study presents a cradle-to-grave life-cycle assessment (LCA) performed to evaluate the overall environmental impacts associated with briquetting post-harvest forest residues and dry sawmill residues (sawdust) in the Pacific Northwest (PNW) region of the United States. Environmental impacts resulting from the two briquette production systems were compared with firewood and propane production, which are common residential heating sources in rural areas of the PNW, on a per 1 MJ of useful energy for domestic heating. In the briquetted post-harvest forest residue system, the feedstock preparation stage had the largest share in global warming (GW) impact, mainly resulting from the drying process (69.5%), followed by transportation. Valorization of post-harvest forest residues, in combination with a briquetter, to produce a bioenergy carrier was revealed to be advantageous in smog, acidification, and eutrophication impact categories, with considerable environmental benefits from avoided pile-and-burn emissions. With all scenarios investigated, briquette production from post-harvest forest residues with high dryer efficiency showed lowest GW impact compared to briquetting sawmill residues and firewood supply chain. For a scenario analysis, LCA showed that using a diesel generator to support the forest residue briquetter operation resulted in 45% higher GW impact compared to use of a wood-gas-powered generator. Keywords: Bioenergy, Biomass densification, Briquette, Forest residues, Life-cycle assessment, Sawdust.

Agriculture↗
DOE OSTI2018

Low-Moisture Switchgrass Bulk-Format Logistics Costs Based on Engineering Data

Abstract. Logistics costs that spanned harvest, transport, storage, preprocessing, and year-round delivery of 371,870 dMg year -1 of milled, low-moisture switchgrass (SG) to a local biorefinery were determined for bulk-format versus round-bale systems. Separate spreadsheet analyses were conducted for three diesel fuel prices ($0.53 L -1 , $0.92 L -1 , and $1.32 L -1 ) because of the wide range of fuel prices during the project. A detailed analysis scenario identified a common harvest period, equipment annual use, other equipment uses, and protected SG storage on gravel pad, along with equipment performances based on previously published tests primarily for commercially available equipment. The bulk-format system used a depot equipped with stacker/reclaimer technology for storage, whereas the round-bale system used field-side bale stacks for storage, with both systems assuming 6% losses, primarily attributed to storage. Results indicated total costs for bulk-format versus round-bale systems of $54.63 per dry Mg (dMg -1 ), $60.41 dMg -1 , and $66.21 dMg -1 versus $54.59 dMg -1 , $62.10 dMg -1 , and $67.93 dMg -1 corresponding with diesel fuel costs of $0.53 L -1 , $0.92 L -1 , and $1.32 L -1 , respectively. The most significant bulk-format system total cost of $22.79 dMg -1 was associated with a stacker/reclaimer, conveyance, and dust collection at the depot, which was 42% of total costs at a diesel fuel cost of $0.53 L -1 . For the round-bale system, bale chopping total costs was highest and represented an average of 27% of total costs, with costs ranging from $14.63 dMg -1 to $19.08 dMg -1 for diesel fuel input costs ranging from $0.53 L -1 to $1.32 L -1 , respectively. For comparison, the forage harvester provided harvesting and chopping in the bulk-format system at total costs ranging from $6.47 dMg -1 to $8.80 dMg -1 across the same range of diesel fuel input cost. The forage harvester provided an economic advantage in size reduction compared to tub grinding. Truck hauling for both the bulk-format and round-bale systems represented significant expenses at all selected fuel costs. In addition, the multiple times that round bales were handled represented accumulating costs that were sensitive to diesel fuel costs. Keywords: Bales, Bioenergy, Bulk format, Densification, Field chop, Logistics, Transportation.

