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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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66 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Designs and Modeling of Architect Multi-material Scintillator System

We present a new conceptual radiation detector, the Architected Multimaterial Scintillator System, that utilizes a scintillator composed of multiple materials arranged in architected structures to enable new capabilities. By structuring differently-dyed materials, the wavelength of the scintillation light encodes additional information in radiation measurements. These structures can be realized through additive manufacture (3D-printing). Two classes of this concept are described and modelled using Monte Carlo simulations to evaluate their performance. The first detector design uses dye microstructures to encode particle tracking information, allowing for directional neutron detection and gamma/neutron discrimination. The second design uses a dye gradient to indicate the position of radiation along the gradient. The simulation results indicate this new concept in radiation detection can achieve strong performance in a variety of capabilities including particle identification, directionality and spectroscopy measurements, and particle position reconstruction.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Toolpath considerations for extrusion: Pellet, filament, concrete, and thermoset

There are a variety of extrusion and deposition-based processes for additive manufacturing, such as fused deposition modeling (FDM), fused filament fabrication (FFF), and directed energy deposition (DED). These processes can use a variety of materials, including thermoplastic pellets, thermoplastic filament, thermoset, concrete, metal wire, metal powder, and more. For all these processes and materials, the underlying toolpath strategies for 3D-printing an object are the same: the object to be printed is sliced into layers, then the layer is optimally fit with toolpaths of a given width, based on specific user settings. However, based on the specific process being used, additional modifiers and toolpathing strategies may be employed to maximize the capabilities of the process and successfully construct an object. This chapter explores the different pathing considerations and additional strategies to be employed in extrusion processes that use thermoplastics, thermosets, and concretes.

Roschli, Alex↗
DOE OSTI2025

Print-and-Plate Architected Electrodes for Electrochemical Transformations Under Flow

Flow cell electrodes are typically composed of porous carbon materials, such as papers, felts, and cloths. However, their random architecture hinders the fundamental characterization of electrode structure-performance relationships during in situ operation of porous electrochemical flow systems. This work describes a “print-and-plate” method that combines direct ink writing of micro-periodic lattices with a two-step metal plating process that converts them into highly conductive (sheet resistance 40 mΩ sq -1 ) electrodes. Their operando performance is assessed in an anthraquinone disulfonic acid half-cell using widefield electrochemical fluorescence microscopy, where output current and fluorescence intensity are in excellent agreement. The pressure drop associated with flow through three electrode designs is determined via simulations from which the most efficient design is identified and manufactured via print-and-plate. Confocal fluorescence microscopy is then used to create a 3D map of the state of charge (SOC) inside this print-and-plate electrode. The experimental state of the charge map is in good agreement with computational predictions. The rapid design, simulation, and fabrication of print-and-plate electrodes enable fundamental investigations of how architected porosity affects electrochemical performance under flow.

3D-printing↗
DOE OSTI2023

Aerosol-Jet Printed Sensors for Environmental, Safety, and Health Monitoring: A Review

An emergent direct-write approach, aerosol-jet printing (AJP), is gaining attention for the deployment of rapid and affordable microadditively manufactured energy-efficient sensors and printed electronics. AJP enables a broad range of ink viscosities (0.001–1 Pa s) for printing diverse materials ranging from ceramics and metals to polymers and biological matter. Reproducible, high-spatial-resolution features (≈10 µm), and wide standoff distances (1–11 mm) between the nozzle and the substrate facilitate conformal printing of complex geometrical designs on nonplanar—e.g., stepped or curved—surfaces. Here this paper aims to provide a comprehensive overview of state-of-the-art AJP-based sensors (e.g., strain and temperature gauges, biosensors, photosensors, humidity and surface acoustic wave sensors, dielectric elastomer actuators, and motion, smoke, and hazardous gas detectors) and to discuss prospective applications. The drive toward cost-effective devices that are smaller, lighter, and better-performing remains a frontier challenge in the field of printed electronics. Consequently, as AJP becomes increasingly utilized in the high-volume manufacturing of miniaturized active and passive sensors, it opens a pathway for facile large-scale fabrication of devices for a wide range of consumer and industrial applications, including transportation, agriculture, infrastructure, aerospace, national defense, and healthcare.

3-dimensional↗
DOE OSTI2023

A Sustainable Multi-Dimensional Printable Material

Polymeric materials are usually tailored for specific functionality. A single polymer exhibiting multiple simultaneous functionalities often requires intricate molecular architecture, which is difficult to manufacture at scale because of its complex synthesis routes. In this work, a facile, partly renewable composition—prepared via reactive melt processing—that induces tunable functionalities such as 3D printability, shape recovery, and self-healing while exhibiting satisfactory mechanical properties is reported. The system with a hydrogen-bonded 3D network consists of thermally reversible nano-scale agglomerates of sustainable, rigid phenolic oligomers and crystallizable flexible polymer. Local molecular mobility and temperature-dependent relaxation and recovery of the non-equilibrium networked states enable exploiting these simultaneous functionalities. Transitions involving solidification and structure stabilization at ambient temperature spanning several hours after preheating only at 70 °C directly contrast typical thermoplastic or thermoplastic elastomer behaviors. Results from this study can inform the design of future rheology modifiers and materials for soft robotics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Reinforced double-threaded slide-ring networks for accelerated hydrogel discovery and 3D printing

Traditionally, slide-ring gels are stretchable but soft as a result of an elasticity-stretchability trade-off. Herein, we introduce a new approach to breaking this trade-off and creating reinforced slide-ring networks with mobile crosslinkers. Our approach involves the construction of a polyethylene glycol double-threaded γ-cyclodextrin-based pro-slide-ring crosslinker that serves as a modular component for 3D printing and copolymerization. The resulting crystalline-domain-reinforced slide-ring hydrogels, or CrysDoS-gels, exhibit both high elasticity and high stretchability. The modular synthesis allows for high-throughput synthesis of CrysDoS-gels, generating a large amount of data for structure-property analysis. Here, by employing data science techniques, such as machine learning and linear regression, not only were we able to identify which chemical components influence the mechanical properties of CrysDoS-gels, but this analysis also aided in the discovery of better-performing CrysDoS-gels. Finally, we demonstrate the potential application of the newly discovered CrysDoS-gels as sensing devices by 3D printing them as stress sensors with high sensitivity and a broad detection range.

