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At least 793 records · Page 44
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Experimental Investigations to Study the Effects of Microwave Treatment Strategy on Tool Performance in Turning Operation

In the present study, microwave treatment has been used to enhance the tribological properties of single-point tungsten carbide (WC) cutting tool inserts such as wear resistance and hardness. The tool hardness and cutting parameters were considered to evaluate the performance of microwave-treated WC inserts in turning operation. The optimum cutting parameters were identified using response surface method (RSM)-based desirability approach. The relationship between cutting parameters and output responses, viz. flank wear, cutting force and surface roughness, was developed using the RSM. The investigations revealed that the increase in tool hardness due to complex carbide formation results in a significant reduction in tool wear, cutting forces and improvement in the surface finish of workpiece. Further, the statistical models results were validated with the experimental results. Metallurgical properties of treated and untreated tool inserts were analyzed using scanning electron microscope, x-ray diffraction method and Vickers microhardness tests. The results highlighted the importance of microwave treatment in enhancing the machining performance in turning operation.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Primary Carbides on the Sharpness of Kitchen Knives Made of 8Cr13MoV Steel

Although there are many primary carbides in the cutting edge of knives made of high-carbon martensitic steel, the effect of primary carbides on the sharpness of knives has not been clarified. In this paper, the evolution of primary carbides during the production process of 8Cr13MoV steel was presented. The effect of size and amount of primary carbides on the sharpness of knives was studied via employing rolling forging and diffusion annealing process, respectively. Results indicated that primary carbides easily fell off from cutting edge during cutting process, which would decrease the wear resistance of knives. The refinement of primary carbides could not only improve the wear resistance of cutting edge, but also weaken the fluctuation of sharpness during the service process of knives. By decreasing the amount of primary carbides, the wear resistance of knives would increase effectively, which improved the cutting performance effectively. Reducing the amount of primary carbides and refining the primary carbides in cutting edge were both effective ways to improve the sharpness of knives.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support

We present that friction stir welding (FSW) is a popular technique to join dissimilar materials in numerous applications. The solid state nature of the process enables joining materials with strikingly different physical properties. For welds in lap configuration, an enhancement to this technology is made by introducing a short, hard insert, referred to as a cutting-scribe, at the bottom of the tool pin. The cutting-scribe induces deformation in the bottom plate which leads to the formation of mechanical interlocks or hook like structures at the interface of two materials. A thermo-mechanical computational model employing a coupled Eulerian-Lagrangian approach is developed to quantitatively capture the morphology of these interlocks during the FSW process. Simulations using this model are validated by experimental observations. In conclusion, the identified interface morphology coupled with the predicted temperature field from this process–structure model can be used to estimate the post-weld microstructure and joint strength.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Bayesian stability and force modeling for uncertain machining processes

Accurately simulating machining operations requires knowledge of the cutting force model and system frequency response. However, this data is collected using specialized instruments in an ex-situ manner. Bayesian statistical methods instead learn the system parameters using cutting test data, but to date, these approaches have only considered milling stability. This paper presents a physics-based Bayesian framework which incorporates both spindle power and milling stability. Initial probabilistic descriptions of the system parameters are propagated through a set of physics functions to form probabilistic predictions about the milling process. The system parameters are then updated using automatically selected cutting tests to reduce parameter uncertainty and identify more productive cutting conditions, where spindle power measurements are used to learn the cutting force model. The framework is demonstrated through both numerical and experimental case studies. Results show that the approach accurately identifies both the system natural frequency and cutting force model.

