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At least 991 records · Page 55
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Improved Cryostat for Cooling a Wide Panel

An improved cryostat has been developed for cooling a wide panel evenly over its surface to a temperature of -423 F (approximately equal to -253 C) by use of liquid helium. Originally, the cryostat was to be used in measuring apparent strains in wide aluminum/lithium panels as functions of temperature in order to develop data for temperature compensation of the readings of strain gauges on a tank containing liquid hydrogen. Relative to the cryostat used previously for this purpose, the improved cryostat can be prepared for a test in less time, and it loses less helium during each test. Each wide panel to be tested is instrumented with thermocouples in preparation for a test. The previous cryostat was made of two aluminum halves that, for each test, were sandwiched together and sealed around the instrumented wide panel to be tested. The panel was thus enclosed in a plenum. The cryostat and adjacent panel areas protruding from the cryostat were then coated with a thermally insulating foam. During a test, liquid helium was made to flow into the plenum through a port on the bottom. The helium vaporized and expanded, filling the plenum with cold helium gas, which eventually flowed out of the plenum through a port on the top. The nature of the flow was such that a significant portion of the helium did not come into contact with the wide panel; hence, cooling was less efficient than it might otherwise have been. After completion of each test, the foam and the cryostat were separated from the panel. The cryostat was cleaned and prepared for installation on another instrumented wide panel for the next test. It took 28 hours to install the cryostat onto the instrumented panel, apply the foam, and perform ancillary operations in preparation for a test. The volume of liquid helium consumed during each test was 750 liters. The improved cryostat (see figure) includes an upper section and a lower section, both of which include permanent housings made of a thermally insulating foam 2-in. (approximately equal to 5-cm) thick. A liquid-helium- injection manifold is attached to the inside of the top section. The bottom section includes an outlet for helium gas. The manifold contains slots that, when the cryostat is installed on the panel, are located approximately 1 in. (approximately equal to 2.5 cm) from the wide panel. The array of slots spans a substantial portion of the area of the panel. The top and bottom sections of the cryostat are sealed to the panel by use of polytetrafluoroethylene cord and aluminum tape. Liquid helium is fed into the manifold from the top. The helium leaves the manifold through the slots and thus impinges directly on the panel. Hence, all the helium entering the cryostat must come into contact with the panel before leaving the cryostat. After a test, the cryostat is removed from the panel and reinstalled onto another panel for the next test. Installation of the cryostat on an instrumented panel takes a negligible amount of time, in comparison with the 28 hours associated with the previous cryostat. The amount of liquid helium consumed during a test in the improved cryostat is 500 liters - 250 liters less than before.

Clifton, W. B.↗
NASA NTRS2012

Joining and Assembly of Bulk Metallic Glass Composites Through Capacitive Discharge

