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At least 1,045 records · Page 58

In situ imaging of three dimensional freeze printing process using rapid x-ray synchrotron radiography

Three dimensional freeze printing (3DFP) combines the advantages of freeze casting and additive manufacturing to fabricate multifunctional aerogels. Freeze casting is a cost-effective, efficient, and versatile method capable of fabricating micro-scale porous structures inside the aerogels for many different applications. The 3DFP provided the capability of fabricating highly customized geometries with controlled microporous structures as well. However, there are still many unexplained phenomena and features because of the complexity of post-processes and indirect observation methods. This study demonstrates the design and construction of the in situ imaging systems, which use the x-ray synchrotron radiography to observe freeze casting and 3DFP processes. With the advantages provided by the in situ x-ray imaging techniques, the ice crystal growth with its unique lamellar structures can be observed during the freeze casting process. Here, the movement of freeze front, material deposition, and growth of ice crystals can also be visualized during the inkjet-based 3DFP process.

3D printing↗

Additive Manufacturing of Polymers: Materials Opportunities and Emerging Applications

Additive manufacturing (AM) has enabled the rapid prototyping of structures with complex geometries constructed via computer aided design (CAD). In recent years, AM has extended beyond simple prototyping and has begun to play a role in the fabrication of active components, especially for applications that do not require materials with robust mechanical properties (i.e. electronic components and biomedical scaffolds). This report reviews the current state of 3D printing with respect to polymeric and composite materials, focusing on applications, printing processes, and material selection perspectives. A particular focus is placed on the polymer chemistry of additive manufacturing in order to elucidate current materials limitations, R&D trends and developmental opportunities. Some unconventional thermoset cure reactions are proposed for AM which may overcome current limitations. In addition, potential degradation characteristics of AM polymer materials and expected property variations in comparison with traditional processing are discussed, which draws attention to the complexity of the structure/processing/property relationships for the optimization of innovative materials. AM polymer manufacturing and 3D printing approaches hold tremendous promises as long as polymer chemistry, material physics and processing aspects (cure on demand) are jointly embraced within evolving research strategies.

36 MATERIALS SCIENCE↗

Oppenheimer Science and Energy Leadership Program (OSELP) Software and Computing Strategy for the Future of Weapons Physics Applications [Slides]

Mission drivers at the national level are evolving to accommodate a broadening landscape. The U.S. faces a rapidly evolving, threat-based environment with an associated expansion of national-level priorities. Priorities continue to include all aspects of sustaining the existing, aging stockpile. Now, however, we must also include consideration of options for a future deterrent, including efficacy of the deterrent against new threats (threat assessment and response), capability needs associated with new materials and modern manufacturing and production processes, and efficiency requirements for a modern workflow for weapons design. Executing this complex strategy will come with challenges. We must execute our current mission, while we prepare for future missions and an increasingly uncertain future.

42 ENGINEERING↗

Autonomous Synthesis of Metastable Materials Using a Modular Mixed-Flow Reactor

Understanding and controlling atomic-level processes at solid-liquid interfaces is key to advancing technologies in energy storage, carbon capture, critical element recovery, and materials synthesis. Many of these processes are dominated by the formation of short-lived intermediate precipitates that determine the final properties of synthesized materials. However, studying these intermediates is challenging due to their sensitivity and the reliance on trial-and-error methods. To address this, we developed an automated variable-volume mixed-flow reactor (MFR) to optimize metastable material synthesis and investigate rapid kinetic processes. This state-of-the-art MFR system, paired with an automated modeling framework, enables efficient synthesis and real-time analysis of transient phases. Benchmarking with advanced capabilities, such as wide-/small-angle X-ray scattering, allows us to resolve fast nucleation and growth dynamics that were previously inaccessible. By combining automation, ML-guided optimization, and tailored kinetic modeling, this approach provides a robust platform for improving material design and achieving precise control over solid-liquid reactions.

