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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Novel Preprocessing Techniques for Enhancing Flowability of Miscanthus

Purpose-grown energy crops possess significant potential as promising feedstocks for biofuel and biochemical production. However, similar to other biomass feedstocks, their utilization has been hindered by handling and feeding challenges such as clogging and segregation, which prevent biorefineries from operating at full capacity. These challenges arise primarily due to particle attributes including irregular shape, high flexibility, and high compressibility, leading to interlocking, high compaction, and significant friction under stress consolidation. To enhance operational reliability, it is crucial to focus on preprocessing techniques to address these issues, alongside accurately characterizing the mechanical and physical properties and flow performance of these feedstocks. This study investigates novel preprocessing techniques, including pelletization and torrefaction, to fundamentally alter these particle attributes and improve flowability. Miscanthus, an herbaceous energy crop, was the primary focus of this study. Samples were processed using a Forest Concepts Crumbler rotary shear system and an oscillating multi-stack screen bed to achieve two nominal (baseline) particle sizes: 6mm and 2mm. The study evaluated the efficiency and energy consumption of size reduction, revealing that while 2mm particles required more energy, they exhibited better flowability and higher yield strength compared to 6mm particles. Shear and compression tests assessed the material's shear strength, internal friction, and elastic modulus, while wedge-shaped hopper tests measured the critical arching distance and mass flow rate. The results provide valuable insights into the mechanical properties and processing efficiency of Miscanthus, contributing to the development of a preprocessing framework that enhances energy efficiency and material flowability in bioenergy production. However, further preprocessing and development are required to optimize this framework fully.

09 - BIOMASS FUELS↗
DOE OSTI2024

Experimental and numerical investigation of fracture conductivity between non-smooth rock surfaces with and without proppant

The enhancement of fracture conductivity is vital for the efficient recovery of subsurface resources, such as geothermal energy and petroleum hydrocarbons. Proppants, granular materials injected into hydraulic fractures to maintain their conductivity, have been studied primarily in the context of smooth fractures (i.e., fractures between smooth rock surfaces). However, non-smooth fractures (i.e., fractures between rough rock surfaces) are common in geoenergy reservoirs and thus require further investigations. In this study, we conducted laboratory measurements of fracture conductivity on shale slabs with non-smooth surfaces and carried out numerical simulation using the lattice Boltzmann (LB) method, which aimed to investigate the conductivity of non-smooth fractures with and without proppants placement. When ceramic proppant with an areal concentration of 2 lb/ft 2 was placed in the fracture, the conductivity was enhanced by roughly 3-8 times compared to fractures without proppant. In fractures with proppant, gas-measured conductivity was higher than that measured with water due to proppant embedment caused by water. The experiments demonstrate the advantages of using proppant in fractures, even if the rock surface roughness can provide certain fracture conductivity via the self-propping mechanism. For fractures without proppants, high rock surface roughness is not necessarily favorable for enhancing fracture conductivity because the self-propping mechanism requires shear slip along the fracture surface. If there is no shear slip, high rock surface roughness can cause a detrimental effect on the fracture conductivity due to the interlocking effect. Utilizing advanced experimental equipment and LB modeling, this research explores the interplays between proppant placement, fracture geometry, and stress conditions to develop a comprehensive understanding of the productivity in non-smooth fractures. Further, the outcomes of this investigation indicate the importance of creating fractures with surface roughness during hydraulic fracturing and will contribute to the development of more efficient stimulation techniques for subsurface energy extraction.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Interlocking metasurfaces

Abstract Interlocking metasurfaces (ILMs) are architected arrays of mating features that enable joining of two bodies. Complementary to traditional joining technologies such as bolts, adhesives, and welds, ILMs combine ease of assembly, removal, and reassembly with robust mechanical properties. Structural in nature, they act in a quasi-continuous manner across a surface and enable joining of complex surfaces, e.g., lattices. In this perspective, we define an ILM, begin exploring the design domain and illustrate its breath, and pragmatically evaluate mechanical performance and manufacturability. ILMs will find applications in various fields from aerospace to micro-robotics, civil engineering, and prosthetics.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Thermodynamics and Structure of Poly[n]catenane Melts.