Agriculture↗
DOE OSTI2020

Techno-Economic Impact of Diesel Fuel, Labor, and Interest Rates on Bulk-Format and Round Bale Logistics Expenses for Switchgrass

Highlights System-wide sensitivity of bulk-format and round bale logistics responded to different degrees of expense inputs. Biomass size-reduction expenses for bulk-format were consistently less than round-bale chopping. Stack/reclaim operations with high-density-capacity equipment for bulk-format were the highest expenses. Clean-sheet design of stacker/reclaimer and self-compacting bulk trailer may significantly reduce expenses. Abstract . Deterministic cost analyses were conducted for a harvest, storage, preprocessing, and supply system providing 371,870 dry Mg (dMg) year-1 of milled switchgrass (SG) to a biorefinery from 21,929 ha of production fields within 72 km of the biorefinery. Varied input costs of diesel fuel, labor, and interest rate were input into a highly detailed cost analysis for bulk-format and baseline round bale logistics. These operational input factors, potentially reflecting an evolving economic climate or paradigm shift, were examined to provide insight into the cost to deliver preprocessed biomass feedstock for centralized commercial-scale conversions. Total annual costs per dry unit of SG were determined for all combinations of diesel fuel prices of $0.53 L-1, $0.92 L-1, and $1.32 L-1; total labor costs of $20.00 h-1, $28.85 h-1, and $40.00 h-1 singly and uniformly applied across all labor inputs; and three representative interest rates of 6%, 8%, and 12%. Increases in total cost most depended on increases in diesel fuel cost, followed by labor rate, and finally interest rate. Increases in fuel costs from $0.53 L-1 to $1.32 L-1 yielded a total cost increase of about $11.56 dMg-1 and $13.36 dMg-1 for bulk-format and round bale logistics, respectively, for all combinations of labor and interest rates. The overall increase in labor rate ($20.00 h-1 to $40.85 h-1) resulted in increased total costs of about $10.32 dMg-1 for bulk-format logistics and $9.94 dMg-1 for round bale logistics for all fuel and interest rates. The overall increase in interest rate (6% to 12%) resulted in increased total costs of about $6.72 dMg-1 for bulk-format logistics and $4.21 dMg-1 for round bale logistics for all fuel and labor rates. Increases in total costs for combined increases in fuel cost, labor rate, and interest rate were $28.60 dMg-1 and $27.48 dMg-1, yielding maximum total costs of $87.87 dMg-1 and $86.53 dMg-1 for bulk-format and round bale logistics, respectively. Costs were determined for existing equipment systems, including novel use of waste compaction and ejector semi-trailers. The highest potential for cost reductions may require clean-sheet equipment designs specifically tailored for SG, such as forage harvesters that direct-cut standing SG, mobilized stacker-reclaimer technology to not inhibit stack-area footprint, self-compacting ejector trailer technology, and bale grinding technology incorporating controlled mass feeding and shear failure elements. Keywords: Bales, Bioenergy, Bulk-format, Densification, Field chop, Logistics, Transportation

Agriculture↗
DOE OSTI2023

Laboratory Experiments Examining the Effect of Thermal and Mechanical Processes on Hydraulic Transmissivity Evolution

Using laboratory slide-hold-slide experiments, at temperatures from 22 to 200 degrees C, to examine effects of fracture reactivation and quasi-static loading on the evolution of fluid transport properties of simulated fractures in Westerly granite. At all temperatures, the in-plane hydraulic transmissivity consistently decays during hold periods resulting in an overall reduction in transmissivity. During the first three to fifteen hours of an experiment, transmissivity decreases rapidly due to the generation of wear products, development of a sliding surface, and compaction of the resulting gouge. Once the sliding surface has developed, the long-term transmissivity decay rate at 22 and 100 degrees C is significantly lower than the transmissivity decay rate during the initial 3-15 hours of the experiment. However, at 200 degrees C, the decay of hydraulic transmissivity remains high throughout the experiment. The long-term decay of hydraulic transmissivity can be fitted with a power law model with more rapid reduction of hydraulic transmissivity at higher temperature. Periods of sliding on the fracture surface result in transient increases in the transmissivity, due to shear dilation, as is expected for Coulomb materials. These transients are superimposed on the long-term decay. When sliding ceases and a new hold period commences, there is a rapid reduction in transmissivity and return to the long-term rate of transmissivity decay. The rate of decay of the transmissivity transients is inversely correlated with temperature, in contrast to the long-term decay and the expected behavior for processes like subcritical crack growth and indentation creep. The higher decay rates that are observed during the initial 3-15 hours of the tests and following sliding, are associated with times that the porosity of the gouge is expected to be high. The difference in decay rates suggests that when the gouge is driven far from equilibrium by active shearing, densification may be dominated by a different mechanism from long-term compaction.

