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At least 811 records · Page 45
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Viscoelastic Modeling of Polymers in ALEGRA with the GAP Model

The Glassy Amorphous Polymer (GAP) model is a viscoelastic/plastic model developed at Los Alamos National Laboratory to accurately model a variety of polymers across a wide range of conditions and loading rates, including shock loading. In the present report we introduce and assess this model, newly implemented in the ALEGRA shock and multiphysics code, using a series of verification and application-related validation problems. We describe the mathematical and theoretical formulation of the model, as well as its implementation in ALEGRA, in detail. We provide verification results that assess the model implementation against published computational results, as well as validation results which we compare to existing experimental results when possible. These comparisons instill confidence in the implementation and indicate that the addition of the GAP model to the ALEGRA code provides users with a high-fidelity polymer modeling capability that is capable of recreating complex polymer phenomena.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Gas Hydrate Saturation Estimation Form Acoustic Log Data in the 2018 Alaska North Slope Hydrate-01 Stratigraphic Test

Completed in December 2018, the Alaska North Slope Hydrate 01 stratigraphic test well provides a wealth of logging-while-drilling (LWD) data for strata to below the base of gas hydrate stability (BGHS). This well is intended to be the first of three wells drilled for a comprehensive long-term gas hydrate production test conducted by the National Energy Technology Laboratory, the Japan Oil, Gas and Metals National Corporation, and the U.S. Geological Survey (USGS). The Hydrate 01 stratigraphic test well confirmed the presence of gas hydrate in two sand reservoirs within the hydrate stability zone, indicating the suitability of this location for a long-term gas hydrate production test.<p>The USGS, using an effective-medium-theory rock-physics approach, has estimated gas hydrate saturations from compressional (P) and shear (S) wave log data acquired in the Hydrate 01 well. We assume that gas hydrate occurs as pore-filling load-bearing material (i.e., part of the grain matrix). For Unit D, approximately 500 feet above the BGHS, both P-wave and S-wave acoustic logs indicate moderate gas hydrate saturations with S-wave results slightly lower than those for P-waves. For the Unit B, located just above the BGHS, we obtain moderate to high gas hydrate saturation estimates from both sonic logs. Our P-wave saturation estimates agree well with results from electrical-resistivity-based estimates, whereas estimates from nuclear magnetic resonance LWD data generally suggest 5 to 10 percent higher saturations; our S-wave results suggest lower saturations. These differences likely indicate complexities in the form of gas hydrate occurrence within the sediment pore space, potentially including differences between hydrate occurrence in Units D and B.</p>

Haines, Seth↗
DOE OSTI2022

Incorporating two-dimensional conduction modeling techniques into an energy simulation program: The EnergyPlus radiant system example

Due to the inherent complexity of multi-dimensional solutions for transient conduction in a multilayered building element, most heat balance-based algorithms assume that conduction occurs only in one dimension—through the building element between the inside and outside environments. Usually, since the length and width of the elements are much greater than the thickness of the element, this is a valid assumption. However, there are some cases such as hydronic radiant slabs where this assumption may not lead to an accurate estimate of the energy consumption of the system. In a hydronic radiant slab, water tubes are embedded in a slab, and hot or chilled water is circulated to meet any heating or cooling loads. The energy consumption of such a system will depend highly on the temperature of the water being sent to the slab (i.e., produced by the boiler or chiller). The temperature of the water that must be sent to the slab will depend on the spacing of the tubes, the multilayer construction of the building element, and the boundary conditions to which the construction is exposed. Thus, to accurately predict the energy consumption of such a system, a transient two-dimensional heat conduction model must be integrated with a heat balance-based simulation. This paper demonstrates the potential loss of accuracy associated with the one-dimensional radiant system models by providing a comparison of one- and two-dimensional solutions using EnergyPlus.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Physics-informed machine learning exploration of Na storage mechanisms in disordered carbon

