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

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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Forest Breeze–Cold Pool Interactions Drive Convective Organization over Heterogeneous Vegetation

Heterogeneous landscapes can influence the development of convection through the generation of thermally driven mesoscale circulations. To assess the impacts of these circulations and their interaction with sea breezes, we simulated convection in an idealized coastal environment using the Regional Atmospheric Modeling System (RAMS). We compared simulations with striped patterns of surface vegetation to those of uniform vegetation to identify the importance of vegetation heterogeneity in impacting convective development. Under dry soil conditions representative of those during the Tracking Aerosol Convection Interactions Experiment (TRACER) and Experiment of Sea Breeze Convection, Aerosols, Precipitation, and Environment (ESCAPE) campaigns in June 2022, we found that these vegetation-induced circulations, referred to in the literature as “forest breezes,” are more important than the sea breeze in determining the location of convection initiation. Convection and precipitation are also found to be favored over forests and suppressed over pasture and suburban landscapes as a result of greater surface sensible heat flux over the forest. Our findings also indicate that forest breezes are important for initiating convection along the boundaries of the forest, but that cold pools may play a key role in propagating the forest breezes toward the center of the forest stripe. In our simulations, the collisions of these breezes in the center of the forest stripe lead to uplift and strong convection there; however, a different width of the forest stripe would alter when the forest breezes collide or whether they collide at all. The presence of these cold pools may therefore impact the “ideal stripe width,” the width of each vegetation stripe which maximizes domain-wide precipitation.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Lake Huron Enhances Snowfall Downwind of Lake Erie: A Modeling Study of the 2010 New Year’s Lake Effect Snowfall Event

In the Northeast and Great Lakes regions of the United States, the influence of multiple lakes on the overlying air can greatly affect lake-effect snowfall over downwind communities. To assess the impact of Lake Huron on snowfall downwind of Lake Erie, we simulated a lake-effect snow event which occurred from 1 to 6 January 2010 using the Regional Atmospheric Modeling System (RAMS). We found that the presence of Lake Huron enhances snowfall downwind of Lake Erie by almost 20% and leads to much heavier local snowfall totals than when Lake Huron is not present. This increase in snowfall is due to a lake-to-lake (L2L) convective band, as secondary circulations associated with lake-effect convection form over Lake Huron and persist overland between the lakes before reintensifying over Lake Erie. As these secondary circulations move over Lake Erie, lifting within the upward branch of the circulations accelerates the development of convection within the L2L band. Surface fluxes and convection over Lake Huron deepen the boundary layer, promoting deeper vertical development of this L2L band over Lake Erie. However, although this boundary layer modification strengthens the L2L band, we found that it actually reduced lake-effect snowfall produced by wind-parallel bands (WPB) in other parts of the lake. This indicates that boundary layer modification from upstream lakes may impact L2L bands differently than WPB which are not connected to upstream secondary circulations.

Lake effects↗
DOE OSTI2023

Abisko: Deep codesign of an architecture for spiking neural networks using novel neuromorphic materials

The Abisko project aims to develop an energy-efficient spiking neural network (SNN) computing architecture and software system capable of autonomous learning and operation. The SNN architecture explores novel neuromorphic devices that are based on resistive-switching materials, such as memristors and electrochemical RAM. Equally important, Abisko uses a deep codesign approach to pursue this goal by engaging experts from across the entire range of disciplines: materials, devices and circuits, architectures and integration, software, and algorithms. Here, the key objectives of our Abisko project are threefold. First, we are designing an energy-optimized high-performance neuromorphic accelerator based on SNNs. This architecture is being designed as a chiplet that can be deployed in contemporary computer architectures and we are investigating novel neuromorphic materials to improve its design. Second, we are concurrently developing a productive software stack for the neuromorphic accelerator that will also be portable to other architectures, such as field-programmable gate arrays and GPUs. Third, we are creating a new deep codesign methodology and framework for developing clear interfaces, requirements, and metrics between each level of abstraction to enable the system design to be explored and implemented interchangeably with execution, measurement, a model, or simulation. As a motivating application for this codesign effort, we target the use of SNNs for an analog event detector for a high-energy physics sensor.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