15 GEOTHERMAL ENERGY↗
DOE OSTI2019

Accurately estimating and minimizing costs for the cellulosic biomass supply chain with statistical process control and the Taguchi Loss Function

This research focuses on the statistical evaluation of the feedstock attributes of the biomass supply chain and the estimation of attribute costs as a function of the feedstock variability. Challenges of using cellulosic feedstocks include the variability of feedstock quality (e.g., ash content and moisture content), which impacts the final cost of the manufactured product. Statistical Process Control (SPC), Taguchi Loss Function, and components of variance techniques were illustrated for quantifying cumulative variance in the biomass supply chain. Costs in the presence of cumulative variance were estimated for switchgrass (Panicum virgatum L.) and loblolly pine residues (Pinus taeda L.). Findings of the study indicated that additional costs from ash content variability in switchgrass increased the net cost by $\$19.15$ per dry tonne. Additional costs from densification due to particle size variation increased net cost by $\$11.59$ per dry tonne. Moisture content variation increased costs by $\$14.86$ per dry tonne. This would represent a 50 to 100% increase in costs due to variation based on a $\$60$ to $\$70$ per dry tonne manufactured product cost. This study illustrates that total costs may be considerably underestimated if the influence of variance for key factors in the supply chain and associated costs are not estimated.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Nanomechanical mapping and strain rate sensitivity of microcrystalline cellulose

Nanoindentation provides a convenient and high-throughput means for mapping mechanical properties and for measuring the strain rate sensitivity of a material. Here, nanoindentation was applied to the study of microcrystalline cellulose. Here, constant strain rate nanoindentation revealed a depth dependence of nanohardness and modulus, mostly attributed to material densification. Nanomechanical maps of storage modulus and hardness resolved the shape and size of voids present in larger particles. In smaller, denser particles, however, where storage modulus varied little spatially, there was still some spatial dependence of hardness, which can be explained by cellulose’s structural anisotropy. Additionally, hardness changed with the indentation strain rate in strain rate jump tests. The resulting strain rate sensitivity values were found to be in agreement with those obtained by other techniques in the literature.

36 MATERIALS SCIENCE↗
DOE OSTI2022

In situ ion irradiation of amorphous TiO 2 nanotubes

Understanding of structural and morphological evolution in nanomaterials is critical in tailoring their functionality for applications such as energy conversion and storage. Here, we examine irradiation effects on the morphology and structure of amorphous TiO 2 nanotubes in comparison with their crystalline counterpart, anatase TiO 2 nanotubes, using high-resolution transmission electron microscopy (TEM), in situ ion irradiation TEM, and molecular dynamics (MD) simulations. Anatase TiO 2 nanotubes exhibit morphological and structural stability under irradiation due to their high concentration of grain boundaries and surfaces as defect sinks. On the other hand, amorphous TiO 2 nanotubes undergo irradiation-induced crystallization, with some tubes remaining only partially crystallized. The partially crystalline tubes bend due to internal stresses associated with densification during crystallization as suggested by MD calculations. Furthermore, these results present a novel irradiation-based pathway for potentially tuning structure and morphology of energy storage materials.

