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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Experimental measurement of the effective contact angle for solvent/packing interactions in a structured packed column for CO 2 capture

The contact angle is a critical factor for determining the effective mass transfer area for carbon dioxide (CO 2 ) capture via the chemical absorption process in a packed column, and thus the overall capture efficiency of the packed column. Many widely used commercial packings involve microscale features (perforation, corrugation, etc.) that may also affect the wetting behavior. This study proposes a systematic method of using a modified Wilhelmy plate to measure the effective contact angle to characterize the solvent and featured packing interaction. In lieu of computational efforts relying on assumptions guided by semi-informed correlation, the proposed method directly measures the effective contact angle as a function of the solvent and packing thermophysical and hydrodynamic properties. The characterization of the effective contact angle is then integrated in the computational fluid dynamics modeling to reduce uncertainty in the prediction of effective mas transfer area. Experiments were conducted for stainless steel coupons using water and aqueous sodium hydroxide (NaOH) solvent for verification of the proposed experimental protocol. The surface tension of the aqueous NaOH solvent was altered using surfactant and antifoam. The effective contact angle increases with the increased value of the surface tension for flat stainless steel sheets. On the other hand, effective contact angles do not vary in Mellapak coupons for aqueous monoethanolamine (MEA) and NaOH solvent. In this case, surface textures and sheet design play a dominant role in the surface tension of solvents. Furthermore, CO 2 loading has a significant effect on the contact angle for Mellapak coupons. As expected, the contact angle decreases with the increasing temperature of CO 2 capture solvents (MEA, EEMPA). The effective contact angle measurement using the Wilhelmy plate method can provide more accurate and efficient solvents for characterizing the solvent-packing surface interactions. Subsequently, the present method enhances the accuracy of the prediction of the effective mass transfer area in carbon capture by solvent absorption.

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

Research Plan and Preliminary Results in Developing the Fabrication Parameters for Alloy 709 in Different Product Forms―Grain Coarsening Temperature Evaluation

The Advanced Reactor Technologies (ART) Program has established a multi-year plan to develop Alloy 709 advanced stainless steel (A709), generate the data package and develop material-specific design parameters in qualifying it as a new structural material for Class A component design in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors. In collaboration with material vendors, the Advanced Materials Development activities under ART have successfully scaled the A709 plate form production from a laboratory heat of 500 pounds to commercial heats totaling 133,000 pounds of A709 plate fabricated from three heats. The goal of the overall A709 development program is to establish the necessary microstructural and mechanical properties relationship for A709 to ultimately develop fabrication parameters for other product forms such as bars, piping and forging using the available ART A709 materials. The objective of this A709 development work at ORNL in FY2023 is to experimentally determine grain coarsening behavior for the A709 heats and to experimentally generate the continuous cooling precipitation (CCP) diagram for A709 using the as-rolled commercial heat plate materials. Integral to this work is the characterization of the as-rolled materials and the determination of an effective solution annealing process. This report summarizes the work performed to identify the grain coarsening temperature for commercial heat 58776-3RB fabricated by G. O. Carlson and heat 529900-02 fabricated by Allegheny Technologies Incorporated (ATI) Flat Rolled Products.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Final Report on Development of Microwave Resonant Cavity Transducer for Fluid Flow Sensing: Development of Microwave Cavity Flow Meter for Advanced Reactor High Temperature Fluids