Bulk metallic glasses (BMGs), a class of amorphous metals defined as having a thickness greater than 1 mm, are being broadly investigated by NASA for use in spacecraft hardware. Their unique properties, attained from their non-crystalline structure, motivate several game-changing aerospace applications. BMGs have low melting temperatures so they can be cheaply and repeatedly cast into complex net shapes, such as mirrors or electronic casings. They are extremely strong and wear-resistant, which motivates their use in gears and bearings. Amorphous metal coatings are hard, corrosion-resistant, and have high reflectivity. BMG composites, reinforced with soft second phases, can be fabricated into energy-absorbing cellular panels for orbital debris shielding. One limitation of BMG materials is their inability to be welded, bonded, brazed, or fastened in a convenient method to form larger structures. Cellular structures (which can be classified as trusses, foams, honeycombs, egg boxes, etc.) are useful for many NASA, commercial, and military aerospace applications, including low-density paneling and shields. Although conventional cellular structures exhibit high specific strength, their porous structures make them challenging to fabricate. In particular, metal cellular structures are extremely difficult to fabricate due to their high processing temperatures. Aluminum honeycomb sandwich panels, for example, are used widely as spacecraft shields due to their low density and ease of fabrication, but suffer from low strength. A desirable metal cellular structure is one with high strength, combined with low density and simple fabrication. The thermoplastic joining process described here allows for the fabrication of monolithic BMG truss-like structures that are 90% porous and have no heat-affected zone, weld, bond, or braze. This is accomplished by welding the nodes of stacked BMG composite panels using a localized capacitor discharge, forming a single monolithic structure. This removes many complicated and costly fabrication steps. Moreover, the cellular structures detailed in this work are among the highest- strength and most energy-absorbent materials known. This implies that a fabricated structure made from these materials would have unequaled mechanical properties compared to other metal foams or trusses. The process works by taking advantage of the electrical properties of the matrix material in the metal-matrix composite, which in this case is a metallic glass. Due to the random nanoscale arrangement of atoms (without any grain boundaries), the matrix glass exhibits a near-constant electrical resistivity as a function of temperature. By placing the composite panels between two copper electrode plates and discharging a capacitor, the entire matrix of the panel can be heated to approximately 700 C in 10 milliseconds, which is above the alloy s solidus but below the liquidus. By designing the geometry of the panels into the shape of an egg box, the electrical discharge localizes only in the tips of each pyramidal cell. By applying a forging load during discharge, the nodes of the panels can be fused together into a single piece, which then dissipates heat through radiation back into a glassy state. This means that two panels can be metallurgically fused into one panel with no heat-affected zone, creating a seamless connection between panels. During the process, the soft metal particles (dendrites) that are uniformly distributed in the glassy matrix to increase the toughness are completely unaffected by the thermoplastic joining. The novelty is that a truss (or foam-like) structure can be formed with excellent energy- absorbing capabilities without the need for machining. The technique allows for large-scale fabrication of panels, well-suited for spacecraft shields or military vehicle door panels. Crystalline metal cellular structures cannot be fabricated using the thermoplastic joining technique described here. If metal panels were te assembled into a cellular structure, they would either have to be welded, brazed, bonded, or fastened together, creating a weak spot in the structure at each connection. Welded parts require a welding material to be added to the joint and exhibit a soft and weak heat-affected zone. Brazing and bonding do not form a metallurgical joint and thus exhibit low strengths, especially when the panels are pulled apart and fasteners require high-stress-concentration holes to be drilled. No equivalent rapid heating method exists for assembling metal panels together into cellular structures, and thus, those parts must be foamed, machined, or investment cast if they are to form a monolithic structure. If the crystalline panels were to be joined using capacitive discharge, as with a spot welder, their bond would be very weak, and the panels would have to be extremely thin. In contrast, the strength of joined BMG parts has been demonstrated to have strength comparable to the parent material. This technique opens up the possibility of using large-scale BMG hardware in spacecraft, military, or commercial applications.