Motivated by recent achievements in the synthesis of interlocking polymers, the structural features of poly[n]catenanes, polymers composed entirely of interlocking rings (or macrocycles), are studied by extensive molecular dynamics simulations in the melt state. The degree of polymerization (number of links) is varied from n = 1 25 and the number of beads per macrocycle is varied from m = 15-50; the results are compared to linear chains of degrees of polymerization N = 15-175. The mechanical bonds in the system cause significant topological contributions to the pressure and potential energy density not seen in other polymer systems. The polymers themselves possess many unusual structural features at short and intermediate length scales, which can be attributed to density inhomogeneities along the polymer contour. Furthermore, the conformations of the individual macrocycles within poly[n]catenanes are quite different from those of ordinary ring polymers and depend on the topology of the macrocycle, that is, whether it is threaded by one ring (chain end) or two (chain center). At larger length scales, the poly[n]catenanes are conformationally similar to ideal linear chains, but unlike traditional (covalent) polymers, they are highly globular at low degrees of polymerization and are extremely flexible relative to their size, which inhibits interchain entanglement. Implications for poly[n]catenane material properties and synthesis are discussed.

Rauscher, Phillip M.↗
DOE OSTI2022

Olympus System Backplane Definition

The purpose of this document is to define the backplane of the Olympus firing system, a modular system based on SpaceWire communication between modules. The backplane provides the connection between the modules, controller (embedded in the front module), the SpaceWire router, and an alternative switch. Those connections include SpaceWire links, interlocks, a key, a dead-man switch (DMS)/charge, timing lines, power distribution, geographical addresses, and communication to the human-machine interface (HMI). This backplane is based on the VMEBus International Trade Association (VITA) 46 Specification (VPX) and OpenVPX standards for a 3U backplane. Unless otherwise specified, those standards apply for signal definitions and mechanical specifications.

42 ENGINEERING↗
DOE OSTI2026

Strength characterization of solar-synthesized cylindrical graphite carbon–carbon composites

The present work describes a new morphology of cylindrical graphite synthesized in a unique manner by direct solar decomposition of methane and reports the mechanical properties of its manifestation in woven carbon–carbon composites. Whereas traditional carbon–carbon composites are formed via epoxy impregnation, the deposited material in the process presented here conformally follows the existing shape and orientation of individual carbon fibers. Through this process, cylindrical graphite fibers are synthesized that possess superior strength due to their graphitic layers that amalgamate into interlocked pathways between disparate fibers. Here, strength measurements, taken in tandem with Raman, XRD, and SEM, paint a picture of the shift from cloth to composite behavior via graphitization of the original substrate combined with sheets of graphene coalescing into a unified composite, with a notable improvement in elastic modulus from 0.19 to 2.66 GPa.

Carbon–carbon composite↗
DOE OSTI2024

Dissimilar Material Joining via Interlocking Metasurfaces

Background The integration of dissimilar materials poses a significant challenge in engineering, necessitating innovative solutions for robust and reliable joining. Interlocking metasurfaces (ILMs) are a new joining technology comprising arrays of autogenous features patterned across two surfaces that interlock to form robust structural joints. Objective Here, this study elucidates the factors influencing the tensile performance of ILM joints formed between dissimilar materials. Methods We employed parametric optimization to identify optimal unit cell geometries for maximal yield strength based on the hypothesis that the elastic tensile properties of the materials are the primary determinants of tensile performance. Experimental validation was performed by mechanically testing the theorized optimal ILM geometry and a range of ILM geometries to capture the overall behavior trends of joints between two additively manufactured polymers, VeroPureWhite (VW) and RGDA8430-DM (8430). Results Experimental validation of optimized designs revealed that additional factors, e.g. flexural strength and localized plasticity, also strongly influenced the tensile performance of T-slot ILMs joining dissimilar materials. The proposed optimal design remained the best performer. Conclusions This study demonstrates the viability of ILMs as a joining method for dissimilar materials. ILMs can join dissimilar materials with no loss in joint yield strength compared to joints composed solely of the weaker of the two constitutive materials. ILMs demonstrated their potential as a versatile and effective joining technology in diverse engineering applications.