Sodium-ion batteries are a cost-effective, sustainable alternative to lithium-ion systems for large-scale energy storage. However, optimizing sodium storage in carbon-based anodes with microstructural complexity and atomic disorder remains a major challenge. The intrinsic inhomogeneity of these materials produces diverse local environments, making it difficult for conventional methods to predict and control ion dynamics. Hard carbon (HC) anodes, composed of ranges of ordered-to-disordered graphitic and amorphous nanodomains, offer tunable ion storage and rate capacity, yet rationale design remains a challenge due to poorly understood correlation between local atomic feature and ion transport mechanism. Here, to address this challenge, we introduce a data-driven framework that integrates validated machine-learned interatomic potentials, large-scale molecular dynamics simulations, and machine learning to elucidate sodium transport mechanisms as a function of carbon and sodium loading densities. By computing per-ion structural descriptors and applying unsupervised learning, we identify distinct diffusion modes governed by microscopic features. Supervised analysis and correlation mapping then establish quantitative links between these transport regimes and processing variables such as bulk carbon density and sodium content. This physics-informed approach establishes quantitative structure–transport relationships and offers actionable design principles for engineering high-performance HC anodes.

Data-driven framework↗
DOE OSTI2023

Guerbet upgrading of ethanol to n -butanol using Ru( iii ) catalysts under air

A series of in situ prepared Ru(III) complexes supported by easily accessible N-donor organic pincer ligands were used as catalysts in the Guerbet upgrading reaction of ethanol under aerobic conditions. Tridentate bis(benzimidazole) ligand systems containing amino-dimethyl (L1) and pyridine (L2) backbones were found to make more efficient catalyst systems as compared to the bidentate bis(benzimidazole) ligand systems containing phenyl (L3) and ethene (L4) backbones. Potassium t-butoxide was found to be the most compatible base for this catalyst system. Reaction with 0.1 mol% of the catalyst and 10 mol% of potassium t-butoxide yielded 27% of n-butanol at 71% selectivity (150 °C, 24 h). Increase in the catalyst or base loading mostly resulted in increased reactivity but selectivity towards the key product n-butanol was found to decrease. On the other hand, reducing the reaction period to 12 h resulted in slightly decreased reactivity but the reaction provides n-butanol with high selectivity (76%). Contrarily, increased reaction period resulted in enhanced conversion of ethanol to higher alcohols. Under moderate and aerobic reaction conditions, the catalytic system was found to efficiently upgrade ethanol to higher alcohols. Furthermore, the decrease in the catalytic activity of the system over time was speculated to be due to the gradual deactivation of the base upon reaction with water (by-product of the Guerbet reaction). Poor solubility of the catalytic system in aqueous solutions makes it unsuitable for direct Guerbet reaction of fermentation broth.

09 BIOMASS FUELS↗
DOE OSTI2022

Phosphate adsorption kinetics and equilibria on natural iron and manganese oxide composites

We report that it is well known that phosphate retention in soils and sediments is strongly influenced by binding to secondary iron oxides, there have been relatively few studies examining its adsorption/desorption behavior on multicomponent particles of realistic natural complexity. In this study, natural Mn-rich limonite (LM), was used to prepare naturally complex Fe- and Mn-oxide composite materials to examine phosphate adsorption/desorption. To clarify the role of the Mn-oxides, results for the LM sample were compared to those for an acid treated version (LAT), in which the acid-extractable Mn-oxide fraction has been selectively eliminated while leaving the Fe-oxide fraction intact. The saturated adsorption capacity on LAT was almost double that on LM, suggesting that phosphate adsorption to the iron oxides is strongly occluded by the Mn-oxide fraction. This result is reinforced by the comparing the pH dependence and fits to adsorption isotherms, and by desorption experiments and STEM-EDS mapping showing that phosphate loading on Mn-oxides was limited. Hence, although the collective results confirm that phosphate uptake and strong binding is selectively controlled by the Fe-oxide fraction, our study reveals that the Mn-oxide fraction strongly interferes with this process. Therefore, phosphate uptake behavior on metal oxides cannot be predicted solely on the basis of the Fe-oxide fraction present, but instead must take into account the deleterious impacts of other intimately associated phases. For co-diagenetic Fe/Mn-oxide composites in particular, Mn-oxides appear to severely limit phosphate uptake on the Fe-oxide fraction, either by hindering access to binding sites on the Fe-oxide or by lowering their affinity for P.