Hofmann, Douglas C.↗
NASA NTRS2013

Planetary Protection Bioburden Analysis Program

This program is a Microsoft Access program that performed statistical analysis of the colony counts from assays performed on the Mars Science Laboratory (MSL) spacecraft to determine the bioburden density, 3-sigma biodensity, and the total bioburdens required for the MSL prelaunch reports. It also contains numerous tools that report the data in various ways to simplify the reports required. The program performs all the calculations directly in the MS Access program. Prior to this development, the data was exported to large Excel files that had to be cut and pasted to provide the desired results. The program contains a main menu and a number of submenus. Analyses can be performed by using either all the assays, or only the accountable assays that will be used in the final analysis. There are three options on the first menu: either calculate using (1) the old MER (Mars Exploration Rover) statistics, (2) the MSL statistics for all the assays, or This software implements penetration limit equations for common micrometeoroid and orbital debris (MMOD) shield configurations, windows, and thermal protection systems. Allowable MMOD risk is formulated in terms of the probability of penetration (PNP) of the spacecraft pressure hull. For calculating the risk, spacecraft geometry models, mission profiles, debris environment models, and penetration limit equations for installed shielding configurations are required. Risk assessment software such as NASA's BUMPERII is used to calculate mission PNP; however, they are unsuitable for use in shield design and preliminary analysis studies. The software defines a single equation for the design and performance evaluation of common MMOD shielding configurations, windows, and thermal protection systems, along with a description of their validity range and guidelines for their application. Recommendations are based on preliminary reviews of fundamental assumptions, and accuracy in predicting experimental impact test results. The software is programmed in Visual Basic for Applications for installation as a simple add-in for Microsoft Excel. The user is directed to a graphical user interface (GUI) that requires user inputs and provides solutions directly in Microsoft Excel workbooks. This work was done by Shannon Ryan of the USRA Lunar and Planetary Institute for Johnson Space Center. Further information is contained in a TSP (see page 1). MSC- 24582-1 Micrometeoroid and Orbital Debris (MMOD) Shield Ballistic Limit Analysis Program Lyndon B. Johnson Space Center, Houston, Texas Commercially, because it is so generic, Enigma can be used for almost any project that requires engineering visualization, model building, or animation. Models in Enigma can be exported to many other formats for use in other applications as well. Educationally, Enigma is being used to allow university students to visualize robotic algorithms in a simulation mode before using them with actual hardware. This work was done by David Shores and Sharon P. Goza of Johnson Space Center; Cheyenne McKeegan, Rick Easley, Janet Way, and Shonn Everett of MEI Technologies; Mark Manning of PTI; and Mark Guerra, Ray Kraesig, and William Leu of Tietronix Software, Inc. For further information, contact the JSC Innovation Partnerships Office at (281) 483-3809. MSC-24211-1 Spitzer Telemetry Processing System NASA's Jet Propulsion Laboratory, Pasadena, California The Spitzer Telemetry Processing System (SirtfTlmProc) was designed to address objectives of JPL's Multi-mission Image Processing Lab (MIPL) in processing spacecraft telemetry and distributing the resulting data to the science community. To minimize costs and maximize operability, the software design focused on automated error recovery, performance, and information management. The system processes telemetry from the Spitzer spacecraft and delivers Level 0 products to the Spitzer Science Center. SirtfTlmProc is a unique system with automated error notification and recovery, with a real-time continuous service that can go quiescent after periods of inactivity. The software can process 2 GB of telemetry and deliver Level 0 science products to the end user in four hours. It provides analysis tools so the operator can manage the system and troubleshoot problems. It automates telemetry processing in order to reduce staffing costs. This work was done by Alice Stanboli, Elmain M. Martinez, and James M. McAuley of Caltech for NASA's Jet Propulsion Laboratory. For more information, contact iaoffice @jpl.nasa.gov. This software is available for commercial licensing. Please contact Dan Broderick at Daniel.F. Broderick@jpl.nasa.gov. Refer to NPO-47803. NASA Tech Briefs, September 2013 29 This rapid response computer program predicts Orbiter Wing Leading Edge (WLE) damage caused by ice or foam impact during a Space Shuttle launch (Program "IMPACT2"). The program was developed after the Columbia accident in order to assess quickly WLE damage due to ice, foam, or metal impact (if any) during a Shuttle launch. IMPACT2 simulates an impact event in a few minutes for foam impactors, and in seconds for ice and metal impactors. The damage criterion is derived from results obtained from one sophisticated commercial program, which requires hours to carry out simulations of the same impact events. The program was designed to run much faster than the commercial program with prediction of projectile threshold velocities within 10 to 15% of commercial-program values. The mathematical model involves coupling of Orbiter wing normal modes of vibration to nonlinear or linear springmass models. IMPACT2 solves nonlinear or linear impact problems using classical normal modes of vibration of a target, and nonlinear/ linear time-domain equations for the projectile. Impact loads and stresses developed in the target are computed as functions of time. This model is novel because of its speed of execution. A typical model of foam, or other projectile characterized by material nonlinearities, impacting an RCC panel is executed in minutes instead of hours needed by the commercial programs. Target damage due to impact can be assessed quickly, provided that target vibration modes and allowable stress are known. This work was done by Robert Clark, Jr., Paul Cotter, and Constantine Michalopoulos of The Boeing Company for Johnson Space Center. For further information, contact the JSC Innovation Partnerships Office at (281) 483-3809. MSC-24988-1 Wing Leading Edge RCC Rapid Response Damage Prediction Tool (IMPACT2) Lyndon B. Johnson Space Center, Houston, Texas (3) the MSL statistics for only the accountable assays. Other options on the main menu include a data editing form and utility programs that produce various reports requested by the microbiologists and the project, and tools to generate the groupings for the final analyses. The analyses can be carried out in three ways: Each assay can be treated separately, the assays can be collectively treated for the whole zone as a group, or the assays can be collected in groups designated by the JPL Planetary Protection Manager. The latter approach was used to generate the final report because assays on the same equipment or similar equipment can be assumed to have been exposed to the same environment and cleaning. Thus, the statistics are improved by having a larger population, thereby reducing the standard deviation by the square root of N. For each method mentioned above, three reports are available. The first is a detailed report including all the data. This version was very useful in verifying the calculations. The second is a brief report that is similar to the full detailed report, but does not print out the data. The third is a grand total and summary report in which each assay requires only one line. For the first and second reports, most of the calculations are performed in the report section itself. For the third, all the calculations are performed directly in the query bound to the report. All the numerical results were verified by comparing them with Excel templates, then exporting the data from the Planetary Protection Analysis program to Excel.