36 MATERIALS SCIENCE↗
DOE OSTI2019

The Oklahoma Geological Survey Statewide Seismic Network

The Oklahoma Geological Survey (OGS) monitors seismicity throughout the state of Oklahoma utilizing permanent and temporary seismometers installed by OGS and other agencies, while producing a real–time earthquake catalog. The OGS seismic network was recently added to the Advanced National Seismic System (ANSS) as a self–supporting regional seismic network, and earthquake locations and magnitudes are automatically reported through U.S. Geological Survey and are part of the ANSS Comprehensive Earthquake Catalog. In Oklahoma, before 2009, background seismicity rates were about 2 M 3.0+ earthquakes per year, which increased to 579 and 903 M 3.0+ earthquakes in 2014 and 2015, respectively. After seismicity peaked, the rate fell to 624, 304, and 194 M 3.0+ earthquakes in 2016, 2017, and 2018, respectively. The catalog is complete down to M 2.2 from mid–2014 to present, despite the significant workload for a primarily state–funded regional network. That astonishing uptick in seismicity has been largely attributed to wastewater injection practices. The OGS provides the Oklahoma Corporation Commission, the agency responsible for regulating oil and gas activities within the state, with technical guidance and earthquake products that inform their “traffic–light” mitigation protocol and other mitigating actions. We have initiated a citizen–scientist–driven, educational seismometer program by installing Raspberry Shake geophones throughout the state at local schools, museums, libraries, and state parks. The seismic hazard of the state portends a continued need for expansion and densification of seismic monitoring throughout Oklahoma.

58 GEOSCIENCES↗
DOE OSTI2011

Assessment of Initial Test Conditions for Experiments to Assess Irradiation Assisted Stress Corrosion Cracking Mechanisms

Irradiation-assisted stress corrosion cracking is a key materials degradation issue in today s nuclear power reactor fleet and affects critical structural components within the reactor core. The effects of increased exposure to irradiation, stress, and/or coolant can substantially increase susceptibility to stress-corrosion cracking of austenitic steels in high-temperature water environments. . Despite 30 years of experience, the underlying mechanisms of IASCC are unknown. Extended service conditions will increase the exposure to irradiation, stress, and corrosive environment for all core internal components. The objective of this effort within the Light Water Reactor Sustainability program is to evaluate the response and mechanisms of IASCC in austenitic stainless steels with single variable experiments. A series of high-value irradiated specimens has been acquired from the past international research programs, providing a valuable opportunity to examine the mechanisms of IASCC. This batch of irradiated specimens has been received and inventoried. In addition, visual examination and sample cleaning has been completed. Microhardness testing has been performed on these specimens. All samples show evidence of hardening, as expected, although the degree of hardening has saturated and no trend with dose is observed. Further, the change in hardening can be converted to changes in mechanical properties. The calculated yield stress is consistent with previous data from light water reactor conditions. In addition, some evidence of changes in deformation mode was identified via examination of the microhardness indents. This analysis may provide further insights into the deformation mode under larger scale tests. Finally, swelling analysis was performed using immersion density methods. Most alloys showed some evidence of swelling, consistent with the expected trends for this class of alloy. The Hf-doped alloy showed densification rather than swelling. This observation may be related to the formation of second-phases under irradiation, although further examination is required

36 MATERIALS SCIENCE↗
DOE OSTI2011

HFC Concrete: A Low-­Energy, Carbon-Dioxide­-Negative Solution for reducing Industrial Greenhouse Gas Emissions (Final Technical Report)

Solidia/CCSM received funding for further research and development of its Low Temperature Solidification Process (LTS), which is used to create hydrate-free concrete (HFC). LTS/HFC is a technology/materials platform that offers wide applicability in the built infrastructure. Most importantly, it provides a means of making concrete without Portland cement. Cement and concrete production is a major consumer of energy and source of industrial greenhouse gas (GHG) emissions. The primary goal of this project was to develop and commercialize a novel material, HFC, which by replacing traditional concrete and cement, reduces both energy use and GHG emissions in the built infrastructure. Traditional concrete uses Portland Cement (PC) as a binder. PC production involves calcination of limestone at ~1450°C, which releases significant amounts of CO 2 gas to the atmosphere and consumes a large amount of energy due to the high temperature required. In contrast, HFC is a carbonate-based hydrate-free concrete (HFC) that consumes CO 2 gas in its production. HFC is made by reaction of silicate minerals with CO 2 at temperatures below 100°C, more than an order-of-magnitude below the temperature required to make PC. Because of this significant difference in temperature, it is estimated that we will be able to reduce energy use in the cement and concrete industry by up to 30 trillion Btu by 2020. Because of the insulating properties of HFC, we believe we will also be able to significantly reduce energy use in the Building sector, though the extent of this saving is not yet quantified. It is estimated that production of a tonne of PC-based concrete requires about 6.2 million Btu of energy and produces over 1 tonne of CO 2 emissions (Choate, 2003). These can be reduced to 1.9 million Btu and 0.025 tonnes of CO 2 emissions per tonne of HFC (with overall CO 2 -negativity possible by increasing carbonation yield). In this way, by replacing PC-based concrete with HFC in infrastructure we can reduce energy use in concrete production by 70%, and reduce CO 2 emissions by 98%; thus the potential to reduce the impact of building materials on global warming and climate change is highly significant. Low Temperature Solidification (LTS) is a breakthrough technology that enables the densification of inorganic materials via a hydrothermal process. The resulting product exhibits excellent control of chemistry and microstructure, to provide durability and mechanical performance that exceeds that of concrete or natural stone. The technology can be used in a wide range of applications including facade panels, interior tiles, roof tiles, countertops, and pre-cast concrete. Replacing traditional building materials and concrete in these applications will result in significant reduction in both energy consumption and CO 2 emissions.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2012

