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At least 991 records · Page 55

Polarized Radar for Detection and Automatic Non-Visual Assessment of Unmanned Aerial Systems

This Laboratory Directed Research and Development (LDRD) effort performed fundamental Research and Development (R&D) to develop a robust radar processing algorithm capable of assessing the difference between an Unmanned Aerial System (UAS) and a biological target such as a bird, based on mathematics applied to the polarized radar returns of the target object, alone. The current threats of using such a UAS as a delivery platform for a host of destructive components is a major concern for the protection of various assets. Most recently, on 14th Sept. 2019, dozens of suicide or kamikaze drones (UAV-X) coordinated an attack on two Saudi oil facilities that demonstrated the potential to disrupt global oil supplies. While radar-based UAS detection systems can detect UAS at ranges greater than 1-km, the issues of excessive Nuisance/False Alarm Rates (NAR/FAR) from natural sources (birds in particular) has not been sufficiently addressed. In this effort we describe and utilize the Adaptive Polarization Difference Imaging-based (APDI) algorithms for the detection and automatic non-visual assessment of Unmanned Aerial System applications. Originally developed for optical imaging and sensing of polarization information in nature, the algorithms developed here are modified to serve for the target detection purposes in counter-UAS (cUAS) environments. We exploit the polarization statistics of the observing scene for detection and identification of changes within the scene and assess from these changes for UAS/bird classifications. Several cases are considered from independent data sources, including numerically generated data, anechoic chamber data as well as experimental radar data, to show the applicability of the techniques developed here. The methods developed in this effort are designed to be used in cUAS setups but have shown promise for a multitude of other radar-based classification uses as well.

47 OTHER INSTRUMENTATION↗

Towards Multifluid Multiphysics Continuum Plasma Simulation for Modeling Magnetically-driven Experiments on Z

Magnetically driven experiments supporting pulsed-power utilize a wide range of configurations, including wire-arrays, gas-puffs, flyer plates, and cylindrical liners. This experimental flexibility is critical to supporting radiation effects, dynamic materials, magneto-inertial-fusion (MIF), and basic high energy density laboratory physics (HEDP) efforts. Ultimately, the rate at which these efforts progress is limited by our understanding of the complex plasma physics of these systems. Our effort has been to begin to develop an advanced algorithmic structure and a R&D code implementation for a plasma physics simulation capability based on the five-moment multi-fluid / full-Maxwell plasma model. This model can be used for inclusion of multiple fluid species (e.g., electrons, multiple charge state ions, and neutrals) and allows for generalized collisional interactions between species, models for ionization/recombination, magnetized Braginskii collisional transport, dissipative effects, and can be readily extended to incorporate radiation transport physics. In the context of pulsed-power simulations this advanced model will help to allow SNL to computationally simulate the dense continuum regions of the physical load (e.g. liner implosions, flyer plates) as well as partial power-flow losses in the final gap region of the inner MITL. In this report we briefly summarize results of applying a preliminary version of this model in the context of verification type problems, and some initial magnetic implosion relevant prototype problems. The MIF relevant prototype problems include results from fully-implicit / implicit-explicit (IMEX) resistive MHD as well as full multifluid EM plasma formulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

SHIELDS

Los Alamos National Lab has developed SHIELDS, a comprehensive software platform that incorporates satellite observational data to determine the near-Earth surface charging environment (SCE) with high accuracy. SHIELDS is an effective line of defense for communication, navigation, and scientific satellites located in the Earth’s magnetosphere by predicting hazards resulting from solar storms. Advance warning of solar storms enables satellite operators to place onboard electronics or instruments in a safe mode until the danger has passed. The platform also supports design of more robust satellites. SHIELDS leverages the Lab’s 50 years designing and building spacebased sensors and studying space weather, and it has won a R&D 100 Award.

97 MATHEMATICS AND COMPUTING↗

Rad-Hard SBC: Radiation-Hardened Single-Board Computer

As global reliance on satellites and their services increases, scientists and engineers will continue to feel pressure to reduce costs, save power, and reduce size and weight. Los Alamos researchers have developed the Rad-Hard SBC to alleviate this pressure. The invention is a radiation- and mechanically-hardened single-board computer that is small, lightweight, and uses less power than any commercially available space-grade computer. Rad-Hard SBC provides an affordable option for long-lasting satellites beyond low-Earth orbits. The computer enables researchers, businesses, and consumers broader access to space assets for their unique needs. The invention builds on the Lab's more than fifty years of experience in designing, manufacturing, and deploying instruments for use on satellites and deep space missions. A R&D 100 Award has recognized the innovation and value of the Rad-Hard SBC.

