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At least 829 records · Page 46
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Technical Note: Multipurpose CT, ultrasound, and MRI breast phantom for use in radiotherapy and minimally invasive interventions

Purpose: To develop a multipurpose gel-based breast phantom consisting of a simulated tumor with realistic imaging properties in CT, ultrasound and MRI, or a postsurgical cavity on CT. Applications for the phantom include: deformable image registration (DIR) quality assurance (QA), autosegmentation validation, and localization testing and training for minimally invasive image-guided procedures such as those involving catheter or needle insertion. Methods: A thermoplastic mask of a typical breast patient lying supine was generated and then filled to make an array of phantoms. The background simulated breast tissue consisted of 32.4 g each of ballistic gelatin (BG) powder and Metamusil™ (MM) dissolved in 800 ml of water. Simulated tumors were added using the following recipe: 12 g of barium sulfate (1.4% v/v) plus 0.000 14 g copper sulfate plus 0.7 g of MM plus 7.2 g of BG all dissolved in 75 ml of water. The phantom was evaluated quantitatively in CT by comparing Hounsfield units (HUs) with actual breast tissue. For ultrasound and MRI, the phantoms were assessed based on subjective image quality and signal-difference to noise (SDNR) ratio, respectively. The stiffness of the phantom was evaluated based on ultrasound elastography measurements to yield an average Young’s modulus. In addition, subjective tactile assessment of phantom was performed under needle insertion. Results: The simulated breast tissue had a mean background value of 24 HU on CT imaging, which more closely resembles fibroglandular tissue (40 HU) as opposed to adipose (−100 HU). The tumor had a mean CT number of 45 HU, which yielded a qualitatively realistic image contrast relative to the background either as an intact tumor or postsurgical cavity. The tumor appeared qualitatively realistic on ultrasound images, exhibiting hypoechoic characteristics compared to background. On MRI, the tumor exhibited a SDNR of 3.7. The average Young’s modulus was computed to be 15.8 ± 0.7 kPa (1 SD). Conclusions: We have developed a process to efficiently and inexpensively produce multipurpose breast phantoms containing simulated tumors visible on CT, ultrasound, and MRI. The phantoms have been evaluated for image quality and elasticity and can serve as a medium for DIR QA, autosegmentation QA, and training for minimally invasive procedures.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2016

SU-F-J-17: Patient Localization Using MRI-Guided Soft Tissue for Head-And-Neck Radiotherapy: Indication for Margin Reduction and Its Feasibility

Purpose: On-board MRI provides superior soft-tissue contrast, allowing patient alignment using tumor or nearby critical structures. This study aims to study H&N MRI-guided IGRT to analyze inter-fraction patient setup variations using soft-tissue targets and design appropriate CTV-to-PTV margin and clinical implication. Methods: 282 MR images for 10 H&N IMRT patients treated on a ViewRay system were retrospectively analyzed. Patients were immobilized using a thermoplastic mask on a customized headrest fitted in a radiofrequency coil and positioned to soft-tissue targets. The inter-fraction patient displacements were recorded to compute the PTV margins using the recipe: 2.5∑+0.7σ. New IMRT plans optimized on the revised PTVs were generated to evaluate the delivered dose distributions. An in-house dose deformation registration tool was used to assess the resulting dosimetric consequences when margin adaption is performed based on weekly MR images. The cumulative doses were compared to the reduced margin plans for targets and critical structures. Results: The inter-fraction displacements (and standard deviations), ∑ and σ were tabulated for MRI and compared to kVCBCT. The computed CTV-to-PTV margin was 3.5mm for soft-tissue based registration. There were minimal differences between the planned and delivered doses when comparing clinical and the PTV reduced margin plans: the paired t-tests yielded p=0.38 and 0.66 between the planned and delivered doses for the adapted margin plans for the maximum cord and mean parotid dose, respectively. Target V95 received comparable doses as planned for the reduced margin plans. Conclusion: The 0.35T MRI offers acceptable soft-tissue contrast and good spatial resolution for patient alignment and target visualization. Better tumor conspicuity from MRI allows soft-tissue based alignments with potentially improved accuracy, suggesting a benefit of margin reduction for H&N radiotherapy. The reduced margin plans (i.e., 2 mm) resulted in improved normal structure sparing and accurate dose delivery to achieve intended treatment goal under MR guidance.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2016