3D-printing↗
DOE OSTI2021

Investigation of chemical stabilities and contact angle of 3D printed polymers with CO 2 capture solvents to enhance absorber performance

Increasing absorption rate in aqueous amine CCS systems is one avenue to decrease capital cost by reducing the overall size of the absorber column. One potential route is by replacing conventional steel packing with custom designed packing made from 3D printed polymers. 3D printing offers endless flexibility in packing designs to better enhance liquid/gas contact, increase CO 2 mass transfer and create compact absorber columns. Additionally, before exploring novel packing designs, it is necessary to identify polymer materials that can be 3D printed while also showing long-term physical and surface property stability upon exposure to corrosive amine solutions. Four polymers that are commonly used for 3D printing were evaluated using CO 2 -loaded amine solution at temperatures typically observed in the absorber column. Three polymers, high-density polystyrene (HDPS), acrylonitrile butadiene styrene (ABS) and nylon were found to be physically stable after 5000 hr of amine exposure at temperatures up to 60 °C. The contact angle (wetting) of water and CO 2 -loaded aqueous amine solution on the polymer surfaces were also stable after exposure to the CO2-loaded amine solution.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The rapid-tome, a 3D-printed microtome, and an updated hand-sectioning method for high-quality plant sectioning

Abstract Background Microscopic analysis of plant anatomy is a common procedure in biology to study structure and function that requires high-quality sections for accurate measurements. Hand sectioning of specimens is typically limited to moderately soft tissue while harder samples prohibit sectioning by hand and/or result in inconsistent thicknesses. Results Here we present both a clearly described hand-sectioning method and a novel microtome design that together provide the means to section a variety of plant sample types. The described hand-sectioning method for herbaceous stems works well for softer subjects but is less suitable for samples with secondary growth (e.g., wood production). Instead, the “Rapid-Tome” is a novel tool for sectioning both soft and tougher high-aspect-ratio samples, such as stems and roots, with excellent sample control. The Rapid-Tome can be 3D-printed in approximately 18 h on a mid-quality printer common at university maker spaces. After printing and trimming, Rapid-Tome assembly takes a few minutes with five metal parts common at hardware stores. Users sectioned a variety of plant samples including the hollow internodes of switchgrass ( Panicum virgatum ), fibrous switchgrass roots containing aerenchyma, and woody branches of eastern red cedar ( Juniperus virginiana ) and American sycamore ( Platanus occidentalis ). A comparative analyses with Rapid-Tome-produced sections readily revealed a significant difference in seasonal growth of sycamore xylem vessel area in spring (49%) vs. summer (23%). Additionally, high school students with no prior experience produced sections with the Rapid-Tome adequate for comparative analyses of various plant samples in less than an hour. Conclusions The described hand-sectioning method is suitable for softer tissues, including hollow-stemmed grasses and similar samples. In addition, the Rapid-Tome provides capacity to safely produce high-quality sections of tougher plant materials at a fraction of the cost of traditional microtomes combined with excellent sample control. The Rapid-Tome features rapid sectioning, sample advancement, blade changes, and sample changes; it is highly portable and can be used easily with minimal training making production of thin sections accessible for classroom and outreach use, in addition to research.

3D-printing↗
DOE OSTI2022

Formulation of PI Aerogels with 3-D Printing Applications

Polyimide-based films were produced with 3-D printing capability consisting of TDI and PMDA monomers with acrylate functionality. The polymer was synthesized using a standard condensation with diisocyanate and dianhydride heated to 95⁰C under water free conditions. This method is relatively fast, cost effective and far more synthetically simple compared to diamine condensations seen in literature. Considering how crucial proper grafting of functional groups was in hierarchy application, various formulation variables were screened. Lastly, films were produced with PI material and the physical and chemical properties were examined using microscope imaging and UV-Vis Spectroscopy. The material was proven to have relatively fast cure times (5-10 minutes) and the films were shown to have long term stability.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Material Extrusion Additive Manufacturing of Wood and Lignocellulosic Filled Composites

Wood and lignocellulosic-based material components are explored in this review as functional additives and reinforcements in composites for extrusion-based additive manufacturing (AM) or 3D printing. The motivation for using these sustainable alternatives in 3D printing includes enhancing material properties of the resulting printed parts, while providing a green alternative to carbon or glass filled polymer matrices, all at reduced material costs. Previous review articles on this topic have focused only on introducing the use of natural fillers with material extrusion AM and discussion of their subsequent material properties. This review not only discusses the present state of materials extrusion AM using natural filler-based composites but will also fill in the knowledge gap regarding state-of-the-art applications of these materials. Emphasis will also be placed on addressing the challenges associated with 3D printing using these materials, including use with large-scale manufacturing, while providing insight to overcome these issues in the future.

36 MATERIALS SCIENCE↗