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At least 73 records · Page 4

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DOE OSTI2025

Initial assessment of alternative carbon fiber geometries for design of cost-effective compressive performance: Size effect studies

Carbon fiber provides opportunity to reduce weight in structural composites, including wind turbine blades, due to the material's superior specific stiffness and specific strength compared to alternatives. Despite these advantages, cost and compressive performance are considered weaknesses for carbon fiber products available today. Studies to produce low-cost carbon fiber alternatives, including the use of textile-derived precursor systems, have shown progress and merit through the DOE/ORNL low-cost carbon fiber initiatives. Here, this work focuses on enabling increases in compressive strength through design of the carbon fiber geometry, applicable to both textile and conventional precursor systems, while also providing opportunities to reduce carbon fiber processing costs. Fiber-resin interface and fiber alignment are among the most frequently cited factors controlling composite compressive performance. However, it is believed that there is opportunity in traditionally unexplored routes to increasing compressive strength through alteration of the carbon fiber geometry by increasing the fiber area moment of inertia and/or the fiber perimeter and interfacial area. This paper presents initial results from manufacturing carbon fiber materials to assess the impacts of carbon fiber size on tested composite compressive performance with projected neutral or even beneficial impact on fiber and composite manufacturing economics. Carbon fiber systems with increasing size illustrate a favorable correlation for compressive performance greater than predicted from a micromechanical failure model. The manufacturing and mechanical test results support the hypothesis of this work that alterations to fiber geometry can be used to produce improvements of the compressive strength of carbon fiber reinforced polymers and provide incentive for related work in designing alternative shapes to further enhance compressive performance.

42 ENGINEERING↗

DOE OSTI2025

Emergence of deep eutectic solvents (DES): chemistry, preparation, properties, and applications in biorefineries and critical materials

The emergence of renewable deep eutectic solvents (DES) as clean and efficient catalysts and solvents has created new opportunities for lignocellulosic biorefineries and critical material sectors, including chemical, energy, pharmaceutical, textile, and hydrometallurgical industries. This review provides an in-depth overview of DES, covering their chemistry, classifications, preparation methods, processing characteristics, and recyclability, while highlighting their unique attributes and industry relevant applications. Emphasis is placed on the integration of DES into advanced biorefinery systems, focusing on their tunable physicochemical and thermodynamic properties for biomass pretreatment and the production of value-added products. The review explores how DES can be tuned for selective dissolution of biomass components and evaluates production and valorization of DES-derived biochemicals, with attention to lignin extraction mechanisms and conversion of biomass into bioproducts and biofuels. Beyond biorefineries, the scope extends to DES applications in electrochemical energy devices, where they serve as electrolytes, synthesis media for electrode materials, and leaching agents in battery recycling. The multifunctional roles of DES in pharmaceutical, hydrometallurgical, and textile sectors are also explored for contributions to sustainable processing. Finally, the review identifies future research directions, outlining benefits, challenges, and knowledge gaps, for continued industrial development.

09 BIOMASS FUELS↗

DOE OSTI2020

Aerosol jet printed capacitive strain gauge for soft structural materials

Soft structural textiles, or softgoods, are used within the space industry for inflatable habitats, parachutes and decelerator systems. Evaluating the safety and structural integrity of these systems occurs through structural health monitoring systems (SHM), which integrate non-invasive/non-destructive testing methods to detect, diagnose, and locate damage. Strain/load monitoring of these systems is limited while utilizing traditional strain gauges as these gauges are typically stiff, operate at low temperatures, and fail when subjected to high strain that is a result of high loading classifying them as unsuitable for SHM of soft structural textiles. For this work, a capacitance based strain gauge (CSG) was fabricated via aerosol jet printing (AJP) using silver nanoparticle ink on a flexible polymer substrate. Printed strain gauges were then compared to a commercially available high elongation resistance-based strain gauge (HE-RSG) for their ability to monitor strained Kevlar straps having a 26.7?kN (6?klbf) load. Dynamic, static and cyclic loads were used to characterize both types of strain monitoring devices. Printed CSGs demonstrated superior performance for high elongation strain measurements when compared to commonly used HE-RSGs, and were observed to operate with a gauge factor of 5.2 when the electrode arrangement was perpendicular to the direction of strain.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Towards Immobilized Proton-Coupled Electron Transfer Agents for Electrochemical Carbon Capture from Air and Seawater