SU-F-J-18: Feasibility of Open Mask Immobilization with Optical Imaging Guidance (OIG) for H&N Radiotherapy

Purpose: Full face and neck thermoplastic masks provide standard-of-care immobilization for patients receiving H&N IMRT. However, these masks are uncomfortable and increase skin dose. The purpose of this pilot study was to investigate the feasibility and setup accuracy of open face and neck mask immobilization with OIG. Methods: Ten patients were consented and enrolled to this IRB-approved protocol. Patients were immobilized with open masks securing only forehead and chin. Standard IMRT to 60–70 Gy in 30 fractions were delivered in all cases. Patient simulation information, including isocenter location and CT skin contours, were imported to a commercial OIG system. On the first day of treatment, patients were initially set up to surface markings and then OIG referenced to face and neck skin regions of interest (ROI) localized on simulation CT images, followed by in-room CBCT. CBCTs were acquired at least weekly while planar OBI was acquired on the days without CBCT. Following 6D robotic couch correction with kV imaging, a new optical real-time surface image was acquired to track intrafraction motion and to serve as a reference surface for setup at the next treatment fraction. Therapists manually recorded total treatment time as well as couch shifts based on kV imaging. Intrafractional ROI motion tracking was automatically recorded. Results: Setup accuracy of OIG was compared with CBCT results. The setup error based on OIG was represented as a 6D shift (vertical/longitudinal/lateral/rotation/pitch/roll). Mean error values were −0.70±3.04mm, −0.69±2.77mm, 0.33±2.67 mm, −0.14±0.94 o, −0.15±1.10o and 0.12±0.82o, respectively for the cohort. Average treatment time was 24.1±9.2 minutes, comparable to standard immobilization. The amplitude of intrafractional ROI motion was 0.69±0.36 mm, driven primarily by respiratory neck motion. Conclusion: OGI can potentially provide accurate setup and treatment tracking for open face and neck immobilization. Study accrual and patient/provider satisfaction survey collection remain ongoing. This study is supported by VisionRT, Ltd.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2016

SU-F-J-126: Influence of Six Dimensional Motions in Frameless Stereotactic Dosimetry Incorporating Rotational Shifts as Equivalent Translational Shifts: A Feasibility Study for Elekta-BrainLAB Stereotactic System

Purpose: Six dimensional positional shifts (translational and rotational) determined by a volumetric imaging system were mathematically combined and incorporated as simple translational shifts and the resultant impact on dose characteristics was studied. Methods: Thirty patients who underwent either single fraction (12 Gy) or five fractions (5 Gy per fraction) stereotactic treatments were included in this study. They were immobilized using a double layered thermoplastic mask from BrainLAB. Isocenter matching was done using infrared marker of ExacTrac. An initial cone beam CT (CBCT) gave positional shifts in 6-dimensions that were applied through 6-D motion enabled couch. A verification CBCT was done following corrections before treatment. These 6-D positional shifts determined at each imaging session from the first CBCT were mathematically combined to give three simple translational shifts. Doses were recalculated in the patient matrix with these positional errors present by moving the whole image dataset. Doses were also recalculated after second CBCT with only residual errors present. PTV dose statistics were compared. Results: For the approved plans V100%(PTV), V100%(GTV), D95%(PTV), D95%(GTV), D1%(PTV) and D1%(GTV) were 96.2±3.0%, 98.2±1.4%, 102%±1.7%, 103±1.2%, 107.9±8.9% and 109.3±7.5% of prescription dose respectively. With the positional errors present (after 1st CBCT) the corresponding values were 86.7±4.9%, 91.3±2.9%, 89.6±4.2%, 95.9±3.7%, 108.3±9.9% and 108.6±4.5%. Post-correction (after 2nd CBCT) with only residual errors present, values were 94.5±5.7%, 97.3±2.9%, 99.3%±3.2%, 102%±2.1%, 107.6±8.5% and 109.0±7.6% respectively. Significant and nominal OAR dose variation was observed between pre- and post-table corrections. Conclusion: Positional errors significantly affect PTV dose statistics. They need to be corrected before delivery of stereotactic treatments although the magnitude of dose changes can vary from patient-to-patient depending on the tumor location. As expected after the table corrections, residual errors result in insignificant dose deviations. For frameless stereotactic treatments having a six-dimensional motion enabled couch is highly recommended to reduce quantum of dose deviations.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