36 MATERIALS SCIENCE↗

First Solar Thermal Energy Planner (STEP 1) and Nationwide Industrial Heat and Power Analysis

The First Solar Thermal Energy Planner (STEP 1) and Nationwide Industrial Heat and Power Analysis (aka the STEP 1 Project or the Project) aimed to (1) developed a brand-new web tool that could provide decision support through free, rapid techno-economic analysis of behind-the-meter solar+storage systems for industrial process heat and (2) conduct high-level analyses of the cost-competitiveness of the same systems across the US in key sectors. The STEP 1 web tool collects key location, land availability, thermal load profile, proccess heat temperature and media, and other key parameters through an easy-to-use user interface (UI). The UI was designed to meet the user at their level of understanding by minimizing the number of required inputs as much as possible while including options for more nuanced inputs if the user desires. STEP 1 advises users on which solar thermal tehcnologies that could fit their needs based on the inputs provided (namely process media and temperature). The tool can model a wide range of solar thermal technologies including flat plate collectors, evacuated tubes, parabolic troughs, linear Fresnel, and molten salt towers all with corresponding thermal energy storage (TES) - solar PV with resistive heating and TES is also included. Once the parameters are collected, a nominal thermal energy production profile for the facility's location is generated using NREL's System Advisory Model (SAM) and then passed to a modified version of NREL's REopt platform to optimize the size (capacity) and dispatch of the solar+storage system to minimize lifecycle costs subject to energy balance, fuel and electricity rates, emission reductions goals, and other constraints. This entire process takes less than 20 minutes, is completely free, requires zero coding skills, and provides the user with a high-level assessment on the techno-economic feasability of deploying solar+storage systems for their energy needs. In addition to the development of the STEP 1 web tool, the project completed two complementary analyses focused on leveraging the backend code of STEP 1, public industrial facility locations and fuel consumption data, and key sector information to assess the economic opportunity of reducing fuel costs at various levels of capacity factor around the US. Both analyses found that there are key markets, locations, industrial sectors (namely food and beverage), and degrees of offset where solar thermal technologies could be cost-effectively deployed, highlighting a key market entry point for these technologies, and assessing deployment potential. In summary, the STEP 1 project improved the opportunities for solar+storage systems to expand into the industrial process heat market through breaking down barriers to assessing these technologies.

14 SOLAR ENERGY↗

Feasibility study for automatic reduction of phase change imagery

The feasibility of automatically reducing a form of pictorial aerodynamic heating data is discussed. The imagery, depicting the melting history of a thin coat of fusible temperature indicator painted on an aerodynamically heated model, was previously reduced by manual methods. Careful examination of various lighting theories and approaches led to an experimentally verified illumination concept capable of yielding high-quality imagery. Both digital and video image processing techniques were applied to reduction of the data, and it was demonstrated that either method can be used to develop superimposed contours. Mathematical techniques were developed to find the model-to-image and the inverse image-to-model transformation using six conjugate points, and methods were developed using these transformations to determine heating rates on the model surface. A video system was designed which is able to reduce the imagery rapidly, economically and accurately. Costs for this system were estimated. A study plan was outlined whereby the mathematical transformation techniques developed to produce model coordinate heating data could be applied to operational software, and methods were discussed and costs estimated for obtaining the digital information necessary for this software.

Nossaman, G. O.↗

The Impact of Information Technology on the Design, Development, and Implementation of a Lunar Exploration Mission

From the beginning to the present expeditions to the Moon have involved a large investment of human labor. This has been true for all aspects of the process, from the initial design of the mission, whether scientific or technological, through the development of the instruments and the spacecraft, to the flight and operational phases. In addition to the time constraints that this situation imposes, there is also a significant cost associated with the large labor costs. As a result lunar expeditions have been limited to a few robotic missions and the manned Apollo program missions of the 1970s. With the rapid rise of the new information technologies, new paradigms are emerging that promise to greatly reduce both the time and cost of such missions. With the rapidly increasing capabilities of computer hardware and software systems, as well as networks and communication systems, a new balance of work is being developed between the human and the machine system. This new balance holds the promise of greatly increased exploration capability, along with dramatically reduced design, development, and operating costs. These new information technologies, utilizing knowledge-based software and very highspeed computer systems, will provide new design and development tools, scheduling mechanisms, and vehicle and system health monitoring capabilities that have hitherto been unavailable to the mission and spacecraft designer and the system operator. This paper will utilize typical lunar missions, both robotic and crewed, as a basis to describe and illustrate how these new information system technologies could be applied to all aspects such missions. In particular, new system design tradeoff tools will be described along with technologies that will allow a very much greater degree of autonomy of exploration vehicles than has heretofore been possible. In addition, new information technologies that will significantly reduce the human operational requirements will be discussed.