Elbrecht, Benjamin James [Sandia National Laborato↗
DOE OSTI2024

Impacts of irregularly-distributed acidified brine flow on geo-chemo-mechanical alteration in an artificial shale fracture under differential stress

The efficacy of geological carbon sequestration is reliant on the integrity of the caprock and its resistance to physical and chemical alteration. Caprocks with high abundance of reactive carbonates like calcite are susceptible to acid-promoted dissolution and can result in structural weakening. This work investigates the effect of acidified brine flow through an artificially fractured, high-carbonate (30 % by XRD) shale under differential compressive stress. Cylindrical samples were cut in half vertically and milled to create an artificial fracture with interlocking asperities and open channels. Samples were sheared with a single applied stress in a custom flow cell housed within an industrial CT scanner. Further, either acidic (pH 4) or reservoir-simulated (pH 9.5) brine was flowed through the artificial fracture for 7–8 days under reservoir pressure and room temperature. Model simulations indicate flow mainly occurred in open channels, with limited flow between overlapping asperities. Analysis of fracture surfaces by optical and scanning electron microscopy show increased surface alteration and roughness after exposure to pH 4 versus pH 9.5 brine indicating mineral dissolution/loss, and this effect is greater in areas that receive the highest brine flows. Similarly, surface analysis by scratch testing shows fracture toughness decreases more after exposure to acidic versus reservoir-simulated brine, with the greatest alteration in areas of highest acidic brine flows. Despite weakening, no shear slip occurred. Overall, the results indicate that acidified brine can result in significant physical and geomechanical alteration of irregular fracture surfaces in shale caprock, with greatest effects in preferential flow regions.

58 GEOSCIENCES↗
DOE OSTI2023

Fluctuating intertwined stripes in the strange metal regime of the Hubbard model

Strongly correlated electron systems host a variety of poorly understood correlations in their high-temperature normal state. Unlike ordered phases defined by order parameters, regions of the normal state are often defined through unconventional properties such as strange metallic transport or spectroscopic pseudogaps. Characterizing the microscopic correlations in the normal state is necessary to elucidate mechanisms that lead to these properties and their connection to ground-state orders. Here, in this paper, we establish the presence of intertwined charge and spin stripes in the strange metal normal state of the Hubbard model using determinant quantum Monte Carlo calculations. The charge and spin density waves constituting the stripes are fluctuating and short ranged; yet they obey a mutual commensurability relation and remain microscopically interlocked, as evidenced through measurements of three-point spin-spin-hole correlation functions. Our findings demonstrate the ability of many-body numerical simulations to unravel the microscopic correlations that define quantum states of matter.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

First-principles investigation of elastic, vibrational, and thermodynamic properties of kagome metals CsM 3 Te 5 (M = Ti, Zr, Hf)

Kagome metals are a unique class of quantum materials characterized by their distinct atomic lattice arrangement, featuring interlocking triangles and expansive hexagonal voids. These lattice structures impart exotic properties, including superconductivity, interaction-driven topological many-body phenomena, and magnetism, among others. The kagome metal CsM 3 ⁢Te 5 (where M = Ti, Zr, or Hf) exhibits both superconductivity and nontrivial topological electronic properties, offering a promising platform for exploring topological superconductivity. This study employs first-principles density functional theory calculations to systematically analyze the elastic, mechanical, vibrational, thermodynamic, and electronic properties of CsM 3 ⁢Te 5 (M = Ti, Zr, Hf). Our calculations reveal that the studied compounds—CsTi 3 ⁢Te 5 , CsZr 3 ⁢Te 5 , and CsHf 3 ⁢Te 5 —are ductile metals with elastic properties akin to the hexagonal Bi and Sb, with average elastic constants, including a bulk modulus of 27 GPa, a shear modulus of 11 GPa, and Young's modulus of 29 GPa. We observe peculiar dispersionless, flat, phonon branches in the vibrational spectra of these metals. Additionally, we thoroughly analyze the symmetries of the zone-center phonon eigenvectors and predict vibrational fingerprints of the Raman- and infrared-active phonon modes. The analysis of thermodynamic properties reveals the Einstein temperature for CsTi 3 ⁢Te 5 , CsZr 3 ⁢Te 5 , and CsHf 3 ⁢Te 5 to be 66, 54, and 53 K, respectively. Our orbital-decomposed electronic structure calculations reveal significant in-plane steric interactions and multiple Dirac band crossings near the Fermi level. We further investigate the role of spin-orbit coupling effect on the studied properties. Furthermore, this theoretical investigation sheds light on the intriguing quantum behavior of kagome metals.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Implications of styrenic triblock copolymer gel mechanics on midblock bridging fraction

