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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 667 records · Page 37
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

High-Resolution Regional Atmosphere–Ocean–Wave Coupled Simulations of Hurricane Henri (2021)

To explore the integrated effects of ocean and ocean surface wave related physical processes on TC simulations, a set of three model simulations is performed. * In experiment 'A', the event is modeled using the Weather Research Forecasting (WRF) model alone with prescribed Sea Surface Temperature (SST) at 6-hour intervals. * In experiment ‘AO,’ WRF is coupled with the Finite Volume Community Ocean Model (FVCOM), enabling variable exchange between atmosphere and ocean, but without considering ocean surface wave-related physical processes. * In experiment ‘AOW’, WRF, FVCOM, and Simulating WAves Nearshore (SWAN) exchange variables with each other every hour through the OASIS3-MCT Coupler to allow direct and indirect atmosphere-ocean-wave interactions. * Observational data are also included in this dataset (Dropsonde, HRD-Radar, NDBC_wave). All simulations are initialized at 18:00 UTC on August 19, 2021, within a domain encompassing the western North Atlantic Ocean. The atmospheric domain features a horizontal resolution of 3 km. The ocean domain, which covers a substantial portion of the WRF ocean domain, employs an unstructured triangular grid with resolutions ranging from 3 km near the coast to 9 km in the open ocean, effectively resolving the complex coastline of the U.S. Northeast Coast. Initial and boundary conditions for the atmosphere model are obtained from the 6-hourly 0.25° NCEP (National Centers for Environmental Prediction) Global Forecast System (GFS; NCEP, 2015) data.

17 WIND ENERGY↗
DOE OSTI2026

High-Resolution Regional Atmosphere–Ocean–Wave Coupled Simulations of Hurricane Henri (2021)

To explore the integrated effects of ocean and ocean surface wave related physical processes on tropical cyclone simulations, a set of three model simulations is performed. * In experiment 'A', the event is modeled using the Weather Research Forecasting (WRF) model alone with prescribed Sea Surface Temperature (SST) at 6-hour intervals. * In experiment ‘AO,’ WRF is coupled with the Finite Volume Community Ocean Model (FVCOM), enabling variable exchange between atmosphere and ocean, but without considering ocean surface wave-related physical processes. * In experiment ‘AOW’, WRF, FVCOM, and Simulating WAves Nearshore (SWAN) exchange variables with each other every hour through the OASIS3-MCT Coupler to allow direct and indirect atmosphere-ocean-wave interactions. * Observational data are also included in this dataset (Dropsonde, HRD-Radar, NDBC_wave). All simulations are initialized at 18:00 UTC on August 19, 2021, within a domain encompassing the western North Atlantic Ocean. The atmospheric domain features a horizontal resolution of 3 km. The ocean domain, which covers a substantial portion of the WRF ocean domain, employs an unstructured triangular grid with resolutions ranging from 3 km near the coast to 9 km in the open ocean, effectively resolving the complex coastline of the U.S. Northeast Coast. Initial and boundary conditions for the atmosphere model are obtained from the 6-hourly 0.25° NCEP (National Centers for Environmental Prediction) Global Forecast System (GFS; NCEP, 2015) data. These CSV files are derived from the NetCDF files in the c0 dataset. Unlike the original format, where geographic coordinates were stored in a separate file, each CSV now embeds the corresponding latitude and longitude values alongside the measured or simulated variables.

17 WIND ENERGY↗
DOE OSTI2025

Modeling Electrodeposition in 3D Porous Architectures for Solid-State Li-Metal Batteries

Li-metal storage in three-dimensional (3D) electrodes is considered a potential dendrite-mitigation strategy. The large surface area and high porosity of these electrodes result in reduced local Li-plating current densities. The porous topology provides a scaffold for Li-deposition and stripping, maintaining both mechanical integrity and Li accessibility. The goal of this study is to understand how characteristics, such as geometry and material properties, affect the current distribution and deposition pattern. To this end, we developed a computational method to track material growth driven by electrodeposition within a complex geometry. This method ensures that the finite-element discretization remains conforming to the moving boundary while preserving an adequate mesh quality, and thus maintains solution accuracy. Using this new computational tool, we analyze the conditions under which porous anode architectures effectively expand the surface area of the charge-transfer interface, and self-regulate current density and dendrite growth.