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

Efficient Data Management in Neutron Scattering Data Reduction Workflows at ORNL

Oak Ridge National Laboratory (ORNL) experimental neutron science facilities produce 1.2 TB a day of raw event-based data that is stored using the standard metadata-rich NeXus schema built on top of the HDF5 file format. Performance of several data reduction workflows is largely determined by the amount of time spent on the loading and processing algorithms in Mantid, an open-source data analysis framework used across several neutron sciences facilities around the world. The present work introduces new data management algorithms to address identified input output (I/O) bottlenecks on Mantid. First, we introduce an in-memory binary-tree metadata index that resemble NeXus data access patterns to provide a scalable search and extraction mechanism. Second, data encapsulation in Mantid algorithms is optimally redesigned to reduce the total compute and memory runtime footprint associated with metadata I/O reconstruction tasks. Results from this work show speed ups in wall-clock time on ORNL data reduction workflows, ranging from 11% to 30% depending on the complexity of the targeted instrument-specific data. Nevertheless, we highlight the need for more research to address reduction challenges as experimental data volumes increase.

Godoy, William↗
DOE OSTI2020

Financing Microgrids in the Federal Sector

Recent high-impact events such as hurricanes and wildfires highlight the need for energy system resilience. One potential impact of these events is the loss of utility grid power to federal sites, negatively affecting the ability to carry out their missions. Depending on the need to sustain critical functions, it may be important to continue operations during an outage of the electric grid, or at least have power restored quickly after the event. One approach to addressing this need is through a microgrid. Microgrids can provide a more reliable solution than the traditional approach of using a backup generator at individual buildings. A microgrid can enhance a site’s electrical power system during normal operations, as well as provide reliable backup power to critical loads when electric utility power is interrupted. Many times, certain components of a microgrid (and potentially the entire system) can be justified economically and paid for out of energy savings or avoided costs. In cases where savings can cover the project costs, one of several privately financed procurement mechanisms may be used to implement the project. However, it can be difficult to achieve enough savings and avoided costs to cover the entire microgrid system, so leveraging these avoided costs in combination with appropriated funds may be necessary to implement the full project. This paper explores procurement options and agreements that may be useful to federal agencies interested in implementing microgrids at their sites. Microgrid complexities, implementation considerations, and suggestions to get started are also discussed. This information will be most useful to agencies when they are exploring electric energy system resilience options and/or considering different procurement options to meet their needs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

UHT-CAMANCHE: Ultra-High Temperature Ceramic Additively Manufactured Compact Heat Exchangers