A portable parton-level event generator for the high-luminosity LHC

The rapid deployment of computing hardware different from the traditional CPU+RAM model in data centers around the world mandates a change in the design of event generators for the Large Hadron Collider, in order to provide economically and ecologically sustainable simulations for the high-luminosity era of the LHC. Parton-level event generation is one of the most computationally demanding parts of the simulation and is therefore a prime target for improvements. We present a production-ready leading-order parton-level event generation framework capable of utilizing most modern hardware and discuss its performance in the standard candle processes of vector boson and top-quark pair production with up to five additional jets.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2020

GADRAS Batch Inject Tool User Guide

Gamma Detector Response and Analysis Software (GADRAS) is used by the radiation detection and emergency response community to perform modeling and spectral analysis for gamma detector systems. Built into GADRAS is the ability to define a detector, geometry, background characteristics and source composition to generate synthetic spectra for drills and exercises (injects). Consequence Management is currently in development of a sample result data simulator tool in which a deposition model is probed for source conditions at moments in time and locations in space. These values are used to generate realistic sample results for use in drills and exercises. In addition to sample results, there is a need to simulate the actual spectra that would be observed in the field by downlooking HPGe instruments given a deposition activity. This way, the FRMAC Gamma Spectroscopist can practice their process of generating quantified results from spectra on realistic data as well. Recognizing the decades of work done in GADRAS to accurately generate synthetic spectra, this team decided to build a link between the new simulator and GADRAS to generate these spectra quickly and easily. The simulator tool will generate a file that specifies the name of the spectra, its location, date/time of measurement, duration of measurement, height off the ground, and the deposition activity and age for every radionuclide in the simulation. Then, a new tool within the Inject Tab of GADRAS was developed to read in this file given a detector selection and generate In-Situ spectra for each row in the file in any file format the user chooses. This way, simulation cell staff can take these files and then upload them to the appropriate data system (RAMS or RadResponder) for use during drills and exercises. An advanced feature of this tool allows for generating any spectra given an appropriate model and mapping of source to model layer in the batch inject tool. This way, spectra from field sample counts, mobile laboratories, or even fixed laboratories can be generated in bulk given an estimate of the radioactivity concentration or total radioactivity in an import file. This expands the capabilities of this tool a great deal and will make it a more useful tool for CM and others to help estimate detector response for nearly any situation. This user guide will explain the steps needed to perform a batch inject file generation.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2020

Multiclass classification experiments

We seek a multiclass classifier that can satisfy the following requirements. 1. Predict among at least three classes. 2. Handle a moderately large number of correlated predictors. 3. Handle mixed categorical and continuous predictors. 4. Handle missing values (in some way). 5. Be trained with about n = 1,000 responses, and 6. Quantify prediction uncertainty. Based on 5. above, it is assumed that accuracy of prediction is paramount (relative to, say, runtime). All methods considered in this document take on the order of minutes (most take seconds) on a 2.8 GHz Quad-Core Intel Core i7 processor with 16GB RAM. Secondly, quantification of uncertainty is assumed to be a secondary task, since, with this small data size, resampling methods (i.e. bootstrapping) are possible. Further studies should quantify the feasibility and accuracy of resampling methods, and/or other methods, for quantifying uncertainty. R was used for all software.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Formulation via Resonant Acoustic Mixing at LANL

Discussions in the middle of 2014 led researchers at LANL to seek an alternate formulation method for making PBX based explosives. We began looking into the use of Resonant Acoustic Mixers (RAM) to formulate explosives and mocks. Acoustic mixing had been used in pharmaceutical plants for mixing medicines and coating materials, so we envisioned transitioning that same technology to the energetics world. Up until this time only the wet slurry formulation method that had been used was from the 1940’s. This wet slurry method had been and still was the standard for all explosive formulations. The possibility of an alternate method needed to be looked at to advance the process by expanding solvent choices, substrates, and reducing costs. Acoustic mixing had been shown to mix powders, slurries, pastes or even liquids. A Resodyn LabRAM was purchased in late 2014 to explore these possible applications to energetics. This LabRAM was in a remote configuration that met our need for explosive operations.