Beaudet, Robert A.↗
NASA NTRS2013

Wing Leading Edge RCC Rapid Response Damage Prediction Tool (IMPACT2)

This rapid response computer program predicts Orbiter Wing Leading Edge (WLE) damage caused by ice or foam impact during a Space Shuttle launch (Program "IMPACT2"). The program was developed after the Columbia accident in order to assess quickly WLE damage due to ice, foam, or metal impact (if any) during a Shuttle launch. IMPACT2 simulates an impact event in a few minutes for foam impactors, and in seconds for ice and metal impactors. The damage criterion is derived from results obtained from one sophisticated commercial program, which requires hours to carry out simulations of the same impact events. The program was designed to run much faster than the commercial program with prediction of projectile threshold velocities within 10 to 15% of commercial-program values. The mathematical model involves coupling of Orbiter wing normal modes of vibration to nonlinear or linear springmass models. IMPACT2 solves nonlinear or linear impact problems using classical normal modes of vibration of a target, and nonlinear/ linear time-domain equations for the projectile. Impact loads and stresses developed in the target are computed as functions of time. This model is novel because of its speed of execution. A typical model of foam, or other projectile characterized by material nonlinearities, impacting an RCC panel is executed in minutes instead of hours needed by the commercial programs. Target damage due to impact can be assessed quickly, provided that target vibration modes and allowable stress are known.

Clark, Robert↗
NASA NTRSDate not supplied

Additive Manufactured Ultra-Fine Lattice Structures for Propulsion Catalysts

Traditional mono-propulsion catalysts consist of coated ceramic or graphite foams that possess anisotropic mechanical and fluid properties limiting design, cost, availability, and operational use. Ultra-fine lattice structures are repeating unit cells with ligament thickness as small as 100 μm produced via Additive manufacture (AM). These lattice structures have the potential to replace coated foams used in a mono-propellant system catalysts. AM ultra-fine lattice structures are designed to mimic the operational intent of coated foams but with improved design flexibility, compressive strength, and flow behavior printed from into a single part directly from the preferred platinum metal alloy. The investigation objective was to conduct feasibility studies of AM ultra-fine lattice structures capable of replacing coated foams with superior functionality. NASA MSFC identified desired lattice characteristics and created designs while EOS developed optimized laser powder bed fusion AM parameters to manufacture Ti6Al4V and tungsten specimens. Optimized designs, computational tools, AM parameters, and post-process methods were developed. Specimens underwent x-ray micro-focus CT, metallographic inspection, compression testing, and flow testing. Results demonstrate that AM ultra-fine lattices improved geometric and performance repeatability with the potential for significantly increased availability while decreasing cost and lead time.

Omar R Mireles↗
NASA NTRS2020

Additive Manufactured Ultra-Fine Lattice Structures for Propulsion Catalysts

Traditional mono-propulsion catalysts consist of coated ceramic or graphite foams that possess anisotropic mechanical and fluid properties limiting design, cost, availability, and operational use. Ultra-fine lattice structures are repeating unit cells with ligament thickness as small as 100 μm produced via Additive manufacture (AM). These lattice structures have the potential to replace coated foams used in a mono-propellant system catalysts. AM ultrafine lattice structures are designed to mimic the operational intent of coated foams but with improved design flexibility, compressive strength, and flow behavior printed from into a single part directly from the preferred platinum metal alloy. The investigation objective was to conduct feasibility studies of AM ultra-fine lattice structures capable of replacing coated foams with superior functionality. NASA MSFC identified desired lattice characteristics and created designs while EOS developed optimized laser powder bed fusion AM parameters to manufacture Ti6Al4V and tungsten specimens. Optimized designs, computational tools, AM parameters, and post-process methods were developed. Specimens underwent x-ray microfocus CT, metallographic inspection, compression testing, and flow testing. Results demonstrate that AM ultra-fine lattices improved geometric and performance repeatability with the potential for significantly increased availability while decreasing cost and lead time.

