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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 991 records · Page 55
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

TU-H-CAMPUS-IeP2-05: Breast and Soft Tissue-Equivalent 3D Printed Phantoms for Imaging and Dosimetry

Purpose: The study has the goal to demonstrate that breast and soft tissue-equivalent phantoms for dosimetry applications in the diagnostic energy range can be fabricated using common 3D printing methods. Methods: 3D printing provides the opportunity to rapidly prototype uniquely designed objects from a variety of materials. Common 3D printers are usually limited to printing objects based on thermoplastic materials such as PLA, or ABS. The most commonly available plastic is PLA, which has a density significantly greater than soft tissue. We utilized a popular 3D printer to demonstrate that tissue specific phantom materials can be generated through the careful selection of 3D printing parameters. A series of stepwedges were designed and printed using a Makerbot Replicator2 3D printing system. The print file provides custom adjustment of the infill density, orientation and position of the object on the printer stage, selection of infill patterns, and other control parameters. The x-ray attenuation and uniformity of fabricated phantoms were evaluated and compared to common tissue-equivalent phantom materials, acrylic and BR12. X-ray exposure measurements were made using narrow beam geometry on a clinical mammography unit at 28 kVp on the series of phantoms. The 3D printed phantoms were imaged at 28 kVp to visualize the internal structure and uniformity in different planes of the phantoms. Results: By utilizing specific in-fill density and patterns we are able to produce a phantom closely matching the attenuation characteristics of BR12 at 28 kVp. The in-fill patterns used are heterogeneous, so a judicious selection of fill pattern and the orientation of the fill pattern must be made in order to obtain homogenous attenuation along the intended direction of beam propagation. Conclusions: By careful manipulation of the printing parameters, breast and soft tissue-equivalent phantoms appropriate for use at imaging energies can be fabricated using 3D printing techniques.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2016

WE-DE-207B-11: Implementation of Size-Specific 3D Beam Modulation Filters On a Dedicated Breast CT Platform Using Breast Immobilization

Purpose: To implement a 3D beam modulation filter (3D-BMF) in dedicated breast CT (bCT) and develop a method for conforming the patient’s breast to a pre-defined shape, optimizing the effects of the filter. This work expands on previous work reporting the methodology for designing a 3D-BMF that can spare unnecessary dose and improve signal equalization at the detector by preferentially filtering the beam in the thinner anterior and peripheral breast regions. Methods: Effective diameter profiles were measured for 219 segmented bCT images, grouped into volume quintiles, and averaged within each group to represent the range of breast sizes found clinically. These profiles were then used to generate five size-specific computational phantoms and fabricate five size-specific UHMW phantoms. Each computational phantom was utilized for designing a size-specific 3D-BMF using previously reported methods. Glandular dose values and projection images were simulated in MCNP6 with and without the 3DBMF using the system specifications of our prototype bCT scanner “Doheny”. Lastly, thermoplastic was molded around each of the five phantom sizes and used to produce a series of breast immobilizers for use in conforming the patient’s breast during bCT acquisition. Results: After incorporating the 3D-BMF, MC simulations estimated an 80% average reduction in the detector dynamic range requirements across all phantom sizes. The glandular dose was reduced on average 57% after normalizing by the number of quanta reaching the detector under the thickest region of the breast. Conclusion: A series of bCT-derived breast phantoms were used to design size-specific 3D-BMFs and breast immobilizers that can be used on the bCT platform to conform the patient’s breast and therefore optimally exploit the benefits of the 3D-BMF. Current efforts are focused on fabricating several prototype 3D-BMFs and performing phantom scans on Doheny for MC simulation validation and image quality analysis. Research reported in this paper was supported in part by the National Cancer Institute of the National Institutes of Health under award R01CA181081. The content is solely the responsibility of the authors and does not necessarily represent the official views of the National Institue of Health.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2016

Sci-Thur PM – Colourful Interactions: Highlights 01: Design to delivery of spatially fractionated mini-beam canine radiotherapy