Stereomicrostructure-regulated biodegradable adhesives

Commercial adhesives are petroleum-based thermoset networks or nonbiodegradable thermoplastic hot melts, making them ideal targets for replacement by biodegradable alternatives. Poly(3-hydroxybutyrate) (P3HB) is a biorenewable and biodegradable alternative to conventional plastics, but microbial P3HB, which has a stereoperfect stereomicrostructure, exhibits no adhesion. Here, in this study, by elucidating the fundamental relationship between chemocatalytically engineered P3HB stereomicrostructures and adhesion properties, we found that biodegradable syndio-rich P3HB exhibits high adhesion strength and outperforms common commercial adhesives, whereas syndiotactic, isotactic, or iso-rich P3HB shows no measurable adhesion. The syndio-rich stereomicrostructure brings about desired thermomechanical and viscoelastic properties of P3HB that enable strong adhesion to a range of substrates tested, including aluminum, steel, glass, and wood, and its performance is insensitive to molar mass and reprocessing or reuse.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Impact of Ultraviolet Irradiation on Stress–Strain Behavior of Syndiotactic 1,2-Polybutadien: The Role of Oxidation

We studied the impact of ultraviolet (UV) irradiation on stress–strain characteristics, derived from uniaxial stretching measurements, and the molecular structure (photoinduced changes) of syndiotactic 1,2-polybutadien, a polymer with thermoplastic elastomer properties. Uniaxial stretching stress–strain curves are recorded for samples subjected to UV irradiation for different times and the effects UV irradiation has on the stress–strain behavior of polymers are analyzed. Long UV irradiation is found to markedly increase the hardening of polymers: Young’s modulus and yield strength increase, while the fracture strain decreases. At the same time, we observe a sharp increase in polymer molecular weight and its considerable oxidation that particularly involves surface layers. The mechanisms of cross-linking between macromolecules and their simultaneous oxidation induced by exposure to UV light are discussed along with the role these processes play in evolution of the physical mechanical properties under UV irradiation.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2010

High-Temperature Motor Windings for Downhole Pumps Used in Geothermal Energy Production

The development of highly reliable downhole equipment is an essential element in enabling the widespread utilization of Enhanced Geothermal Systems (EGS). The downhole equipment used in these systems will be required to operate at high voltages and temperatures on the order of 200 to 250°C (and eventually to 300°C). These conditions exceed the practical operating ranges of currently available thermoplastic wire insulations, and thus limit the operating lifetime of tools such as Electric Submersible Pumps (ESPs). In this work, high-temperature insulations based on composite materials were developed and demonstrated. The products of this work were found to exhibit electrical resistivities and dielectric breakdown strengths that PEEK at temperatures above 250C. In addition, sub-scale motor windings were fabricated and tested to validate the performance of this technology

15 GEOTHERMAL ENERGY↗
DOE OSTI2011

United States Automotive Materials Partnership LLC (USAMP) (Final Report Compilation)