Ceramographic Examinations of Irradiated AGR-1 Fuel Compacts

The AGR 1 experiment involved irradiating 72 cylindrical fuel compacts containing tri-structural isotropic (TRISO)-coated particles to a peak burnup of 19.5% fissions per initial metal atom with no in-pile failures observed out of almost 300,000 particles. Five irradiated AGR 1 fuel compacts were selected for microscopy that span a range of irradiation conditions (temperature, burnup, and fast fluence). These five compacts also included all four TRISO coating variations irradiated in the AGR experiment. The five compacts were cross-sectioned both transversely and longitudinally, mounted, ground, and polished after development of careful techniques for preserving particle structures against preparation damage. Approximately 40 to 80 particles within each cross section were exposed near enough to mid-plane for optical microscopy of kernel, buffer, and coating behavior. The microstructural analysis focused on kernel swelling and porosity, buffer densification and fracture, debonding between the buffer and inner pyrolytic carbon (IPyC) layers, and fractures in the IPyC and SiC layers. Three basic particle morphologies were established according to the extent of bonding between the buffer and IPyC layers: complete debonding along the interface (Type A), no debonding along the interface (Type B), and partial debonding (Type AB). These basic morphologies were subdivided according to whether the buffer stayed intact or fractured. The resulting six characteristic morphologies were used to classify particles within each cross section, but no spatial patterns were clearly observed in any of the cross-sectional morphology maps. Although positions of particle types appeared random within compacts, examining a total of 830 classified particles allowed other relationships among morphological types to be established.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2012

Plasma-based Accelerator with Magnetic Compression

Electron dephasing is a major gain-inhibiting effect in plasma-based accelerators. A novel method is proposed to overcome dephasing, in which the modulation of a modest (~$\mathcal{O}$(10 kG)), axial, uniform magnetic field in the acceleration channel leads to densification of the plasma through magnetic compression, enabling direct, time-resolved control of the plasma wave properties. The methodology is broadly applicable and can be optimized to improve the leading acceleration approaches, including plasma beat-wave, plasma wakefield, and laser wakefield acceleration. The advantages of magnetic compression compared to other proposed schemes to overcome dephasing are identified.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2013

High Pressure Response of Siliceous Materials

Several siliceous (i.e., materials containing, resembling, relating to or consisting of silica or silicon dioxide) materials were examined in this study conducted by Oak Ridge National Laboratory and sponsored by the US Army TARDEC. Some were glasses (fused silica or fused quartz, Starphire soda lime silicate glass, hydrated Starphire, BOROFLOAT borosilicate glass, an iron-containing soda lime silicate glass, opal (a hydrated silicate glass), ROBAX glass ceramic, and others were single crystal (α-quartz) and polycrystalline (Coesite - a high pressure phase of crystalline quartz) ceramics. Some of these materials are presently used in transparent armor systems or are under consideration for such. The testing of these materials allowed for comparisons of glass types, glass versus glass ceramics, effect of water content, and comparison of amorphous versus crystalline materials of the same composition. The responses of these materials to high pressure loading were studied using spherical indentation testing, diamond anvil cell testing, and laser shock testing. So besides the focus of this study being on the siliceous materials, as much emphasis was placed on the efficacy of these three test methods to exploit high pressure responses. Each test is different and enables the study of different aspects of high pressure response as highlighted below. 1. Spherical indentation, when using small indenter diameters, produces both high pressure and shear, and the loading and unloading histories enabled quantification of apparent yield stress and semi-quantification of energy absorption capability (hysteresis) of the various siliceous materials. 2. Diamond anvil cell testing produces a hydrostatic stress, and when concurrently used with Raman Spectroscopy, enabled the potential identification of changes of state of material as a function of quantified pressure for the various siliceous materials. Permanent densification was also detectable. 3. Laser shock testing produces high pressures but under dynamic conditions (impact event less than 30 ns), so this enabled the study of the effect of rate on high pressure. A previously unobserved damage mechanism was revealed with this testing, and the ease or difficulty of laser-shock-induced damage initiation was deemed to be relatable to the native surface flaw population that exists on these materials.

