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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 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

Description and evaluation of an interference assessment for a slotted-wall wind tunnel

A wind-tunnel interference assessment method applicable to test sections with discrete finite-length wall slots is described. The method is based on high order panel method technology and uses mixed boundary conditions to satisfy both the tunnel geometry and wall pressure distributions measured in the slotted-wall region. Both the test model and its sting support system are represented by distributed singularities. The method yields interference corrections to the model test data as well as surveys through the interference field at arbitrary locations. These results include the equivalent of tunnel Mach calibration, longitudinal pressure gradient, tunnel flow angularity, wall interference, and an inviscid form of sting interference. Alternative results which omit the direct contribution of the sting are also produced. The method was applied to the National Transonic Facility at NASA Langley Research Center for both tunnel calibration tests and tests of two models of subsonic transport configurations.

Kemp, William B., Jr.↗
DOE OSTI2021

NMR Spectroscopy for Protein Higher Order Structure Similarity Assessment in Formulated Drug Products

Peptide and protein drug molecules fold into higher order structures (HOS) in formulation and these folded structures are often critical for drug efficacy and safety. Generic or biosimilar drug products (DPs) need to show similar HOS to the reference product. The solution NMR spectroscopy is a non-invasive, chemically and structurally specific analytical method that is ideal for characterizing protein therapeutics in formulation. However, only limited NMR studies have been performed directly on marketed DPs and questions remain on how to quantitively define similarity. Here, NMR spectra were collected on marketed peptide and protein DPs, including calcitonin-salmon, liraglutide, teriparatide, exenatide, insulin glargine and rituximab. The 1D 1 H spectral pattern readily revealed protein HOS heterogeneity, exchange and oligomerization in the different formulations. Principal component analysis (PCA) applied to two rituximab DPs showed consistent results with the previously demonstrated similarity metrics of Mahalanobis distance (D M ) of 3.3. The 2D 1 H- 13 C HSQC spectral comparison of insulin glargine DPs provided similarity metrics for chemical shift difference (Δδ) and methyl peak profile, i.e., 4 ppb for 1 H, 15 ppb for 13 C and 98% peaks with equivalent peak height. Finally, 2D 1 H- 15 N sofast HMQC was demonstrated as a sensitive method for comparison of small protein HOS. The application of NMR procedures and chemometric analysis on therapeutic proteins offer quantitative similarity assessments of DPs with practically achievable similarity metrics.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS2023

NASA Space Environment Analog for Training, Engineering, Science, and Technology (SEATEST) 6 Detailed Final Report

After more than 50 years since the last crewed lunar landing, plans for more missions to the moon are in development. For these missions, efficient and sustainable logistics will be critical. Additionally, innovative methods of cargo transfer to and from a lunar outpost should be considered for successfully establishing a permanent presence on the moon. SEATEST (Space Environment Analog for Training, Engineering, Science, and Technology) is an immersive mission-analogous operational atmosphere where buoyancy effects and supplemental weights can simulate partial gravity conditions similar to those astronauts will experience on the moon. SEATEST 6 took place at the University of Southern California (USC) Wrigley Marine Science Center on Santa Catalina Island from July 18-30, 2023. The analog was used to collect preliminary logistics data on two different offloading conceptual methods (a davit and a zipline) during a simulated lunar mission. Pre-test analysis indicated for a crew of two on a 14-day mission, approximately three Medium Pressurized Logistics Containers (MPLC) sized logistics containers (or a total of 37.5 single Cargo Transfer Bag Equivalents (CTBE)) would be needed to support a mission. A Computer-Aided Design (CAD) analysis was employed on the SEATEST airlock mockup to determine how many logistic containers would fit with two suited crewmembers, don/doff stands, and hatch operations. It was determined that for SEATEST, a total of 15 1.0 Small Pressurized Logistics Containers (SPLCs) and 8 2.0 SPLCs would adequately fit into the approximate 9.5 cubic meter airlock volume. This does not fully represent a complete 14-day logistic supply; however, it does provide a preliminary estimate to initiate design conversations between logistics teams and crew at this early stage of development. Data were collected in eight logistics transfer scenarios over two days with four scenarios per day. Five test subject crew participated in scenarios as pairs. Scenarios included two sizes of logistics containers – 1.0 SPLC (equivalent to a single Cargo Transfer Bag (CTB) and 2.0 SPLC (equivalent to two CTBs). Planed evaluations included the use of a logistics port compared to transfer through an Airlock hatch, offloading methods based on either a davit or a zipline system, choreography of cargo in the airlock to permit ingress and suit doffing, and dust removal protocols for an understanding of the overall impact to transfer ops. Data collected included objective data (task times for conducting overall tasks and subtasks, full audio/video of test activities, and inadvertent “dings” on hardware) and subjective data (crew consensus of: task acceptability and capability assessment ratings related to best practices, considerations, and constraints for EVA-driven logistics transfer ConOps, sim quality of the test environment, and more general debrief comments). The two logistic offloading transfer concepts (davit, zipline) presented both advantages and limitations. The davit’s flexibility in allowing the crew to pick up the containers without physical interaction was well regarded by the crew. Some limitations of select davit hardware components were noted, but the overall concept was acceptable. The zipline system proved to be the most efficient way of moving logistics from the lander to the airlock and eliminated the need for dust operations. However, extended and repetitive lifting of containers to the line could be fatiguing. In conclusion, logistics transfer could hypothetically be achieved without an offloading method; however, the time requirement for such operations would be prohibitive. Results of crew subjective feedback proposed a combined or hybrid davit/zipline method to increase efficiency.