42 ENGINEERING↗
DOE OSTI2016

Production and distillative recovery of valuable lignin-derived products from biocrude

Value-added chemicals present in liquid products from direct liquefaction of biomass can be recovered as bioproducts in an integrated biorefinery to enhance the economic viability of biomass-to-liquid fuel technologies and afford a higher return on investment. In recent efforts, RTI International is exploring and developing processes that could be used to produce bioproducts in addition to liquid fuel from biocrude intermediates. The present study focused on the production and recovery of high-value lignin-derived compounds from biocrude. Catalytic pyrolysis with a nonzeolite, alumina-based catalyst was used to produce the biocrude from loblolly pine in RTI's 1-tonne per day pilot-scale plant. Distillation was evaluated as a potential separation method given that the biocrude is relatively thermally stable and distillable compared to raw pyrolysis oils. The distillation studies were performed with a laboratory distillation unit (PETRODIST 300 CC) and the biocrude was fractionated into four distillate cuts: cut 1 (IBP-110 °C), cut 2 (110–200 °C), cut 3 (200–300 °C), and cut 4 (300–400 °C). In a case study, cut 3 was distilled further to concentrate the lignin-derived chemicals boiling between 200 and 270 °C. The results showed that a biocrude containing about 10 wt% guaiacols could be concentrated to about 35 wt% of guaiacols (representing 75% recovery) in the first distillation step. The second distillation step increased the concentration of guaiacols to about 53 wt% (representing 80% recovery). Furthermore, these findings suggest that it is possible to isolate and concentrate the lignin-derived products using a distillation column with a number of plates/trays. The yields, physicochemical properties, and chemical composition of the fractions, as well as the overall distillation separation efficiency, are reported.

09 BIOMASS FUELS↗
DOE OSTI2024

Voltage and temperature effects on low cobalt lithium-ion battery cathode degradation

Degradation of low cobalt lithium-ion cathodes was tested using a full factorial combination of upper cut-off voltage (4.0 V and 4.3 V vs. Li/Li + ) and operating temperature (25 °C and 60 °C). Half-cell batteries were analyzed with electrochemical and microstructural characterization methods. Electrochemical performance was assessed with galvanostatic cycling, cyclic voltammetry (CV), and electrochemical impedance spectroscopy (EIS) supported by distribution of relaxation times (DRT) analysis. Electrode microstructure was characterized with scanning electron microscopy (SEM), X-ray diffraction (XRD), and X-ray absorption near edge structure (XANES) imaging. Higher cut-off voltage cycling shows presence of NiO x formation, a low diffusivity rock-salt phase, in both CV and XRD data. XRD patterns confirmed that the rock-salt phase was beginning to form at the low cut-off voltage at high temperature, but in much lower intensity than at the high cut-off voltage. Higher temperature accelerates degradation processes at both voltages. Degradation factors at high temperature include NiO x formation, cathode material dissolution, and electrolyte decomposition. SEM analysis suggests that supporting phases may isolate and disconnect active material particles reducing capacity retention and battery life cycle. DRT analysis and XANES imaging show that both high temperature samples revealed a NiO x phase based on an increased diffusive impedance and a visible shift in the XANES spectra. The low cut-off voltage, high temperature sample showed a split peak and shift to lower energies indicating early formation of the NiO x phase. The diffusive impedance, which hinders intercalation and deintercalation, is driven by the formation of the NiO x phase. While primarily driven by cut-off voltage, elevated temperature also contributes to this degradation mechanism.

electrochemical impedance spectroscopy↗
DOE OSTI2015

Structural and functional studies of bioobjects prepared from femoral heads

Results of examination of physicomechanical characteristics of samples of medial femoral head cuts are presented. The samples of medial femoral head cuts resected in 6 patients with coxarthrosis in primary endoprosthetic replacement of a coxofemoral joint have been tested for micro- and nanohardness. Young’s modulus and elemental composition of bone tissue have been investigated. To estimate the architectonics of cancellous tissue of the femoral head, adjacent cuts of the same patient have been analyzed. The porosity of bone tissue was estimated from macroscopic images obtained using macrophotography. The total porosity is calculated as the ratio of the total length of straight line segments overlapping pores to the total length of secants. A three-point bending test of the samples has shown that their strength changed from 0.187 to 1.650 MPa and their elasticity modulus changes from 1.69 to 8.15 MPa. The microhardness of the samples changes in the range 220–265 MPa and the average microhardness of medial femoral head cuts is 240 MPa. The elemental composition of medial femoral head cuts is represented by basic Ca, P, O, Na and Mg elements as well as by Sn, S, Fe, Cr, and C in microamounts. The atomic Ca to P ratio for bone tissue is 1.55. It is revealed that pores of the upper part of the femoral head have a more regular shape and in the lower part they are more elongated along the cut and occupy a larger volume. The lower part of the femoral head has a higher porosity (39 and 33%) than the upper part (34 and 30%). The total porosity of all samples does not exceed 37%.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2015