Triblock copolymer gels have garnered considerable scientific interest over the past few decades and are used in a variety of applications including consumer cushioning, pressure-sensitive adhesives, and ballistics gels. While many of their applications rely upon understanding mechanical properties, mechanical studies of block copolymer gels are relatively disjointed with each focusing on specific copolymers, which inherently have a fixed molecular weight and composition. Here, the present study examines the quasistatic mechanical response of styrenic triblock copolymer gels composed of seven unique triblock copolymers at various concentrations. Resultant stress-extension data is fitted with the slip-tube network (STN) theory that describes gel mechanics based upon crosslinked network (G c ) and chain entanglement (G e ) modulus contributions. Collectively, modulus contributions imply that midblock bridging is independent of copolymer identity (i.e., molecular weight and block fraction) and dependent on triblock copolymer concentration via F b ∝ φ ABA 0.91±0.39 over the concentration range examined (φ ABA = 0.05–0.39). Gels composed of a complementary diblock-triblock copolymer pair were subsequently analyzed to explore the influence of interlocking loop-loop and loop-bridge pairs within the effective midblock bridging population. These results point to the presence of a physically significant quantity of interlocked loops, but quantitative analysis was inconclusive.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Disulfonated Poly(arylene ether sulfone) Random Copolymers Containing Hierarchical Iptycene Units for Proton Exchange Membranes

Two series of disulfonated iptycene-based poly(arylene ether sulfone) random copolymers, i.e., TRP-BP (triptycene-based) and PENT-BP (pentiptycene-based), were synthesized via condensation polymerization from disulfonated monomer and comonomers to prepare proton exchange membranes (PEMs) for potential applications in electrochemical devices such as fuel cell. To investigate the effect of iptycene units on membrane performance, these copolymers were systematically varied in composition (i.e., iptycene content) and the degree of sulfonation (i.e., 30–50%), which were characterized comprehensively in terms of water uptake, swelling ratio, oxidative stability, thermal and mechanical properties, and proton conductivity at various temperatures. Comparing to copolymers without iptycene units, TRP-BP and PENT-BP ionomers showed greatly enhanced thermal and oxidative stabilities due to strong intra- and inter-molecular supramolecular interactions induced by hierarchical iptycene units. In addition, the introduction of iptycene units in general provides PEMs with exceptional dimensional stability of low volume swelling ratio at high water uptakes, which is ascribed to the supramolecularly interlocked structure as well as high fractional free volume of iptycene-based polymers. It is demonstrated that the combination of high proton conductivity and good membrane dimension stability is the result of the synergistic effects of multiple factors including free volume (iptycene content), sulfonation degree, hydrophobicity, and swelling behavior (supramolecular interactions).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Microstructural examination of interactions between chromia-based refractory and nuclear glass in a melter

This study shows the effects of nuclear waste glass production on Monofrax K-3 refractory corrosion. A continuously fed research-scale melter containing an Fe- and Ni-rich simulated nuclear waste feed with borosilicate glass-forming chemicals was cyclically melted at 1150°C and idled at 1050°C for a total of 11 weeks. Chemical maps using scanning electron microscopy show the interactions between the quenched melt and the refractory. Nanoscale X-ray-computed tomography was used for a three-dimensional visualization of certain parts of the interface. Unreacted K-3 consists of primarily corundum (Al,Cr) 2 O 3 and spinel (Fe 2+ ,Mg)(Al,Cr) 2 O 4 interlocking crystalline phases. Some of the Cr from the refractory interacts with the Ni and Fe from the melt to form a reaction layer comprising (Ni,Fe 2+ )(Cr,Fe 3+ ) 2 O 4 spinel crystals. Simultaneously, melt components (Na,Si) infiltrate into the refractory. This interaction proceeds at the expense of the integrity of the refractory structure. Intact refractory grains (e.g., (Al,Cr) 2 O 3 ) as well as the reaction layer itself can lose mechanical integrity and spall off into the melt, especially near the top of the melter. As the reaction layer can be a protective boundary for the refractory against further melt infiltration, a reduction in the reaction layer thickness allows an increase in refractory corrosion.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design

Unique friction-based self-piercing riveting (F-SPR) was employed to join high-strength, low-ductility aluminum alloy 7055 for lightweight vehicle applications. This study aimed to maximize the joint strength of the AA7055 F-SPR joint while avoiding cracking issues due to low ductility at room temperature. A fully coupled Eulerian–Lagrangian (CEL) model was employed to predict the process temperature during F-SPR, and the temperature field was then mapped onto a 2D axisymmetric equivalent model for accelerated numerical analysis. The geometry, dimensions, and material strength of the rivet, as well as the depth of the die cavity and plunging depth, were investigated to enhance joint formation. Also, a static finite-element analysis model was developed to predict and analyze the stress distribution in the rivet under different mechanical testing loading conditions. Overall, the numerical model showed good agreement with the experiment results, such as joint formation and mechanical joint strength. With the aid of virtual fabrication through numerical modeling, the joint design iterations and process development time of F-SPR were greatly reduced regarding the goal of lightweight, high-strength aluminum joining.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Snapshots of Ce 70 Toroid Assembly from Solids and Solution

