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At least 1,027 records · Page 57

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DOE OSTI2014

Studies on the Module Structure for the NOvA Liquid Scintillator Neutrino Detector

This thesis contains studies pertinent to the construction of modules for the NOνAexperiment detectors. The tensile strength of acrylic and epoxy adhesives used in construction of the detector was studied over time and with various surface preparations. Sanding and corona discharge surface treatments increased the bond strength of the acrylic by 10-20%; aging in oil did not affect the acrylic bond strength while aging in air at 50°C for 9 months (equivalent to approximately 5 years at room temperature) increased the acrylic bond strength by 25%. For the epoxy, corona discharge treated samples’ strength increased slightly after aging while the strength of sanded samples in air remained consistent and sanded samples in oil decreased by 17% when aged at 50°C for 1.5 years (equivalent to approximately 10 years at room temperature).All materials used in the detector were studied to determine if degrading interaction would occur with the pseudocumene liquid scintillator. Substances such as acrylic adhesive and PTFE paste were found to interact with the scintillator while materials such as a variety of PVCs, epoxy adhesives, and PTFE tape were found to be non-reactive with the scintillator. Following the appearance of cracks on manifold covers in installed modules, studies were carried out to help to determine the cause and mitigation of these cracks. Manifold covers that had been pressure tested at various pressures during the check of the seals during the manufacturing process were examined for the formation of cracks. “Containment units” were used to constrain the swelling of the manifold covers during pressure testing. Internal cracks were visible on the majority of manifold covers tested at 1.4 bar with the original containment units. It was found that reducing the pressure testing of the modules from 1.4 bar to 0.7 bar and increasing the rigidity of the pressure test containment units eliminated the formation of visible cracks in the manifold covers. Stress concentration in small fillet radius injection molded PVC was studied. GeonM3500 PVC has a yield strength 12% greater than Geon M3800 PVC originally used for the manifold covers but increased the stress concentrated failure time by 6600% and was thus chosen to mold new manifold covers after a redesign to eliminate stress concentrating features.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2022

Hexagonal Distributed Embedded Energy Converters (HexDEECs)

The HexDEEC is a small, characteristic length approximating a centimeter, energy transducer that converts the dynamic deformations of its elastomer housing into electricity through a variable capacitance charging-discharging cycle. This device is a type of Distributed Embedded Energy Converter Technology (DEEC-Tec), a new domain for marine renewable energy research that utilizes a conglomeration of small distributed embedded energy converters (DEECs) that, in aggregate, form larger metamaterial frameworks. These resulting DEEC-Tec metamaterials can then, in turn, be used to construct flexible ocean wave energy converters called flexWECs, which can utilize a broad band of ocean wave frequencies and lack highly loaded rigid bodies. These systems also provide new avenues of wave energy harvesting such as actively transforming topologies (e.g., shape and form) and morphologies (e.g., stiffness and damping throughout its entire structure) in real time. Presented, is one specific type of DEEC: the HexDEEC, which is currently being developed by the United States National Renewable Energy Laboratory. This transducer shows promise in aiding the adoption and further development of the DEEC-Tec domain. The following presentation focuses on the promise of this technology and current work being done to analyze the performance of an individual HexDEEC design. The HexDEEC is composed of a hyperelastic hexagonal housing, nominally silicon rubber, with six electrodes on its inner faces. The upper three electrodes share the same charge while the lower three electrodes oppose the upper electrode charges. Externally, the HexDEEC has two arms extending away from the middle vertices of the hexagon. Via principles governing the relationship between electrical capacitance and electrical potential (voltage and charge), electricity is generated when the HexDEEC's arms are dynamically pulled or released under tensile loading, as doing so causes the distance between the upper and lower sets of electrodes to change - varying the energy converter's overall capacitance. Analytical and numerical modeling is being used to evaluate the mechanics and electrical energy generated by the HexDEEC. Equations to describe the capacitance and electrostatic forces acting on this unique system have been developed and implemented into the numerical modeling software STAR-CCM+, along with models to describe its hyperelastic material, such as the Mooney-Rivlin 3-parameter model. So far, an initial design has been analyzed and we plan to further optimize it to increase power production. Individual HexDEECs have been fabricated by drawing uncured liquid silicon rubber into molds via vacuum pressure. To simplify manufacturing, HexDEEC sub-components - e.g., electrodes, wires - can be placed within those molds such that they are directly embedded into the hexagonal housing during the curing process. Furthermore, DEEC-Tec metamaterials can be created by interweaving or sequentially layering multiple HexDEEC strands together. The HexDEEC based metamaterial could then generate electricity through its gross deformations. Ultimately, HexDEECs represent a specific type of energy transducer that can be leveraged, by the DEEC-Tec domain, to create metamaterials used to construct novel flexWECs.