NuSTAR observations of the powerful radio-galaxy Cygnus A

We present NuSTAR observations of the powerful radio galaxy Cygnus A, focusing on the central absorbed active galactic nucleus (AGN). Cygnus A is embedded in a cool-core galaxy cluster, and hence we also examine archival XMM-Newton data to facilitate the decomposition of the spectrum into the AGN and intracluster medium components. NuSTAR gives a source-dominated spectrum of the AGN out to >70 keV. In gross terms, the NuSTAR spectrum of the AGN has the form of a power law (Γ∼1.6−1.7) absorbed by a neutral column density of N{sub H}∼1.6×10{sup 23} cm{sup −2}. However, we also detect curvature in the hard (>10 keV) spectrum resulting from reflection by Compton-thick matter out of our line of sight to the X-ray source. Compton reflection, possibly from the outer accretion disk or obscuring torus, is required even permitting a high-energy cut off in the continuum source; the limit on the cut-off energy is E{sub cut}>111 keV(90% confidence). Interestingly, the absorbed power law plus reflection model leaves residuals suggesting the absorption/emission from a fast (15,000−26,000 km s{sup −1} ), high column-density (N{sub W}>3×10{sup 23} cm{sup −2}), highly ionized (ξ∼2500 erg cm s{sup −1}) wind. A second, even faster ionized wind component is also suggested by these data. We show that the ionized wind likely carries a significant mass and momentum flux, and may carry sufficient kinetic energy to exercise feedback on the host galaxy. If confirmed, the simultaneous presence of a strong wind and powerful jets in Cygnus A demonstrates that feedback from radio-jets and sub-relativistic winds are not mutually exclusive phases of AGN activity but can occur simultaneously.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2017

Exploring JLA supernova data with improved flux-averaging technique

In this work, we explore the cosmological consequences of the ''Joint Light-curve Analysis'' (JLA) supernova (SN) data by using an improved flux-averaging (FA) technique, in which only the type Ia supernovae (SNe Ia) at high redshift are flux-averaged. Adopting the criterion of figure of Merit (FoM) and considering six dark energy (DE) parameterizations, we search the best FA recipe that gives the tightest DE constraints in the ( z {sub cut}, Δ z ) plane, where z {sub cut} and Δ z are redshift cut-off and redshift interval of FA, respectively. Then, based on the best FA recipe obtained, we discuss the impacts of varying z {sub cut} and varying Δ z , revisit the evolution of SN color luminosity parameter β, and study the effects of adopting different FA recipe on parameter estimation. We find that: (1) The best FA recipe is ( z {sub cut} = 0.6, Δ z =0.06), which is insensitive to a specific DE parameterization. (2) Flux-averaging JLA samples at z {sub cut} ≥ 0.4 will yield tighter DE constraints than the case without using FA. (3) Using FA can significantly reduce the redshift-evolution of β. (4) The best FA recipe favors a larger fractional matter density Ω {sub m} . In summary, we present an alternative method of dealing with JLA data, which can reduce the systematic uncertainties of SNe Ia and give the tighter DE constraints at the same time. Our method will be useful in the use of SNe Ia data for precision cosmology.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Consistency of cosmic shear analyses in harmonic and real space