Omar R Mireles↗
NASA NTRSDate not supplied

Additive Manufacture of Ultra-Fine Lattice Structures of Green Propulsion Catalysts

Traditional mono-propulsion catalysts consist of coated ceramic or graphite foams that possess anisotropic mechanical and fluid properties limiting design, cost, availability, and operational use. Ultra-fine lattice structures are repeating unit cells with ligament thickness as small as 100 μm produced via Additive manufacture (AM). These lattice structures have the potential to replace coated foams used in a mono-propellant system catalysts. AM ultrafine lattice structures are designed to mimic the operational intent of coated foams but with improved design flexibility, compressive strength, and flow behavior printed from into a single part directly from the preferred platinum metal alloy. The investigation objective was to conduct feasibility studies of AM ultra-fine lattice structures capable of replacing coated foams with superior functionality. NASA MSFC identified desired lattice characteristics and created designs while EOS developed optimized laser powder bed fusion AM parameters to manufacture Ti6Al4V and tungsten specimens. Optimized designs, computational tools, AM parameters, and post-process methods were developed. Specimens underwent x-ray microfocus CT, metallographic inspection, compression testing, and flow testing. Results demonstrate that AM ultra-fine lattices improved geometric and performance repeatability with the potential for significantly increased availability while decreasing cost and lead time.

Omar Mireles↗
DOE OSTI2023

Lightweight inorganic membrane module

An apparatus and system for separating a liquid from a mixed gas stream includes a porous graphite foam support comprising graphite foam with pores having a first pore size and a membrane support surface. A porous condensation membrane layer is provided on the membrane support surface, and interlocked with the pores of the graphite foam. The condensation membrane layer includes capillary condensation pores having a second pore size that is less than the first pore size. A mixed gas stream passageway is in fluid communication with the condensation membrane layer. A liquid collection assembly collects condensed liquid from the condensation pores and the graphite foam support pores. A gas inlet is provided for flowing the mixed gas stream into the mixed gas stream passageway. A gas outlet is provided for exhausting gas from the mixed gas stream passageway. A method for separating a liquid from a mixed gas stream is also disclosed.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Development of a high fidelity model of the CROCUS experimental reactor

Measurements of scalar flux distributions with fine spatial and energy resolutions are needed to remedy one of the validation shortcomings of the novel neutronics full core solvers, such as MPACT and nTRACER. While a very detailed resolution of the flux can be calculated with such codes, only a limited experimental data set is available to check their accuracy. Such type of measurements are on-going at the zero power reactor CROCUS, operated at the Laboratory for Reactor Physics and System Behaviours of the EPFL, thanks to the development of advanced miniature neutron detection systems. This kind of experimental data would provide the community with a suitable benchmark for the validation of high fidelity neutronics solvers. In parallel, a multi-physics solver for steady-state and transient analysis of nuclear reactors, named GeN-Foam, has been developed. Based on the finite-volume OpenFOAM library, GeN-Foam provides us with enough flexibility to analyze non-conventional reactor geometries such as that of CROCUS. While CROCUS heterogeneities cannot be modeled by MPACT and nTRACER for the moment, GeN-Foam offers a unique opportunity to build a high fidelity model which mimics these codes' method to reach sub-pin simulation resolution. This document aims at describing the work achieved to get from the existing GeN-Foam model of the CROCUS reactor based on a structured mesh and using the neutron diffusion, the first high-fidelity model using discrete ordinates method as an approximation to neutron transport and an unstructured mesh for inter lattice water gap description and sub-pin heterogeneous modeling. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Low-Temperature Processing of Pyrolysis Bio-Oil for Sustainable Biographite Production