Wereszczak, Andrew A.↗
DOE OSTI2012

Ceramographic Examinations of Irradiated AGR-1 Fuel Compacts

The AGR-1 experiment involved irradiating 72 cylindrical fuel compacts containing tri-structural isotropic (TRISO)-coated particles to a peak burnup of 19.5% fissions per initial metal atom with no in-pile failures observed out of almost 300,000 particles. Six irradiated AGR 1 fuel compacts were selected for microscopy that span a range of irradiation conditions (temperature, burnup, and fast fluence). These six compacts also included all four TRISO coating variations irradiated in the AGR experiment. The six compacts were cross-sectioned both transversely and longitudinally, mounted, ground, and polished after development of careful techniques for preserving particle structures against preparation damage. From 36 to 79 particles within each cross section were exposed near enough to midplane for optical microscopy of kernel, buffer, and coating behavior. The microstructural analysis focused on kernel swelling and porosity, buffer densification and fracture, debonding between the buffer and inner pyrolytic carbon (IPyC) layers, and fractures in the IPyC and SiC layers. Three basic particle morphologies were established according to the extent of bonding between the buffer and IPyC layers: complete debonding along the interface (Type A), no debonding along the interface (Type B), and partial debonding (Type AB). These basic morphologies were subdivided according to whether the buffer stayed intact or fractured. The resulting six characteristic morphologies were used to classify particles within each cross section, but no spatial patterns were clearly observed in any of the cross-sectional morphology maps. Although positions of particle types appeared random within compacts, examining a total of 931 classified particles allowed other relationships among morphological types to be established.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2011

Fabrication of metal matrix composite by semi-solid powder processing

Various metal matrix composites (MMCs) are widely used in the automotive, aerospace and electrical industries due to their capability and flexibility in improving the mechanical, thermal and electrical properties of a component. However, current manufacturing technologies may suffer from insufficient process stability and reliability and inadequate economic efficiency and may not be able to satisfy the increasing demands placed on MMCs. Semi-solid powder processing (SPP), a technology that combines traditional powder metallurgy and semi-solid forming methods, has potential to produce MMCs with low cost and high efficiency. In this work, the analytical study and experimental investigation of SPP on the fabrication of MMCs were explored. An analytical model was developed to understand the deformation mechanism of the powder compact in the semi-solid state. The densification behavior of the Al6061 and SiC powder mixtures was investigated with different liquid fractions and SiC volume fractions. The limits of SPP were analyzed in terms of reinforcement phase loading and its impact on the composite microstructure. To explore adoption of new materials, carbon nanotube (CNT) was investigated as a reinforcing material in aluminum matrix using SPP. The process was successfully modeled for the mono-phase powder (Al6061) compaction and the density and density distribution were predicted. The deformation mechanism at low and high liquid fractions was discussed. In addition, the compaction behavior of the ceramic-metal powder mixture was understood, and the SiC loading limit was identified by parametric study. For the fabrication of CNT reinforced Al6061 composite, the mechanical alloying of Al6061-CNT powders was first investigated. A mathematical model was developed to predict the CNT length change during the mechanical alloying process. The effects of mechanical alloying time and processing temperature during SPP were studied on the mechanical, microstructural and compositional properties of the Al6061-CNT composites. A shear lag model was applied to predict the mechanical property (hardness) of the composite. This work demonstrated the promising potential of SPP in the fabrication of particle/fiber (nanotube) reinforced MMCs.