The conceptual basis for this project is the convergence of advanced ultra-high temperature ceramic materials and additive manufacturing technologies to produce compact ceramic heat exchangers with complex internal flow path geometries. Task areas were broadly divided into materials and manufacturing development, heat exchanger design, component testing, and techno-economic analysis. Technical challenges included the design and commissioning of new test facilities, improving feature resolution and deposition rate of ceramic additive manufacturing techniques, establishing process-structure-property relationships in additively manufactured ultra-high temperature ceramics, and assessing high temperature materials compatibility in CO 2 environments. The primary candidate material evaluated in this work is a composite comprising zirconium diboride (ZrB2) with 30 vol. % silicon carbide (SiC) which was selected based on its desirable combination of high temperature mechanical properties, high thermal and electrical conductivities, and oxidation resistance. High solids loaded ZrB2-SiC pastes suitable for extrusion-based additive manufacturing were developed for the first time as part of this work. Materials compatibility studies indicate this material oxidizes in CO 2 to form a protective borosilicate scale which transforms to pure silica above 1000°C. Parts made by additive manufacturing displayed enlarged grain sizes produced by pressureless sintering as compared to hot-press sintering. Increases in microstructural coarseness have outsized effect on oxidation performance up to 1400°C due to incomplete oxidation of coarse large diameter SiC particles resulting in lower amounts of silica that apparently inhibit protective scale formation. Additive manufacturing as a forming technique did not appear to significantly affect thermal conductivity, hardness, or elastic modulus, though flexural strength was reduced by half or more as compared to traditionally hot-pressed materials. This effect was attributed to the presence of strength-limiting flaws (ca. 40 microns in size) originating from extrudate inhomogeneities that could potentially be eliminated with further process improvements. Attempts to attain economies of scale for production of multi-kilowatt scale heat exchangers by ceramic additive manufacturing proved difficult. Lack of automation and a modest extrusion rate while retaining fine feature resolution made the overall process labor intensive and limited experimental throughput. A number of full-scale components were taken through post-process heat treatments including drying, binder burnout, and sintering; however, none survived without significant flaws or cracks. Therefore, no operational data from a newly installed heat exchanger test loop were able to be obtained during the performance period. Continued research and development is recommended to improve economic feasibility of ceramic additive manufacturing by standardizing the use of advanced sensors, artificial intelligence, and automation tools to reduce associated labor costs and accelerate production rates. The materials and manufacturing techniques demonstrated in this work are likely to find applications in defense and energy applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Best Practices for Resilience in Smart Grid-Interactive Efficient Buildings

The Federal Energy Management Program (FEMP) supports federal agencies' energy decisions with information and guidance on design, funding, and operations to ensure federal buildings are efficient and resilient. The modernization of building infrastructure and the evolution of buildings to support decarbonization involves complex implementation of multiple components across several systems. This includes energy-efficient equipment, on-site energy generation and storage systems, and control systems. These systems have operational modes that can operate more efficiently if they are able to behave responsively to the conditions of the electrical grid. These grid-interactive efficient buildings (GEB) allow facilities to manage power demand according to operational constraints and market signals issued by grid operators. With proper design and planning, these same capabilities have the potential to enable building and facility resilience - coordinating with microgrids, maintaining power on critical circuits to sustain essential operations, and monitoring building health and safety status during an outage. By managing the load of buildings, GEBs can also reduce the cost of backup generation and make better use of renewable power sources on site. This document outlines some of the processes and considerations to guide the design and operation of GEBs in ways that promote facility resilience.

building decarbonization↗
DOE OSTI2020

Late Holocene history of Tokotan Lake (Kuril Archipelago, Russian Far East): The use of lacustrine records for paleoclimatic reconstructions from geologically dynamic settings

A high-resolution, multiproxy analysis of a core from Tokotan Lake, Urup Island, illustrates the complex paleoenvironmental signals that can be preserved in sedimentary deposits from geologically active areas, such as the Kuril Archipelago. Diatom and geochemical analyses of the Tokotan core suggest a shallowing and lessening of the lake area over the last ~3450 cal BP. Without other proxies, the record could be interpreted as showing a general decrease in precipitation over the Late Holocene. However, palynological data indicate no change in vegetation, thereby implying no significant climatic variation. Neither of these paleoclimatic interpretations agrees with Late Holocene reconstructions from the Kuril Archipelago or the Russian mainland. Paleomagnetic data imply variable sediment sources during the lake's history, indicating alterations within the Tokotan catchment (e.g., shifts in gradients or sediment loads in the inflowing streams). Such changes would be particularly important in the Shabalina River, which today has formed a partial dam across the lake's outlet. Here, the results of the Tokotan study indicate that other factors (e.g., volcanism, seismic activity, sea-level changes) rather than climate were more probable determinants of the Late Holocene lake record. Given the geologic dynamism of the region, it is perhaps not surprising that paleo-records from the Kuril Islands display an inconsistency in the numbers and/or duration of proposed Holocene climatic oscillations, underscoring the importance of multiproxy investigations in areas that are or have been geologically dynamic.