42 ENGINEERING↗

Detector Instrumentation, Energy Reconstruction and Data Analysis in the DUNE and NOvA Neutrino Experiments

Neutrino oscillations are so far the only experimental observation beyond the standard model since its development four decades ago. The remaining fundamental questions that can be answered by long-baseline neutrino oscillations are (1) the CP violation (whether neutrinos and antineutrinos behave the same way in oscillation), and (2) the mass hierarchy ($m_3>m_{1,2}$ or $m_{1,2}>m_3$), and (3) the octant of $\theta_{23}$ ($\theta_{23}>45^\circ, =45^\circ$ or $<45^\circ$). The PI's group at UCI focuses on long-baseline neutrino experiments DUNE and NOvA, key components of DOE's Intensity Frontier program. NOvA is the current major U.S.-based long-baseline neutrino experiment aiming to solve the mass hierarchy and $\theta_{23}$ octant. It is taking $\nu$ and $\bar{\nu}$ data from the NuMI beam at Fermilab. DUNE is the next-generation flagship neutrino experiment in the U.S. which is designed to decisively determine neutrino CP violation, mass hierarchy and $\theta_{23}$ octant. DUNE is Fermilab's first priority, and has been established as an international collaboration. During the period covered by the report, the PI's group has been exceptionally productive, with leading contributions to DUNE argon-purity monitoring detectors, NOvA/DUNE deep-learning reconstruction, and NOvA oscillation and near detector (ND) analyses. The group also is actively involved in DUNE/NOvA detector operation, data production, calibration, software upgrade and maintenance, and ProtoDUNE cold electronic QA/QC. Specifically, we have made accomplishments in the following four research projects: 1) Purity monitor R\&D and data analysis for DUNE, 2) Deep-learning-based energy reconstruction at NOvA and DUNE, 3) Oscillation analysis at NOvA, and 4) $\nu$-e elastic scattering analysis at NOvA.

47 OTHER INSTRUMENTATION↗

Proactive Data Containers for Scientific Storage (Final Report)

Emerging HPC systems are expected to be deployed with an unprecedented level of complexity, due to a deep system memory/storage hierarchy and heterogeneity of the storage hardware. This hierarchy is expected to range from CPU cache through several levels of volatile memory to nonvolatile memory, traditional hard disks, and tape. Simple and efficient methods of data management and movement through this hierarchy is critical for scientific applications using exascale systems. Existing storage system and I/O (SSIO) technologies face severe challenges in dealing with these requirements. POSIX and MPI I/O standards that are the basis for existing I/O libraries and parallel file systems present fundamental challenges in the areas of scalable metadata operations, semantics-based data movement performance tuning, asynchronous operation, and support for scalable consistency of distributed operations. Moving toward new paradigms for SSIO in the extreme-scale era, we have proposed to investigate novel object-based data abstractions and storage mechanisms that take advantage of the deep storage hierarchy and enable proactive automated performance tuning. In order to achieve these overarching goals, we initiated an effort to develop a fundamental new data abstraction, called Proactive Data Containers (PDC). A PDC is a container within a locus of storage (memory, NVRAM, disk, etc.) that stores science data in an object-centric manner. Managing data as objects enables powerful optimization opportunities for data movement and transformations. The R&D focus of this project are: 1) formulation of object-oriented PDCs and their mapping in different levels of the exascale storage hierarchy; 2) efficient strategies for moving data in deep storage hierarchies using PDCs; 3) techniques for transforming and reorganizing data based on application requirements; and 4) novel analysis paradigms for enabling data transformations and user-defined analysis on data in PDCs. Toward achieving these overarching goals, we designed an object-centric application programing interface (API) for HPC, scalable metadata management for object-centric storage systems, and data movement optimizations such as Data Elevator for moving data between two levels of storage devices and TAPIOCA for efficient aggregation of data on compute nodes. We then implemented several components of the PDC system. They include metadata management, data placement services, remote procedure calls, data aggregation, etc. We have put them together into the overall PDC framework.