DEEC-Tec↗

DOE OSTI2022

Hexagonal Distributed Embedded Energy Converters (HexDEECs)

Distributed Embedded Energy Converter Technologies (DEEC-Tec) is a new domain for marine renewable energy research that utilizes a conglomeration of small distributed embedded energy converters (DEECs) that, in aggregate, form larger metamaterial frameworks. These resulting DEEC-Tec metamaterials can then, in turn, be used to construct flexible ocean wave energy converters called flexWECs. DEEC-Tec enables flexWECs: (i) to be inherently broad-banded ocean wave frequency energy converters and (ii) to have an inherent lack of highly loaded rigid bodies. The DEEC-Tec domain also benefits the marine renewable energy domain by inherently availing ways that marine energy can be harvested and converted that heretofore has not yet been considered possible: real-time execution of transforming topologies (e.g., actively changing a flexWEC's shape and form) and morphologies (e.g., actively changing a flexWEC's stiffness and damping throughout its entire structure). Presented, is one specific type of DEEC, a HexDEEC, that shows promise in aiding the adoption and further development of the DEEC-Tec domain - it is a small energy transducer being developed by the United States National Renewable Energy Laboratory. The HexDEEC is a small (characteristic length approximating a centimeter) energy transducer that converts the dynamic deformations of an elastomer into electricity through a charging-discharging cycle of a capacitor whose capacitance is varied by those elastic deformations. The HexDEEC is composed of a hyperelastic hexagonal housing (nominally silicon rubber) with six electrodes on its inner faces. The upper three electrodes share the same charge while the lower three electrodes oppose the upper electrode charges. Externally, the HexDEEC has two arms extending away from the middle vertices of the hexagon. Via principles governing the relationship between electrical capacitance and electrical potential (voltage and charge), electricity is generated when the HexDEEC's arms are dynamically pulled or released under tensile loading as doing so causes the distance between the upper and lower sets of electrodes to change - varying the energy converter's overall capacitance. Analytical and numerical modeling have already been used to estimate the electrical energy produced by a HexDEEC. The cursory models approximate the HexDEEC as a parallel plate variable capacitor - simplifying from six to two opposing plates with a constant dielectric volume between those two plates. To account for the elastic HexDEEC material properties, software such as SolidWorks and STAR-CCM+ have been used to generate hyperelastic models; notably, Mooney-Rivlin based models. Individual HexDEECs have been fabricated by drawing uncured liquid silicon rubber into molds via vacuum pressure. To simplify manufacturing, HexDEEC sub-components - e.g., electrodes, wires - can be placed within those molds such that they are directly embedded into the hexagonal housing during the curing process. Furthermore, DEEC-Tec metamaterials can be created by interweaving or sequentially layering multiple HexDEEC strands together. The HexDEEC based metamaterial could then generate electricity through its gross deformations. Ultimately, HexDEECs represent a specific type of energy transducer that can be leveraged, by the DEEC-Tec domain, to create metamaterials used to construct novel flexWECs.

DEEC-Tec↗

DOE OSTI2023

Composite components and methods of manufacturing composite components using magnetic forces at fiber preform seams

A method of manufacturing a composite component according to various aspects of the present disclosure includes disposing a fiber preform in a mold. The fiber preform includes a first portion having a first edge and a second portion having a second edge. The first edge and the second edge cooperate to at least partially define a gap. One of the first portion or the second portion includes a first ferromagnetic material and the other of the first portion or the second portion includes a first magnetic or magnetizable component. The method further includes closing the gap by generating a magnetic field from the first magnetic or magnetizable component. The method further includes injecting a polymer precursor into the mold. The method further includes forming the composite component by solidifying the polymer precursor to form a polymer. The composite component includes the fiber preform and the polymer.