We are investigating a microwave resonant cavity transducer for flow sensing in the vessel of a high temperature fluid advanced reactor (AR), such as a molten salt cooled reactor (MSCR) or a sodium fast reactor (SFR). This transducer is a hollow metallic cylindrical cavity, with one of the flat walls of the cylinder flexible enough to undergo microscopic deflection due to dynamic fluid pressure. Membrane deflection leads to a shift in the microwave resonant frequency, which can be detected with a spectrum analyzer. We have developed a continuum electromechanics model of the microwave resonant cavity transducer performance. The deflection of the membrane is calculated using equations from the theory of plates and shells for deflection of radially constrained thin circular disk under uniform load. The microwave frequency shift is calculated using the equations from the microwave cavity perturbation theory. The transducer model was validated with proof-of-concept experimental data of water flow sensing with a Brass 360 right circular cylinder with 22.2mm diameter and 203µm thick wall. The cavity was excited through a subwavelength hole in TE 011 mode with resonant frequency f ≈ 17.8GHz. Subsequently, we have performed a preliminary proof-of-principle test of flow sensing in high temperature liquid sodium in environment. For this test, we have developed a cylindrical resonator with the same dimensions as for the Brass 360 cavity. The resonator for high temperature liquid sodium test was machined from stainless steel 316 and electroplated with silver on the interior surfaces. We have also developed and insertion probe consisting of a 50cm WR-42 brass waveguide enclosed in a protective SS316 tube. The cavity was excited through a subwavelength hole on the side of the wall of the cylinder in the TE 011 mode with resonant frequency f ≈ 17.8GHz. The liquid sodium setup consists of a cylindrical vessel with a center feed line, where a transducer inserted through the top cap of the vessel measures velocity of the impinging liquid jet. The sodium flow sensing study was performed in a liquid sodium vessel at 340°C temperature and ambient pressure. The flow rate was changed by varying sodium pump power, and a frequency shift of several hundred kHz was observed. The transducer was removed after 70 days of testing. No visual damage was observed, and the electromagnetic response remained the same. As a calibration experiment, we have assembled a water vessel with a center feed, and with dimensions similar to those of the liquid sodium setup. Water flow sensing was performed before and after liquid sodium test. The responses in both cases are similar and agree with COMSOL computer simulations. Because long-term (multi-year) experimental tests of transducer resilience to harsh environment are not practical, we have developed a probabilistic model of creep to estimate transducer resilience to the harsh environment. The probabilistic model considers diffusion creep under the condition of high temperature and low stress, where the stress and temperature are allowed to be random variables with Gaussian distributions. Using the probabilistic model, we estimate inelastic membrane deflections due to creep for several temperature ranges. We conclude that for temperatures less than 650°C, creep has negligible long-term effect on the transducer performance.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Analyzing Mechanical integrity of Microwave resonant Cavity flowmeter

The microwave resonant cavity flow sensor has been proposed to address the difficulties of measuring high-temperature molten salt flow in reactor vessels. The flow sensor consists of a metallic cylindrical cavity coupled to a microwave waveguide. The cylindrical cavity has one of the flat surfaces thin enough to undergo microscopic deflection due to dynamic pressure of the exerted by the flowing fluid. Deflection of the membrane causes a shift in the microwave resonant frequency. Fluid velocity can be estimated from the calibration curve. The objective of this report is to investigate mechanical integrity of the flowmeter’s membrane. The membrane is a thin stainless-steel circular plate with a clamped edge, subjected to uniform load. By calculating the stress on the plate due to deflection and, comparing the stress to the material ultimate tensile strength and yield strength, it can be estimated if the plate will fail. If the maximum stress is greater than the yield strength, the plate will undergo plastic deformation, and the sensor will be disabled. A stress greater than the ultimate tensile strength will cause the plate to fracture. The stress on the plate was calculated with an analytic closed form solution model, and with COMSOL Structural Mechanics Module which does not involve any approximations. Stresses in both the analytic model and COMSOL numerical model were calculated for stainless steel 316 thin circular plates under room temperature conditions, where the fluid is water. The diameter of the circular plate is approximately one inch, and thickness is 10mil. Fluid flow velocity is in the range from 0.5m/s to 1m/s. The results from the two models are similar. Both the analytic model and COMSOL model showed that maximum stresses on the plate, which are at the radial boundary of the plate, are three orders of magnitude smaller than the yield strength and ultimate tensile strength. This indicates that the sensor is at a low risk of mechanical failure.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Fundamental Thermodynamic, Kinetic, and Mechanical Properties of Lithium and Its Alloys