36 MATERIALS SCIENCE↗
DOE OSTI2020

JANA2 LDRD (Final Project Report)

The project sought to develop a second generation of the JANA reconstruction framework that leverages modern programming features (C++11 and C++14) while maintaining its basic user centric design. The goals included making the project easy to deploy to large HPC facilities such as NERSC and to include detailed documentation to allow scientists outside of Jefferson Lab to use it at such a facility. This would position JLab to play a key role in the larger Laboratory based computing ecosystem under the ASCR initiative. The experience gained will help inform the design of Exascale class applications for experimental nuclear physics. Developing a next generation JANA provides an advantage over older serial frameworks or ones retro-fitted to provide some multi-threading support. That technique requires significantly more memory than multi-threading which leads to compute jobs being limited by available RAM, and not fully utilizing the available CPU. The smaller memory footprint of multi-threaded programs also leads to increased efficiency due to fewer cache misses. It is for these and other reasons that multi-threading is the more accepted industry standard in the modern era.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Full-Loop Simulation of the Combustion of Biomass in a Circulating Fluidized Bed Combustor

Interest in circulating fluidized bed (CFB) boilers as a power generation technology has skyrocketed in recent years because of several advantages this technology offers over conventional boilers, such as increased gas-solid mixing, which results in higher combustion efficiency, and the ability to use lower rank fuels. CFB combustors are operated at lower temperatures than conventional thermal power generation combustors, thus reducing NO x emissions, while SO 2 emissions can be conveniently controlled through the addition of Ca-based sulfur sorbents within the combustor. This report summarizes the development of a comprehensive computational fluid dynamics (CFD) model for biomass combustion in a 50 kW th CFB combustor employing the multiphase particle-in-cell (PIC) approach in the open-source Multiphase Flow with Interphase eXchanges (MFiX) Software Suite at the U.S. Department of Energy (DOE) National Energy Technology Laboratory (NETL). The experimental combustor was designed, built, and operated at CanmetENERGY, Natural Resources Canada in Ottawa, Canada. This work is the culmination of a multi-year collaboration between NETL and CanmetENERGY. The hydrodynamics in the full loop are validated against cold-flow experiments conducted at CanmetENERGY. To mimic the dense packing in the standpipe in the absence of a collisional model in the MFiX-PIC approach, the ram valve in the return leg is partially closed to obstruct the flow. A combustion reaction scheme was developed that considers the volatiles released by the fuel as a lumped species that fully converts to CO 2 and H 2 O. The so-called enhanced simplified combustion scheme produces an excellent match with experimental data in terms of the species concentrations of CO 2 and O 2 at the outlet and the freeboard, demonstrating the utility of the comprehensive model for a range of flow conditions and operating temperatures. Furthermore, the model can be readily adapted to simulate combustion of a variety of biomass fuels as well as co-fired systems under air and oxy-fuel conditions.

09 BIOMASS FUELS↗
DOE OSTI2021

Towards memristor supremacy with novel machine learning algorithms

The von Neumann architecture for current computers is slowly showing signs of limitations, due to the finite bus rate between the RAM (memory) and the CPU (computing unit). In-Memory computing is an alternative to this architecture, which however is still in the early stages of development. Memristors are an analog and classical alternative, as these components can act both as a memory, or as a simple computing unit. When wired together, these can in fact be used for a variety of applications. During the course of our research, we have developed an in-depth experimental understanding of both the limitations and the real possibilities of these devices, and developed automated algorithms for their characterization; at the theoretical level, we have incorporated the experimental features to implement novel analog computing units for specific tasks. We have shown that memristors can tackle QUBO and cubic optimization problems, and exhibit tunneling phenomena.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Shear Assisted Processing and Extrusion (ShAPE) of Aluminum Alloy 7075, 2024, and Al-12.4TM