Logistics↗
NASA NTRS2000

Data Retrieval Algorithms for Validating the Optical Transient Detector and the Lightning Imaging Sensor

A linear algebraic solution is provided for the problem of retrieving the location and time of occurrence of lightning ground strikes from an Advanced Lightning Direction Finder (ALDF) network. The ALDF network measures field strength, magnetic bearing, and arrival time of lightning radio emissions. Solutions for the plane (i.e., no earth curvature) are provided that implement all of these measurements. The accuracy of the retrieval method is tested using computer-simulated datasets, and the relative influence of bearing and arrival time data an the outcome of the final solution is formally demonstrated. The algorithm is sufficiently accurate to validate NASA:s Optical Transient Detector and Lightning Imaging Sensor. A quadratic planar solution that is useful when only three arrival time measurements are available is also introduced. The algebra of the quadratic root results are examined in detail to clarify what portions of the analysis region lead to fundamental ambiguities in sc)iirce location, Complex root results are shown to be associated with the presence of measurement errors when the lightning source lies near an outer sensor baseline of the ALDF network. For arbitrary noncollinear network geometries and in the absence of measurement errors, it is shown that the two quadratic roots are equivalent (no source location ambiguity) on the outer sensor baselines. The accuracy of the quadratic planar method is tested with computer-generated datasets, and the results are generally better than those obtained from the three-station linear planar method when bearing errors are about 2 deg.

Koshak, W. J.↗
NASA NTRS1997

ALDF Data Retrieval Algorithms for Validating the Optical Transient Detector (OTD) and the Lightning Imaging Sensor (LIS)

A linear algebraic solution is provided for the problem of retrieving the location and time of occurrence of lightning ground strikes from in Advanced Lightning Direction Finder (ALDF) network. The ALDF network measures field strength, magnetic bearing, and arrival time of lightning radio emissions and solutions for the plane (i.e.. no Earth curvature) are provided that implement all of these measurements. The accuracy of the retrieval method is tested using computer-simulated data sets and the relative influence of bearing and arrival time data on the outcome of the final solution is formally demonstrated. The algorithm is sufficiently accurate to validate NASA's Optical Transient Detector (OTD) and Lightning Imaging System (LIS). We also introduce a quadratic planar solution that is useful when only three arrival time measurements are available. The algebra of the quadratic root results are examined in detail to clarify what portions of the analysis region lead to fundamental ambiguities in source location. Complex root results are shown to be associated with the presence of measurement errors when the lightning source lies near an outer sensor baseline of the ALDF network. For arbitrary noncollinear network geometries and in the absence of measurement errors, it is shown that the two quadratic roots are equivalent (no source location ambiguity) on the outer sensor baselines. The accuracy of the quadratic planar method is tested with computer-generated data sets and the results are generally better than those obtained from the three station linear planar method when bearing errors are about 2 degrees.