Spatial fractionation of radiation using arrays of narrow parallel micro-planar beams (less than 1 mm), is a relatively new concept with many unknowns specifically within the underlying biology of cell death. A tungsten collimator has been designed to produce mini-beams with a Varian linear accelerator for translational animal research into the effectiveness of spatial fractionation mini-beam radiotherapy (MBRT). This work presents the treatment planning process and workflow for the application of MBRT treatments within a clinical study. For patient dose calculations, the MBRT collimator was incorporated into a Monte Carlo based treatment planning system called MMCTP. Treatment planning was split between Eclipse and MMCTP, as the field apertures were determined within Eclipse prior to being sent to MMCTP for dose calculations. The calculated plan was transferred back into Aria with updated MUs per field for patient treatment. Patients were positioned within a vac-lock bag lying prone with a bite block and a thermoplastic mask to immobilize the head. Prior to treatment, a delivery verification plan was created within MMCTP. DQA output measurements of the treatment fields agreed with the calculated dose to within 1.5%. We have presented a workflow for MBRT treatments that include the planning technique, dose calculation method, DQA process and data integration into a record and verify system. The clinical study following this workflow represent the first series of linac based MBRT patients and depending on the clinical outcome of the study, our technique could be applied to human MBRT treatments.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2016

Sci-Thur PM – Brachytherapy 06: 3D Printed Surface Applicators for High Dose Rate Brachytherapy

Purpose: The purpose of this work is to develop a new applicator for administering high dose rate (HDR) brachytherapy using 3D printing technology. Primary advantages of using a 3D printed applicator will be to offer a more streamlined approach for therapists and patients while achieving better conformity, reproducibility, and patient specific applicators. Methods: A phantom study was conducted to measure the effectiveness of a 3D printed surface applicator by analyzing tumours on three locations of the body: the foot, nose, and scalp. The applicator was designed using Eclipse and further modified using Blender to create the catheter tunnels before being printed on a Lulzbot Taz 5 3D printer. A radiation plan was made using Oncentra Brachytherapy for a control treatment option using Freiburg Flaps and one with the novel method of a 3D printed applicator. A comparative analysis was made using D90, D100, V100, V150, and V200 Results: The 3D printed applicator showed comparable dose coverage with significant improvements on highly irregular surfaces when analyzed against a plan made using Freiburg Flaps. Although both plans exhibited complete tumour coverage, the 3D applicator showed improvements in D90 and V150 and the 3D applicator had a dose homogeneity index (DHI) of 0.99 compared to a DHI of 0.97 for the control. Therapist prep time also dropped significantly due to the lack of need for a thermoplastic mesh. Conclusions: 3D printed applicators for treatment of superficial sites proved to offer more patient convenience, less prep time, better conformity and tighter margins.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Application of entropy and signal energy for ultrasound-based classification of three-dimensional printed polyetherketoneketone components

This paper describes a preliminary method for the classification of annealed and unannealed polyetherketoneketone (PEKK) components manufactured using a material extrusion three-dimensional (3D) printing process. PEKK is representative of a class of high-performance thermoplastics that are increasingly employed as feedstocks for use in 3D printing. PEKK components may be used continuously at elevated temperatures, are chemically resistant, and able to withstand large mechanical loads. These properties render PEKK suitable as a metal component replacement in aerospace applications, high-temperature industrial applications, and surgical implants. The structure of PEKK is semi-crystalline with the specific crystallinity correlating to the final properties during application, making determination of this property crucial. This study compares three different signal processing techniques intended to distinguish annealed (high crystallinity) from unannealed (low crystallinity) components using backscattered ultrasound. The first is energy-based and is unable to detect annealing. The second two are based on different entropies of the backscattered signal: a limiting form of Renyi's entropy and a limiting form of joint entropy. The joint entropy values for the annealed and unannealed specimens fall into two non-overlapping intervals and have a statistical separation of two standard deviations.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Closed-loop additive manufacturing of upcycled commodity plastic through dynamic cross-linking

A sustainable closed-loop manufacturing would become reality if commodity plastics can be upcycled into higher-performance materials with facile processability. Such circularity will be realized when the upcycled plastics can be (re)processed into custom-designed structures through energy/resource-efficient additive manufacturing methods, especially by approachable and scalable fused filament fabrication (FFF). Here, we introduce a circular model epitomized by upcycling a prominent thermoplastic, acrylonitrile butadiene styrene (ABS) into a recyclable, robust adaptive dynamic covalent network (ABS-vitrimer) (re)printable via FFF. The full FFF processing of ABS-vitrimer overcomes the major challenge of (re)printing cross-linked materials and produces stronger, tougher, solvent-resistant three-dimensional objects directly reprintable and separable from unsorted plastic waste. This study thus offers an imminently adoptable approach for advanced manufacturing toward the circular plastics economy.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Resilient high-temperature reverse osmosis desalination membranes