ABSTRACT Recent cosmic shear studies have reported discrepancies of up to 1σ on the parameter ${S_{8}=\sigma _{8}\sqrt{{\Omega _{\rm m}}/0.3}}$ between the analysis of shear power spectra and two-point correlation functions, derived from the same shear catalogues. It is not a priori clear whether the measured discrepancies are consistent with statistical fluctuations. In this paper, we investigate this issue in the context of the forthcoming analyses from the third year data of the Dark Energy Survey (DES Y3). We analyse DES Y3 mock catalogues from Gaussian simulations with a fast and accurate importance sampling pipeline. We show that the methodology for determining matching scale cuts in harmonic and real space is the key factor that contributes to the scatter between constraints derived from the two statistics. We compare the published scales cuts of the KiDS, Subaru-HSC, and DES surveys, and find that the correlation coefficients of posterior means range from over 80 per cent for our proposed cuts, down to 10 per cent for cuts used in the literature. We then study the interaction between scale cuts and systematic uncertainties arising from multiple sources: non-linear power spectrum, baryonic feedback, intrinsic alignments, uncertainties in the point spread function, and redshift distributions. We find that, given DES Y3 characteristics and proposed cuts, these uncertainties affect the two statistics similarly; the differential biases are below a third of the statistical uncertainty, with the largest biases arising from intrinsic alignment and baryonic feedback. While this work is aimed at DES Y3, the tools developed can be applied to Stage-IV surveys where statistical errors will be much smaller.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Shear-based deformation processing of age-hardened aluminum alloy for single-step sheet production

Shear-based deformation processing by hybrid cutting-extrusion and free machining are used to make continuous strip, of thickness up to one millimeter, from low-workability AA6013-T6 in a single deformation step. The intense shear can impose effective strains as large as 2 in the strip without pre-heating of the workpiece. The creation of strip in a single step is facilitated by three factors inherent to the cutting deformation zone: highly confined shear deformation, in situ plastic deformation-induced heating and high hydrostatic pressure. The hybrid cutting-extrusion, which employs a second die located across from the primary cutting tool to constrain the chip geometry, is found to produce strip with smooth surfaces (S a < 0.4 μm) that is similar to cold-rolled strip. The strips show an elongated grain microstructure that is inclined to the strip surfaces – a shear texture – that is quite different from rolled sheet. Furthermore, this shear texture (inclination) angle is determined by the deformation path. Through control of the deformation parameters such as strain and temperature, a range of microstructures and strengths could be achieved in the strip. When the cutting-based deformation was done at room temperature, without workpiece pre-heating, the starting T6 material was further strengthened by as much as 30% in a single step. In elevated-temperature cutting-extrusion, dynamic recrystallization was observed, resulting in a refined grain size in the strip. Implications for deformation processing of age-hardenable Al alloys into sheet form, and microstructure control therein, are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2022

SMC Reinforced by Recycled or Textile Carbon Fiber

There is a significant need to expand material options for SMC that has traditionally used glass fibers for decades. There are several integral issues related to chopping and conveying a range of materials including glass, carbon, basalt, thermoplastic tapes, and recycled fibers. These are in a variety of forms including continuous tows, discontinuous agglomerates such as pyrolyzed carbon fibers that could be used to produce a range of SMC intermediates. Standard/conventional SMC processing is limited to cutting rotors specifically for glass and compounding with thermoset polyesters and some epoxies. The multi-material, multi-format line developed in this project is flexible to enable custom conveying and uses an interchangeable rotor dedicated for specific material types. The overall tasks undertaken in this project included: evaluation of the fiber feed mechanism, effect of textile grade carbon, evaluating servo motor controlling of conveyor, evaluate doctor box resin feed, evaluate compaction unit, evaluation of different formulations, and develop automation such as PLC programming. The new multi-material SMC line Version 2 (SCM-V2) incorporated servo motors over induction motors which gave the overall cutter system precision control and made it quiet. The addition of a 14-roll compaction unit at the end of the line in SMC-V2 enabled higher material wet out which was a limitation in the SMC Version 1 (SMC-V1). The cutters were further updated to reduce the cantilever overhang of the fiber which enabled more uniform cut lengths for glass, carbon, and basalt fibers. The overall instrumentation and system control including a remote control operation was enabled in the SMC-V2. The line speed is capable of 10-20 ft/minute. The cutting modules were designed and engineered for cutting glass, basalt and textile grade carbon in 300k and 450-600k format widths. The cutting trials were established for a range of fiber types. The study also demonstrated the utility of the line to cut and produce basalt fiber SMC. Initial trials were conducted on the properties from recycled carbon fiber (rCF) mats in epoxy resin. Overall, the Covid19 situation constrained the team from accessing the SMC line for over 18 months. Despite this challenge major advancements were made.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Finite Element Modeling of Orthogonal Machining of Brittle Materials Using an Embedded Cohesive Element Mesh