Koshak, W. J.↗
NASA NTRS2017

Treatment of Overlapping Gaseous Absorption with the Correlated-k Method in Hot Jupiter and Brown Dwarf Atmosphere Models

The correlated-k method is frequently used to speed up radiation calculations in both one-dimensional and three-dimensional atmosphere models. An inherent difficulty with this method is how to treat overlapping absorption, i.e. absorption by more than one gas in a given spectral region. We have evaluated the applicability of three different methods in hot Jupiter and brown dwarf atmosphere models, all of which have been previously applied within models in the literature: (i) Random overlap, both with and without resorting and rebinning, (ii) equivalent extinction and (iii) pre-mixing of opacities, where (i) and (ii) combine k-coefficients for different gases to obtain k-coefficients for a mixture of gases, while (iii) calculates k-coefficients for a given mixture from the corresponding mixed line-by-line opacities. We find that the random overlap method is the most accurate and flexible of these treatments, and is fast enough to be used in one-dimensional models with resorting and rebinning. In three-dimensional models such as GCMs it is too slow, however, and equivalent extinction can provide a speed-up of at least a factor of three with only a minor loss of accuracy while at the same time retaining the flexibility gained by combining k-coefficients computed for each gas individually. Pre-mixed opacities are significantly less flexible, and we also find that particular care must be taken when using this method in order to to adequately resolve steep variations in composition at important chemical equilibrium boundaries. We use the random overlap method with resorting and rebinning in our one-dimensional atmosphere model and equivalent extinction in our GCM, which allows us to e.g. consistently treat the feedback of non-equilibrium chemistry on the total opacity and therefore the calculated P-T profiles in our models.

atmospheres↗
DOE OSTI2021

Spread Spectrum Symbol Detection With Blind Interference Suppression in FBMC-SS

Recent works have demonstrated Filter Bank Multicarrier Spread Spectrum (FBMC-SS) to be a robust communication scheme in the presence of high-power interferers. Existing FBMC-SS symbol detector designs based on analysis filter banks (AFB) suggest using an optimal combining scheme to suppress the interferers, necessitating some noise/interference power estimation method. In this paper, we introduce a symbol detector with blind interference suppression by extending a recently developed packet detection method. We then provide an analysis to show that the existing AFB-based symbol detector and the one proposed in this paper are equivalent in typical usage scenarios. A fully-fledged receiver design is proposed utilizing this symbol detector, with specifics presented for estimation of the channel impulse response and carrier frequency offset (CFO). We also outline a method of iterating upon the channel and CFO estimations to improve the quality of both parameters. Moreover, a modification to allow improved performance of the symbol detector at high SNR is provided. Finally, simulated performance results are presented to corroborate these findings and demonstrate the efficiency of this receiver design.

99 GENERAL AND MISCELLANEOUS↗
NASA NTRS2007

Photometric Calibration of Consumer Video Cameras

Equipment and techniques have been developed to implement a method of photometric calibration of consumer video cameras for imaging of objects that are sufficiently narrow or sufficiently distant to be optically equivalent to point or line sources. Heretofore, it has been difficult to calibrate consumer video cameras, especially in cases of image saturation, because they exhibit nonlinear responses with dynamic ranges much smaller than those of scientific-grade video cameras. The present method not only takes this difficulty in stride but also makes it possible to extend effective dynamic ranges to several powers of ten beyond saturation levels. The method will likely be primarily useful in astronomical photometry. There are also potential commercial applications in medical and industrial imaging of point or line sources in the presence of saturation.This development was prompted by the need to measure brightnesses of debris in amateur video images of the breakup of the Space Shuttle Columbia. The purpose of these measurements is to use the brightness values to estimate relative masses of debris objects. In most of the images, the brightness of the main body of Columbia was found to exceed the dynamic ranges of the cameras. A similar problem arose a few years ago in the analysis of video images of Leonid meteors. The present method is a refined version of the calibration method developed to solve the Leonid calibration problem. In this method, one performs an endto- end calibration of the entire imaging system, including not only the imaging optics and imaging photodetector array but also analog tape recording and playback equipment (if used) and any frame grabber or other analog-to-digital converter (if used). To automatically incorporate the effects of nonlinearity and any other distortions into the calibration, the calibration images are processed in precisely the same manner as are the images of meteors, space-shuttle debris, or other objects that one seeks to analyze. The light source used to generate the calibration images is an artificial variable star comprising a Newtonian collimator illuminated by a light source modulated by a rotating variable neutral- density filter. This source acts as a point source, the brightness of which varies at a known rate. A video camera to be calibrated is aimed at this source. Fixed neutral-density filters are inserted in or removed from the light path as needed to make the video image of the source appear to fluctuate between dark and saturated bright. The resulting video-image data are analyzed by use of custom software that determines the integrated signal in each video frame and determines the system response curve (measured output signal versus input brightness). These determinations constitute the calibration, which is thereafter used in automatic, frame-by-frame processing of the data from the video images to be analyzed.