3D electrode architectures↗
DOE OSTI2022

Pit rim decomposition into multiple quantum dots on surfaces of epitaxial thin films grown on pit-patterned substrates

Here, we report results of dynamical simulations according to an experimentally validated surface morphological evolution model on the formation of regular arrays of quantum dot molecules (QDMs) consisting of 1D arrays of smaller interacting quantum dots (QDs). These QD arrays form along the sides of each pit rim on the surface of a coherently strained thin film epitaxially deposited on a semiconductor substrate, the surface of which consists of a periodic pattern of inverted prismatic pits with rectangular pit openings. We find that this complex QDM pattern results from the decomposition of the pit rim from a “quantum fortress” with four elongated QDs into four 1D arrays of multiple smaller QDs arranged along each side of the pit rim. Systematic parametric analysis indicates that varying the pit opening dimensions and the pit wall inclination directly impacts the number of QDs in the resulting QDM pattern, while varying the pit depth only affects the dimensions of the QDs in the nanostructure pattern. Therefore, the number, arrangement, and sizes of QDs in the resulting pattern of QDMs on the film surface can be engineered precisely by proper tuning of the pit design parameters. Our simulation results are supported by predictions of morphological stability analysis, which explains the pit rim decomposition into multiple QDs as the outcome of a tip-splitting instability and provides a fundamental characterization of the post-instability nanostructure pattern. Our theoretical findings can play a vital role in designing optimal semiconductor surface patterns toward enabling future nanofabrication technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Magnetic Breakdown and Topology in the Kagome Superconductor CsV 3 Sb 5 under High Magnetic Field

The recently discovered layered kagome metals of composition AV 3 Sb 5 (A = K, Rb, Cs) exhibit a complex interplay among superconductivity, charge density wave order, topologically nontrivial electronic band structure and geometrical frustration. Here, we probe the electronic band structure underlying these exotic correlated electronic states in CsV 3 Sb 5 with quantum oscillation measurements in pulsed fields up to 86 T. The high-field data reveal a sequence of magnetic breakdown orbits that allows the construction of a model for the folded Fermi surface of CsV 3 Sb 5 . The dominant features are large triangular Fermi surface sheets that cover almost half the folded Brillouin zone. These sheets have not yet been detected in angle resolved photoemission spectroscopy and display pronounced nesting. In conclusion, the Berry phases of the electron orbits have been deduced from Landau level fan diagrams near the quantum limit without the need for extrapolations, thereby unambiguously establishing the nontrivial topological character of several electron bands in this kagome lattice superconductor.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Systematic uncertainties in the measurement of the neutron lifetime using the Lunar Prospector neutron spectrometer

The lifetime of free neutrons measured in the laboratory has a longstanding disparity of ≈9 s. A space-based technique has recently been proposed to independently measure the neutron lifetime using interactions between the galactic cosmic rays and a low atmosphere planetary body. This technique has not produced competitive results yet due to constraints of nonoptimized data that contain large systematic errors. We use data from the neutron spectrometer on-board NASA's Lunar Prospector, and study two large systematics in the measurement of neutron lifetime: the lunar subsurface temperature and the lunar surface composition. We use the HeCd and HeSn neutron spectrometer data when the spacecraft was in a highly elliptical orbit during the orbit insertion period. We report the neutron lifetime using four different models that each have different choices of surface temperature and composition. The 5° [Prettyman et al ., J. Geophys. Res.: Planets 111, 2005JE002656 (2006)] and 2° [Wilson et al., Phys. Rev. C 104, 045501 (2021)] rebinned maps result in 777.6±11.7 s and 739.6±10.8 s, respectively. For the 20° map (Prettyman et al., 2006), constant equatorial and a latitude-dependent temperature model result in 738.6±10.8 s and 767.3±11.2 s, respectively. Increasing the complexities of the models accounting for the systematic effects increase the measured lifetime. However, the reported measurements are not competitive with the laboratory results due to large unaccounted systematics resulting from nonoptimized measurements and modeling assumptions. This work serves as a study of systematic uncertainties for future neutron lifetime measurements using the space-based technique. We estimate the effect on the lifetime from the choice of temperature model to be to be 28.7 ±15.5 s, and choice of compositional map (for 20° and 5° maps) to be 10.3 ±12.2 s.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2019