Gross, Anthony R.↗

OSIRIS-REx Curation: The First Year with Bennu Samples on Earth

The OSIRIS-REx (Origins, Spectral Interpretation, Resource Identification, and Security – Regolith Explorer) sample return capsule landed on the Utah Test and Training Range (UTTR) on September 24, 2023. Preparations for the curation of the sample from asteroid Bennu inside of this capsule spanned more than a decade. On the morning of landing, the sample return capsule was brought to a temporary cleanroom at UTTR for initial de-integration and connection of the sample canister to a nitrogen gas purge to protect the sample from modification by the terrestrial atmosphere. In the week following landing, the sample canister was flown to Houston while on nitrogen purge, transferred to a nitrogen atmosphere glovebox at NASA Johnson Space Center in which the canister lid was removed revealing small amounts of sample on the inside of the canister lid and avionics deck, some of this sample was allocated rapidly to the mission sample analysis team as “quick look” samples. Next, the Touch-and-Go sample acquisition mechanism (TAGSAM) head was disassembled inside of a specially designed glovebox. A challenge arose during one of the last stages of disassembly when two fasteners resisted being loosened. The curation team was able to remove 70.3 grams of asteroid sample from the TAGSAM head with those fasteners in-place and began initial sample processing which supported long-term curation of hermetically sealed and frozen samples, transfer of some samples to remote storage, and allocation of aggregate samples to the mission sample analysis team. Meanwhile, curation engineers developed a tool to remove the stubborn fasteners without contaminating the remaining sample, enabling the remaining bulk sample to be transferred to long-term storage trays in January 2024. With this second part of the bulk sample, the returned bulk asteroid sample reached 121.6 grams. During disassembly and prior to sealing the bulk sample trays into long-term storage containers, archival photographs were collected. Select particles are gradually being XCT scanned while inside of containers that hold a nitrogen atmosphere. The initial OSIRIS-REx sample catalog was released in spring 2024 with an update in fall 2024. The curation team will be busy working to allocate samples to scientists around the world for the foreseeable future.

Curation↗

OLED Fundamentals: Materials, Devices, and Processing of Organic Light-Emitting Diodes

What is an organic light emitting diode (OLED)? Why should we care? What are they made of? How are they made? What are the challenges in seeing these devices enter the marketplace in various applications? These are the questions we hope to answer in this book, at a level suitable for knowledgeable non-experts, graduate students and scientists and engineers working in the field who want to understand the broader context of their work. At the most basic level, an OLED is a promising new technology composed of some organic material sandwiched between two electrodes. When current is passed through the device, light is emitted. The stack of layers can be very thin and has many variations, including flexible and/or transparent. The organic material can be polymeric or composed small molecules, and may include inorganic components. The electrodes may consist of metals, metal oxides, carbon nanomaterials, or other species, though of course for light to be emitted, one electrode must be transparent. OLEDs may be fabricated on glass, metal foils, or polymer sheets (though polymeric substrates must be modified to protect the organic material from moisture or oxygen). In any event, the organic material must be protected from moisture during storage and operation. A control circuit, the exact nature of which depends on the application, drives the OLED. Nevertheless, the control circuit should have very stable current control to generate uniform light emission. OLEDs can be designed to emit a single color of light, white light, or even tunable colors. The devices can be switched on and off very rapidly, which makes them suitable for displays or for general lighting. Given the amazing complexity of the technical and design challenges for practical OLED applications, it is not surprising that applications are still somewhat limited. Although organic electroluminescence is more than 50 years old, the modern OLED field is really only about half that age – with the first high-efficiency OLED demonstrated in 1987. Thus, we expect to see exciting advances in the science, technology and commercialization in the coming years. We hope that this book helps to advance the field in some small way. Contributors to this monograph are experts from top academic institutions, industry and national laboratories who provide comprehensive and up-to-date coverage of the rapidly evolving field of OLEDs. Furthermore, this monograph collects in one place, for the first time, key topics across the field of OLEDs, from fundamental chemistry and physics, to practical materials science and engineering topics, to aspects of design and manufacturing. The monograph synthesizes and puts into context information scattered throughout the literature for easy review in one book. The scope of the monograph reflects the necessity to focus on new technological challenges brought about by the transition to manufacturing. In the Section 1, all materials of construction of the OLED device are covered, from substrate to encapsulation. In Section 2, for the first time, additional challenges in devices and processing are addressed. This book is geared towards a broad audience, including materials scientists, device physicists, synthetic chemists and electrical engineers. Furthermore, this book makes a great introduction to scientists in industry and academia, as well as graduate students interested in applied aspects of photophysics and electrochemistry in organic thin films. This book is a comprehensive source for OLED R&D professionals from all backgrounds and institutions.