The United States Automotive Materials Partnership LLC (USAMP) was formed in 1993 as a partnership between Chrysler Corporation, Ford Motor Company, and General Motors Corporation. Since then the U.S. Department of Energy (DOE) has supported its activities with funding and technical support. The mission of the USAMP is to conduct vehicle-oriented research and development in materials and materials processing to improve the competitiveness of the U.S. Auto Industry. Its specific goals are: (1) To conduct joint research to further the development of lightweight materials for improved automotive fuel economy; and (2) To work with the Federal government to explore opportunities for cooperative programs with the national laboratories, Federal agencies such as the DOE and universities. As a major component of the DOE's Office of FreedomCAR and Vehicle Technologies Program (FCVT) collaboration with the USAMP, the Automotive Lightweighting Materials (ALM) program focuses on the development and validation of advanced materials and manufacturing technologies to significantly reduce automotive vehicle body and chassis weight without compromising other attributes such as safety, performance, recyclability, and cost. The FCVT was announced in FY 2002 and implemented in FY 2003, as a successor of the Partnership for a New Generation of Vehicles (PNGV), largely addressed under the first Cooperative Agreement. This second USAMP Cooperative Agreement with the DOE has expanded a unique and valuable framework for collaboratively directing industry and government research efforts toward the development of technologies capable of solving important societal problems related to automobile transportation. USAMP efforts are conducted by the domestic automobile manufacturers, in collaboration with materials and manufacturing suppliers, national laboratories, universities, and other technology or trade organizations. These interactions provide a direct route for implementing newly developed materials and technologies, and have resulted in significant technical successes to date, as discussed in the individual project summary final reports. Over 70 materials-focused projects have been established by USAMP, in collaboration with participating suppliers, academic/non-profit organizations and national laboratories, and executed through its original three divisions: the Automotive Composites Consortium (ACC), the Automotive Metals Division (AMD), and Auto/Steel Partnership (A/SP). Two new divisions were formed by USAMP in 2006 to drive research emphasis on integration of structures incorporating dissimilar lightweighting materials, and on enabling technology for nondestructive evaluation of structures and joints. These new USAMP divisions are: Multi-Material Vehicle Research and Development Initiative (MMV), and the Non-Destructive Evaluation Steering Committee (NDE). In cooperation with USAMP and the FreedomCAR Materials Technical Team, a consensus process has been established to facilitate the development of projects to help move leveraged research to targeted development projects that eventually migrate to the original equipment manufacturers (OEMs) as application engineering projects. Research projects are assigned to one of three phases: concept feasibility, technical feasibility, and demonstration feasibility. Projects are guided through ongoing monitoring and USAMP offsite reviews, so as to meet the requirements of each phase before they are allowed to move on to the next phase. As progress is made on these projects, the benefits of lightweight construction and enabling technologies will be transferred to the supply base and implemented in production vehicles. The single greatest barrier to automotive use of lightweight materials is their high cost; therefore, priority is given to activities aimed at reducing costs through development of new materials, forming technologies, and manufacturing processes. The emphasis of the research projects reported in this document was largely on applied research and evaluation of mass savings opportunities through the aggressive application of lightweight materials, advanced computational methods, and the demonstration of production capable manufacturing processes intended for high-volume applications, all directed towards the FreedomCAR Program goals. Priority lightweighting materials include advanced high-strength steels (AHSS), aluminum, magnesium, titanium, and composites such as metal-matrix materials, and glass- and carbon-fiber-reinforced thermosets and thermoplastics. Besides developing valuable new design and material property information, several projects have extensively used computer-based product modeling and simulation technologies to optimize designs and materials usage while addressing the cost-performance issues. The purpose of this Summary Final Closeout Report is to document the successes, degree of progress, technology dissemination efforts, and lessons learned.