Agglomeration Mechanism of Complex Ti-Al Oxides in Liquid Ferrous Alloys Considering High-Temperature Interfacial Phenomenon

This work presents the agglomeration mechanism of complex Ti-Al oxides in the liquid ferrous alloy. Cluster characteristics were investigated using Al and Ti/Al-complex deoxidation method in lab scale. The time-dependent size distribution, total number per volume, average size, and circularity of the clusters were quantitatively analyzed. Furthermore, high-temperature confocal laser scanning microscopy was utilized to directly observe the cluster formation of Ti-Al oxides. A capillary force model including wettability parameters was applied to compare the agglomeration capabilities of different types of non-metallic inclusions. When a low Ti is added into melt, the agglomeration of TiO{sub x}·FeO liquid inclusions is one of the key factors to decrease the frequency of cluster formation. When the Al is added into melt, the heterogeneous precipitation on TiO{sub x}·FeO surfaces is the main reaction process. Ti-Al oxides have lower agglomeration ability than that of Al{sub 2}O{sub 3}, which in turn, contribute to a low agglomeration frequency as well.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A Theory of Ultrafast Charge Transfer Relaxation with Non-Innocent Solvent Molecules

In this work we revisit the photodynamics of tetracyanoethylene-hexamethylbenzene (TCNE- HMB), the molecular complex studied by Hochstrasser et al. [J. Chem. Phys. 100, 4797–4810, 1994] that has long challenged the applicability of Marcus’s theory of elec- tron transfer for predicting photochemical reactions. Using a novel black-box electronic structure algorithm (time-dependent density functional theory with one double, TD- DFT-1D) to efficiently run molecular dynamics that can treat charge recombination, we run ab initio surface hopping molecular dynamics and confirm that, for a polar solvent, charge recombination rates can be incredibly fast (indeed faster than the sol- vent relaxation time); for non-polar solvents, the rate is much slower. We demonstrate that, although Marcus theory cannot be directly applied, these nonequilibrium (and sometimes incredibly fast) photoexcited dynamics can be effectively explained within a two-state model without any evidence of a transition through a conical intersection. Most importantly, for this paradigmatic model system, we are able to identify two nuclear coordinates of interest (rather than the single coordinate predicted by Marcus or a full set of internal quantum modes studied by Bixon and Jortner): the solvent relaxation in the first shell (that strongly modulates the energies of the charge trans- fer state and differentiates time scales for relaxation) and a nuclear displacement in the TCNE-HMB complex arising from a handful of vibrations that induces non-Born Oppenheimer motion and eventually facilitates an abrupt electronic transition to the ground state. Altogether, these findings suggest a tractable generalization of Marcus theory for future simulations of photochemistry with non-innocent solvent environ- ments in the spirit of a Hamiltonian suggested by Stuchebrukhov (J. Chem. Phys. 107, 3821, 1997).

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

Low-Level Liquid-Bearing Clouds Contribute to Seasonal Lower Atmosphere Stability and Surface Energy Forcing over a High-Mountain Watershed Environment

Measurements of atmospheric structure and surface energy budgets distributed along a high-altitude moun tain watershed environment near Crested Butte, Colorado, from two separate, but coordinated, field campaigns, Surface Atmosphere Integrated field Laboratory (SAIL) and Study of Precipitation, the Lower Atmosphere, and Surface for Hydrometeorology (SPLASH), are analyzed. This study identifies similarities and differences in how clouds influence the radiative budget over one snow-free summer season (2022) and two snow-covered seasons (2021/22; 2022/23) for this alpine location. A relationship between lower-tropospheric stability stratification and longwave radiative flux from the presence or absence of clouds is identified. When low clouds persisted, often with signatures of supercooled liquid in win ter, the lower troposphere experienced weaker stability, while radiatively clear skies that are less likely to be influenced by liquid droplets were associated with appreciably stronger lower-tropospheric stratification. Corresponding surface turbu lent heat fluxes partitioned differently based upon the cloud–stability stratification regime derived from early morning radiosounding profiles. Combined with the differences in the radiative budget largely resulting from dramatic seasonal dif ferences in surface albedo, the lower atmosphere stratification, surface energy budget, and near-surface thermodynamics are shown to be modified by the effective longwave radiative forcing of clouds. The diurnal evolution of thermodynamics and surface energy components varied depending on the early morning stratification state. Thus, the importance of quies cent versus synoptically active large-scale meteorology is hypothesized as a critical forcing for cloud properties and associ ated surface energy budget variations. The physical relationships between clouds, radiation, and stratification can provide a useful suite of metrics for process understanding and to evaluate numerical models in such an undersampled, highly com plex terrain environment.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Follistatin Forms a Stable Complex With Inhibin A That Does Not Interfere With Activin A Antagonism

