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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 OSTI2021

Quantifying the temperature of heated microdevices using scanning thermal probes

Quantifying the temperature of microdevices is critical for probing nanoscale energy transport. Such quantification is often accomplished by integrating resistance thermometers into microdevices. However, such thermometers frequently become structurally unstable and fail due to thermal stresses at elevated temperatures. Here, we show that custom-fabricated scanning thermal probes (STPs) with a sharp tip and an integrated heater/thermometer can accurately measure the temperature of microdevices held at elevated temperatures. This measurement is accomplished by introducing a modulated heat input to the STP after contacting the microdevice with the STP's tip and characterizing the DC and AC components of the STP's temperature. From these measured temperature components, the tip-to-sample thermal resistance and the microdevice surface temperature are deduced simultaneously via a simple lumped-capacitance model. The advances presented here can greatly facilitate temperature measurements of a variety of heated microdevices.

42 ENGINEERING↗
DOE OSTI2022

Femtosecond ultraviolet laser absorption spectroscopy for simultaneous measurements of temperature and OH concentration

This Letter reports a femtosecond ultraviolet laser absorption spectroscopy (fs-UV-LAS) for simultaneous in situ measurements of temperature and species. Here, this fs-UV-LAS technique was demonstrated based on X 2 Π-A 2 Σ + transitions of OH radicals near 308 nm generated in low temperature plasmas and flames. The fs-UV-LAS technique has revealed three major diagnostic benefits. First, a series of absorption features within a spectral bandwidth of ~3.2 nm near 308 nm were simultaneously measured and then enabled simultaneous multi-parameter measurements with enhanced accuracy. The results show that the temperature and OH concentration could be measured with accuracy enhanced by 29–88% and 58–91%, respectively, compared to those obtained with past two-narrow-line absorption methods. Second, an ultrafast time resolution of ~120 picoseconds was accomplished for the measurements. Third, due to the large OH X 2 Π-A 2 Σ + transitions in the UV range, a simple single-pass absorption with a 3-cm path length was allowed for measurements in plasmas with low OH number density down to ~2 × 10 13 cm –3 . Also due to the large OH UV transitions, single-shot fs absorption measurements were accomplished in flames, which was expected to offer more insights into chemically reactive flow dynamics.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Source shape estimation for neutron imaging systems using convolutional neural networks

Neutron imaging systems are important diagnostic tools for characterizing the physics of inertial confinement fusion reactions at the National Ignition Facility (NIF). In particular, neutron images give diagnostic information on the size, symmetry, and shape of the fusion hot spot and surrounding cold fuel. Images are formed via collection of neutron flux from the source using a system of aperture arrays and scintillator-based detectors. Currently, reconstruction of fusion source geometry from the collected neutron images is accomplished by solving a computationally intensive maximum likelihood estimation problem via expectation maximization. In contrast, it is often useful to have simple representations of the overall source geometry that can be computed quickly. In this work, we develop convolutional neural networks (CNNs) to reconstruct the outer contours of simple source geometries. We compare the performance of the CNN for penumbral and pinhole data and provide experimental demonstrations of our methods on both non-noisy and noisy data.

Machine learning, neutron imaging, source reconstr↗
DOE OSTI2020

Mapping the Temperature-dependent and network site-specific onset of spectral diffusion at the surface of a water cluster cage

We explore the kinetic processes that sustain equilibrium in a microscopic, finite system. This is accomplished by monitoring the spontaneous, time-dependent frequency evolution (the frequency autocorrelation) of a single OH oscillator, embedded in a water cluster held in a temperature-controlled ion trap. The measurements are carried out by applying two-color, IR-IR photodissociation mass spectrometry to the D3O+?(HDO)(D2O)19 isotopologue of the “magic number” protonated water cluster, H+?(H2O)21. The OH group can occupy any one of the five spectroscopically distinct sites in the distorted pentagonal dodecahedron cage structure. The OH frequency is observed to evolve over tens of milliseconds in the temperature range (90-120 K). Starting at 100 K, large “jumps” are observed between two OH frequencies separated by ~300 cm-1 indicating migration of the OH group from the bound OH site at 3350 cm-1 to the free position at 3686 cm-1. Increasing the temperature to 110 K leads to partial interconversion among many sites. All sites are observed to interconvert at 120 K such that the distribution of the unique OH group among them adopts the form one would expect for a canonical ensemble. The spectral dynamics displayed by the clusters thus offer an unprecedented view into the molecular-level processes that drive spectral diffusion in an extended network of water molecules.

Yang, Nan↗
DOE OSTI2021

The Manhattan Project Nuclear Science and Technology Developments at Los Alamos: A Special Issue of Nuclear Technology

The year 2020 marked the 75th anniversary of the Trinity experiment, the world’s first nuclear explosion, on July 16, 1945, near Alamogordo, New Mexico. Trinity was a vital proof step toward the culmination of the Manhattan Project and the end of World War II. The technical accomplishments made by scientists and engineers from the United States, United Kingdom, and Canada (some originating in Germany, Hungary, Italy, France, and other countries) were recognized by many events in 2020, including a visit to New Mexico’s Los Alamos National Laboratory by U.S. Department of Energy (DOE) National Nuclear Security Administration (NNSA) dignitaries; historical documentaries. The importance of Trinity as a foundational accomplishment for the broad nuclear science and engineering community is clear; indeed, New Mexico’s chapter of the American Nuclear Society (ANS) is referred to as the Trinity Section. The events surrounding Trinity have even entered into high culture with recent performances of John Adams’s opera Doctor Atomic in San Francisco, Amsterdam, Chicago, New York, and Santa Fe.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