OLED↗

Cementation of Nuclear Wastes: From Past to Future in a Sustainable Approach - 18266

Cementation of nuclear wastes is a widespread technology due to several factors such as excellent feedback from past experience, simplicity of implementation and versatility. Indeed, as nuclear wastes come in many physical states (bulk wastes, powders, sludges), cementation is the immobilisation process that can easily accommodate this large range of wastes provided the appropriate mixing technology is used: heterogenous cementation (grouting of bulky wastes) or homogenous cementation (intermixing process between the powder or the sludge and the cementitious material). However, nuclear wastes equally present an important chemical variability. This is especially true as New Areva's range of nuclear activities covers the entire fuel cycle: mining, conversion, enrichment and recycling and dismantling and decommissioning. The chemical interactions between the waste and the cement matrix are carefully studied by New Areva's R and D teams in order to provide comprehensive solutions by developing cement formulations which are adapted to wastes characteristics. The aim of the studies is to obtain cement waste-forms that meet the waste acceptance criteria, the final product being thus in perfect adequacy with the disposal requirements. For over 30 years New Areva has been developing cement formulations adapted to the physical and chemical specificities of the wastes accounting for constrains imposed by waste characteristics. The overall approach includes the definition of the appropriate cement composition at laboratory scale, engineering design, equipment manufacturing, testing and commissioning of the cementation facilities. With this strong technical background, a specific methodology has been developed by New Areva teams in order to allow a rapid screening of possible solutions for a given waste (in terms of cement chemistry adapted to the waste) in a learn-fast approach that is based on theoretical analysis and small-scale tests. The methodology was applied for wastes presenting a complex nature (such as reactive metals, ion exchange resins, oils and solvents, mercury, etc), known to interact with Portland cement from a chemical point of view and leading to durability issues of the wasteform (swelling, strength reduction, leaching) and thus reducing the final waste loading. Once the screening process is over, the main drivers for choosing the most appropriate solution to be further developed at pilot scale are: reducing the overall volume and the impact of the final waste package, ensure the waste package performance as defined by the disposal requirements and control the long-term behaviour in final disposal. Moreover, a modelling approach is addressed, aiming to develop a thermo-chemo-mechanical (THM) concrete models that are able to predict the behaviour of the structure (waste form) in time. The aim of the present paper is to describe the main principles within the developed methodology and illustrate it by using a few specific examples. Several distinct cement formulations are developed for complex wastes, limiting the chemical interaction between the cement matrix and the given wastes, obtaining better waste loadings and better overall durability behaviour which facilitates long term behaviour demonstration. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Incorporation of market signals for the optimal design of post combustion carbon capture systems

Recent studies have shown that fossil generators equipped with post-combustion carbon capture (PCC) systems are needed to reduce the cost of deep decarbonization. Such generators need to be flexible and responsive to grid conditions, particularly in a high variable renewable energy (VRE) environment. In this work, we evaluate the net present value (NPV) of retrofitting an existing natural gas combined cycle (NGCC) unit with a flexible PCC system while incorporating market signals from a high VRE grid. We use our industrial partner’s NGCC configuration as representative of existing NGCC units and Svante’s rapid-temperature swing adsorption (TSA) for PCC. Because of its ability to rapidly startup/shutdown and ramp-up/ramp-down, the chosen capture technology is very attractive for load-following operations. For a given set of market signals, we formulate a two-stage stochastic multi-period optimization problem, under the price-taker assumption, to simultaneously optimize the design of the capture system and operation of the entire plant. Rigorous models for the NGCC unit, PCC system, and compression system are developed using commercial process simulators and validated with either plant or vendor data. For computational tractability, we develop surrogate/reduced-order models for use in the optimization problem. The surrogate model for the NGCC plant is constructed by linearizing the rigorous dynamic model at 75% load, while data-driven nonlinear surrogate models for the capture and compression systems are constructed using simulation data from the rigorous models. The optimization problem, formulated as a mixed integer bilinear program, is implemented in the IDAES® integrated platform and solved to global optimality using Gurobi 9.5. Using this formulation, we determine the profitability of retrofitting an existing NGCC unit with the chosen capture system for multiple regions in the U.S. under two scenarios with different carbon prices. Importantly, the results show that the optimal decision strongly depends on the region and on the carbon price, thereby demonstrating the importance of the inclusion of market signals in the design process.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Blockchain for Fault-Tolerant Grid Operations