Catalytic graphitization of pyrolysis bio-oil with iron (Fe) can produce an anode material for lithium-ion batteries (LIBs) at a moderate temperature. The key challenge to scaling up the process is foaming, which occurs due to the oxidation of Fe by the organic acids present in bio-oil. This study explored five different pathways to control foaming in bio-oil upon Fe addition, including (i) defoamers use, (ii) use of iron oxide (Fe2O3) as graphitization catalyst, (iii) pH adjustment of bio-oil, (iv) bio-oil coking (300-500 degrees C), and (v) low-temperature pretreatment of bio-oil (150-200 degrees C). The low-temperature pretreatment successfully avoided foaming by removing the volatile acids in bio-oil. The bio-oil was solidified and powdered for even mixing with the Fe catalyst. The biographite catalytically prepared at 1500 degrees C following this pathway demonstrated nearly theoretical specific gravimetric capacity (~370 mAh/g), high initial Coulombic efficiency (90.03%), and minimal capacity fading after 50 cycles in LIB half-cells. The low-temperature pretreatment pathway also addressed the viscosity, swelling, and aging issues associated with bio-oil processing and will make scale-up endeavors more attainable.

09 BIOMASS FUELS↗
DOE OSTI2024

Tailoring Pore Architecture and Heteroatom Functionality of Polymeric Waste-Derived Nanoporous Carbon for CO 2 Capture Applications

This study proposes upcycling polymeric waste, i.e., waste floral foam, into high-performance nanoporous carbon that efficiently captures CO 2 . This paper presents strategies for improving the properties of nanoporous carbon, which aid in a superior CO 2 capture performance. Initially, pristine nanoporous carbon was produced from waste floral foam using various KOH impregnation ratios. The nanoporous carbon with a 1:2 (waste floral foam:KOH) ratio exhibiting optimal CO 2 capture capability was further advanced through single and dual atom doping. The doping of N and codoping of N,S atoms into the nanoporous carbon altered its textural and surface chemical properties, making them efficient for CO 2 capture. Comparative CO 2 capture studies of pristine nanoporous carbon (NC-x), N-doped nanoporous carbon (N-NC2), and N,S-codoped nanoporous carbon (N,S-NC2) demonstrate the superiority of N-doping. N-doped nanoporous carbon exhibited the largest ultramicroporosity (0.3100 cm3/g, 63.43%) and highest heteroatom content (34.94 atomic %), contributing to its enhanced CO 2 capture capability (4.54 mmol/g). Finally, implementing the “waste-to-depollution” approach, this research lays the groundwork for producing low-cost, environmentally friendly nanoporous carbon with remarkable CO 2 capture attributes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Green Catalysts for Reprocessing Thermoset Polyurethanes

Polyurethane (PU) thermosets are usually landfilled at the end of their service lifetimes and cannot be recycled through conventional means. Although dibutyltin dilaurate (DBTDL) is an effective catalyst for reprocessing PU thermosets, organotins are immunotoxic and teratogenic, which is concerning for catalysts embedded within covalent adaptable networks (CANs). Here, we identify Zr(acac) 4 and Zr(tmhd) 4 as catalysts to reprocess PU CANs more sustainably. Thermoset PU foams containing Zr-based catalysts exhibit characteristic stress relaxation times between 6 and 200 s, similar or faster than DBTDL. These catalysts are capable of reprocessing a PU foam for four or five cycles. Dynamic mechanical thermal analysis indicates that zirconium-based catalysts preserve glass transition temperature and crosslink density between cycles and are promising catalysts for bulk reprocessing of thermoset PUs. Here, a solvent-free reprocessing method was developed by co-milling the PU foam and the Zr catalyst. Ultimately, these reprocessing methods using Zr-based catalysts will impart greater sustainability and circularity to PU plastics.