The most common aluminum alloys utilized in the aerospace industry are 7075 and 2024 due to their high strength-to-weight ratio compared to advanced high strength steels and other aluminum alloys. Despite excellent performance, these aluminum alloys have seen limited use outside of the aerospace industry due in part to high cost. If high-performance aluminum extrusions could be made more cost effectively by eliminating energy intensive process steps typical of conventional extrusion, then numerous opportunities exist for more widespread adoption. A key reason for the high cost of 7075 and 2024 extrusions (25-75% higher than 6061) is their slow extrusion speed. 7075 and 2024 are limited to 2 m/min and 3.5 m/min respectively, in contrast to 6061 which can be extruded at 20–80 m/min. In addition to slow speed, aluminum alloys require numerous thermal treatments throughout the extrusion process including homogenization and pre-heating prior to extrusion, and solution heat treating and artificial aging after extrusion. Each of these steps contribute to the total energy consumed during manufacturing of extruded components. This project investigates the use of ShAPE to improve extrusion speed and reduce, or even eliminate, the typical thermal treatments for high strength aluminum alloys, all while improving material performance. The overarching goal of this project was to demonstrate that Shear Assisted Processing and Extrusion (ShAPE) can manufacture high-performance aluminum alloy tubing with lower manufacturing energy and improved mechanical properties compared to conventional extrusion. Unlike conventional extrusion where the billet is rammed against a stationary die using a strictly linear motion, the ShAPE process superimposes a rotational shear force by spinning the die while the billet is plunged. Compared to conventional linear extrusion, the ShAPE process imparts significantly more strain into the feedstock material, which enables the formation of novel microstructures. These microstructures manifest an array of property and process improvements for extrusion of high-performance aluminum alloys. The following accomplishments were achieved for this project: Extrusion of 7075 at 12.2 meters/min compared to 2 meters/min for conventional extrusion; Elimination of 7075 billet homogenization (430 °C for 20 hours) which is required prior to conventional extrusion; Elimination of 7075 billet pre-heating (400 °C for 1 hour) in a separate furnace which is required prior to conventional extrusion; Achieved 7075-T6with yield strength = 595 MPa, ultimate tensile strength = 531MPa, and elongation = 17.4% for extrusions made from unhomogenized billets. Exceeds the ASTM and ASM standard, and typical industry values; Achieved 7075-T5 (i.e., no solution heat treatment) with yield strength = 588 MPa, ultimate tensile strength = 535 MPa, and elongation = 14.8% for extrusions made from homogenized billets; Extrusion of 2024 at 7.4 meters/min compared to 3.5 meters/min for conventional extrusion; Achieved 2024-T8510 yield strength = 522 MPa, ultimate strength = 510MPa, and elongation = 7.1% for extrusions made from wrought billets. Exceeds the ASTM and ASM standard, and typical industry values; Extrusion of Al-12.4TM high-performance aluminum powder directly into tubing, in a single step, which eliminates process steps typical of powder metallurgy extrusion.

36 MATERIALS SCIENCE↗
DOE OSTI2022

2021 NIRT Mini Drill (After Action Report)

During the summer and fall of 2021, several functional area drills were held that focused on exercising Consequence Management’s (CM) ability to extract and use data from RadResponder for the purpose of answering intermediate-phase questions presented as technical inject requests for information (RFI) in Sandia National Laboratories (SNL) Consequence Management Operational System (COSMOS) software. The scenario chosen was that of Northern Lights 2016 (NL16) which was a large-scale nuclear power plant (NPP) release exercise in the state of Minnesota. The NL16 data was extracted from the Radiological Assessment and Monitoring System (RAMS) event where it was created and was reformatted for implanting to a new RadResponder event. Next, the beta-version of a laboratory sample data simulator was used to generate more sample data that was injected to the event. Five “mini-drills” were devised with each prompt defined by a data-based need. For each drill, a team of assessment and NARAC scientists worked the problem using the drill prompt and the available data in RadResponder. The teams held a kickoff meeting, had several days to work the problem, and then reported their results as well as observations in a hotwash. Several areas for improvement in both the software and process were identified during the course of these drills. This report will document the process of addressing each RFI and the discovered gaps in both software capability and methodology so that they can be considered for future development and investment by the CM and NIRT programs.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2022