Distribution system fault/failure has a direct impact on customers. Distribution systems are not designed with the contingency of one or more elements failing as the transmission system, however, distribution systems are more likely to have faults in comparison to transmission and generation systems. Most of the distribution systems have a radial design with the protection system assumption of unidirectional power flow. The radial design results in the disconnection of customers for any given component failure. The rapid deployment of distributed energy resources conflicts with the assumption of unidirectional power flow. To maintain/improve the distribution system fault tolerance for a grid with high penetration of distributed energy resources requires improvement. Blockchain can add value to improve fault-tolerant grid operations. That can be achieved using blockchain’s core features of distributed consensus-based decision-making process and immutability. In the process of preparing for an event or system restoration, there is a need for reliable data and system situational awareness. The system situational awareness enables accurate planning for possible scenarios and system restoration after an event, an area where blockchain’s distributed architecture can help. The value of blockchain for a fault-tolerant grid operation is elaborated with three use cases: 1) fault location, isolation, and service restoration; 2) topology identification; and 3) data configuration. These use cases demonstrate how blockchain-based architecture can facilitate bridging the vulnerabilities of the existing implementation.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Overview - Electric fields

The electric fields session is designed to review progress in observation, theory, and modeling of magnetospheric electric fields, and to expose important new results. The present report comments on the state and prospects of electric field research, with particular emphasis on relevance to quantitative modeling of the magnetospheric processes. Attention is given to underlying theories and models. Modeling philosophy is discussed relative to explanatory models and representative models. Modeling of magnetospheric electric fields, while in its infancy, is developing rapidly on many fronts employing a variety of approaches. The general topic of magnetospheric electric fields is becoming of prime importance in understanding space plasmas.

Cauffman, D. P.↗

VLSI technology for smaller, cheaper, faster return link systems

Very Large Scale Integration (VLSI) Application-specific Integrated Circuit (ASIC) technology has enabled substantially smaller, cheaper, and more capable telemetry data systems. However, the rapid growth in available ASIC fabrication densities has far outpaced the application of this technology to telemetry systems. Available densities have grown by well over an order magnitude since NASA's Goddard Space Flight Center (GSFC) first began developing ASIC's for ground telemetry systems in 1985. To take advantage of these higher integration levels, a new generation of ASIC's for return link telemetry processing is under development. These new submicron devices are designed to further reduce the cost and size of NASA return link processing systems while improving performance. This paper describes these highly integrated processing components.

Nanzetta, Kathy↗

Re-Design and Beat Testing of the Man-Machine Integration Design and Analysis System: MIDAS

The Man-machine Design and Analysis System (MIDAS) is a human factors design and analysis system that combines human cognitive models with 3D CAD models and rapid prototyping and simulation techniques. MIDAS allows designers to ask 'what if' types of questions early in concept exploration and development prior to actual hardware development. The system outputs predictions of operator workload, situational awareness and system performance as well as graphical visualization of the cockpit designs interacting with models of the human in a mission scenario. Recently, MIDAS was re-designed to enhance functionality and usability. The goals driving the redesign include more efficient processing, GUI interface, advances in the memory structures, implementation of external vision models and audition. These changes were detailed in an earlier paper. Two Beta test sites with diverse applications have been chosen. One Beta test site is investigating the development of a new airframe and its interaction with the air traffic management system. The second Beta test effort will investigate 3D auditory cueing in conjunction with traditional visual cueing strategies including panel-mounted and heads-up displays. The progress and lessons learned on each of these projects will be discussed.

Shively, R. Jay↗

Nuclear Thermal Rocket Element Environmental Simulator (NTREES) Upgrade Activities

A key technology element in Nuclear Thermal Propulsion is the development of fuel materials and components which can withstand extremely high temperatures while being exposed to flowing hydrogen. NTREES provides a cost effective method for rapidly screening of candidate fuel components with regard to their viability for use in NTR systems. The NTREES is designed to mimic the conditions (minus the radiation) to which nuclear rocket fuel elements and other components would be subjected to during reactor operation. The NTREES consists of a water cooled ASME code stamped pressure vessel and its associated control hardware and instrumentation coupled with inductive heaters to simulate the heat provided by the fission process. The NTREES has been designed to safely allow hydrogen gas to be injected into internal flow passages of an inductively heated test article mounted in the chamber.