Lithium alloying reactions are beneficial in promoting uniform plating and stripping of lithium metal in all-solid-state batteries. First-principles calculations are performed to predict thermodynamic, kinetic, and mechanical properties of lithium and several important Li–M alloys (M = Mg, Ag, Zn, Al, Ga, In, Sn, Sb, and Bi). While the Li–Mg binary system forms a solid solution, most other lithium–metal alloys prefer stoichiometric intermetallic compounds with common local motifs that enable fast Li diffusion. Lithium and Li-rich alloys exhibit an unusually flat energy landscape along paths that connect BCC to close-packed structures like FCC and HCP, with important implications for mechanical properties. Very low migration barriers for Li diffusion that rival those of superion conductors are predicted, both in pure Li and in Li–M intermetallics. However, vacancy concentration, which is crucial for substitutional diffusion, is predicted to be low in metallic Li and most Li–M intermetallics. Compounds such as B32 LiAl and LiGa as well as D0 3 Li 3 Sb and Li 3 Bi exhibit structural vacancies at higher ends of their voltage windows, which together with low migration barriers leads to exceptionally high Li mobilities. In the Li–Mg solid solution, the addition of Mg is found to decrease the vacancy tracer diffusion coefficient by an order of magnitude.

36 MATERIALS SCIENCE↗
DOE OSTI2025

X-Ray Microtomography Measurements of Coevolving Particle Size and Shape

This study measures simultaneous changes in particle size and shape during grain crushing and proposes quantitative metrics to track their coevolving statistical distribution. Idealized granular materials with widely different initial particle shapes (i.e., spheres, quasi-ellipsoids, plates, and rods) are compressed oedometrically at vertical stress levels sufficient to induce particle breakage. X-ray microtomography and digital image analysis are then used to track changes in particle-scale characteristics. The observations indicate that more irregular particles tend to exhibit a higher degree of breakage compared to more spherical grains subjected to an equivalent stress level. Despite these differences, the measurements also indicate that all the tested particle sets approach a common attractor (expressed in terms of aspect ratio, flatness, and elongation), regardless of their initial morphology. A new shape evolution index is proposed to quantify such trends. With this new metric, it is shown that in all the tested materials, the particle shape evolves faster than size, especially for the more regular morphologies, thus implying that the shape tends to reach its attractor point before the grading reaches its ultimate particle size distribution. Furthermore, this finding underpins an ultimate stage of crushing-driven compression that occurs with particle size reduction but minimal shape changes (i.e., self-replicating shapes due to fractures).

Oedometric compression↗
DOE OSTI2020

An outbreak of Septoria canker caused by Sphaerulina musiva on Populus trichocarpa in eastern Oregon

Branch and stem cankers were observed in a Populus trichocarpa L. plantation in late summer of 2018 near Boardman, Oregon USA. Stem cankers were flat faced with swollen margins and the bark in the center of the cankers was black and depressed (Figure 1). 254 out of 1054 trees (25%) observed had cankers. Symptomatic stems and branches from several trees were brought to Oregon State University for identification. Cankers were surface-disinfested in a 5% NaOCl for 2 min and rinsed twice in deionized H 2 O for 2 min. Bark was removed from cankers and pieces of wood at the margin between healthy and necrotic tissue were plated on KV8 medium amended with streptomycin sulfate at 100 mg liter–1 and chloramphenicol (Amresco) at 240 mg liter–1 (Dunnell and LeBoldus 2017). Eight sporulating colonies typical of Sphaerulina musiva (Peck) Quaedvlieg, Verkley, and Crous (Syn. = Septoria musiva Peck) developed within 7 days of plating. S. musiva was identified by morphological characteristics (conidium size = 28–54 × 3.5–4 µm) and confirmed by comparing the sequence of the ITS region (accession numbers: MN275180-MN275187) to JX901814 with 99% identity. We tested 13 additional cankers collected from the plantation using S. musiva specific primers (Abraham et al. 2018). Eight of the 13 samples were positive for S. musiva DNA. Dormant cuttings from three genotypes of P. trichocarpa (BESC-184; BESC-259; BESC-388) were collected in a field planting near Oregon State University (OSU). These were planted in cone-tainers in the greenhouse at OSU and grown to approximately 30 cm in height. Four replicates of each of the three genotypes were inoculated in the greenhouse with one Oregon isolate using a suspension of 1x10 6 conidia ml-1. The entire tree was sprayed until runoff using a spray bottle (LeBoldus et al. 2010). The experimental design was a completely randomized design with four replicates of each genotype. Sterile deionized H 2 O was sprayed on one control tree of each genotype. The mean number of resulting cankers were BESC-184 = 11, BESC-259 = 1, and BESC-388 = 13.75. The controls did not develop any cankers. The pathogen was successfully reisolated from one canker from each genotype. Sphaerulina musiva can cause severely damaging leaf spot and stem canker diseases in the eastern and central USA and Canada (Bier 1939; Herath et al. 2016). Susceptible Populus species and hybrids develop cankers which can girdle and weaken stems, leading to breakage or tree death (Bier 1939). A previous survey of the region did not detect S. musiva (Newcombe et al. 1995). This outbreak of Septoria canker underscores the potential threat of this pathogen to P. trichocarpa in the Pacific Northwest where it is a keystone species in riparian ecosystems.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Contoured PPM-EMAT Design for Ultrasonic Communication On Metallic Pipe Channels