97 MATHEMATICS AND COMPUTING↗

Grid-Interactive Efficient Buildings Technical Report Series: Overview of Research Challenges and Gaps

These reports evaluate state-of-the-art and emerging building technologies that have significant potential to provide grid services. The reports also identify major research challenges and gaps facing the technologies as well as opportunities for technology-specific R&D. The GEB Technical Report Series will help inform and guide BTO's portfolio and serve as a foundational resource for the larger building research community. On-site behind-the-meter generation, battery storage, and electric vehicles are also an important part of the distributed energy resource (DER) optimization strategy for buildings. In general, the component technology reports do not focus on distributed generation or battery storage, but the Whole-Building Controls, Sensors, Modeling, and Analytics report discusses how a building can optimize across all DERs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Combustion Research I.1 Sprays, Flow, Heat Transfer and Turbulent Mixing

LANL is working with the Partnership for Advance Combustion Engines (PACE) a DOE sponsored consortium of national laboratories for the research and development for creating smarter engine design tools for sustainable transportation. Much of that effort is focused on heat, mass and momentum transfer within and engine. LANL’s focus in 2019, in particular under PACE has been spray modeling and engine mixture formulation, development of conjugate heat transfer analysis (heat transfer to the environment surrounding the combustion chamber). Our efforts relay on the Fast, Easy, Accurate and Robust Continuum Engineering (FEARCE) software developed at LANL as the next generation of engine modeling software for turbulent reactive and multiphase flow, a 2019 R&D 100 winner. This work is relevant to the DOE Vehicle Technologies Office efforts at addressing national energy security as well. Less dependence on petroleum products leads to greater energy security. By Environmental Protection Agency standards, some vehicles are now reaching 42–50 mpg mark. These are conventional gasoline engines. With continued investment and research into new technical innovations, the potential exists to save more than 4 million barrels of oil per day or approximately $200 to $400 million per day. This would be a significant decrease in emissions and use of petroleum and a very large stimulus to the U.S. economy. Better understanding of fuel injection and fuel–air mixing, thermodynamic combustion losses, and combustion/emission formation processes enhances our ability to minimize fuel use and unwanted emissions. Helping to accomplish this understanding, the FEARCE modeling program is working to provide state-of-theart capability for accurately simulating combustion processes: to have a predictive methodology in a software helping industry and researchers not only meet national goals on fuel usage and emissions, but global goals. In addition, a predictive, robust, and accurate capability for simulating the engine combustion process helps to minimize time and labor for development of new engine technology.

33 ADVANCED PROPULSION SYSTEMS↗

Swept-Frequency Acoustic Interferometry (SFAI) and Related Technologies

Researchers at Los Alamos National Lab have developed acoustic technologies to accurately discern the characteristics of materials within closed containers non-invasively. SFAI and related technologies use high-frequency sound to characterize liquids, gasses, mixtures, emulsions, and other fluids inside pipes and containers. SFAI offers the potential to measure material characteristics and two-and three-phase flows within pipes including flow rates and water- and gas-volume fractions all with a small-footprint device. SFAI is an enabling component of a 2014 R&D 100 Award Winner.

36 MATERIALS SCIENCE↗

PVMI Bay Area Photovoltaic Consortium (Final Report)

The Bay Area Photovoltaic Consortium (BAPVC) was formed to fund university research on technologies industry will use and thereby investigate new ways for the photovoltaic (PV) industry and university scientists to identify and explore research priorities. Our thesis is that great innovation is more likely stimulated by the collective efforts of manufacturing and academic experts working together rather than direction from either community alone. The consortium is quite effective in promoting the interactions needed to form collaborative teams, often engaging industry members as research participants. All similar university research consortia employ their industry members in advisory capacity. In BAPVC, industry members deliver far more than guidance and advice. They are part of the management team. They review and down select proposals, review projects, and guide the university researchers is setting their research directions. The BAPVC Industry Board holds executive authority over the strategy and operations of the consortium. BAPVC is a consortium led by Stanford University (SU) and University of California at Berkeley (UCB) joined by three leading DOE labs—Lawrence Berkeley National Laboratory, SLAC National Laboratory, and the National Renewable Energy Lab. BAPVC’s success is attributed to its three pillars of support. Three Pillars: (1) Industry sets research agenda, assures relevance, provides path to commercial impact, and contributes funding. (2) Universities and National Labs conduct innovative research and provide workforce development. (3) US Department of Energy provides leadership, support and guidance. Since inception in 2011, BAPVC funded 72 projects involving 26 organizations. Bringing together the differing backgrounds of industry and university participants stimulates innovation. BAPVC’s cultivation of larger collaborative projects among university investigators has also produced notable results. This report will highlight BAPVC contributions in several exciting PV technologies including perovskite/silicon tandem cells, CdTe, reliability and adhesion metrology, ultra-thin silicon cells and application of carrier selective contacts in silicon PV that all owe a portion of their success to cross-consortium collaboration. More importantly, many of the BAPVC-fostered teams have successfully bid for additional support from other sources and continue to expand their productivity. In one case, we report a recent Nature Energy paper published by a team including both university members and two industry members (separate companies) in a collaborative analysis of thin-film tandem cells. Our original proposal set ambitious goals – “BAPVC is composed of the industry members and prestigious universities needed to add substantial value to the open and competitive process of providing universities all over the nation with funding to perform industry-relevant R&D…Our consortium will accelerate the coordination of stakeholders across the solar industry and academic sectors into a cohesive research force developing innovative solutions to the key industrial issues.” While the PV landscape has undergone vast change during the period of this award, BAPVC and its research and industry members have adapted, delivering the promised cohesive research force for the benefit of DOE and the public.