Electrochemical CO 2 separation has drawn attention as a promising strategy for using renewable energy to mitigate climate change. Redox-active compounds that undergo proton-coupled electron transfer (PCET) are an impetus for pH-swing-driven CO 2 capture at low energetic costs. However, multiple barriers hinder this technology from maturing, including sensitivity to oxygen and the slow kinetics of CO 2 capture. Here, we use vapor phase chemistry to construct a textile electrode comprising an immobilized PCET agent, poly(1-aminoanthraquinone) (PAAQ), and incorporate it into redox flow cells. This design contrasts with others that use dissolved PCET agents by confining proton-storage to the surface of an electrode kept separate from an aqueous, CO 2 -capturing phase. This system facilitates carbon capture from gaseous sources (a 1% CO 2 feed and air), as well as seawater, with the latter at an energetic cost of 202 kJ/mol CO2 , and we find that quinone moieties embedded within the electrode are more stable to oxygen than dissolved counterparts. Simulations using a 1D reaction-transport model show that moderate energetic costs should be possible for air capture of CO 2 with higher loadings of polymer-bound PCET moieties. The remarkable stability of this system sets the stage for producing textile-based electrodes that facilitate pH-swing-driven carbon capture in practical situations.

Ali, Fawaz↗

DOE OSTI2023

Low Cost Glass-Ceramic Matrix Composite Heat Exchanger

As part of ARPA-E’s High Intensity Thermal Exchange through Materials and Manufacturing Processes (HITEMMP) program, this project sought to develop novel heat exchanger (HX) capabilities to enable efficient and power dense power generation cycles. This class of HX comes under the category of ceramic/composite materials with the higher temperature goal in the program of ≥1100 °C inlet temperature operation. The enabling capability of this effort is the use of glass-ceramic matrix composite (GCMC) material which provides the high temperature durability of a ceramic, the flaw tolerance of a composite, a significantly faster and lower cost manufacturing process than conventional matrix CMCs and very low porosity levels < 0.5%. For thin-walled HX structures and the need to minimize leakage, the low porosity differentiator is particularly important. RTRC has prior experience with this material system and in the current project advanced the component design and manufacturing methods into new territory to produce features required for effective heat exchange under high pressures. In this approach, silicon carbide fiber is fabricated into a fiber preform using various textile processes. Graphite tooling is used both during the build-up of the fiber preform (interior tooling) and after the fiber preform has been completed (exterior tooling). This tooling assembly is heated to high temperature in an environment that has been evacuated and backfilled with inert gas. A reservoir of specialty glass is present and once the desired temperature has been reached to achieve the desired glass viscosity, an actuator distributes the glass throughout the fiber preform using passageways which are part of the tooling design in a process known as glass transfer molding. After the tooling has been removed, the composite is heat treated to convert the amorphous glass to a crystalline ceramic, providing improved properties. The project was divided into three phases focusing on the following: 1) 10 kW HX design and coupon-level tube sheet fabrication, 2) 10 kW HX fabrication, 3) 50 kW HX fabrication. During Budget Period 1 (BP1), additional risks were encountered and the need for additional funds was agreed upon by ARPA-E program leadership. Due to a variety of factors, the contract modification required nominally 18 months to execute at which time the HITEMMP program was effectively concluding. Because of this and the time that would be required to perform BP2 tasks, it was decided to conclude the project at the end of BP1. During the design of the 10 kW HX, manufacturing constraints were learned and incorporated, leading to a revised configuration for the fiber preform and HX. Heat exchange and pressure drop predictions also played a role in modifying the original design concept to be a higher aspect ratio shell-and-tube HX, simplifying the manufacturing process and improving the heat exchanger performance. Good gravimetric and volumetric thermal power densities of 11.2 kW/kg and 10,200 kW/m3 for the entire HX were projected that involved thermo-structural Finite Element Analysis to determine the structural mass needed for the high operation pressures of 250 bar cold inlet and 80 bar hot inlet. Fiber preforms using textile processes were produced for multiple headered tube sheets. Additional challenges were encountered during the glass transfer molding step for which solutions were identified, but programmatics did not allow them to be implemented in BP1. While complete HX test articles were not fabricated, the benefits of this GCMC material for a variety of high temperature applications remain.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2021