Aitharaju, Venkateshwar R.↗

DOE OSTI2023

Methods of making and using bulk products including fiber-containing particles with dual-tapered shape

Recycled carbon fibers are processed by rotational tumbling in a mixture with binder material to prepare fiber-containing particles having a dual-tapered shape and general alignment of fibers with a longitudinal direction of the particles. Bulk products including such fiber-containing particles are compounded with polymer and pelletized to prepare fiber-reinforced composite pellets, which are useful for applications such as injection molding to prepare molded products of carbon fiber-reinforced composite material with recycled carbon fibers.

Harris, Jordan Gray↗

DOE OSTI2017

Dexterity and Worker Comfort in an Ergonomically Designed Glovebox Glove

Gloveboxes are prolifically used in nuclear facilities as the primary means of separation between the hazardous material and operators. Due to extended duration and high repetition of hand tasks in glovebox gloves, improperly fitting gloves can be uncomfortable and increase injury risks. Poor fit can increase time necessary to perform work tasks and stress the glove itself. The Plutonium Facility has the largest inventory of glovebox gloves at Los Alamos National Laboratory (LANL) with approximately 6000 gloves installed. The current glove mold dates back to the 1960's and is not based on the true anatomy of the hand. Design flaws (poor anatomical fit and biomechanics) are directly related to injuries of the elbow (lateral epicondylitis) and thumb (DeQuervain's tenosynovitis) injuries. The current design also contributes to 30% of unplanned glove openings. A new glovebox glove was developed and manufactured, incorporating over forty dimensions to produce the most comprehensive ergonomically sound design. The new design received a LANL patent (patent attorney docket No: LANS 36USD1 'Protective Glove'), one of 20 highest patents awarded by the Richard P. Feynman Center for Innovation. A SolidWorks model was given to the manufacturer for production of the glove mold.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

In the current study, steel samples were etched and hooks on several successive layers of longitudinal and transverse slab sections were obtained to investigate the three-dimensional (3-D) distribution of hooks in low-carbon continuous casting slabs. The data from industrial trials and numerical calculation were used to explain the variation in the distribution and morphology of hooks. Around the slab perimeter, the mean depth of hooks at the center and edge of the wide face and the edge of the narrow face was larger than that of other locations. The 3-D hook demonstrated a varied characteristic on different layers, as the observed surface changed in the longitudinal direction. By several layers of the transverse section being polished off, hooks in the transverse direction below the slab surface were obtained, in which the truncated hook and the joint hook between the wide face and narrow face were observed at the slab corner. The same oscillation mark could show as hook type and depression type, depending on the occurrence of the overflow between the solidified meniscus and the copper plate. Industrial trials and the numerical calculation illustrated that the transient variation of hooks in the 3-D space was related to the level fluctuation of molten steel in the mold and temperature fluctuation with casting time and the fluid flow and temperature near the meniscus. Finally, the influence area and volume of hooks on the capture of inclusions and bubbles were discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Manufacturing and characterization of continuous fiber-reinforced thermoplastic tape overmolded long fiber thermoplastic

Light-weight construction, design freedom, integration of functions, and compelling cost element are desired by Original Equipment Manufacturers (OEMs) and their suppliers. The emergence of overmolding of continuous-discontinuous reinforcement enables design freedom and ability to tailor stiffness, strength, and damage tolerance for structural applications. In this work, long fiber thermoplastics (LFT) are overmolded with continuous fiber-reinforced thermoplastic (CFRTP) tape are combined using extrusion compression molding process to evaluate the structural performance. The CFRTP tape overmolded LFT samples were characterized using nondestructive and destructive techniques to track fiber alignment, fiber distribution, manufacturing defects, interfacial bonding of the tape – LFT and effect of CFRTP tape on LFT. Mode 1 fracture toughness, G 1c for tape overmolded LFT was higher by 25–30% compared to literature reported G 1c . This response was attributed to excellent fiber distribution, good fiber wetting, and absence of voids at the interface. Three-point bend test indicated that CFRTP tape overmolded LFT composites were better able to resist damage under the bending load compared to constituent LFT composite. Flexural strength of the overmolded composite was higher by 119–142%, and modulus higher by 77–65% compared to constituent LFT composite. Simulated flexural results accurately represents the mechanical behavior of composites. Here, the penetration energy of tape overmolded LFT composites determined by LVI test was in the range of 27.66–30.15 J, which is significantly higher than constituent LFT composite, 7.76 J. CFRTP tape overmolded LFT composite exhibits progressive fiber fracture, matrix cracking, and interfacial debonding failure, whereas, constituent LFT composite showed catastrophic fiber fracture.

42 ENGINEERING↗