Crystallization at the solid–liquid interface is difficult to spectroscopically observe and therefore challenging to understand and ultimately control at the molecular level. The Ce70-torroid formulated [Ce IV 70 (OH) 36 (O) 64 (SO 4 ) 60 (H 2 O) 10 ] 4– , part of a larger emerging family of M IV 70 -materials (M = Zr, U, Ce), presents such an opportunity. We elucidated assembly mechanisms by the X-ray scattering (small-angle scattering and total scattering) of solutions and solids as well as crystallizing and identifying fragments of Ce 70 by single-crystal X-ray diffraction. Fragments show evidence for templated growth (Ce 5 , [Ce 5 (O) 3 (SO 4 ) 12 ] 10- ) and modular assembly from hexamer (Ce 6 ) building units (Ce 13 , [Ce 13 (OH) 6 (O) 12 (SO 4 ) 14 (H 2 O) 14 ] 6– and Ce 62 , [Ce 62 (OH) 30 (O) 58 (SO 4 ) 58 ] 14- ). Ce 62 , an almost complete ring, precipitates instantaneously in the presence of ammonium cations as two torqued arcs that interlock by hydrogen boding through NH 4 + , a structural motif not observed before in inorganic systems. The room temperature rapid assemblies of both Ce 70 and Ce 62 , respectively, by the addition of Li + and NH 4 + , along with ion-exchange and redox behavior, invite exploitation of this emerging material family in environmental and energy applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Dynamics of poly[n]catenane melts

Inspired by advances in the chemical synthesis of interlocking polymer architectures, extensive molecular dynamics simulations have been conducted to study the dynamical properties of poly[n]catenanes-polymers composed entirely of interlocking rings-in the melt state. Both the degree of polymerization (number of links) and the number of beads per ring are systematically varied, and the results are compared to linear and ring polymers. Herein, a simple Rouse-like model is presented, and its analytical solution suggests a decomposition of the dynamics into "ring-like" and "linear-like" regimes at short and long times, respectively. In agreement with this picture, multiple sub-diffusive regimes are observed in the monomer mean-squared-displacements even though interchain entanglement is not prevalent in the system. However, the Rouse-type model does not account for the topological effects of the mechanical bonds, which significantly alter the dynamics at intermediate length scales both within the rings and at the chain segment scales. The stress relaxation in the system is extremely rapid and may be conveniently separated into ring-like and linear-like contributions, again in agreement with the Rouse picture. However, the viscosity has a non-monotonic dependence on the ring size for long chains, which disagrees strongly with theoretical predictions. This unexpected observation cannot be explained in terms of chain disentanglement and is inconsistent with other measures of polymer relaxation. Possible mechanisms for this behavior are proposed and implications for materials design are discussed.

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

The Toughness of Interlocking Metasurfaces

Interlocking metasurfaces (ILMs) are arrays of autogenous latching unit cells patterned across a surface. These create structural joints similar to bioinspired suture joints but patterned over a 2D surface rather than a 1D seam. This enables ILMs to be an alternative to conventional joining technologies such as bolts, welds, and adhesives. However, compared to conventional joining methods, relatively little is known of the engineering considerations for designing structural ILMs. Herein, the interfacial toughness of an archetypal ILM is examined for the first time. Under the conditions studied here, the ILM is substantially tougher than the material from which it is made, in this case, exhibiting up to a 50% increase in interfacial crack initiation energy over the solid base material, a photocured 3D‐printed polymer. Through experimental tests using in‐situ digital image correlation along with complementary computational analyses, the mechanism of toughening in the ILM structure and the origins of toughness anisotropy are revealed. The increase in toughness is associated with cross‐cell interactions, that is, load‐sharing across unit cells, which give rise to a finite process zone length with different effective material properties. In this way, ILM toughening is analogous to crack blunting in ductile materials or fiber bridging in composites; yet here, the ILM is composed of a single‐phase base material and so the architected toughening is geometric in nature and hence amenable to future topological optimization.

fracture↗