National Ignition Facility. Facility and Infrastructure Systems Maintenance Plan

Ensuring the reliability of the NIF, including its support systems, laser systems, target diagnostic systems, and utilities, is essential to the availability of the NIF in its support of NNSA missions. NIF is a key capability in the DOE Stockpile Stewardship Program and supports high energy physics experiments for nuclear weapons, energy, and astrophysics applications. High system reliability provides opportunities for shots and scientific discoveries with opportunities to enhance and upgrade capabilities. This Maintenance Plan (MP) identifies the policies and procedures used to perform and support asset management of the NIF Facility and Infrastructure Systems (FInS), NIF Lasers & Alignment (LASE), NIF Target Experimental Operations (TOPS), NIF Target Area Science and Engineering (TASE), and NIF&PS Control Systems (NCS). The FInS systems include the facility, HVAC, contamination control, beampath, and Line Replaceable Units (LRUs) as well as utilities which create the beampath environments, such as vacuum, argon, or clean dry air. The LASE systems are Programmatic systems which include laser diagnostics, alignment, power conditioning, pulsed power, and input laser systems. The TOPS and TASE systems are also Programmatic systems which include target and diagnostic delivery systems and positioners, many different insertable and fixed target diagnostics, and cryogenic and target gas fill systems. Finally, the NCS systems include both software and hardware for industrial and shot operation control systems. Policies governing administrative and operational practices related to maintenance of FInS, LASE, TOPS, TASE, and NCS systems are described in this plan. In addition, the plan provides processes and procedures for managing, tracking, and documenting the work. This document, the NIF Operations Management Plan, NIF-5020544 (Ref. 1), and NIF Shot Operations Plan, NIF-5018506 (Ref. 2), together satisfy the requirements of the Conduct of Operations. Duties, responsibilities, and reporting requirements of the various positions associated with FInS, LASE, and TOPS maintenance are detailed in this plan. The FInS systems include both Real Property systems with asset management requirements specified in DOE Order 430.1C (Ref. 3) and Programmatic systems. In addition, for FInS, there is a list of the System Level Maintenance Plans (SLMPs) in NIF-1007419198 (Ref. 4) which provide the system descriptions and maintenance plan and schedule. In addition, the list includes the Reliability Centered Maintenance (RCM) and Experience Centered Maintenance (ECM) evaluations that have been performed for applicable FInS systems as well as reliability criticality per Section 3.5. The -AM version of the NIF Maintenance Plan focuses on the reliability program for FInS, LASE, TOPS, TASE, and NCS within the context of the overall NIF Reliability, Availability, and Maintainability (RAM) program and incorporates changes since the -AL version from August 2011 and has been updated to be fully consistent with the updates to Ref. 1. It also includes asset management considerations, updates to the Work Order (WO) process within the NIF Computerized Maintenance Management System (CMMS) which is EAM infor® System Maintenance and Reliability Tracking (SMaRT) (Ref. 5), and updates to metrics and key performance indicators (KPIs).

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Adrian Portales Coop Internship Report

Using the thesis of W.R. Nolan (cite) as a guide, Cobalt Iron (CoFe) powders were reacted with 0.1 wt.% and 0.2 wt.% phosphoric acid in a 20:1 ratio of acetone to phosphoric acid. The powders were then dried at room temperature. The resulting phosphate coated CoFe was then mixed with 0.75 wt.% of the lubricant N,N' ethylene bis-stearamide (trade name: Acrawax C) and hot pressed to form a consolidated soft magnetic material referred to as CoFeP. With an avenue of synthesis for CoFeP determined, a proper amount of stock was synthesized for continuous “brick” production. While under current optimization, these 1x1 mm magnetic bricks will ultimately be placed and secured along the inside wall of each MK Magnetics transformer core by an appropriate CoFeP dispersed epoxy. As of now each brick has been produced though a pressing and annealing process via square 2x2 cm die. Before a brick is made a pressure calculation is run to ensure the dies maximum operating pressure is not exceeded. Figure 1. ensures the user’s safety by showing that the tons-on-ram required for a 2x2 cm square die to reach 760 MPa is below the point of die failure.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Cryocooler conduction-cooled SRF accelerator design for industrial applications

Principal Investigator Dr. Ram Dhuley has led R&D efforts at the U.S. Department of Energy's Fermi National Accelerator Laboratory to design a cryocooler conduction-cooled SRF accelerator for e-beam irradiation treatment of wastewater. This is a spotlight on the accelerator design and its enabling core technologies.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

LH CO 2 MENT Colorado Project (Final Report)