Machining of brittle materials is common in the manufacturing industry, but few modeling techniques are available to predict materials’ behavior in response to the cutting tool. The paper presents a fracture-based finite element model, named embedded cohesive zone–finite element method (ECZ–FEM). In ECZ–FEM, a network of cohesive zone (CZ) elements are embedded in the material body with regular elements to capture multiple randomized cracks during a cutting process. The CZ element is defined by the fracture energy and a scaling factor to control material ductility and chip behavior. The model is validated by an experimental study in terms of chip formation and cutting force with two different brittle materials and depths of cut. The results show that ECZ–FEM can capture various chip forms, such as dusty debris, irregular chips, and unstable crack propagation seen in the experimental cases. For the cutting force, the model can predict the relative difference among the experimental cases, but the force value is higher by 30–50%. The ECZ–FEM has demonstrated the feasibility of brittle cutting simulation with some limitations applied.

Takabi, Behrouz↗
NASA NTRS1982

Diamond Sheet: A new diamond tool material

Diamond sheet is termed a diamond tool material because it is not a cutting tool, but rather a new material from which a variety of different tools may be fabricated. In appearance and properties, it resembles a sheet of copper alloy with diamond abrasive dispersed throughout it. It is capable of being cut, formed, and joined by conventional methods, and subsequently used for cutting as a metal bonded diamond tool. Diamond sheet is normally made with industrial diamond as the abrasive material. The metal matrix in diamond sheet is a medium hard copper alloy which has performed well in most applications. This alloy has the capability of being made harder or softer if specific cutting conditions require it. Other alloys have also been used including a precipitation hardened aluminum alloy with very free cutting characteristics. The material is suitable for use in a variety of cutting, surfacing, and ring type tools, as well as in such mundane items as files and sandpaper. It can also be used as a bearing surface (diamond to diamond) and in wear resistant surfaces.

Mackey, C. R.↗
NASA NTRS1990

Hydromechanical Advanced Coal Excavator

Water-jet cutting reduces coal dust and its hazards. Advanced mining system utilizes full-face, hydromechanical, continuous miner. Coal excavator uses high-pressure water-jet lances, one in each of cutting heads and one in movable lance, to make cuts across top, bottom and middle height, respectively, of coal face. Wedge-shaped cutting heads advance into lower and upper cuts in turn, thereby breaking coal toward middle cut. Thrust cylinders and walking pads advance excavator toward coal face.

Estus, Jay M.↗
NASA NTRS1988

Design of a rotary stepped auger for a lunar environment

A lunar outpost will have need for deep drilling operations for both explorative and practical purposes. As in any drilling operation, the cuttings must be cleared from the hole. The hard vacuum of the lunar environment renders conventional flushing methods of cutting removal unfeasible, and requires a new system of removal. A rotary stepped auger (RSA) is a simple mechanical method of removing dry cuttings from a deep hole, and is ideally suited to the lunar environment. The RSA consists of a helical auger with stepped ramps which allow cuttings to slide up the helix, but will prevent them from sliding back down. The auger is driven in a pulsed manner by applying a periodic function of acceleration to the auger shaft. These pulses will compel the cuttings to slide up the auger's helix while the stepped ramps prevent the cuttings from backsliding while the auger accelerates. A mathematical model of the RSA was developed and experimentally evaluated. The math model produced a good baseline design, but the experimental model required some tuning to account for the approximations made in the math model. This design is suited for lunar drilling because it is mechanically simple, integral to the drill string, requires no fluids, is suited to the dry soil, and has relatively low weight and power requirements.