Ultrasonic guided waves can be used as the carriers of information in ultrasonic communication for pipe or plate channels. Permanent Periodic Magnet (PPM) Electromagnetic Acoustic Transducer (EMAT) can potentially provide unique capabilities for a communication system as a non-contact transmitter and receiver, which can selectively generate different modes of shear-horizontal (SH) waves. The SH wave shows the potentials in achieving high bitrate without error in ultrasonic communication. However, when a steel pipe is used as the communication channel, especially one with a radius comparable to the size of the transducer, no guided wave signal can be excited or detected by existing PPM-EMAT's with flat coupling surface. In this paper, a 3D printed magnet holder is designed which can shape the magnet array. Also, the transmitter/receiver coils are made of flexible printed circuit which can fit over the curvature of the pipe channels. The contoured PPM-EMAT transmitter and receiver can conform to the surface of the steel pipe channel in order to generate and detect torsional waves. Experimental tests of signal transmission with PPM-EMAT on a 160cm-long stainless steel pipe determine the optimal frequency for communication to be 916KHz. Information transmission experimental results confirm the validity of contoured PPM-EMAT for communication with a bitrate of 5kbps.

Huang, Xin↗
DOE OSTI2020

Drop impact on hot plates: contact times, lift-off and the lamella rupture

When a liquid drop impacts on a heated substrate, it can remain deposited, or violently boil in contact, or lift off with or without ever touching the surface. The latter is known as the Leidenfrost effect. The duration and area of the liquid–substrate contact are highly relevant for the heat transfer, as well as other effects such as corrosion. However, most experimental studies rely on side view imaging to determine contact times, and those are often mixed with the time until the drop lifts off from the substrate. In this work, we develop and validate a reliable method of contact time determination using high-speed X-ray imaging and total internal reflection imaging. We exemplarily compare contact and lift-off times on flat silicon and sapphire substrates. We show that drops can rebound even without formation of a complete vapor layer, with a wide range of lift-off times. On sapphire, we find a local minimum of lift-off times that is much shorter than expected from capillary rebound in the comparatively low-temperature regime of transition boiling/thermal atomization. We elucidate the underlying mechanism related to spontaneous rupture of the lamella and receding of the contact area.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

Study of SXR/EUV radiation of exploded foils and wires with spectral, spatial and temporal resolution simultaneously on KING electric discharge facility.

The results of studies of the soft X-ray and extreme ultraviolet (SXR/EUV) radiation of thin flat aluminum foils and wires under the explosion in an electric discharge on the compact high-current KING generator are presented. These studies were based on the SXR/EUV spectroscopy with a spectral resolution of 6 Å, a temporal resolution of 5 ns and a spatial resolution of 200 μm. To study the plasma radiation of exploded foils and wires in the SXR/EUV range, we used a transmission diffraction grating spectrograph which in combination with two additional slits provided spectral and spatial resolution. The spectrograph was coupled with a 4-frame recorder based on a microchannel plate for providing temporal resolution. The analysis and comparison of the spectral, spatial, temporal, and energy characteristics of the SXR/EUV radiation of plasma formed under the explosion of foils and wires of a similar mass made of aluminum was carried out. Here, the spectra were calculated as well and the plasma parameters and their changes in time and space were estimated on the basis of these calculations and comparison with relevant experimental results. Experiments have shown that when foils explode, a single intense source of SXR/EUV radiation is formed with radiated energy in the range of 10-20 J and a power of up to 100 MW in the quantum energy range from 30 to 250 eV. At the same time, the radiation power under the explosion of foils turned out to be about twice above the power under the explosion of wires of comparable mass.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Explosion dynamics of thin flat foils at high current density