Thermodynamic Analysis of Thermo-vacuum Clothes Drying Operation

Clothes drying accounts for a significant amount of energy consumed in residential and commercial sectors. A thermal vacuum clothes drying technology (TVCD) is proposed as an advanced clothes dryer which can significantly reduce the energy requirements by expediting the drying process. In the conventional convective clothes dryer, hot dry air is introduced into the drum which gets in direct contact to dry the clothes. This process is energy inefficient since the significant amount of heat and the water carried out with the exhaust stream are wasted. In contrast to the conventional convective drying technique, the drying mechanism of TVCD is through nucleate boiling at low temperature due to reduced vessel pressure. The process is not only efficient but also reduces the required time for drying. The objective of this paper is to develop a comprehensive thermodynamic model to predict the transient drying process of TVCD. The three-stage system model including the detail analysis of individual components is capable of simulating the variation of the water content in the textile under various operational conditions. The preliminary results show that the drying time of 3 lb textile from 70% to 2.5% in TVCD is approximately four times less than the time required in the conventional clothes dryer. Parametric studies are carried out to understand the effect of operation conditions and component geometry on the system performance. Energy consumption of the system is also analyzed.

Yang, Cheng-Min↗

DOE OSTI2023

System and method for thermally adaptive materials

An adaptive textile that includes a plurality of a first fiber having a first expansion coefficient and a plurality of a second fiber having a second expansion coefficient. There is a difference between the expansion coefficient of the first fiber and the expansion coefficient of the second fiber; at least one of the first or second fibers is a twisted coil actuator; and linear displacement of the twisted coil actuator causes the adaptive textile to bend.

Ridley, Brent↗

DOE OSTI2022

Bifunctional Asymmetric Fabric with Tailored Thermal Conduction and Radiation for Personal Cooling and Warming

Personal thermal management is emerging as a promising strategy to provide thermal comfort for the human body while conserving energy. By improving control over the heat dissipating from the human body, personal thermal management can provide effective personal cooling and warming. Here, we propose a facile surface modification approach to tailor the thermal conduction and radiation properties based on commercially available fabrics, to realize better management of the whole heat transport pathway from the human body to the ambient. Additionally, a bifunctional asymmetric fabric (BAF) offering both a cooling and a warming effect is demonstrated. Due to the advantages of roughness asymmetry and surface modification, the BAF demonstrates an effective cooling effect through enhanced heat conduction and radiation in the cooling mode; in the warming mode, heat dissipation along both routes is reduced for personal warming. As a result, a 4.6 °C skin temperature difference is measured between the cooling and warming BAF modes, indicating that the thermal comfort zone of the human body can be enlarged with one piece of BAF clothing. We expect this work to present new insights for the design of personal thermal management textiles as well as a novel solution for the facile modification of available fabrics for both personal cooling and warming.

42 ENGINEERING↗

DOE OSTI2026

Photooxidation of Organic Sulfide Enhanced by Heavy Atom Effect in Porphyrin Metal–Organic Frameworks with a Sea Topology