58 GEOSCIENCES↗
DOE OSTI2026

A Comparative Study of Ethanol Upgrading to Butadiene Over Rare Earth Elements Incorporated in Dealuminated Beta Zeolites

Copper and rare earth element-containing dealuminated Beta zeolites (CuREE/deAlBeta) are promising catalysts for the conversion of ethanol to C 3+ olefins en route to sustainable aviation fuel. Product selectivities over CuREE/deAlBeta depend on the identity of the REE. Here, in this study, a suite of La/deAlBeta catalysts of varied La loading are prepared, and their reactivities, selectivities, and apparent C-C coupling kinetics in the cascade reaction between ethanol and acetaldehyde are reported. Ex situ and in situ titrations to quantify Lewis acidic La sites quantify distinct numbers of sites, suggesting a distribution of site types. Across a series of REE/deAlBeta catalysts (REE = Y, La, Lu, Yb, Gd), the selectivity to secondary products correlates with the pyridine heats of adsorption at REE Lewis acid sites. The turnover frequency (per Lewis acid site) for C–C coupling was similar across the series of REE/deAlBeta catalysts. Y/deAlBeta and La/deAlBeta, which have the most disparate secondary product selectivities, had similar kinetics for C–C coupling. These findings demonstrate the complexity of quantifying active sites in REE/deAlBeta zeolites, and the sensitivity of the selectivity, but not the reactivity for C–C coupling, to the identity of the REE atom in REE/deAlBeta zeolites.

alcohol upgrading↗
DOE OSTI2022

Developing an ELM Ecosystem Dynamics Model on GPU with OpenACC

Porting a complex scientific code, such as the E3SM land model (ELM), onto a new computing architecture is challenging. The paper presents design strategies and technical approaches to develop an ELM ecosystem dynamics model with compiler directives (OpenACC) on NVIDIA GPUs. The code has been refactored with advanced OpenACC features (such as deepcopy and routine directives) to reduce memory consumption and to increase the levels of parallelism through parallel loop reconstruction and new data structures. As a result, the optimized parallel implementation achieved more than a 140-time speedup (50 ms vs 7600 ms), compared to a naive implementation that uses OpenACC routine directive and parallelizes the code across existing loops on a single NVIDIA V100. On a fully loaded computing node with 44 CPUs and 6 GPUs, the code achieved over a 3.0-times speedup, compared to the original code on the CPU. Furthermore, the memory footprint of the optimized parallel implementation is 300 MB, which is around 15% of the 2.15 GB of memory consumed by a naive implementation. This study is the first effort to develop the ELM component on GPUs efficiently to support ultra-high-resolution land simulations at continental scales.

Schwartz, Peter↗
DOE OSTI2026

Development and Validation of the Near-Miss Safety Score (NMSS) Framework for Heavy-Duty Vehicle Safety Assessment

Heavy-duty commercial vehicles present unique safety challenges due to their size, articulation dynamics, and operational complexity. As Advanced Driver Assistance Systems (ADAS) and Automated Driving Systems (ADS) become more common in Class 8 tractor-trailers, traditional crash-based metrics are no longer sufficient to evaluate safety performance. This study introduces the Near-Miss Safety Score (NMSS)—a quantitative, physics-informed framework developed as a leading indicator of safety for advanced commercial vehicle technologies. NMSS quantifies how close a vehicle or operator comes to a collision or safety-critical event by integrating vehicle kinematics (relative distance, velocity, and acceleration) with driver or system response latency and time-to-collision. A modifier function adjusts the base score for vehicle-specific and environmental factors such as trailer articulation, load distribution, braking condition, and roadway environment. The framework enables systematic evaluation of ADAS/ADS performance under a range of operational and degraded conditions. By capturing near-miss dynamics rather than relying on crash data, NMSS provides a proactive approach to risk assessment, accelerates technology validation, and enhances interpretability for regulators and fleet operators. The proposed NMSS was validated using data collected from a motorcoach platform, demonstrating the framework’s applicability to heavy-duty safety evaluation and performance benchmarking. Results and key insights are presented in this paper.