The objective of Electricore’s pre-FEED project “LH CO 2 MENT COLORADO PROJECT” is to accelerate the implementation of a 1.5 million tonnes per year (TPY), and first-of-a-kind (FOAK) at world scale, Svante VeloxoTherm™ carbon capture plant. This project represents a quantum leap to a large-scale facility that will launch Svante’s carbon capture technology into the next era of accomplishments and market acceptance. By completing the Front-End Loading (FEL) Feasibility Study Report (FEL-2) for a fit-for-purpose design at the HOLCIM cement plant, located near Florence Colorado, USA, this technology can be proven as the future of large-scale deployment for carbon capture and storage. This carbon capture plant was designed with the goal of reaching a target of near Net Zero Emissions by capturing 90% of the carbon dioxide (CO 2 ) emissions from the HOLCIM cement plant and from the boiler which produces steam required to regenerate the adsorbent. Additionally, this project will be leveraging a renewable Power Purchase Agreement (PPA) using solar energy to acquire power at the target price of 0.04 $/kWh or less. In its current configuration CO 2 emissions from the HOLCIM cement plant is around 700 – 800 kg/ton of clinker produced. The proposed new carbon capture plant will allow a reduction of CO 2 emissions to about 100 kg/ton of clinker produced. The scope of work consists of the process design and capital & operating cost estimation (Class IV) for a total plant capacity of 4,750 TPD of pipeline grade CO 2 . The Svante VeloxoTherm™ technology is comprised of a Rotary Adsorption Machine (RAM) for intensified Thermal Swing Adsorption (TSA) using Structured Adsorbent Beds (SABs) and related Balance of Plant (BOP), including CO 2 compression. A business case (financial analysis) evaluation has been undertaken for the Owner’s management review. Recommendations on how best to proceed to the next stage of the project have been conveyed and are documented within this report. This analysis has relied on a detailed and comprehensive Project Financial Model, evaluating the Total Project IRR (after tax, unlevered, and including all forecast 45Q PTCs and 100% tax efficiency) – the project financial analysis (as opposed to standard TEA analysis) only considered a 12 year plant economic lifetime as a result of 45Q being the sole driver considered at this stage. The Total Project IRR was evaluated across a large number of potential scenarios. The evaluation demonstrated that if the 45Q PTD is increased to $85/MT for sequestration, there are a large number of feasible scenarios which demonstrate economic returns.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

HPC Analytics of Fused Thermal Plants Data to Optimize Operating Envelope

In this project, ORNL extensively reviewed the ORAP RAM data, and it guided us to develop machine learning models that can predict time to next failures and forecast failure trends, which will be useful for optimizing power plant operation strategies. More specifically, we trained multiple random forest models and evaluated the model accuracy to validate with 10+ years of historical data. In addition, we implemented a web-based graphical user interface system for the models to show how our models can be used in more intuitive ways. This proof of concept allowed exploration of model use with power plant operators in mind. Developed machine learning models will be helpful for managing risks, planning maintenance and operation, ultimately reducing the down time and increasing the service hours. For future work, there are several interesting research topics including but not limited to model enhancement, creating synergy with traditional failure modeling approaches, and data-driven actionable recommendation and suggestions.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Process Intensification for Nanocomposite Aluminum Extrusions: CRADA 411 (Final Report)

The project evaluated the feasibility of using Shear Assisted Processing and Extrusion (ShAPE) for the fabrication of extrusions with a diameter of 0.5” and higher from an Al-alloy powder feedstock that contains nanoscale second phases for achieving enhanced elevated temperature strength. PNNL has previously extruded 0.2” diameter rods with high strength aluminum alloy powder Al-12.4TM. This project aimed to scale the process up to a diameter of 1.0” at a length of >24” while retaining the excellent mechanical properties achieved for the 0.2” diameter rods. As part of the project, extrusion dies were fabricated with various design features. As an example, scroll features on the tool die face was introduced to enhance powder mixing, and reduce extrusion load. Varying extrusion ratios were used to obtain better microstructural homogeneity. Use of tool design features together with the optimization of process parameters helped in the fabrication of extrusions that were up to 48” long with a diameter of 0.5” using Al-12.4 TM powder feedstock in a two-step process involving cold compaction followed by extrusion. Extrusions with a diameter of 1.0” could also be fabricated, but limitations on the extent of consolidation were experienced as a result of the torque and ram force capacity of the current ShAPE machine.

36 MATERIALS SCIENCE↗