Dardet, Eduardo↗
NASA NTRS1995

Dynamics and pattern of a managed coniferous forest landscape in Oregon

We examined the process of fragmentation in a managed forest landscape by comparing rates and patterns of disturbance (primarily clear-cutting) and regrowth between 1972 and 1988 using Landsat imagery. A 2589-km(exp 2) managed forest landscape in western Oregon was classified into two forest types, closed-canopy conifer forest (CF) (typically, greater than 60% conifer cover) and other forest and nonforest types (OT) (typically, less than 40 yr old or deciduous forest). The percentage of CF declined from 71 to 58% between 1972 and 1988. Declines were greatest on private land, least in wilderness, and intermediate in public nonwilderness. High elevations (greater than 914 m) maintained a greater percentage of CF than lower elevations (less than 914 m). The percentage of the area at the edge of the two cover types increased on all ownerships and in both elevational zones, whereas the amount of interior habitat (defined as CF at least 100 m from OT) decreased on all ownerships and elevational zones. By 1988 public lands contained approximately 45% interior habitat while private lands had 12% interior habitat. Mean interior patch area declined from 160 to 62 ha. The annual rate of disturbance (primarily clear-cutting) for the entire area including the wilderness was 1.19%, which corresponds to a cutting rotation of 84 yr. The forest landscape was not in a steady state or regulated condition which is not projected to occur for at least 40 yr under current forest plans. Variability in cutting rates within ownerships was higher on private land than on nonreserve public land. However, despite the use of dispersed cutting patterns on public land, spatial patterns of cutting and remnant forest patches were nonuniform across the entire public ownership. Large remaining patches (less than 5000 ha) of contiguous interior forest were restricted to public lands designated for uses other than timber production such as wilderness areas and research natural areas.

Spies, Thomas A.↗
NASA NTRS2010

Ultrasonic/Sonic Rotary-Hammer Drills

Ultrasonic/sonic rotary-hammer drill (USRoHD) is a recent addition to the collection of apparatuses based on ultrasonic/sonic drill corer (USDC). As described below, the USRoHD has several features, not present in a basic USDC, that increase efficiency and provide some redundancy against partial failure. USDCs and related apparatuses were conceived for boring into, and/or acquiring samples of, rock or other hard, brittle materials of geological interest. They have been described in numerous previous NASA Tech Briefs articles. To recapitulate: A USDC can be characterized as a lightweight, lowpower, piezoelectrically driven jackhammer in which ultrasonic and sonic vibrations are generated and coupled to a tool bit. A basic USDC includes a piezoelectric stack, an ultrasonic transducer horn connected to the stack, a free mass ( free in the sense that it can bounce axially a short distance between hard stops on the horn and the bit), and a tool bit. The piezoelectric stack creates ultrasonic vibrations that are mechanically amplified by the horn. The bouncing of the free mass between the hard stops generates the sonic vibrations. The combination of ultrasonic and sonic vibrations gives rise to a hammering action (and a resulting chiseling action at the tip of the tool bit) that is more effective for drilling than is the microhammering action of ultrasonic vibrations alone. The hammering and chiseling actions are so effective that unlike in conventional twist drilling, little applied axial force is needed to make the apparatus advance into the material of interest. There are numerous potential applications for USDCs and related apparatuses in geological exploration on Earth and on remote planets. In early USDC experiments, it was observed that accumulation of cuttings in a drilled hole causes the rate of penetration of the USDC to decrease steeply with depth, and that the rate of penetration can be increased by removing the cuttings. The USRoHD concept provides for removal of cuttings in the same manner as that of a twist drill: An USRoHD includes a USDC and a motor with gearhead (see figure). The USDC provides the bit hammering and the motor provides the bit rotation. Like a twist drill bit, the shank of the tool bit of the USRoHD is fluted. As in the operation of a twist drill, the rotation of the fluted drill bit removes cuttings from the drilled hole. The USRoHD tool bit is tipped with a replaceable crown having cutting teeth on its front surface. The teeth are shaped to promote fracturing of the rock face through a combination of hammering and rotation of the tool bit. Helical channels on the outer cylindrical surface of the crown serve as a continuation of the fluted surface of the shank, helping to remove cuttings. In the event of a failure of the USDC, the USRoHD can continue to operate with reduced efficiency as a twist drill. Similarly, in the event of a failure of the gearmotor, the USRoHD can continue to operate with reduced efficiency as a USDC.

Badescu, Mircea↗