The photoactivity of three porphyrin-based metal-organic frameworks (PMOFs) incorporating Al, Ga, and In nodes was systematically evaluated using the photooxidation of an organic sulfide (2-chloroethyl ethyl sulfide, or CEES; a mustard gas simulant). Faster photodegradation of CEES was observed for PMOFs with heavier metal nodes, placing In-PMOF as the most efficient photocatalyst in the series. Guided by this insight, we developed CSLA-10, a MOF integrating In nodes and Sn-doped porphyrin linker to synergistically amplify heavy-atom effects at both the nodes and ligand levels. CSLA-10 exhibited the fastest reported CEES photooxidation to date, achieving a half-life of 38 s in methanol under blue LED irradiation. When grafted onto textiles, CSLA-10 enabled solvent-free CEES degradation in air/O 2 with a half-life of 2.7 min and complete conversion within 7 min, representing the most rapid full degradation reported under solvent-free conditions. Furthermore, this work establishes a dual heavy-atom strategy for enhancing intersystem crossing and singlet oxygen generation in porphyrin MOFs, providing a rational design principle for next-generation photocatalysts for the degradation of toxic organic sulfides.

Metal-organic frameworks↗

DOE OSTI2024

ABC -Auxetics: An Implicit Design Approach for Negative Poisson's Ratio Materials

A novel methodology is introduced for designing auxetic (negative Poisson's ratio) structures based on topological principles and is demonstrated by investigating a new class of auxetics based on two-dimensional (2D) textile weave patterns. Conventional methodology for designing auxetic materials typically involves determining a single deformable block (a unit cell) of material whose shape results in auxetic behavior. Consequently, patterning such a unit cell in a 2D (or 3D) domain results in a larger structure that exhibits overall auxetic behavior. Such an approach naturally relies on some prior intuition and experience regarding which unit cells may be auxetic. Second, tuning the properties of the resulting structures is typically limited to parametric variations of the geometry of a specific type of unit cell. Thus, most of the currently known auxetic structures belong to a selected few classes of unit cell geometries that are explicitly defined in accordance with a specified topological (i.e., grid structure). Herein, a new class of auxetic structures is demonstrated that, while periodic, can be generated implicitly, i.e., without reference to a specific unit cell design. The approach leverages weave-based parameters (A–B–C), resulting in a rich design space for auxetics that is previously unexplored.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Embedded Fluidic Sensing and Control with Soft Open‐Cell Foams

Abstract The synthesis of soft matter intelligence with circuit‐driven logic has enabled a new class of robots that perform complex tasks or conform to specialized form factors in unique ways that cannot be realized through conventional designs. Translating this hybrid approach to fluidic systems, the present work addresses the need for sheet‐based circuit materials by leveraging the innate porosity of foam—a soft material—to develop pneumatic components that support digital logic, mixed‐signal control, and analog force sensing in wearables and soft robots. Analytical tools and experimental techniques developed in this work serve to elucidate compressible gas flow through porous sheets, and to inform the design of centimeter‐sized foam resistors with fluidic resistances on the order of 10 9 Pa s m −3 . When embedded inside soft robots and wearables, these resistors facilitate diverse functionalities spanning both sensing and control domains, including digital logic using textile logic gates, digital‐to‐analog signal conversion using ladder networks, and analog sensing of forces up to 40 N via compression‐induced changes in resistance. By combining features of both circuit‐based and materials‐based approaches, foam‐enabled fluidic circuits serve as a useful paradigm for future hybrid robotic architectures that fully embody the sensing and computing capabilities of soft fluidic materials.

Rajappan, Anoop↗

DOE OSTI2025

Coaxial Direct Ink Writing of Cholesteric Liquid Crystal Elastomers in 3D Architectures

Abstract Cholesteric liquid crystal elastomers (CLCEs) hold great promise for mechanochromic applications in anti‐counterfeiting, smart textiles, and soft robotics, thanks to the structural color and elasticity. While CLCEs are printed via direct ink writing (DIW) to fabricate free‐standing films, complex 3D structures are not fabricated due to the opposing rheological properties necessary for cholesteric alignment and multilayer stacking. Here, 3D CLCE structures are realized by utilizing coaxial DIW to print a CLC ink within a silicone ink. By tailoring the ink compositions, and thus, the rheological properties, the cholesteric phase rapidly forms without an annealing step, while the silicone shell provides encapsulation and support to the CLCE core, allowing for layer‐by‐layer printing of self‐supported 3D structures. As a demonstration, free‐standing bistable thin‐shell domes are printed. Color changes due to compressive and tensile stresses can be witnessed from the top and bottom of the inverted domes, respectively. When the domes are arranged in an array and inverted, they can snap back to their base state by uniaxial stretching, thereby functioning as mechanical sensors with memory. The additive manufacturing platform enables the rapid fabrication of 3D mechanochromic sensors thereby expanding the realm of potential applications for CLCEs.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Mechanochromic Palettes Based on Optical Rotation in Cholesteric Liquid Crystal Elastomers for Visual Signalling