This paper presents characteristic features of the explosion of thin flat foils for currents and pulse risetimes ranging from 8 kA at 350 ns to 1000 kA at ~100 ns. Foils made of aluminum, copper, nickel, and titanium with thicknesses of 1–100 µm are tested. Various diagnostics in the optical, UV, and x-ray spectral ranges are used to image the exploding foils from initial breakdown to complete destruction or pinching. It is shown that foil explosion is a complex process that depends on many factors, but features common to all foils are found that do not depend on the parameters of the generators or, accordingly, on the energy deposited in the foil: for example, the breakdown of flat foils under different conditions occurs at the edges of the foil. For the first time, the formation of a precursor over the central part of the foil is shown, which significantly changes the dynamics of the foil explosion.

36 MATERIALS SCIENCE↗
DOE OSTI2022

The Critical Stack Pressure to Alter Void Generation at Li/Solid-Electrolyte Interfaces during Stripping

The lithium stripping process generates vacancies, which may accumulate as voids and lead to uneven current distribution and dendrite growth in the following plating cycles. A stack pressure is typically required during stripping, but how to optimize the stack pressure is not clear. In this work, extremely lithiophilic Li/Li 2 O and lithiophobic Li/LiF interfaces were used to reveal the combining effect of interface interaction and stack pressure induced lithium creep on the stripping critical current density (CCD). A multiscale simulation scheme with Density Functional Theory (DFT), kinetic Monte Carlo (KMC) simulations, and an analytical model was developed. The analytical model predicted lithiophobic interfaces require a higher stack pressure than lithiophilic interfaces to reach the same CCD. The KMC simulations also showed higher stack pressure is needed at lithiophobic interfaces to accelerate Li vacancy diffusion into the bulk and maintain a flat surface. This stack pressure needs to be high enough to alter the Li forward-and-backward hopping barriers at the interface. This multiscale simulation scheme illustrates the importance to include the chemical-mechanical effects during Li stripping morphology evolution. It can be used to design ideal interlayer coating materials to maintain a flat Li surface during cycling.

25 ENERGY STORAGE↗
DOE OSTI2024

Shock tube experiments on the three-layer Richtmyer–Meshkov instability

Here, a vertical shock tube is used for experiments on the three-layer Richtmyer–Meshkov instability. Two closely spaced membrane-less interfaces are formed by the flow of two different sects of three gases: one with air above CO 2 above SF 6 and the other with helium above air above SF 6 . The lightest of the three gases enters the shock tube at the top of the driven section and flows downward. Conversely, the heaviest gas enters at the bottom of the shock tube and flows upward while the intermediate density gas enters at the middle through porous plates. All three gases are allowed to escape through holes at the layer location, leaving an approximately 30-mm layer of intermediate-density gas suspended between the lightest gas from above and the heaviest gas from below. A single-mode, two-dimensional initial perturbation is then imposed on the lower interface by oscillating the shock tube in the horizontal direction. The flow is visualized by seeding the intermediate gas with particles and illuminating it with a pulsed laser. Image sequences are then captured using high-speed video cameras. Perturbation amplitude measurements are made from the three-layer system and compared with measurements from 2, two-layer systems. It is observed that the presence of the upper, initially flat interface produces a decrease in growth of instability amplitude in the nonlinear phase over an equivalent single-interface configuration.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

Understanding the interaction of extension twinning and basal-plate precipitates in Mg-9Al using precession electron diffraction

Precession electron diffraction is used to characterize the interaction between ${10\bar{1}2}$ tensile twins and basal plate-like precipitates in a post-deformed, precipitate-dispersed Mg-9Al micropillar. We observed a heterogeneous distribution of precipitates in the micropillar sample, which enabled the study of the different stages involved in twin precipitate interactions. We show that twin nucleation was promoted, taking place on the surface, as well as from the interior of the micropillar. Twin tip propagation and twin growth were hindered by the precipitates. Twin tips either were arrested by precipitates and new twins formed on the other side of the precipitate, or continued to grow around the precipitate without the re-nucleation events. During twin thickening, the precipitates did not significantly alter the shear-dominant twin boundary migration mechanism, as evidenced by the relatively flat twin boundaries around the partially embedded precipitates. However, the twin boundary migration was retarded by the precipitates, especially in regions confined by closely-spaced precipitates.