14 SOLAR ENERGY↗

A Model for Lean Corporate/ Startup Interfaces: Unlocking Resources of Midcap Corporations Providing a Pathway to Advanced Energy Technologies

Commercializing energy technologies through traditional market pathways is challenging for early-stage energy innovators. Development cycles in energy are long and expensive, and adoption is difficult, making energy technologies of limited interest to venture capital relative to industries with faster growth and shorter product life cycles such as life sciences and software. As such, partnerships with established corporations are one of the most promising, and in some cases only, go-to-market pathways for energy technologies. Startups often seek to work with, large well-known Fortune 500 (and similar) companies. However, the size and risk aversion of those firms often makes partnering challenging. It can take well over 12 months for a large corporation to agree to commercial terms and get internal board / management approval to move forward with a binding agreement with a startup for even a simple starting partnership. This timeline is prohibitive for most early-stage companies who are both time and money constrained, and often working in highly competitive commodity sectors. Mid-cap corporations ($\$ $100M to $\$ $10B) are a promising but untapped resource for partnering with technology developers because they are often nimbler, tend to be fiercely competitive, and are looking for new revenue or cost-saving opportunities. These factors make them both more receptive to disruptive technologies, and more capable of integrating them. However, while Fortune 500 companies often have venturing groups that facilitate the initial connection process, most midcap incumbents do not have the resources to create standalone corporate venture groups. As a result, although they could help each other significantly (startup technologies make midcaps more competitive; midcaps offer a faster commercialization pathway to startups), midcap companies and startups rarely work together. In 2017, ADL Ventures (ADL) received Award #DE-EE0008111 from DOE EERE’s Innovative Pathways program to unlock the domain expertise and material resources of midcap companies. The goal of the award was to support energy technology commercialization via an innovation platform for startups to interface with midcap corporations. During the grant period, we have developed a novel open innovation platform that allows financially conservative incumbents to efficiently engage with energy innovators and startups, thereby unlocking the incumbents’ domain expertise, strategic capital, R&D facilities, supply chain, and pathways to market. We have executed full-scale open innovation challenges for three clients, exceeding the initial proposed goal of two. We also built a diversified opportunity pipeline which resulted in four projects contracted for 2020, meeting the goals of the proposal, with others pending.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Modelling the Value of Networked, Small-Hydro Generators for Storage and Dispatch Capability on the Grid

Natel Energy, Inc. (Natel), Alameda, California, has developed a new type of fish-friendly, low-head hydropower turbine, the hydroEngine (R), that is designed to provide reliable, dispatchable power and ancillary services at significantly reduced civil works costs. For the U.S. Department of Energy's (DOE) Small Business Voucher for Hydropower, Third Round, Natel and NREL will model and evaluate the potential value streams of a portfolio of networked small hydropower generators. The project is designed to advance the understanding of the value of small hydro generation to the grid of the future. It will help support dialog with potential customers and stakeholders regarding the value of the Natel's technologies and inform future R&D efforts in this area.