36 MATERIALS SCIENCE↗
DOE OSTI2012

PNNL Technical Support to The Implementation of EMTA and EMTA-NLA Models in Autodesk ® Moldflow ® Packages

Under the Predictive Engineering effort, PNNL developed linear and nonlinear property prediction models for long-fiber thermoplastics (LFTs). These models were implemented in PNNL’s EMTA and EMTA-NLA codes. While EMTA is a standalone software for the computation of the composites thermoelastic properties, EMTA-NLA presents a series of nonlinear models implemented in ABAQUS ® via user subroutines for structural analyses. In all these models, it is assumed that the fibers are linear elastic while the matrix material can exhibit a linear or typical nonlinear behavior depending on the loading prescribed to the composite. The key idea is to model the constitutive behavior of the matrix material and then to use an Eshelby-Mori-Tanaka approach (EMTA) combined with numerical techniques for fiber length and orientation distributions to determine the behavior of the as-formed composite. The basic property prediction models of EMTA and EMTA-NLA have been subject for implementation in the Autodesk ® Moldflow ® software packages. These models are the elastic stiffness model accounting for fiber length and orientation distributions, the fiber/matrix interface debonding model, and the elastic-plastic models. The PNNL elastic-plastic models for LFTs describes the composite nonlinear stress-strain response up to failure by an elastic-plastic formulation associated with either a micromechanical criterion to predict failure or a continuum damage mechanics formulation coupling damage to plasticity. All the models account for fiber length and orientation distributions as well as fiber/matrix debonding that can occur at any stage of loading. In an effort to transfer the technologies developed under the Predictive Engineering project to the American automotive and plastics industries, PNNL has obtained the approval of the DOE Office of Vehicle Technologies to provide Autodesk, Inc. with the technical support for the implementation of the basic property prediction models of EMTA and EMTA-NLA in the Autodesk ® Moldflow ® packages. This report summarizes the recent results from Autodesk Simulation Moldlow Insight (ASMI) analyses using the EMTA models and EMTA-NLA/ABAQUS ® analyses for further assessment of the EMTA-NLA models to support their implementation in Autodesk Moldflow Structural Alliance (AMSA). PNNL’s technical support to Autodesk, Inc. included (i) providing the theoretical property prediction models as described in published journal articles and reports, (ii) providing explanations of these models and computational procedure, (iii) providing the necessary LFT data for process simulations and property predictions, and (iv) performing ABAQUS/EMTA-NLA analyses to further assess and illustrate the models for selected LFT materials.

damage analysis↗
DOE OSTI2016

SDU6 Interior Liner Testing & Evaluation

Two liner materials (Marseal® M-3500 and REMA Chemoline® 4CN) proposed for use as a liner inside the Saltstone Disposal Unit 6 (SDU6) were subjected to specific ASTM tests (tensile and lap-shear) after immersion in 50% and 100% simulant solutions for 1000 hours at the Savannah River Ecology Laboratory. Both liner materials exhibited good resistance to the simulant chemistry, at least based on the tests performed and the test duration/conditions imposed. In lap-shear tests, both materials failed in the base material rather than peeling apart, confirming good adhesion. The REMA 4CN bromobutyl elastomer showed superior bonding characteristics and absence of warping or delamination at the conditions tested. The Marseal M-3500 material (PVC/EVA blend with polyester reinforcement) exhibited deformation and debonding in some locations. The cause of the deformation and delamination observed in the Marseal M-3500 material is not fully known, but possibly attributed to thermomechanical stress at immersion temperatures, and the thermoplastic nature of the material. The immersion temperature (68 °C) is slightly greater than the maximum use temperature limit quoted for the Marseal M- 3500 liner (65 °C), though the basis for the service limit is unknown. The testing performed was limited in scope and only for these two liner materials. These tests were primarily performed to screen for severe incompatibility or short-term degradation in Saltstone bleedwater simulants at bounding solution temperatures. Additional testing is recommended to assess long-term performance and the overall service life of the liner.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Big Area Additive Manufacturing (BAAM) Materials Development and Reinforcement with Advanced Composites

Additive manufacturing (AM) by extrusion deposition is rapidly developing as an energy efficient process that greatly reduces development time for new products including vehicle structures. Development of reinforced thermoplastic compounds that are specifically tailored to the AM process and possess the properties necessary for engineering structures is currently underway. This project focused on developing a fundamental understanding of printability by performing a number of polymer characterization tests, initial printability screenings, and basic mechanical property determinations for a number of compounds. Structural evaluations of more complex printed articles were also performed in order to build a database of mechanical performance for validation of structural simulations planned for Phase II. Included in the structural tests were components that were reinforced using a number of methods including over-wrapping with dry fabric and resin infusing to form an advanced composite having the shape of the 3D printed structure. The results indicate a number of factors that affect printability of materials, and initial structural analysis shows that the data generated will be useful for model validation.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Continuous Fiber Composite Electrofusion Couplers (Final Report)