36 MATERIALS SCIENCE↗
DOE OSTI2020

An in situ shearing x-ray measurement system for exploring structures and dynamics at the solid–liquid interface

Revealing interfacial structure and dynamics has been one of the essential thematic topics in material science and condensed matter physics. Synchrotron-based x-ray scattering techniques can deliver unique and insightful probing of interfacial structures and dynamics, in particular, in reflection geometries with higher surface and interfacial sensitivity than transmission geometries. We demonstrate the design and implementation of an in situ shearing x-ray measurement system, equipped with both inline parallel-plate and cone-and-plate shearing setups and operated at the advanced photon source at Argonne National Laboratory, to investigate the structures and dynamics of end-tethered polymers at the solid-liquid interface. With a precise lifting motor, a micrometer-scale gap can be produced by aligning two surfaces of a rotating upper shaft and a lower sample substrate. A torsional shear flow forms in the gap and applies tangential shear forces on the sample surface. The technical combination with nanoscale rheology and the utilization of in situ x-ray scattering allow us to gain fundamental insights into the complex dynamics in soft interfaces under shearing. In this work, we demonstrate the technical scope and experimental capability of the in situ shearing x-ray system through the measurements of charged polymers at both flat and curved interfaces upon shearing. Furthermore, through the in situ shearing x-ray scattering experiments integrated with theoretical simulations, we aim to develop a detailed understanding of the short-range molecular structure and mesoscale ionic aggregate morphology, as well as ion transport and dynamics in soft interfaces, thereby providing fundamental insight into a long-standing challenge in ionic polymer brushes with a significant technological impact.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Sudden-Discharge Cycling Characteristics and Millisecond Dynamic Behaviors of a HTS Stainless-Steel Insulated Double-Pancake Coil With Thin Copper Plates

We have tested an intermediate-sized HTS stainless-steel (co-wound) insulated double pancake coil (~132 turns per coil) and discovered dynamic effects during sudden discharge on both millisecond and second scales. For soft break, the power supply is turned off suddenly but the shunt resistor (164 milliohm) is still connected; for hard break, a high voltage contactor is used to suddenly open the circuit so that the leads are completely open. Hard break is dangerous to traditionally insulated LTS magnets, but the SS-insulated HTS DPC retained integrity over ¡80 charge-discharge cycles. Voltage decay curves for soft and hard breaks are studied on short and long timescales. On long timescales, we observe the expected exponential decay and measure the time constant to calculate contact resistance. On short timescales, we observe highly dynamic effects: a hyper-exponential decay suggesting that the inductance or contact resistance is suddenly changing with time, likely an indication of the RL circuit forming. Moreover, peak voltage immediately (ms) after the sudden discharge were collected and compared. It is found that the peak voltage in soft-discharge is proportional to the applied current, while the those in hard-break has a unique pattern and tends to stay flat even though the applied current increases.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

RapidClave® Technology Demonstrations - I

This demonstration sought to show a dramatic reduction in tool cost for RapidClave® tooling, taking advantage of recent modifications made on the RapidClave® system. Instead of building tools with complex internal heating, simple aluminum tools would be produced and heated externally through the recently added hot plate and air blower inside the RapidClave® system. Baselining against this tooling is the legacy RapidClave® tooling, as well as compression tooling, which would be the incumbent processing technique that the RapidClave® is displacing. Both an automotive and aerospace application were used to evaluate the tooling and process. Specifically, a four-piece Volkswagen hood structure was selected as an appropriate automotive geometry, while a wing structure representative of a current wing entering limited production was provided by Cornerstone Research Group for evaluating aerospace applications. In total, six tools were fabricated, and costs were compared against compression tooling quotes of the same tool geometry. A cost savings of over 80% was shown on all the tools. This demonstration also produced parts in the RapidClave® using the abovementioned tools to validate the low-cost tooling and the machine modifications. Solvay recommended two prepreg systems, CYCOM® EP2750 and SolvaLite™ 712, as appropriate for aerospace and automotive applications, respectively. Flat panels of each material were fabricated to verify cure parameters before proceeding with actual part fabrication. On-tool cycle times of approximately 30 minutes was achieved, with modifications identified to lower the time further.

36 MATERIALS SCIENCE↗