Conventional thin-film composite (TFC) reverse osmosis (RO) membranes experience irreversible performance loss at high temperatures, restricting their use in industries with high-temperature streams, including oil and gas, pharmaceuticals, electronics, power generation, food production, and hybrid desalination plants. However, the mechanisms driving the performance decline of TFC membranes at high temperatures remain poorly understood. Herein, we combine controlled experiments, molecular dynamics simulations, and micromechanical modeling to elucidate TFC failure mechanisms and to evaluate thermally resilient thin-film cross-linked (TFX) composite membrane. Upon exposure to elevated temperatures (>60°C), salt rejection of TFC dropped from ~99 to <90%, with irreversible structural damage in the polysulfone layer, confirmed by scanning electron microscopy. In contrast, the TFX membrane maintained ~99% salt rejection and showed no signs of physical degradation up to 80°C. Our combined analyses revealed that TFC membrane failure arises from irreversible pore expansion in the thermoplastic polysulfone support, leading to polyamide film rupture and delamination. TFX membranes resist thermal deformation, enabling ultrahigh-temperature RO desalination and water reuse.

Wu, Jishan [Rice Univ., Houston, TX (United States↗
DOE OSTI2023

Chemically recyclable polyolefin-like multiblock polymers

Polyolefins are the most important and largest volume plastics produced. Unfortunately, the enormous use of plastics and lack of effective disposal or recycling options have created a plastic waste catastrophe. Here in this work, we report an approach to create chemically recyclable polyolefin-like materials with diverse mechanical properties through the construction of multiblock polymers from hard and soft oligomeric building blocks synthesized with ruthenium-mediated ring-opening metathesis polymerization of cyclooctenes. The multiblock polymers exhibit broad mechanical properties, spanning elastomers to plastomers to thermoplastics, while integrating a high melting transition temperature (T m ) and low glass transition temperature (T g ), making them suitable for use across diverse applications (T m as high as 128°C and T g as low as –60°C). After use, the different plastics can be combined and efficiently deconstructed back to the fundamental hard and soft building blocks for separation and repolymerization to realize a closed-loop recycling process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Alkylidene functionalization produces highly recyclable and scalable polyhydroxyalkanoates

Recyclable polymers that can be produced at scale and readily tuned within the same polymer framework for specific properties are important to achieving a circular materials economy. To this end, synthetic poly(3-hydroxyalkanoate)s (PHAs) have emerged as high-performance, chemically recyclable variants of biological PHAs, but their difficult monomer syntheses and suboptimal recycling efficiencies pose challenges for large-scale deployment. In this study, we investigated a β-isopropylidene PHA, i-PHA, for which the lactone monomer can be synthesized by existing industrial methods from biomass-derived isobutyric acid. The alkylidene substituent prevents decarboxylative degradation typically observed during PHA depolymerization, enabling near-quantitative chemical recycling to monomer. Controlled hydrogenation of the β-isopropylidene side group produces PHAs with diverse performance metrics that are competitive with a range of commodity polymers, spanning strong fibers to ductile thermoplastics to superglue epoxy resins.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Reactive Extrusion of Waste Plastics with Compatibilizer and Lightly Pyrolyzed Crumb Rubber for Asphalt Modification

Modifying asphalt is a potentially high-value application for reusing waste plastics because of the high-volume usage of asphalt in highway construction. However, simply blending hot plastics and asphalt encounters difficulties related to the poor solubility of polymers, which limits the formation of a swollen network with asphalt molecules. The polymer phases also tend to coalesce and separate from asphalt during high-temperature storage in static conditions. The present study developed an innovative process to stabilize waste plastics in asphalt and improve binder storage stability by using lightly pyrolyzed crumb rubber together with a chemical compatibilizer. Both polymers were extruded to produce a thermoplastic elastomer (TPE) for asphalt modification. The mechanical performance and chemical reactions of TPEs were characterized via tension test and Fourier transform infrared spectroscopy. The storage stability and rheological properties of modified binder blends were evaluated through laboratory asphalt stability test and dynamic shear rheometer test. Polymer phases and network structures were characterized through optical microscopy. It was found that the pyrolyzed and reactive extrusion process improved the rubber solubility and polymer interaction, and therefore the storage stability of modified binder blends. The co-existence of rigid plastic and soft rubbery regimes in an entangled network provided a promising pathway to improve the mechanical performance of asphalt binders in both high- and low-temperature domains.