The objective of this three-year project was to develop a pipe coupler for high-pressure (100bar service, 350bar burst) composite hydrogen pipelines, without the use of elastomeric sealing mechanisms (e.g. o-rings), thereby avoiding seal maintenance costs and effort associated with digging up subterranean lines over a pipe’s lifetime of up to 50 years. The project aimed to build on past designs at (TRL 3), to adapt their use to hydrogen delivery and test in a relevant environment (TRL 5). This work is toward the DOE’s objective to reduce the technical barrier of high as-installed cost of pipelines, by utilizing fiber reinforced plastic (FRP) pipe. Further DOE targets include those from the Fuel Cell Technologies Office Multi-Year Research, Development, and Demonstration Plan: Milestone 1.5: Coordinating with the H2 Production and Storage sub-programs, identify optimized delivery pathways that meet a H2 delivery and dispensing cost of <\$ 2/gge for use in consumer vehicles. (4Q, 2020) Milestone 6.3: By 2020, reduce the cost of hydrogen delivery from the point of production to the point of use in consumer vehicles to <\$ 2/gge of hydrogen for the gaseous delivery pathway (4Q, 2020). This project headed by Automated Dynamics (now Trelleborg) with partners Savanah River National Laboratory, and NOV Fiber Glass Systems, emerged due to a similar previous project with the DOE, completed by SNRL and NOV Fiber Glass Systems (formerly Fiberspar) in 2014, that evaluated the mechanical suitability of FRP (composite) lines for these same high pressures. That projected concluded with a favorable outlook on using composite lines and required a suitable pipe coupler. The resulting coupler design from this current project employs electrofusion due to its proven use on low pressure unreinforced lines and for its simplicity in the field. This electrofusion coupler design utilizes established concepts for pipe couplers and combines them in a new and unique method. Existing pipe couplers are employed on thermoset pipes in high pressure, with elastomeric seals as the sealing mechanism, and on thermoplastic low-pressure pipes by way of electrofusion. However, no EF coupler is available for composite pipelines for 350bar hydrogen containment.

08 HYDROGEN↗
DOE OSTI2022

Discontinuous Aligned Carbon Fiber Intermediates for Automotive and Related Applications

This work focused on preferentially aligning discontinuous carbon fibers in wet-laid or air-laid processes. It is well known that aligned fibers provides higher directional strength and stiffness. Discontinuous fibers further allow higher degree of draw and formability as the gaps in the fibers allow for higher material movement. The current processes are limited in their ability to align carbon fibers during processing. The aligned fibers have several benefits - (a) in applications where chopped fibers can replace continuous fibers for targeted strength and stiffness metrics, but at a substantially reduced cost; (b) they can tolerate deeper draws than continuous fiber composites in thermo-stamping and compression molding processes; (c) they can be tailored for pultrusion and unidirectional applications. Although pultrusion is primarily a process that adopts continuous fibers, stitch bonded entangled discontinuous fibers can provide unique intermediates. This is analogous to natural coir fibers which get aligned and entangled to produce ropes/rods for example, (d) they can be processed in cross-ply and multi-directional formats, like composite laminates. In this work Neenah Paper partnered with IACMI, UT and ORNL to evaluate structure-process-property relationships with Zoltek carbon fiber. A few process parameters such as machine speed, weight basis, fiber length, effect of fiber sizing, direction of mat lay-up etc. were investigated. The produced mats were converted to thermoplastic composite laminates using polyamide 6 (PA6, nylon) resin. The specific objective of this project is to produce a wet-laid nonwoven carbon fiber mat with a high degree of unidirectional fiber alignment, using discontinuous carbon fibers. The report provides details about the processing, characterization, and lower-upper bound properties.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Production of high-performance biodegradable polyurethane products made from algae precursors