Siekmann, Adam [ORNL] (ORCID:0000000284653935)↗
DOE OSTI2022

Acoustic force spectroscopy reveals subtle differences in cellulose unbinding behavior of carbohydrate-binding modules

Protein adsorption to solid carbohydrate interfaces is critical to many biological processes, particularly in biomass deconstruction. To engineer more-efficient enzymes for biomass deconstruction into sugars, it is necessary to characterize the complex protein–carbohydrate interfacial interactions. A carbohydrate-binding module (CBM) is often associated with microbial surface-tethered cellulosomes or secreted cellulase enzymes to enhance substrate accessibility. However, it is not well known how CBMs recognize, bind, and dissociate from polysaccharides to facilitate efficient cellulolytic activity, due to the lack of mechanistic understanding and a suitable toolkit to study CBM–substrate interactions. Our work outlines a general approach to study the unbinding behavior of CBMs from polysaccharide surfaces using a highly multiplexed single-molecule force spectroscopy assay. Here, we apply acoustic force spectroscopy (AFS) to probe a Clostridium thermocellum cellulosomal scaffoldin protein (CBM3a) and measure its dissociation from nanocellulose surfaces at physiologically relevant, low force loading rates. An automated microfluidic setup and method for uniform deposition of insoluble polysaccharides on the AFS chip surfaces are demonstrated. The rupture forces of wild-type CBM3a, and its Y67A mutant, unbinding from nanocellulose surfaces suggests distinct multimodal CBM binding conformations, with structural mechanisms further explored using molecular dynamics simulations. Applying classical dynamic force spectroscopy theory, the single-molecule unbinding rate at zero force is extrapolated and found to agree with bulk equilibrium unbinding rates estimated independently using quartz crystal microbalance with dissipation monitoring. However, our results also highlight critical limitations of applying classical theory to explain the highly multivalent binding interactions for cellulose–CBM bond rupture forces exceeding 15 pN.

09 BIOMASS FUELS↗
DOE OSTI2022

A Micromorphic Length-Scale Coupling Framework for the Determination of Higher-Order Constitutive Models and the Multi-Scale Simulation of Heterogeneous Materials [Thesis]

Heterogeneous materials and materials with complex microstructures pose a unique challenge in the development of accurate models of their response to external stimuli. These difficulties principally arise due to the difficulty in characterizing and modeling the constituents and their interactions. It is usually possible, though non-trivial, to construct an explicit representation of the microstructure (a direct numeric simulation or DNS) but the method by which the complex modes of deformation and other processes can be homogenized to a reduced-order approximation is frequently unclear. Many homogenization approaches are ad-hoc and lack a strong justification beyond ease of computation. Furthermore, the homogenization approach can, in some cases, not utilize the full breadth of information available in the computation of the macro-scale stresses and deformation measures. It is also noteworthy that homogenization, by its very nature, will tend to obfuscate details of processes occurring at the lower length-scale. It is therefore of interest to include as much information as possible in the construction of the reduced-order model so as to be predictive in a variety of loading environments. We here present a length-scale bridging technique based upon the micromorphic continuum mechanics of Eringen which incorporates volume and surface area averages as a part of its construction. This approach enforces the balance equations at the micro-scale and then studies the effect of the spatially varying nature on the macro-scale. This leads, naturally, to further balance equations which are solved at the macro-scale. This work details a homogenization framework which arises naturally from the micromorphic construction of Eringen attempting to introduce no definitions beyond which are justifiable from micro-structural considerations. One of the results of this effort is the so-called “micromorphic filter” which has been developed and applied to several DNS to demonstrate its effectively. In order to determine the macroscopic degrees of freedom we utilize the special case of an overlap coupling technique where the macro-scale is fully constrained to the micro-scale. This enables us to study the resulting material properties as expected but also allows us to further study the boundary conditions on the additional degrees of freedom at the macro-scale.