Ma, Yuetan↗
DOE OSTI2025

Compatibilization Strategy and Mechanism for Co-stabilizing Commingled Plastics and Pyrolyzed Rubber in Asphalt

Hot mix asphalt mixture is considered the ideal approach to reuse waste plastics in high-value applications because of its very high amount of usage in highway construction. However, the differences in polarity and density between polymers and asphalt lead to polymer coalescence and therefore the poor storage stability of modified asphalt. These challenges are exalted when recycling commingled plastics. This study introduced an innovative compatibilization strategy and mechanism for co-stabilizing commingled plastics and pyrolyzed rubber in asphalt. Commingled plastics were first grafted with maleic anhydride for surface activation, followed by reactive kneading with pyrolyzed rubber and crosslinking agent to form an integrated thermoplastic elastomer (ITPE) for asphalt modification. The mechanical, thermal, and interfacial behaviors of the ITPE were evaluated through tensile testing, thermogravimetric analysis, and scanning electron microscopy. The storage stability and rheological properties of the modified binder blends were evaluated through the cigar tube test and dynamic shear rheometer testing. Results demonstrated a successful formation of imide bonds in the ITPE, which can improve the strength, ductility, and thermal stability of rubber–plastic composites. Appropriate utilization of crosslinking agents can improve both rutting and fatigue resistance of ITPE-modified asphalt with good storage stability because of the co-existence of rigid plastic and soft rubbery regimes and the formation of a crosslink network. Furthermore, excessive content of crosslinker led to severe phase separation and reduced storage stability of modified binder blends. Extra crosslinker tended to float in asphalt because of its low density and caused an excessive formation of the crosslink network in the top section of the asphalt.

asphalt binder modifiers↗
DOE OSTI2013

Multiscale analysis of stamp forming of a woven composite

The stamp forming of a woven composite with thermoplastic matrix was investigated in this study. A Mesoscale finite element model of a unit cell of a 2 x 2 twill weave of pre-impregnated tows was used to estimate the effective in-plane shear properties for modeling forming processes and predicting formability. In-plane shear stiffness was shown to be a controlling factor in the formability of unconsolidated textile sheets. The Stamp forming of a cone-shaped part was modeled for comparison with the experiments. Results show that the simplified process modeling scheme has the potential to predict issues with wrinkling during die closure. Furthermore, the present work suggests that complex representations of the relatively small fiber direction strains may be unwarranted for this type of process modeling.

Garnich, Mark R.↗
DOE OSTI2017

Structural Evaluation of Complex Subcomponents Manufactured by Large Scale Extrusion Deposition of Carbon Fiber Reinforced ABS

The large scale extrusion deposition process has recently been commercialized in the form of additive manufacturing machines such as the BAAM from Cincinnati Inc., which enables layered production of chopped fiber reinforced thermoplastic polymer systems. The application of this process to the automotive market is being pursued by Local Motors to enable rapid design to market cycles and build on-demand capability for a wide range of vehicle styles from a distributed network of micro-factories. This endeavor will require an understanding of the structural performance of components with complex geometries, where the properties are known to vary as a function of printing conditions, as well as orientation and shape. In order to rapidly build a database of structural performance, a beam specimen with outer dimensions of 914 x 305 x 64 mm3 was selected to be subjected to bending, torsion, and shear loading with full field displacement measurement by digital image correlation (DIC). A total of 25 different specimen configurations were designed including variation of print geometry, reinforcement by foam filling, and overwrapping with advanced composites. This work documents the results of the study and presents the relative performance of the structures in addition to the approach to simulation that is being initiated to serve as a framework for efficient design of structures manufactured in this way. The results are presented as a table of structural efficiency including stiffness and strength as functions of mass for each design. Additional results will also be provided in the form of surface displacements from DIC; future work will utilize this data to better optimize simulations for predicting structural performance of articles manufactured by this process.