Mechanochromic photonic materials present promising prospects for enhancing diverse facets of human life. Cholesteric liquid crystal elastomers (CLCEs) present immediate mechanochromic properties, allowing their utility in various fields, including camouflages, textiles, and anticounterfeiting. Nonetheless, it is essential to provide differentiated color information corresponding to diverse types and degrees of deformation for practical use in real life. Herein, the mechanochromic responses of CLCEs are investigated using their optical rotation under compression and uniaxial stretching. The CLCEs exhibit the same reflection colors indistinguishable for compression and uniaxial stretching due to their contracted pitches. In contrast, the linearly polarized light passing through deformed CLCEs can be modulated by optical rotation, resulting in distinct transmission colors that can be discerned through mechanical deformations. A visual signaling system with color information derived from optical rotation is demonstrated. By comprehending and manipulating the mechanoresponsive behavior of CLCEs, these materials can be advanced into innovative solutions with enhanced functionality and performance, thereby broadening their applications for human life enhancement.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Hydrolysis of Polyamide 6 to ε‐Caprolactam over Titanium Dioxide

Polyamides (PAs) are an important component of discarded textiles and food packaging. Chemical recycling can recover PA monomers, enabling repolymerization to produce virgin-grade PA. However, contemporary PA chemical recycling methods employ homogeneous catalysts that are hard to separate. Anatase TiO 2 is reported as a catalyst for PA6 hydrolysis at 270 °C for 0.5 h, achieving a maximum ε-caprolactam (CL) yield of 81% (limited by thermodynamic equilibrium). The CL yield decreases upon catalyst reuse, due to loss of catalyst surface area induced by significant changes in catalyst crystallinity and texture. Pretreating the catalyst hydrothermally stabilizes it against morphological changes, yielding repeatable CL yields. Altogether, this study discloses a heterogeneous catalyst capable of producing repeatable equilibrium CL yields via PA6 hydrolysis under industrially relevant reaction temperatures and times (<3 h, 250–330 °C).

depolymerization↗

DOE OSTI2023

Effect of recycled fibers and shredded intermediates variation on the mechanical properties and energy absorption of fiber‐reinforced composite panels

Abstract The global composite industry generates large quantities of waste which mostly ends up in landfills due to a lack of established end‐use applications for multiple waste streams. The scrap from end‐of‐life (EoL) includes manufacturing waste such as dry chopped fiber tows, loose fibers, shredded fibers from fabric textile operations, cured/semi‐cured prepregs, and fully cured composite structure waste from aircraft, automobiles, wind blades, boats, and pressure vessels. In this work, different composite waste streams were reduced to shredded intermediates, followed by simple blending, and subjected to wet compression molding to produce composite panels. The panels/plaques were tested for mechanical properties (flexure and impact), fiber‐matrix wet‐out, and property bounds. It was found that wet‐compression molding was a viable and scale‐able approach to produce recycled panels from EoL composites shredded scrap. Furthermore, full‐scale size panels for use in truck bodies and intermodal shipping container flooring were manufactured and their impact resistance was tested using a drop weight impact test. They were tested both for high‐ and low‐velocity load. In the case of high‐velocity load, the average impact load was 14,673 N; the average absorbed energy was 101.6 J; the average elastic energy was 11.7 J and the impact resistance was 1065 J/m. In the case of the low‐velocity drop weight impact test, it was found that the average impact load was 7877.358 N; the average absorbed energy was 9.718 J; the average elastic energy was 9.14 J, and the impact resistance was 184.1 J/m. The shredded composite was shown to be a candidate material for the manufacture of truck bodies and intermodal containers’ flooring panels. Highlights By using shredded intermediates from different composite waste streams, it is possible to manufacture composite panels. Wet–compression process is an appropriate technique for manufacturing recycled fiber composite panels. Regardless of the source of scrap, the mechanical properties of the produced composite panels were improved. The recycling process technology can be transformed to commercial scale to produce full‐size transportation flooring panels. A product pathway is established in consideration of lower cost and improved recyclability.