Abstract Inhibins are transforming growth factor-β family heterodimers that suppress follicle-stimulating hormone (FSH) secretion by antagonizing activin class ligands. Inhibins share a common β chain with activin ligands. Follistatin is another activin antagonist, known to bind the common β chain of both activins and inhibins. In this study, we characterized the antagonist-antagonist complex of inhibin A and follistatin to determine if their interaction impacted activin A antagonism. We isolated the inhibin A:follistatin 288 complex, showing that it forms in a 1:1 stoichiometric ratio, different from previously reported homodimeric ligand:follistatin complexes, which bind in a 1:2 ratio. Small angle X-ray scattering coupled with modeling provided a low-resolution structure of inhibin A in complex with follistatin 288. Inhibin binds follistatin via the shared activin β chain, leaving the α chain free and flexible. The inhibin A:follistatin 288 complex was also shown to bind heparin with lower affinity than follistatin 288 alone or in complex with activin A. Characterizing the inhibin A:follistatin 288 complex in an activin-responsive luciferase assay and by surface plasmon resonance indicated that the inhibitor complex readily dissociated upon binding type II receptor activin receptor type IIb, allowing both antagonists to inhibit activin signaling. Additionally, injection of the complex in ovariectomized female mice did not alter inhibin A suppression of FSH. Taken together, this study shows that while follistatin binds to inhibin A with a substochiometric ratio relative to the activin homodimer, the complex can dissociate readily, allowing both proteins to effectively antagonize activin signaling.

Endocrinology & Metabolism↗
DOE OSTI2021

Deep learning techniques to disentangle water use efficiency, climate change, and carbon sequestration across ecosystem scales

Focal Areas: We plan to use machine learning (ML) to disentangle the impact of climate change on plant water use efficiency (WUE) across the leaf level, structured canopy, and community ecosystem scales. Due to the complex behavior of modeling plant WUE’s connection to carbon storage (and hidden co-varying interactions) we suggest that physics-based deep learning must be utilized. The second topic we propose is, based on a better understanding of WUE response to climate change, there is a need to predict how WUE will limit or enhance the recycling of water from transpiration by vegetation back to the land surface worldwide, and thus impact water storage capacity (i.e., natural and reservoirs), using machine learning optimization techniques such as genetic algorithms.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Vibrational metrics for the evaluation of internal conditions in a scaled nuclear dry storage cask

In many countries, permanent repositories for high burnup spent nuclear fuel assemblies have yet to be established. As a result, much of the spent fuel from nuclear reactors is contained within dry storage casks, with many being beyond their designed service life. The assessment of the internal structural integrity of these casks and the fuel assemblies contained therein is of critical importance for both extended storage and transport to permanent repositories. The large size, structural complexity, and inaccessibility of the interior of the casks make this task challenging. To address these difficulties, a 1:6 scaled model based closely on the design of a Transnuclear (TN-32) dry storage cask was fabricated to facilitate controlled studies of these structures in the laboratory. Vibrational spectroscopy was used to evaluate the state of the cargo and internal structures within the cask utilizing only measurements on the outer surface. Using modes identified through Finite Element modeling corresponding to those previously measured on a full-scale TN-32 cask, we report on the development of amplitude- and phase-based metrics that are sensitive to internal conditions in the lab cask. Steel rod bundles and steel shot were used as surrogates for intact and damaged fuel assemblies, and various internal configurations of these materials were investigated. Finally, the metrics were based on acquired spectra involving the (1, 2) global bending mode and the (2, 1) radial-with-shearing mode. The results show that the metrics are sensitive to the condition of a single assembly and have some ability to determine the locations of damaged and empty slots.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

On the Breakdown of ENSO's Relationship With Thermocline Depth in the Central-Equatorial Pacific

Recent classification of El Nino-Southern Oscillation (ENSO) into two types, Eastern (EP) and Central (CP) events, has highlighted the importance of the central Pacific. We show here that the local correlation between ENSO subsurface temperatures (T sub ) in the upper 100-m and thermocline depth anomalies breaks down in the central equatorial Pacific, whereas T sub remains well correlated with sea surface height anomalies. This observed difference in the central equatorial Pacific is simulated by almost all climate models. It arises from a vertically slanted Tsub anomaly structure that is unique to the central equatorial Pacific. We show that this feature is an adiabatic response to wind-driving that is even present in a linear dynamic model, as long as the model has enough baroclinic modes to adequately represent the observed vertical complexity. Our findings have implications for better understanding the different importance of thermocline feedback in CP and EP events.