13 HYDRO ENERGY↗

RETRO RX

RETRO Rx is an R&D 100 Gold Award-winning suite of tools that provides a new class of analytics in the space between traditional epidemiological models and unanalyzed spreadsheets of data. Unlike traditional models, these tools provide analysts, scientists, practitioners, and decision makers a way to easily and effectively do sophisticated analyses using a simple user interface. AIDO guides users at the early stages of a disease outbreak by comparing the current parameters to historic outbreaks. RED Alert constructs a broad historical picture of disease incidence (recent outbreak included) to detect disease reemergence at its earliest stages, locally and globally. RETRO Rx compiles data and presents analysis in a clear, concise visual format to support disease mitigation and prevention planning. Both are available currently as web-based apps. A prototype of the RED Alert mobile app with enhanced functionality is available for beta testing and AIDO mobile app development is planned.

59 BASIC BIOLOGICAL SCIENCES↗

The ABALONE Photosensor Panel Technology for Rare Decay and Rare Particle Detection

Our technology offers superior performance and cost-effectiveness that enables unprecedentedly sensitive next-generation detectors for the discovery of Dark Matter and other elusive phenomena. It addresses other important societal needs including previously nonexistent ultrasensitive medical scanners for early-stage cancer screening and radiation detection for homeland security. Our Phase-1 SBIR Project has provided the proof of concept for a particular embodiment of our detectors, and paved the way for a more detailed R&D effort, to be conducted if Phase-2 SBIR grant were awarded. This effort was supposed to be concerted in close collaboration with our customers/partners from several application areas in the fields of elementary particle and nuclear physics, as well as homeland (nuclear) security.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

High Momentum Transfer Nucleon Elastic Electromagnetic Form Factor Measurements Using Super BigBite Spectrometer at Jefferson Lab

The nucleons - protons and neutrons - are the basic building blocks of atomic nuclei. We now know that the nucleon consists of fundamental particles called quarks and gluons. The quarks interact with each other by exchanging gluons via the strong interaction. Understanding the quark-gluon structure of the nucleon, especially the confinement of quarks within the nucleon in its ground state, remains one of the main unsolved puzzles of particle physics. The nucleon electromagnetic form factors are directly related to the internal structure of the nucleon. A new generation of high precision experiments, GEp-V, GEn-II, GEn-RP, and GMn, measuring the ground state nucleon space-like electro-magnetic form factor at high momentum transfer is underway at Jefferson Lab experimental Hall-A as part of the Super Bigbite Spectrometer (SBS) program. This series of experiments will provide a new level of understanding of the nucleon structure. These experiments are highly demanding due to the extremely fast drop off of the elastic cross section with the increasing four-momentum transfer squared(Q2). This thesis provides an overview of the SBS physics program and reports on the extensive R&D program carried out to achieve the high rate running conditions essential for carrying out the SBS experiments. SBS will provide an intermediate solid angle of approximately 35 msr, which is significantly larger than the solid angle of other dipole based spectrometers at Jefferson lab. Of course, there are much larger acceptance spectrometers at Jefferson Lab, CLAS12 for example. What is special about SBS is that it provides a sizable acceptance while operating at the highest possible luminosity at Jefferson Lab. With this combination of medium acceptance and the highest available luminosity, SBS provides an unparalleled opportunity to explore the nucleon in its ground state with unprecedented resolution. The relatively large acceptance of SBS is achieved by using a large gap dipole magnet and placing it close to the target. An unavoidable consequence of this is that the SBS GEM trackers and other detectors have a clear line-of-sight view of the target and a portion of the beam-line. As a result, the background hit rate in the SBS front GEM trackers is expected to be up to 500 kHz/cm2, over the entire active area of 6000 cm2. To the best of our knowledge, this extremely high rate over such a large area is unprecedented in any particle tracking system used anywhere in the world before. Correctly reconstructing the particle tracks of interest in this very high background environment is achieved by using especially adapted high rate techniques at every step of the tracking process: optimizing the GEM module and tracker design at the hardware level, using high bandwidth electronics and real time Field Programmable Gate Array (FPGA) based background suppression techniques at the Data Acquisition (DAQ) level, and developing highly specialized tracking algorithms to pick out the signal hits from among the vast amount of background hits. In order to ensure a smooth start and running of the SBS experiments, it is extremely crucial that these techniques are developed, implemented, and tested under realistic conditions well before the actual start of the SBS experimental program. A detailed Geant4 simulation of the experiment was combined with a digitization package to generate the detector level pseudodata similar to what is expected in the actual experiments. The digitization procedures were calibrated against actual GEM data from cosmic-ray runs, X-ray tests, beam test runs in experimental Hall-A, and the PRad experiment in Hall B. Then, optimized tracking algorithms were developed and implemented in an analysis program used to analyze these pseudo-data and to extract expected high-level parameters. These extracted quantities were then compared with the input parameters from the simulation to verify and determine the performance characteristics for the SBS tracker. From this work, a final tracking efficiency of 69% at 25% occupancy was achieved, with the required reconstruction accuracy, for the GMn experiment, the first experiment in the SBS program, with background level at 100 kHz/cm2. These demonstrated parameters are adequate for the successful running of not only the GMn experiment but as well as for GEn-RP and GEn-II experiments, the second and third experiments in the program. This work builds the solid ground to further improve the tracking performance for these experiments and achieve similar conditions for the running of the GEp-V experiment, the most demanding experiment in the SBS program, with an expected background level at 500 kHz/cm2.