36 MATERIALS SCIENCE↗
DOE OSTI2012

First-Principles Flocculation as the Key to Low Energy Algal Biofuels Processing

This document summarizes a three year Laboratory Directed Research and Development (LDRD) program effort to improve our understanding of algal flocculation with a key to overcoming harvesting as a techno-economic barrier to algal biofuels. Flocculation is limited by the concentrations of deprotonated functional groups on the algal cell surface. Favorable charged groups on the surfaces of precipitates that form in solution and the interaction of both with ions in the water can favor flocculation. Measurements of algae cell-surface functional groups are reported and related to the quantity of flocculant required. Deprotonation of surface groups and complexation of surface groups with ions from the growth media are predicted in the context of PHREEQC. The understanding of surface chemistry is linked to boundaries of effective flocculation. We show that the phase-space of effective flocculation can be expanded by more frequent alga-alga or floc-floc collisions. The collision frequency is dependent on the floc structure, described in the fractal sense. The fractal floc structure is shown to depend on the rate of shear mixing. We present both experimental measurements of the floc structure variation and simulations using LAMMPS (Large-scale Atomic/Molecular Massively Parallel Simulator). Both show a densification of the flocs with increasing shear. The LAMMPS results show a combined change in the fractal dimension and a change in the coordination number leading to stronger flocs.

Hewson, John C.↗
DOE OSTI2013

Crystalline Ceramic Waste Forms: Comparison Of Reference Process For Ceramic Waste Form Fabrication

The research conducted in this work package is aimed at taking advantage of the long term thermodynamic stability of crystalline ceramics to create more durable waste forms (as compared to high level waste glass) in order to reduce the reliance on engineered and natural barrier systems. Durable ceramic waste forms that incorporate a wide range of radionuclides have the potential to broaden the available disposal options and to lower the storage and disposal costs associated with advanced fuel cycles. Assemblages of several titanate phases have been successfully demonstrated to incorporate radioactive waste elements, and the multiphase nature of these materials allows them to accommodate variation in the waste composition. Recent work has shown that they can be produced from a melting and crystallization process. The objective of this report is to explore the phase formation and microstructural differences between lab scale melt processing in varying gas environments with alternative densification processes such as Hot Pressing (HP) and Spark Plasma Sintering (SPS). The waste stream used as the basis for the development and testing is a simulant derived from a combination of the projected Cs/Sr separated stream, the Trivalent Actinide - Lanthanide Separation by Phosphorous reagent Extraction from Aqueous Komplexes (TALSPEAK) waste stream consisting of lanthanide fission products, the transition metal fission product waste stream resulting from the transuranic extraction (TRUEX) process, and a high molybdenum concentration with relatively low noble metal concentrations. Melt processing as well as solid state sintering routes SPS and HP demonstrated the formation of the targeted phases; however differences in microstructure and elemental partitioning were observed. In SPS and HP samples, hollandite, pervoskite/pyrochlore, zirconolite, metallic alloy and TiO 2 and Al 2 O 3 were observed distributed in a network of fine grains with small residual pores. The titanate phases that incorporate M +3 rare earth elements were observed to be distinct phases (ex. Nd 2 Ti 2 O 7 with less degree of substitution as compared to the more homogeneous melt processed samples where a high degree of substitution and variation of composition within grains was observed. Liquid phase sintering was enhanced in reducing gas environments and resulted in large (10-200 microns) irregular shaped grains along with large voids associated with the melt process; SPS and HP samples exhibited finer grain size with smaller voids. Metallic alloys were observed in the bulk of the sample for SPS and HP samples, but were found at the bottom of the crucible in melt processed trials. These results indicate that for a first melter trial, the targeted phases can be formed in air by utilizing Ti/TiO 2 additives which aid phase formation and improve the electrical conductivity. Ultimately, a melter run in reducing gas environments would be beneficial to study differences in phase formation and elemental partitioning.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