58 GEOSCIENCES↗
DOE OSTI2021

Sequential Abiotic-Biotic Processes Drive Organic Carbon Transformation in Peat Bogs

Peatlands, which store one-third of the terrestrial carbon (C), are subject to large disturbances under a changing climate. It is crucial to understand how microbial and physiochemical factors affect the vulnerability of these large C stores to predict climate induced greenhouse gas fluxes. Here, we used a combination of mass spectrometry and spectroscopy techniques, to understand sequential biotic and abiotic degradation pathways of Sphagnum fallax leachate in an anaerobic incubation experiment, in the presence and absence of microorganisms. Removal of microorganisms was carried out by passing aqueous samples through 0.2 µm filters. In this work, our results revealed that Sphagnum fallax leachate degradation by abiotic reactions is a significant contributor to CO 2 production. Further, abiotic factors, such as low pH, are responsible for partial dissolved organic carbon (DOC) degradation that produces bioavailable compounds that shift microbial metabolic pathways and stimulate respiration in peat bogs. Acid-catalyzed hydrolysis of Sphagnum-produced glycosides can provide the microbial communities with glucose and stimulate microbial respiration of DOC to CO 2 . These results, while unique to peatlands, demonstrate the importance and underscore the complexity of sequential abiotic and biotic processes on C cycling in peat bogs. It is therefore crucial to incorporate abiotic degradation and sequential below-ground biotic and abiotic interactions into climate models for a better prediction of the influence of climate change on DOC stability in peatlands. These findings might not be representative of other ecosystems with different environmental conditions including mineral-rich peatlands and plant matter in surface peat horizons that comprise discrete microbial populations, and DOC composition.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Electronic structure theory on modeling short-range noncovalent interactions between amino acids

While short-range noncovalent interactions (NCIs) are proving to be of importance in many chemical and biological systems, these atypical bindings happen within the so-called van der Waals envelope and pose an enormous challenge for current computational methods. We introduce SNCIAA, a database of 723 benchmark interaction energies of short-range noncovalent interactions between neutral/charged amino acids originated from protein x-ray crystal structures at the “gold standard” coupled-cluster with singles, doubles, and perturbative triples/complete basis set [CCSD(T)/CBS] level of theory with a mean absolute binding uncertainty less than 0.1 kcal/mol. Subsequently, a systematic assessment of commonly used computational methods, such as the second-order Møller−Plesset theory (MP2), density functional theory (DFT), symmetry-adapted perturbation theory (SAPT), composite electronic-structure methods, semiempirical approaches, and the physical-based potentials with machine learning (IPML) on SNCIAA is carried out. It is shown that the inclusion of dispersion corrections is essential even though these dimers are dominated by electrostatics, such as hydrogen bondings and salt bridges. Overall, MP2, ωB97M-V, and B3LYP+D4 turned out to be the most reliable methods for the description of short-range NCIs even in strongly attractive/repulsive complexes. SAPT is also recommended in describing short-range NCIs only if the δMP2 correction has been included. The good performance of IPML for dimers at close-equilibrium and long-range conditions is not transferable to the short-range. We expect that SNCIAA will assist the development/improvement/validation of computational methods, such as DFT, force-fields, and ML models, in describing NCIs across entire potential energy surfaces (short-, intermediate-, and long-range NCIs) on the same footing.