Vaidya, Uday↗

DOE OSTI2020

Structure, properties, and applications of polyacrylonitrile/carbon nanotube ( CNT ) fibers at low CNT loading

Abstract Bi‐component, polyacrylonitrile (PAN)/carbon nanotube (CNT) fibers were processed, at different core‐sheath area ratios, by gel spinning. A percolated CNT network at 10 wt% CNT in the sheath enhanced electrical conductivity as compared to the neat PAN fiber, while PAN polymer in the core contributed to the good mechanical properties. Fibers with relatively thin sheath allowed overall CNT loading as low as 3.7 wt% to be made with good electrical conductivity, and PAN stabilization by Joule heating was demonstrated. Such fibers with combined good mechanical properties and electrical conductivity can also potentially be used for electrical heating of fabrics, for making smart textiles, and for electromagnetic interference shielding.

Lu, Mingxuan↗

DOE OSTI2024

Effects of Copolymer Structure on Enzyme-Catalyzed Polyester Recycling

Polyesters are an omnipresent material used for a variety of applications (e.g., bottles, packaging, textile, windshield), roughly comprising 8% of plastics produced worldwide. Enzymatic recycling is an emerging solution to deal with the increasingly diverse polyesters that are not suitable for mechanical recycling. However, enzyme activity and efficiency are still the limiting factors impeding enzymatic recycling for different plastic waste forms. The effects of thermal and structural properties (e.g., glass transition temperature, crystallinity, specific surface area), which are determined by chemical composition and preprocessing, directly influence enzyme recycling efficiency. This work investigates two extrusion methods (single screw and twin-screw extrusion) to pretreat a range of copolyesters (RPET, PETG, Ecozen, Tritan and PBT) and modify their properties (i.e., glass transition temperature (T g ), crystallinity (%), and molecular weight (M n )). A PET-specific enzyme, leaf-branch compost cutinase (LCC ICCG ), produced from a fed-batch fermentation of Escherichia coli BL21(DE3), was used for the enzymatic depolymerization of different polyesters. Several copolyesters showed improved depolymerization after pretreatment, as measured by rate and amount of monomers produced. Furthermore, those that did not depolymerize were found to have exceptionally high glass transition temperature or percent crystallinity, highlighting the importance of these physical parameters on conversion efficiency.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Structure Development in Cross-Linked, Soybean Oil-based Waterborne Polyurethanes

Development of waterborne polyurethanes (WPU) using bio-based sources represents a step towards sustainable materials science and industry. We synthesized bio-based cationic water-dispersed crosslinked polyurethanes from high oleic soybean oil (HOSO) polyol, isophorone diisocyanate, and methyldiethanol amine, with varying ionic group contents after neutralization with acetic acid. Our primary objective was to analyze how crosslinking affects the dispersion process and film properties in multifunctional systems. The synthesis-structure-property relationship is elucidated through comprehensive analyses of the products at different stages of the synthesis. The dispersion of the WPU particles in water must occur prior to gelation during the final preparation, leading to incomplete conversion and the formation of imperfect networks. Insight into the synthesis process and polymer structure was gained by simulating polymer network parameters. Morphological analyses using synchrotron-based X-ray scattering and atomic force microscopy revealed a hierarchical structure within the WPU films. Importantly, all the films prepared in this study, without using coalescence agents, have low water absorption and high water contact angles, demonstrating their potential for textile and leather coatings and other applications.

bio-based polymers↗