Suggs, Robert↗
NASA NTRS1986

Equivalent plate analysis of aircraft wing box structures with general planform geometry

A new equivalent plate analysis formulation is described which is capable of modeling aircraft wing structures with a general planform such as cranked wing boxes. Multiple trapezoidal segments are used to represent such planforms. A Ritz solution technique is used in conjunction with global displacement functions which encompass all the segments. This Ritz solution procedure is implemented efficiently into a computer program so that it can be used by rigorous optimization algorithms for application in early preliminary design. A direct method to interface this structural analysis procedure with aerodynamic programs for use in aeroelastic calculations is described. This equivalent plate analysis procedure is used to calculate the static deflections and stresses and vibration frequencies and modes of an example wing configuration. The numerical results are compared with results from a finite element model of the same configuration to illustrate typical levels of accuracy and computation times resulting from use of this procedure.

Giles, G. L.↗
DOE OSTI2020

Volumetric analysis and mesh generation of real and artificial microstructural geometries

Producing a viable finite element mesh of realistic microstructural structural geometry is a critical step in analyzing the thermo-mechanical behavior of complex multi-material composites. Advancements in imaging technology such as micro computed tomography have allowed modelers to access high resolution mesoscale geometries for direct numerical simulation. However, converting from voxel based 3D images to usable finite element meshes has been challenging. A robust method including algorithms and software scripts for generating finite element meshes from 3D imaged microstructures is presented in this paper. It includes a routine for inserting cohesive elements around material interfaces to enable modeling of interface properties including delamination and damage. The algorithms and procedures presented in this method leverage currently available software packages for processing surface based geometry into volume based meshes. In addition to converting real geometry from physical imaging systems, algorithms for producing numerically generated and statistically equivalent microstructural geometry are also included. These artificial microstructures can be a valuable resource for modelers when physical specimens do not exist or are limited in quantity: Method establishes a workflow from voxel data to viable finite element mesh including interface information, and Includes a method for synthetic geometry generation based on metrics from real microstructures.

36 MATERIALS SCIENCE↗
NASA NTRS1975

Chandrasekhar-type algorithms for fast recursive estimation in linear systems with constant parameters

In this recursive method proposed, the gain matrix for the Kalman filter and the convariance of the state vector are computed not via the Riccati equation, but from certain other equations. These differential equations are of Chandrasekhar-type. The 'invariant imbedding' idea resulted in the reduction of the basic boundary value problem of transport theory to an equivalent initial value system, a significant computational advance. Initial value experience showed that there is some computational savings in the method and the loss of positive definiteness of the covariance matrix is less vulnerable.

Choudhury, A. K.↗
NASA NTRS1992

Conservative-coordinate transformations for atmospheric measurements

This lecture describes a technique by which atmospheric measurements of trace species with medium to long lifetimes can be 'coincidentally' compared and validated even though measurements are taken at different locations and different times In other words, the method, under suitable counditions, can remove a large amount of the natural meteorological variability. The technique involves the use of quasi-Lagrangian or conservative coordinates - air parcel tags which are invariant or nearly invariant under the motion of the parcel. The technique is called 'reconstruction', since measurements taken at one location can be reconstructed at different locations. In order to do this, the data are transformed into the conservative coordinates and accumulated. Within the conservative reference frame, much of the meteorological variability is removed. Once enough data are obtained within the system, the observations can be tranformed back into physical space at any location and compared with other measurements. The method by which the trace species data are obtained makes no difference; satellite, balloon, rocket, aircraft and ground-based data all become equivalent and can be intercompared. The conservative-coordinate system not only allows for intercomparison of data, but shows how data can be taken in such a way as to maximize the physical scope of the information. In other words, the method automatically suggests when conditions might be suitable to obtain information with different environmental situations. It also allows for the forecast of constituent fields using only the meteorological forecasts and limited observational data.