Emrich, William↗

The Magnetospheric Multiscale Magnetometers

The success of the Magnetospheric Multiscale mission depends on the accurate measurement of the magnetic field on all four spacecraft. To ensure this success, two independently designed and built fluxgate magnetometers were developed, avoiding single-point failures. The magnetometers were dubbed the digital fluxgate (DFG), which uses an ASIC implementation and was supplied by the Space Research Institute of the Austrian Academy of Sciences and the analogue magnetometer (AFG) with a more traditional circuit board design supplied by the University of California, Los Angeles. A stringent magnetic cleanliness program was executed under the supervision of the Johns Hopkins University,s Applied Physics Laboratory. To achieve mission objectives, the calibration determined on the ground will be refined in space to ensure all eight magnetometers are precisely inter-calibrated. Near real-time data plays a key role in the transmission of high-resolution observations stored onboard so rapid processing of the low-resolution data is required. This article describes these instruments, the magnetic cleanliness program, and the instrument pre-launch calibrations, the planned in-flight calibration program, and the information flow that provides the data on the rapid time scale needed for mission success.

Magnetosphere↗

Reducing Mass of Steel Auto Bodies using Thin Advanced High Strength Steel with Carbon-Fiber Reinforced Epoxy

Diversitak, a company based in Detroit, MI, has developed a proprietary, low specific gravity, carbon fiber-reinforced epoxy (CFRE) under U.S. patent number 9,963,58832. Preliminary testing on this new material conducted in collaboration with ArcelorMittal Steel Company proved out the CFRE concept. A thin layer of this CFRE was applied to a stamped sheet of steel with residual stamping oils from a mill, in a time corresponding to automotive processing (e.g., ~15 seconds), and processed following automotive e-coat procedures (phosphating + 175–200°C heating), to complete the curing. No problems with adherence or performance were noted. While the CFRE does add weight to a thin gauge steel panel, it weighs much less than what is displaced by using thicker conventional mild steel gauges. The application of the coating showed a significant increased dent resistance, oil canning resistance, and part stiffness.This current two-year project was designed to mature this new technology to near manufacturing readiness to reduce the weight of a vehicle and lower the cost of weight reduction. The process involves the use of thinner gauge steels than are currently used. The collaborative development team included two industrial manufacturers: Diversitak and ArcelorMittal Steel Company; LightMAT; and two National Laboratories: Oak Ridge National Laboratory (ORNL) and Idaho National Laboratory (INL). The team developed a new manufacturing process to reduce the weight of a vehicle and lower the cost of weight reduction, as well as a better understanding of how to apply the coating so that it will perform to a high standard in-service. The team also performed an in-depth study to determine the long-term durability of the materials manufactured using this technology and well-known automotive industry standard tests.The overall process involved stiffening the thinner gauge steel by applying the CFRE on only one side. To accomplish this goal, the optimal reinforcement fiber length and fiber concentration was first determined. This was followed by measuring the coefficient of thermal expansion (CTE) in all three directions, so it could be fed into manufacturing models and methods for rapidly and inexpensively applying the coating. This was followed by panel level evaluations of the coating and steel combination, and then by full part demonstration of the technology on door panels. The final step was corrosion testing of the parts.ArcelorMittal characterized the advanced high strength steel (AHSS) (e.g., metallurgy-heat treatment for required AHSS properties as a function of the sheet thickness, state of internal stress) and quantified CFRE adhesion to the steel as a function of sheet preparation (e.g., rolling and stamping).ORNL optimized the fiber length, fiber concentration, and coating thickness for best vehicle function and performance at the least cost. Along with the suppliers, ORNL developed a durable CFRE application process (e.g., gun material, design, robotic dispensing process) and identified the adhesion stability of the CFRE during process holding. An approach to ensure that application/curing timing conforms to conventional assembly line speed and plant cycle times was determined. ORNL also determined the CTE of the material in all three directions and performed material scanning electron microscopy (SEM) analyses.INL characterized the corrosion properties of the steel panels coated with CFRE. The panels were investigated for corrosion resistance and stability as replacement materials used in automotive body panels to reduce mass. The coupons tested at INL were supplied by Diversitak after an optimized CFRE formulation was achieved in the already coated form for corrosion testing.

99 GENERAL AND MISCELLANEOUS↗