Bedsole, Robert↗
DOE OSTI2023

Recyclable Cellulose Fiber Reinforced Vitrimer Composite

Vitrimer is an innovative class of polymeric materials which demonstrates traditional thermoset-like mechanical and chemical resilience while still being able to flow on demand like a traditional thermoplastic through covalently adaptive dynamic linkages. Herein, high-performance cellulose fiber reinforced vitrimer composites are developed using an epoxy-based vitrimer and natural cellulose paper. The reinforced vitrimer composite was fabricated by impregnating the porous structure of cellulose paper with two curable monomers, followed by in-situ polymerization of the monomers inside the fibrous scaffold. The introduction of hydroxyl group present on the cellulosic framework assisted in a faster topological rearrangement of the crosslinked matrix through transesterification exchange reaction, thus imparting various sought-after properties like shape recovery and recyclability via simple thermal reprocessing. Moreover, the reinforced vitrimer composite exhibits superior tensile properties as high as 90 MPa with 15-25 volume% vitrimer loading due to the interfacial adhesion via ester exchange reaction between the epoxy matrix and functionalities on the cellulosic fibers. Noteworthily, the key ingredients of the resulting composite (i.e., epoxy-based vitrimer and cellulose fibers) can be comfortably recycled without using aggressive chemical treatment, enabling composite to be easily recycled or disposed of at the end of service life and assist in reducing the subsequent manufacturing cost. This study would shed light on the development of a recyclable polymer composite with exceptional mechanical properties while simultaneously demonstrating self-healing and shape memory capabilities.

Rohewal, Sargun Singh↗
DOE OSTI2025

Advances in additive manufacturing, materials, and applications with AI/ML

There is high interest in making digital manufacturing a central facet of the new manufacturing landscape. However, in the materials science world, there is much work and opportunity to realize the full potential of artificial intelligence/machine learning (AI/ML) with regard to the structure–composition–processing–property (SCPP) relationship. For polymers (thermoplastics, thermosets, elastomers) and composites (nanocomposites), the origin of their high performance and even recyclability starts with design and formulation. Processing methods enable more property development based on curing, shape-factor forming, and anisotropic directionality. In subtractive manufacturing, high-performance and engineering polymers can be shaped and milled to very high tolerance and specifications and used as replacements for metals and alloys. In conclusion, this typically relies on digital manufacturing methods but tends to be wasteful in materials.

Lara-Ceniceros, Tania E. [Centro de Investigación ↗
DOE OSTI2012

Form and Aging of Plutonium in Savannah River Site Waste Tank 18

Process modeling; injection molding; long-fiber thermoplastic; fiber orientation; fiber lengt This report provides a summary of the effects of aging on and the expected forms of plutonium in Tank 18 waste residues. The findings are based on available information on the operational history of Tank 18, reported analytical results for samples taken from Tank 18, and the available scientific literature for plutonium under alkaline conditions. These findings should apply in general to residues in other waste tanks. However, the operational history of other waste tanks should be evaluated for specific conditions and unique operations (e.g., acid cleaning with oxalic acid) that could alter the form of plutonium in heel residues. Based on the operational history of other tanks, characterization of samples from the heel residues in those tanks would be appropriate to confirm the form of plutonium. During the operational period and continuing with the residual heel removal periods, Pu(IV) is the dominant oxidation state of the plutonium. Small fractions of Pu(V) and Pu(VI) could be present as the result of the presence of water and the result of reactions with oxygen in air and products from the radiolysis of water. However, the presence of Pu(V) would be transitory as it is not stable at the dilute alkaline conditions that currently exists in Tank 18. Most of the plutonium that enters Savannah River Site (SRS) high-level waste (HLW) tanks is freshly precipitated as amorphous plutonium hydroxide, Pu(OH) 4(am) or hydrous plutonium oxide, PuO 2(am,hyd) and coprecipitated within a mixture of hydrous metal oxide phases containing metals such as iron, aluminum, manganese and uranium. The coprecipitated plutonium would include Pu 4+ that has been substituted for other metal ions in crystal lattice sites, Pu 4+ occluded within hydrous metal oxide particles and Pu 4+ adsorbed onto the surface of hydrous metal oxide particles. The adsorbed plutonium could include both inner sphere coordination and outer sphere coordination of the plutonium. PuO 2(am,hyd) is also likely to be present in deposits and scales that have formed on the steel surfaces of the tank. Over the operational period and after closure of Tank 18, Ostwald ripening has and will continue to transform PuO 2(am,hyd) to a more crystalline form of plutonium dioxide, PuO 2(c) . After bulk waste removal and heel retrieval operations, the free hydroxide concentration decreased and the carbonate concentration in the free liquid and solids increased. Consequently, a portion of the PuO 2(am,hyd) has likely been converted to a hydroxy-carbonate complex such as Pu(OH) 2 (CO 3 ) (s) . or PuO(CO 3 ) · xH 2 O (am) . Like PuO 2(am,hyd) , Ostwald ripening of Pu(OH) 2 (CO 3 ) (s) or PuO(CO 3 ) · xH 2 O (am) would be expected to occur to produce a more crystalline form of the plutonium carbonate complex. Due to the high alkalinity and low carbonate concentration in the grout formulation, it is expected that upon interaction with the grout, the plutonium carbonate complexes will transform back into plutonium hydroxide. Although crystalline plutonium dioxide is the more stable thermodynamic state of Pu(IV), the low temperature and high water content of the waste during the operating and heel removal periods in Tank 18 have limited the transformation of the plutonium into crystalline plutonium dioxide. During the tank closure period of thousands of years, transformation of the plutonium into a more crystalline plutonium dioxide form would be expected. However, the continuing presence of water, reaction with water radiolysis products, and low temperatures will limit the transformation, and will likely maintain an amorphous Pu(OH) 4 or PuO 2(am,hyd) form on the surface of any crystalline plutonium dioxide produced after tank closure. X-ray Absorption Spectroscopic (XAS) measurements of Tank 18 residues are recommended to confirm coordination environments of the plutonium. If the presence of PuO(CO 3 ) (am,hyd) is confirmed by XAS, it is recommended that experiments be conducted to determine if plutonium carbonates are transformed back into PuO 2(am,hyd) upon contact with grout.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2012