Schoeberl, M. R.↗
DOE OSTI2023

Rapid Simulation of Unconventional Reservoirs by Multidomain Multiresolution Modeling Based on the Diffusive Time of Flight

Summary The fast marching method (FMM)-based rapid flow simulation has been shown to accelerate simulation efficiency by orders of magnitude by transforming 3D simulation to equivalent 1D simulation using the concept of the “diffusive time of flight” (DTOF). However, the 1D transformation does not directly apply to multiwell problems. In this paper, we propose a novel DTOF-based multidomain multiresolution discretization scheme to accelerate multiwell simulation of unconventional reservoirs. Our method formulates multiwell simulation problems based on the DTOF which displays the pressure front propagation in unconventional reservoirs. The DTOF contours are used to partition the reservoir into local and shared domains. A local domain is where the flow is dominated by a single well, and the shared domain is where the fluid flow is influenced by multiple wells. The DTOF contours expand independently in local domains and interfere in the shared domain. After the partitioning, each domain is discretized using a multiresolution scheme whereby the original 3D fine mesh is preserved near the wells to account for detailed physics including gravity, and the rest of the domain is discretized into 1D mesh based on the DTOF contours to alleviate the simulation workload. The power and efficacy of our approach are demonstrated using synthetic and field-scale simulation models with different degrees of geologic and well-completion complexity. The simulation results, number of active cells, and computation time for the proposed discretization scheme are compared with the original high-fidelity 3D model for each case. The results show that the proposed method is suitable for multiwell simulation problems in unconventional reservoirs and can accelerate flow simulations by orders of magnitude with minimal loss of accuracy. The novelty of this work is the creation of DTOF-derived multiresolution discretization with local and shared domains to simplify and accelerate the calculation of subsurface flow problems, especially in unconventional reservoirs. Our workflow can be easily interfaced with commercial simulators, making it suitable for large-scale field applications.

Engineering↗
NASA NTRS2021

Multiobjective Multidisciplinary Optimization of Low-Boom Supersonic Transports Using Multifidelity Models

A multidisciplinary optimization (MDO) method has been developed to design a computational fluid dynamics (CFD) based low-boom configuration that can be obtained from a Pareto solution of a low-fidelity multiobjective MDO problem with mission constraints. This paper refines the developed MDO method by using multifidelity models for CFD-based multiobjective MDO and a better method for the system-level trade between the target low boom ground noise level and the overland range. The refined MDO method can generate a low-boom configuration that satisfies the mission requirements, has the lowest takeoff gross weight and the longest range for the low-boom mission, trims the low-boom cruise flight with fuel redistributions, and has a reversed equivalent area distribution closely matching a low-boom target with ground noise level below 70 PLdB. The validity of the refined MDO method is demonstrated by a design study of a low-boom supersonic transport that carries 40 passengers, flies a low-boom mission with cruise Mach of 1.7 and range of 3500 nm, and cruises overwater at Mach 1.8 with range of 3882 nm. Moreover, the refined MDO method eliminates the difference between the assumed cruise weight for CFD-based low-boom inverse design optimization and the estimated cruise weight of the optimal inverse design solution with respect to the mission requirements.

MDO↗
DOE OSTI2021

Rapid prediction of fuel research octane number and octane sensitivity using the AFIDA constant-volume combustion chamber

Current research octane number (RON) and motor octane number (MON) gasoline performance characterization techniques use dated, complex engine testing methodology and limit researchers’ ability to easily characterize small volumes of experimental fuels. A novel methodology is presented that correlates measured ignition delay (ID) time to RON in an Advanced Fuel Ignition Delay Analyzer (AFIDA) constant-volume combustion chamber device at a single pressure/temperature condition, with an r2 of 0.99 and standard error (SE) of 1.0. The correlation of the slope of the ID time between two additional temperature points to octane sensitivity (S) produces an r2 of 0.97 and SE of 0.69; however, fuels with S>12 are indistinguishable. These results are based on methodology calibration using 31 primary and toluene reference fuels containing 0%-40% ethanol with RON values ranging from 85 to 113. Validation of these methods using a 102-sample fuel matrix spanning an array of base fuels and additive chemistry designed to test the robust applicability of the method, along with pump gasoline and high-octane surrogate blend samples, demonstrates an r2 of 0.94 and SE of 1.3 for the RON correlation over all samples, whereas the equivalent S correlation produces an r2 of 0.78 and SE of 1.2 by excluding two additives, 3-pentanone and diisobutylene, which displayed poor S correlation results. This novel AFIDA analysis method can be performed in 1 h and with 40 mL of fuel, offering significant improvements in time and volume requirements over traditional techniques.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Sustainable bioleaching of lithium-ion batteries for critical materials recovery