Catalysts↗
DOE OSTI2021

Development of Stochastic Voronoi Lattice Structures via Two-Photon Polymerization

Low-density polymer foams of varying sizes, shapes, and densities are of specific interest to the inertial confinement fusion (ICF) program and related high-energy density plasma physics research. Historically, these foams are comprised of polystyrene or other low atomic number materials and have densities in the 30 to 300 mg/cm 3 range. However, at the lower end of this density range, these traditional polymer foams become fragile and difficult to cast and machine into the geometries needed. Recently, the need by experimentalists for materials with densities below 30 mg/cm 3 has increased. To address these needs, we are developing three-dimensional (3-D) printing techniques to create high-precision, low-density, and repeatable complex lattice structures. Using two-photon polymerization 3-D printing, we recently developed the first 5 mg/cm3 low-density lattice structure having an annular hemispherical shape. These microscale to mesoscale structures were modeled and designed using the nTopology software, specifically utilizing the "Voronoi volume lattice" and "random points in body" option blocks. All printing operations were performed using the Nanoscribe Photonic Professional GT instrument. Characterization of these 3-D structures was conducted using various microscopic and X-ray tomographic imaging techniques. Furthermore, overall printed part sizes ranged from 1 to 5 mm in diameter and were composed of lattice ligaments having thicknesses in the 3- to 5-µm range. These structures have been incorporated into ICF targets recently shot on both the University of Rochester’s Laboratory of Laser Energetics Omega laser and the National Ignition Facility.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Validation Study of Experimental Insulating and Air-Sealing Technology for Enclosed Roof Cavities

Validation Study of Experimental Insulating and Air-Sealing Technology for Enclosed Roof Cavities, explores a new minimally invasive system known as Pinhole Insulation ® for retroft insulation of cathedral ceilings, flat roofs, dormer roofs, and other enclosed roof cavities. It also explores the validation of the associated equipment, software, and materials used in this application. The Pinhole Insulation process essentially consists of drilling a ¼” hole in the ceiling surface and then injecting closed cell polyurethane foam such that the foam is deposited on the interior surface of the exterior roof sheathing. In a typical cathedral ceiling with R19 batts, the R value will be improved by at least 60% and the cavity will become completely air sealed. The system is quick, minimally invasive and at least an order of magnitude less expensive than alternatives such as removing the ceiling surface and spraying closed cell foam.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Tunable Metamaterials for Impact Mitigation

Traditional methods of shielding fragile goods and human tissues from impact energy rely on isotropic foam materials. The mechanical properties of these foams are inferior to an emerging class of metamaterials called plate lattices, which have predominantly been fabricated in simple 2.5-dimensional geometries using conventional methods that constrain the feasible design space. Here in this work, additive manufacturing is used to relax these constraints and realize plate lattice metamaterials with nontrivial, locally varying geometry. The limitations of traditional computer-aided design tools are circumvented and allow the simulation of complex buckling and collapse behaviors without a manual meshing step. By validating these simulations against experimental data from tests on fabricated samples, sweeping exploration of the plate lattice design space is enabled. Numerical and experimental tests demonstrate plate lattices absorb up to six times more impact energy at equivalent densities relative to foams and shield objects from impacts ten times more energetic while transmitting equivalent peak stresses. In contrast to previous investigations of plate lattice metamaterials, designs with nonuniform geometric prebuckling in the out-of-plane direction is explored and showed that these designs exhibit 10% higher energy absorption efficiency on average and 25% higher in the highest-performing design.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A novel defoamer for processing nuclear waste: Testing and performance

Abstract Legacy radioactive waste from nuclear weapons material processing is the biggest environmental challenge in the state of South Carolina, and one of the biggest in the United States. Although substantial progress has been made in processing and vitrifying high‐level radioactive waste at the Savannah River site, approximately 35 million gallons remains to be treated and dispositioned. In this article, we show the development of a new defoamer for use in the processing of high‐level radioactive waste. The application of the new defoamer is not only more effective at controlling foam but will shorten the batch processing time leading to safer and more efficient processing. This has the potential to help shorten the overall site mission lifetime, saving the federal government hundreds of millions of dollars. The novel aspect of the new defoamer is its effectiveness and stability in the harsh conditions needed for processing high‐level radioactive waste: high temperatures, pH 4–13, strong oxidizing and reducing agents, and numerous metal catalysts. The defoamer will replace an existing antifoam agent that decomposes to form multiple flammable gases. Because the existing antifoam agent decomposes quickly, processing changes increased processing time. Statement of novelty We demonstrate that a new defoamer has been developed for use in processing high‐level radioactive waste. This novel defoamer is effective and stable in the harsh processing conditions with no detectable flammable by‐products. Because the existing antifoam agent decomposes quickly, processing changes, including lowering acid addition rates and evaporation rates, increased processing time. The new defoamer is not only more effective at controlling foam but will shorten the batch processing time and lead to safer and more efficient processing by eliminating the production of flammable gases. Statement of industrial relevance Foaming is of great concern in many industrial processes involving three‐phase gas/liquid/fine‐solids systems, like in water evaporation, mineral floatation, air sparging in situ remediation techniques, and in those found in the paper industry.