Di, Danning↗

Next Generation Noble Liquid Detectors

The research program here combines Generic and Directed R\&D for Liquid Noble Gas detectors for neutrino physics and dark matter. In neutrino physics and dark matter research, we are addressing some of the most fundamental questions in particle physics today by studying these tiny particles in the electron family. To study them, detectors must be large, high precision, and ideally have the ability to collect detailed information from both charge and light from neutrino and dark matter interactions. Precision detection combined with large scales can be challenging. Liquid Argon detectors mitigate some of these challenges given the nature of its interaction medium and it’s relatively inexpensive cost per ton. Significant progress has been made in the last 15 years in developing these kinds of detectors to be built and operated at large scales. However there are still challenges and new ideas in moving these detectors from ton scale to kiloton scale. To be able to get the most out of these kinds of detectors directed questions with respect to specific components running and colleting data in the detectors must be understood. As well, new ideas on how to best combine charge and light measurements may lead to new ways to learn new things with these detectors. Experimental test stands to conduct this work, as is done in this proposal, to accomplish both of these goals are critical to address both of these questions. In the test stand enabled under this grant at Yale University’s Wright lab, new developments in efficient small scale setups were developed, instrumentation developed for running and future experiments (the SBND experiment at Fermilab at present, the DUNE experiment in the future) were and will be tested, and new ideas for charge and light determination for new measurements are under study. The long term impact of this work in neutrino physcis is both for the short and long baseline programs originating at Fermi National Accelerator Laboratory. At long baselines, the US flagship DUNE experiment will measure neutrino properties through neutrino oscillations using a beam originating at Fermilab and a massive LArTPC detector sited about a mile underground at the Sanford Underground Research Facility in Lead, South Dakota. Studies here on the high voltage for thes detectors, and ongoing work on charge and light production and collection in the TPC are relevant for the design and data taking of this and other LArTPC detectors to enable them to best measure the neutrinos created at Fermilab that then pass through the detector in South Dakota. What we learn in these detectors may ultimately change the course of how we understand neutrino’s impact in the early universe. What we learn about how to improve this detection technology and develop new ideas in Lar detectors in general may impact both future neutrino experiments and dark matter experiments.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Additive Manufacturing Fabrication of PEEK Counter-Current Centrifugal Contactor Components

Additive manufacturing (AM, also known as 3D printing) offers significant advantages for the fabrication of annular centrifugal contactor-separator (CCS) stages, particularly when complemented by post-processing via traditional machining. The shortcomings of 3D printing of CCSs are offset by its low cost, quick turnaround, and ability to manufacture enhanced mixing sections and multistage modules. High-density acrylic materials show promise for improved chemical resistance and mechanical properties. The demonstration of the MOEX process using acrylic AM CCS stages confirmed their full functionality and showed significant flexibility in geometry design while using relatively low-cost plastic materials. Over the past two years, AM has been used to produce low-cost centrifugal contactor components, ranging from bench-scale laboratory testing to a full-scale industrial process with on-hand availability of spare parts and great flexibility in design modifications and quick testing and implementation. However, the shortcomings of stereo lithography assembly (SLA)-printed acrylic components became apparent rather quickly. By the completion of the initial MOEX demonstration using the 9-stage 2-cm CCS bank, nearly half of the rotors had begun to fail from pitting and cracking. These problems were most likely caused by swelling of the rotor due to liquid absorption, resulting in improper excess run out, mechanical abrasion, and chemical exposure of the roughened surface. Additional deterioration of the acrylic stages was later discovered when the interiors of the acrylic housings began to experience flaking and delamination as the plastic dried out several weeks after the tests. All of these issues caused severe limitations to the lifespan of the CCS stages, which are acceptable for R&D but undesirable for commercial-scale production.

42 ENGINEERING↗