The demand for lithium-ion batteries (LIBs) has increased substantially over the last few decades due to their longer lifetime, greater resistance to self-discharge, and higher output voltage compared to other battery types. With the global trend of electrifying vehicle fleets, the number of LIBs reaching their end-of-life (EOL) is expected to grow substantially in the next decade. These EOL LIBs represent a significant secondary source of materials (e.g., Li, Co, Ni, Mn) that can be recovered and reused in LIBs or other products. In this study, we developed a bioleaching process that could recover critical materials from EOL LIBs in an economical and environmentally sustainable manner under industrially relevant conditions. Black mass, i.e., cathode-containing powder, prepared from EOL LIBs was leached using a biolixiviant produced from corn stover by Gluconobacter oxydans bacteria. Iron(II) was used as a reducing agent to promote metal dissolution. Techno-economic analysis (TEA) estimated a potential average profit margin of 21% for processing 10,000 t of black mass per year, which represents approximately 30% of the available black mass in the US in 2020. Life cycle assessment (LCA) demonstrated that bioleaching of spent LIBs could be more environmentally sustainable than alternative hydrometallurgical recovery methods such as hydrochloric acid leaching (16-19 kg vs. 43-91 kg CO 2 equivalent global warming potential per kg of recovered cobalt). The TEA results are highly dependent on the cost of black mass production, which varies by EOL LIB collection and transportation costs. Finally, emerging technologies for deactivating used LIBs for fire safety at collection centers will allow the transport of EOL LIBs as non-hazardous materials, lower the cost of preparing black mass and thereby increase economic prospects for EOL LIBs recycling using this approach.

25 ENERGY STORAGE↗
DOE OSTI2024

Solving differential‐algebraic equations in power system dynamic analysis with quantum computing

Abstract Power system dynamics are generally modeled by high dimensional non‐linear differential‐algebraic equations (DAEs) given a large number of components forming the network. These DAEs' complexity can grow exponentially due to the increasing penetration of distributed energy resources, whereas their computation time becomes sensitive due to the increasing interconnection of the power grid with other energy systems. This paper demonstrates the use of quantum computing algorithms to solve DAEs for power system dynamic analysis. We leverage a symbolic programming framework to equivalently convert the power system's DAEs into ordinary differential equations (ODEs) using index reduction methods and then encode their data into qubits using amplitude encoding. The system non‐linearity is captured by Hamiltonian simulation with truncated Taylor expansion so that state variables can be updated by a quantum linear equation solver. Our results show that quantum computing can solve the power system's DAEs accurately with a computational complexity polynomial in the logarithm of the system dimension. We also illustrate the use of recent advanced tools in scientific machine learning for implementing complex computing concepts, that is, Taylor expansion, DAEs/ODEs transformation, and quantum computing solver with abstract representation for power engineering applications.

computational complexity↗
DOE OSTI2022

Solid Phase Processing of Lead-Free Brass with Carbon Additives

Currently, “lead-free” brass alloys (like C27450/C27451/C6930), used extensively in drinking water fixtures and automotive, electrical, and electronic applications contain maximum 0.25% lead to maintain mechanical performance and machinability. Adding graphite to brass as an alternative to lead, using casting, powder metallurgy, and extrusion methods, has been explored previously. However, all these methods have proven to be energy-, time-, and resource-intensive, while not enabling performance equivalent to that of C36000 brass. In this project, we developed a one-step approach using friction extrusion and ShAPE to make lead-free brass/graphite components such as wires, rods and tubes with mechanical performance equivalent to commercial lead-free brass alloys. Manufacturing temperatures were maintained ~550-730 °C with feed rates ranging between 4 – 25 mm/min. Results show larger grains at the center of the rods and wires with smaller grains developing at the edges. Graphite particles were sheared in the direction of extrusion with higher strains observed towards the edges. Hardness of the brass/graphite samples was over 25% higher than that of the corresponding brass-only samples (rods and wires), also friction extruded. Our results show that the sub-micron graphite plays an important role in limiting process temperature and restraining grain growth during friction extrusion, thus reducing grain size in composites.

36 MATERIALS SCIENCE↗