Lambert, Dan P.↗
DOE OSTI2025

3D printing of packaging inserts from biomass-fungi composites: Environmental sustainability analysis

In this study, a comprehensive Life cycle assessment (LCA) is conducted on molded packaging inserts from expanded polystyrene (EPS) foam, molded packaging inserts from biomass-fungi composite, and 3D-printed packaging inserts from biomass-fungi composite under the low mix / high volume (LMHV) scenario and molded and machined packaging inserts from EPS foam, molded and machined packaging inserts from biomass-fungi composite, and 3D-printed packaging inserts from biomass-fungi composite under the high mix / low volume (HMLV) scenario. Six environmental impact categories—climate change, acidification, eutrophication, fossil resource scarcity, land use, and water consumption—are analyzed to evaluate the environmental trade-offs associated with each type of packaging inserts. Under the LMHV scenario, molded packaging inserts from biomass-fungi composite emerge as the best option due to their lower impact on climate change, acidification and water consumption compared to other types of packaging inserts. Conversely, molded packaging inserts from biomass-fungi composite face challenges in land use and eutrophication, primarily due to raw material production. LCA also reveals that 3D-printed packaging inserts from biomass-fungi composite are the most environmentally favorable option under the HMLV scenario, due to significantly lower contributions to climate change, eutrophication, and water consumption compared to other types of packaging inserts. Conversely, 3D-printed packaging inserts from biomass-fungi composite face challenges in acidification and land use, primarily due to raw material production. As part of the LCA, sensitivity analyses show that sourcing energy from 100% renewable sources substantially lowers climate change impacts across all packaging types, while varying transportation distances results in only minor changes, indicating the dominant role of upstream material and manufacturing processes. Additional sensitivity analysis is conducted under the HMLV scenario to assess the impact of material removal during machining on the environment. The amount of material removal is varied from 10 to 70% for the sensitivity analysis and it highlights that the amount of material removed during machining has no significant impact on climate change for packaging inserts from EPS foam. However, molded and machined packaging inserts from biomass-fungi composite show an increasing trend in climate change with higher amount of material removal, while 3D-printed packaging inserts from biomass-fungi composite exhibit a decreasing trend, driven by reduced raw material usage and energy consumption.

09 BIOMASS FUELS↗
DOE OSTI2022

Research on oxygen solubility in aqueous amine solvents with common additives used for CO 2 chemical absorption

Oxidative degradation in amine based post-combustion carbon capture (PCCC) leads to solvent losses and decreased solvent performance. Oxygen (O 2 ) in the flue gas is dissolved into the aqueous solvent and can reactively degrade the amine component. Advanced aqueous amine solvents are designed to contain additional surfactant and anti-foam additives as well as two types of corrosion inhibitors. These additives contribute to improve the solvent performance while reducing foaming and corrosion of expensive equipment. This work examines the impact of these additives on oxygen solubility (or dissolved oxygen - DO) in various aqueous amines used in PCCC including ethanolamine (MEA), 1-amino-2-propanol (A2P), 2-amino-1-propanol (2A1P), 2-(methylamino)-ethanol (NMEA), 2-(ethylamine)-ethanol (2EAE), diethanolamine (DEA), methyl-diethanolamine (MDEA), dimethylethanolamine (DMEA), piperazine (PZ), 1,2-ethyldiamine (EDA), and 1,6 hexadiamine (HDA). Further, the impact of carbon loading on oxygen solubility with and without these additives was also examined. The surfactant and anti-foam additives had minimal impact on DO for all the solvents investigated. The two anticorrosion additives had opposite effects in the measured DO, 2- mercaptobenzothiazole (MBT) decreased the DO concentration, and sodium metavanadate showed an increase. These results indicate that several of these common additives can be expected to minimally affect DO related oxidative degradation in these advance amine solvents.

60 APPLIED LIFE SCIENCES↗