42 ENGINEERING↗
DOE OSTI2020

Determining Compression Characteristics of Honeycomb Material - 19674

The objective is to determine compression test characteristics of stainless steel honeycomb material to be able to represent honeycomb structures accurately in analytical models used to simulate hypothetical accident scenarios of shipping packages. Honeycomb is a material used primary in the aerospace industry due to its high strength-to-weight ratio. Because it doesn't have a shelf life and can withstand high heats, it is an excellent candidate for a structural material in package designs. Honeycomb has orthotropic material properties. The honeycomb currently being evaluated is made of metal ribbons spot welded together to form hexagon pattern between metal plates. The hexagon ribbons are brazed to the metal plates. The complexity of the honeycomb significantly lengthens the simulation time, which is further complicated when the brazing, welding, and imperfections of the material is considered. This means to affectively represent the honeycomb in simulation programs, such as Abaqus, the material needs to be approximated as a uniform orthotropic material. This requires material properties in each of the three directions, T, W, and L. The T direction is defined as the 'strong' direction, perpendicular to the honeycomb sheet. The L direction is parallel the ribbon and the W direction is perpendicular to the ribbon. Honeycomb has 3 different compression stages. Stage 1 is the initial compression where the honeycomb maintains its structural integrity and does not permanently deform from loads from normal operations. Stage 2 is when the initial buckling causes irreversible damage to the honeycomb. Stage 2 is the one we are most interested in because it absorbs the most energy from a hypothetical accident scenario. During Stage 2, the honeycomb fails layer-by-layer, indicating that the more layers, the longer material crushing is sustained, and thus the more energy that is absorbed. Stage 3 is final compression, similar to compressing solid metal. During stage 3 the stress increases with a diminishing rate of elongation and the honeycomb is completely failed where the plates between the honeycomb core sandwich the crushed honeycomb ribbon. The stress-strain graph bellow shows compression test of 3 different samples in the T direction. The red lines divide the three stages. The far left is Stage 1, the middle stage 2, and the right stage 3. The data collected is displayed in the table below. The expressions in the table represent the regression formula that represents each stage of the compression on a stress-strain graph. Stage 1 is assumed to intersect with the origin; data for stage 3 for the crush in W and L directions where unable to be gathered due to the nature of failure for those directions. Stage 1 and 2 are linear regressions while stage 3 is a degree 2, to best match the curve. Linear regression is used on stage 2 because ultimately that represents the energy absorbed. With more data, a degree n x 2 regression would be a more appropriate regression for stage 2, where n is the number of layers. The table below is the approximation of each scenario and stage. Each stage starts and ends at the intersection of the next stage. There where two main objectives for these tests: firstly to understand how honeycomb performs under extreme compression, and secondly to be able to numerically represent the honeycomb structure. Both of these where completed to varying degrees. It is important understood how the honeycomb fails. If it is crushed in the T direction it retains its integrity even after being crushed, however when crushed in the L and W crush direction, if it fails, it disintegrates, and loses all integrity. Also, the more layers the more time the material spends in stage 2. Failure is started by buckling, thus if there is any imperfection, the stress will not spike but transition straight into stage 2. The data collected and aggregated can be used for initial simulation of honeycomb used in packages. The initial testing has set the ground work for more data to be collected in order to verify results and to allow more confidence in the simulation results. This is only the initial data collected. The next steps is to continue to collect more data to verify results and to test more variants of honeycomb, with different brazing, layers, and shape.

36 MATERIALS SCIENCE↗