Compatibility Study for Plastic, Elastomeric, and Metallic Fueling Infrastructure Materials Exposed to Aggressive Formulations of Ethanol-blended Gasoline

In 2008 Oak Ridge National Laboratory began a series of experiments to evaluate the compatibility of fueling infrastructure materials with intermediate levels of ethanol-blended gasoline. Initially, the focus was elastomers, metals, and sealants, and the test fuels were Fuel C, CE10a, CE17a and CE25a. The results of these studies were published in 2010. Follow-on studies were performed with an emphasis on plastic (thermoplastic and thermoset) materials used in underground storage and dispenser systems. These materials were exposed to test fuels of Fuel C and CE25a. Upon completion of this effort, it was felt that additional compatibility data with higher ethanol blends was needed and another round of experimentation was performed on elastomers, metals, and plastics with CE50a and CE85a test fuels. Compatibility of polymers typically relates to the solubility of the solid polymer with a solvent. It can also mean susceptibility to chemical attack, but the polymers and test fuels evaluated in this study are not considered to be chemically reactive with each other. Solubility in polymers is typically assessed by measuring the volume swell of the polymer exposed to the solvent of interest. Elastomers are a class of polymers that are predominantly used as seals, and most o-ring and seal manufacturers provide compatibility tables of their products with various solvents including ethanol, toluene, and isooctane, which are components of aggressive oxygenated gasoline as described by the Society of Automotive Engineers (SAE) J1681. These tables include a ranking based on the level of volume swell in the elastomer associated with exposure to a particular solvent. Swell is usually accompanied by a decrease in hardness (softening) that also affects performance. For seal applications, shrinkage of the elastomer upon drying is also a critical parameter since a contraction of volume can conceivably enable leakage to occur. Shrinkage is also indicative of the removal of one or more components of the elastomers (by the solvent). This extraction of additives can negatively change the properties of the elastomer, leading to reduced performance and durability. For a seal application, some level of volume swell is acceptable, since the expansion will serve to maintain a seal. However, the acceptable level of swell is dependent on the particular application of the elastomer product. It is known that excessive swell can lead to unacceptable extrusion of the elastomer beyond the sealed interface, where it becomes susceptible to damage. Also, since high swell is indicative of high solubility, there is a heightened potential for fluid to seep through the seal and into the environment. Plastics, on the other hand, are used primarily in structural applications, such as solid components, including piping and fluid containment. Volume change, especially in a rigid system, will create internal stresses that may negatively affect performance. In order to better understand and predict the compatibility for a given polymer type and fuel composition, an analysis based on Hansen solubility theory was performed for each plastic and elastomer material. From this study, the solubility distance was calculated for each polymer material and test fuel combination. Using the calculated solubility distance, the ethanol concentration associated with peak swell and overall extent of swell can be predicted for each polymer. The bulk of the material discussion centers on the plastic materials, and their compatibility with Fuel C, CE25a, CE50a, and CE85a. The next section of this paper focuses on the elastomer compatibility with the higher ethanol concentrations with comparison to results obtained previously for the lower ethanol levels. The elastomers were identical to those used in the earlier study. Hansen solubility theory is also applied to the elastomers to provide added interpretation of the results. The final section summarizes the performance of the metal coupons.

02 PETROLEUM↗