Chemistry↗
DOE OSTI2025

Time-resolved tracking of cellulose biosynthesis and assembly during cell wall regeneration in live Arabidopsis protoplasts

Cellulose, the most abundant polysaccharide on earth composing plant cell walls, is synthesized by coordinated action of multiple enzymes in cellulose synthase complexes embedded within the plasma membrane. Multiple chains of cellulose fibrils form intertwined extracellular matrix networks. It remains largely unknown how newly synthesized cellulose is assembled into an intricate fibril network on cell surfaces. Here, we have established an in vivo time-resolved imaging platform to continuously visualize cellulose biosynthesis and fibril network assembly onArabidopsis thalianaprotoplast surfaces as the primary cell wall regenerates. Our observations provide the basis for a model of cellulose fibril network development in protoplasts driven by an interplay of multiscale dynamics that includes rapid diffusion and coalescence of nascent cellulose fibrils, processive elongation of single fibrils, and cellulose fibrillar network rearrangement during maturation. This study provides fresh insights into the dynamic and mechanistic aspects of cell wall synthesis at the single-cell level.

Science & Technology - Other Topics↗
DOE OSTI2024

Prefabricated Zero Ascend Omnispecies (ZAO) Modular Fish Passage Modules Using Advanced Manufacturing Techniques

The Zero Ascend Omnispecies (ZAO) fish passage attraction module “ZAO Attractor” is a novel system designed to facilitate upstream passage for a broad spectrum of fish species, with a particular focus on American shad and river herring (alewife and/or blueback herring). Combining the use of prefabricated, modular components with advanced manufacturing, the ZAO aims to provide a cost-effective and scalable solution for fish passage attractions across various hydropower sites. The system features a surface level entry, so fish do not need to climb. In addition, it is designed to be adjusted and repositioned to create the most effective attraction flows by managing the outflows from hydropower turbines. Budget Period 1 (BP1) focused on the design and modeling of the ZAO Attractor and demonstrated the engineering feasibility of a modular, prefabricated, hydrodynamically efficient structure with surface level entry and passage. It was discovered that there were limited published studies on the direct correlation between quantified flow patterns and fish attraction, emphasizing the need for controlled studies to observe and measure these effects. In Budget Period 2 (BP2), controlled studies with live fish were prioritized to address these complexities. In conclusion, the ZAO fish passage attraction module presents a promising approach to fish passage at hydropower stations, with the potential to balance environmental concerns with renewable energy development. However, further field validation and optimization are necessary to ensure its effectiveness and practicality in real-world applications.

13 HYDRO ENERGY↗
DOE OSTI2021

Development of Additively Manufactured Complex Tools for Autoclave Cure Composites