We successfully developed and scaled the production of high-performance, fully biodegradable thermoplastic polyurethanes (TPUs) derived from algae-based precursors. By employing innovative flow chemistry and chemo-enzymatic methodologies, the research team produced materials with up to 100% bio-based content that match or exceed the mechanical properties of traditional petroleum-based plastics. These algae-derived TPUs were proven to be fully home-compostable, achieving over 90% decomposition within 110 to 120 days while demonstrating practical advantages such as reduced solvent requirements in fabric coating applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Toward the Advanced Manufacturing of Land-Based Wind Turbine Blades

The National Renewable Energy Laboratory and General Electric (GE) are partners within the Additive and Modular-Enabled Rotor Blades and Integrated Composites Assembly (AMERICA) project. AMERICA aims to develop advanced manufacturing solutions to reduce labor and cycle time while increasing recyclability of wind turbine blades. The project is funded by the U.S. Department of Energy's Advanced Manufacturing Office. This paper describes the techno-economic and life cycle analysis of the novel manufacturing process applied to the 15-meter long tip of the blade of a representative 3.4 MW land-based wind turbine. We establish a comparison to a standard manufacturing process, highlighting challenges and opportunities. Several uncertainties affect the analysis, but we highlight an opportunity space. With the current set of assumptions, the tip adopting advanced manufacturing is predicted to lower labor by 21%, cycle time by 39%, and total blade tip costs by 15% while simultaneously increasing production quality and adopting recyclable thermoplastic resin. A life cycle analysis returns comparable metrics for climate change impact and embodied energy between the two processes.

3D printing↗
NASA NTRS1967

Polymer Research

Network density of filled composites, nitroso compound reactions with hydrocarbons, cryogenic bladder bag materials, thermoplastic rubbers as binders, and other polymer research studies

COMPOSITE MATERIAL↗
NASA NTRSDate not supplied

Evaluation Marcelling in Composites using Ultrasonic Guided Wave

Thermoplastic composite (TPC) material seldom manifests in-plane fiber waviness during manufacturing. In-plane fiber waviness is called marcelling. Marcelling com-promises the composite strength and performance. When present in a structure, marcelling is not only a surface defect but can extend partially along the thickness of the composite. There is no established nondestructive evaluation (NDE) method to detect and quantify marcelling in composite. Ultrasonic guided waves can saturate the complete thickness of a composite structure. Thus, physics of guided wave creates an opportunity to detect and quantify the marcelling in composites. Before guided waves could be used to detect marcelling, it is necessary to quantify the marcelling in the structure and identify the marcelling affected zones (MAZE). In this research first, high frequency scanning acoustic microscopy (SAM) was performed to quantify the marcelling and statistical distribution of the defects at different MAZE was obtained. Next the MAZE with known statistical distribution of quantified marcelling (marcelling wavelength and marcelling amplitude) was inspected using ultrasonic guided wave setup. The method quantified the guided wave feature as a function of quantitative degree of marcelling. The overarching objective of this research is to implement post process NDE inspection of TPC large structures where in plane fiber waviness or marcelling can be detected and MAZEs could be identified. Primary fining is that the reduction of wave velocity and amplitude of ultrasonic guided wave could be good indicators of MAZE. However, more rigorous calibration is necessary where inspection direction is carefully devised with respect to the marcelling.

HiCAM↗
NASA NTRS2026

Cryogenic Mixed Mode I – Mode II Fracture Toughness of Various Polymer Composite Materials

The present study investigates the mixed mode interlaminar fracture toughness of six polymer matrix composite materials at both room temperature and cryogenic liquid nitrogen temperature. The single leg bending test employed gives a mix of Mode I (opening) and Mode II (in-plane shearing) cracking. The tested thermoplastic-matrix composites were shown to have total mixed mode toughnesses 3.1–4.3 times higher than those of representative thermoset resin composites.

Carbon fiber↗