IACMI Project 4.9, Tooling for Composites with Washout Features Produced by Additive Manufacturing, assembled a team including the industry lead, Ability Composites, NREL and Colorado State University (CSU). Ability Composites had originally expressed interest in alternate methods of producing tooling for composite parts. In follow-up discussions, it became clear that one of the bigger tooling challenges revolved around small production volume composite parts that were tooled on washout material due to the complex geometry. To build an understanding of the potential, both from a technology and a cost perspective, for replacing conventional washout tooling with 3D printed thermoplastic tooling, a number of commercially available dissolvable FDM printing materials were evaluated, leading to tooling representative of commercial articles of interest to Ability Composites. Ultimately, Ability Composites was able to directly compare autoclave processed prepreg composite parts produced on conventional washout tooling to composite parts molded on 3D printed dissolvable tooling produced at CSU. Small, laboratory test specimens were developed to investigate the structural performance of the candidate materials under autoclave processing conditions, which were nominally 121 °C (250 °F) and 345 kPa (50 psi). In addition, several internal structural configurations (infills) were evaluated under autoclave conditions using model materials. The results of these tests indicated that two materials, Stratasys ST 130 and Infinite Materials Solutions Aquasys 180 (AQ 180), were the best candidates, given the specified autoclave processing conditions. ST-130 was slightly more robust than AQ-180; however, the AQ-180 was carried forward as it was dissolvable in water, not requiring the basic solution needed to dissolve ST-130. Based on the preliminary material and 3D printed structures evaluations, larger tools with a truncated square pyramid geometry were created to produce prepreg composite test articles for 3D printed dissolvable tool evaluation under standard autoclave fabrication conditions. Two tools were manufactured using ST-130 and one tool using traditional ceramic washout tooling media. The tools were evaluated for geometric fidelity and surface roughness changes before and after carbon fiber/epoxy prepreg composites were manufactured on the tooling. The autoclave processing did not impact the geometry significantly and was completed at 121 °C and 345 kPa, indicating satisfactory tool performance. The results from surface roughness testing of both the resulting composite and the associated tooling indicated that an adequate surface resulted without the need for a surface sealing step, as was required for the conventional washout tooling. Based on results of the truncated pyramid tests as a basis, ST-130, AQ-120 and AQ-180 materials were carried forward to the tool geometry of interest to Ability Composites. These hollow rectangular bent ducts, which were complex in nature and not extractable after cure, were used to understand the impacts of tool material and thickness. One ST-130 tool was produced as a partially solid part, with an enclosed 40% dense infill region to reduce weight and material use. This was the same approach evaluated in the truncated pyramid portion of the study. This tool was to be envelope vacuum bagged and directly compared to a monolithic tool of conventional washout material. The traditional monolithic ceramic tool was manufactured by Ability composites using CNC-based subtractive methods. An additional five dissolvable polymer tools, manufactured from ST-130, AQ-120, and AQ-180, using a hollow design were 3D printed and used to produce carbon fiber/epoxy composite evaluation articles. These hollow dissolvable tools were expected to be less influenced by the autoclave conditions as the wall was solid and vacuum bagging was inside and outside the tool. This alternative geometry was also evaluated as an option in techno-economic modeling. Print times were reduced from in excess of 3 days to under 30 hours, while surface quality and and tool integrity were substantially improved in the transition from the partially solid tool to the hollow tooling concept. Ability Composites produced autoclave-cured prepreg ducts on each of these tools. The autoclave conditions utilized were more severe than those of the initial trials, reaching temperatures of 160 °C and a pressure of 414 kPa. Under these conditions, the partially solid 3D printed tool with skin and 40% dense infill crushed significantly; however, the thicker ST-130 hollow tool showed good promise, deforming only slightly. The thinner hollow tool walls were unsuccessful as were the other materials. Overall, the hollow tool manufacturing process saved significant amounts of time and material in manufacturing as compared to the solid ducts and produced composite surface quality improvements compared to the traditional washout tooling. The TEM was developed to allow direct comparisons between conventional washout tool manufacturing processes and those developed at CSU. It also allowed for two separate 3D printed tool geometries to be analyzed and compared. In this case, the square bent duct tool geometry was determined to be representative of common washout tools. This geometry was compared with a scaled-up version of it to assess differences in the two manufacturing processes based on tool size. The model was developed to make use of user input in the form of geometry details, process steps, manufacturing parameters, bulk material costs, capital equipment costs, and general costs to calculate overall labor, material, capital equipment, and energy costs per manufactured tool for the conventional and additive manufacturing processes for the two representative geometries. It was also able to estimate step-by-step process times for the manufacturing process and geometries. Based on significant input from Ability Composites and CSU from their knowledge gained from hands-on manufacturing of the 3D printed bent duct tool geometry, costs and process times were calculated for the two manufacturing processes. Results showed that the additive manufacturing techniques developed at CSU can substantially reduce the costs of tool manufacturing by reducing labor times and material usage. This is because additive manufacturing is a relatively hands-off process and allows for the tool design to be optimized to reduce material usage. The disadvantage, however, is that process times for additive manufacturing are significantly longer. The three-dimensional (3D) printing process is slow if tight tolerances are required, but the analysis did show that print times could be reduced with the hollow tool geometry. Also, further advances in additive manufacturing could expedite the process. Costs and process times for the tool washout process were calculated separately. They showed that costs are relatively insignificant when compared to the overall tool manufacturing processes, but with increases in tool size, costs for the conventional manufacturing approach are larger than for additive manufacturing. Again, the washout process for conventional tools is very hands-on, whereas for additively manufactured tools the print medium is dissolved in an automated detergent bath at the sacrifice of process time. The analysis showed that optimizing the additively manufactured tools may also reduce washout times. Overall, Project 4.9 demonstrated that commercially available dissolvable 3D printing materials exist that can be used to produce dissolvable tooling capable of surviving prepreg composites fabrication under autoclave conditions of 121 °C (250 °F) and 345 kPa (50 psi). An alternative hollow dissolvable tool design was developed which was structurally superior to the initial concept and was cost and time effective versus conventional washout tooling. The 3D printed sacrificial tool required no added surface sealing steps prior to composite part layup and cure, offering a significant advantage over the porous conventional washout tooling.

36 MATERIALS SCIENCE↗