Characterizing gravitational wave detector networks: from A # to cosmic explorer

Gravitational-wave observations by the laser interferometer gravitational-wave observatory (LIGO) and Virgo have provided us a new tool to explore the Universe on all scales from nuclear physics to the cosmos and have the massive potential to further impact fundamental physics, astrophysics, and cosmology for decades to come. In this paper we have studied the science capabilities of a network of LIGO detectors when they reach their best possible sensitivity, called A # , given the infrastructure in which they exist and a new generation of observatories that are factor of 10 to 100 times more sensitive (depending on the frequency), in particular a pair of L-shaped cosmic explorer (CE) observatories (one 40 km and one 20 km arm length) in the US and the triangular Einstein telescope with 10 km arms in Europe. We use a set of science metrics derived from the top priorities of several funding agencies to characterize the science capabilities of different networks. The presence of one or two A # observatories in a network containing two or one next generation observatories, respectively, will provide good localization capabilities for facilitating multimessenger astronomy (MMA) and precision measurement of the Hubble parameter. Two CE observatories are indispensable for achieving precise localization of binary neutron star events, facilitating detection of electromagnetic counterparts and transforming MMA. Their combined operation is even more important in the detection and localization of high-redshift sources, such as binary neutron stars, beyond the star-formation peak, and primordial black hole mergers, which may occur roughly 100 million years after the Big Bang. The addition of the Einstein Telescope to a network of two CE observatories is critical for accomplishing all the identified science metrics including the nuclear equation of state, cosmological parameters, the growth of black holes through cosmic history, but also make new discoveries such as the presence of dark matter within or around neutron stars and black holes, continuous gravitational waves from rotating neutron stars, transient signals from supernovae, and the production of stellar-mass black holes in the early Universe. For most metrics the triple network of next generation terrestrial observatories are a factor 100 better than what can be accomplished by a network of three A # observatories.

Einstein telescope↗
DOE OSTI2024

Difficult Measurements of Materials Systems at Cryogenic Temperatures: Cryo-EELS and Cryo-4D-STEM

Scanning/transmission electron microscopy (S/TEM) in materials science has traditionally been accomplished at room temperature due to their solid state in this temperature range and relative insensitivity to radiolysis damage. Cooling to cryogenic temperatures tended to introduce instabilities such as vibration and drift and can lead to the buildup of carbon contamination or ice reducing contrast. The need to expand TEM experimental techniques into new fields such as quantum and battery materials led to new efforts to reduce these instabilities while achieving temperatures at or well below liquid nitrogen (77 K). Further, developments in detector and spectrometer technology brought new capabilities for high resolution electron energy loss spectroscopy (EELS) and scanning nanodiffraction (4D-STEM). These experimental modalities can require even tighter controls of drift, vibration, and exposure time. Here this presentation will discuss accomplishing difficult experiments at cryogenic temperatures in honor of the late Dr. Lena Kourkoutis who inspired and led many such experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Direct Power Control of Back to Back Modular Multilevel Converter with Advanced Grid Support Functions for Grid Forming Application

Possibility of using back-to-back modular multilevel converter system with a direct power control architecture has been investigated in this paper. The rectifier side is controlled to be in grid following mode whereas the inverter side is controlled in grid forming mode. Both the sides’ local controllers use Lyapunov energy function based architecture to accomplish the objective of active and reactive power control as well as maintaining a fixed user defined voltage over the dc bus on the rectifier side. Therefore, the proposed direct power control architecture has embedded dc bus control architecture to maintain fixed user defined value of the capacitors. Similar architecture is implemented on the inverter side to accomplish either voltage control during grid forming or power control during grid following. Advanced grid support functionalities based on IEEE-1547-2018 is implemented and utilized to generate the reference values for either the rectifier or the inverter sides. The overall system is modeled based on MATLAB/Simulink and PLECS domain and various important case studies to verify the efficacy of the overall system has been presented.

direct power control (DPC)↗
DOE OSTI2020

Decentralized Control of Cascaded H-Bridge Inverters for Medium-Voltage Grid Integration: Preprint

This paper introduces a fully decentralized control strategy that allows for individualized active and reactive power control of H-bridge inverters connected in series. After formulating a model of the system power flows, we outline a communications-free approach where each inverter can act on independent commands. Inverter-level feedback is accomplished locally via a measurement of current flowing through the stack. A key feature is the lack of any centralized control routines or phase-locked loop. In this framework, the reactive power control loops achieve voltage synchronization among the converters and the grid, and the active power control loops modulate the terminal voltage amplitudes that influence power delivery. Furthermore, pole placement via state feedback is used to ensure stability of voltage synchronization while also enabling tracking of bidirectional power commands. Simulations are presented to validate the proposed approach.

communication-free modular converter control↗
DOE OSTI2023

Modified Virtual Oscillator Based Operation of Grid Forming Converters with Single Voltage Sensor

Virtual oscillator based control architecture for grid forming converter with inner current control loop for additional objective accomplishments is proposed in this paper. In general, virtual oscillator is based on Lienard type of oscillator equation with a cubic nonlinearity. Virtual oscillator alone cannot accommodate unbalanced or harmonic mitigation while operating converters in grid forming mode. Therefore, to accomplish better tracking performance, incorporating the provision for nonlinear and/or unbalanced loads, an inner current control loop is utilized which is based upon Lyapunov energy function type control architecture due to its advantages. To reduce the overall cost of implementation and ensure proper phase difference in the generated voltages, the implemented virtual oscillator operates with only one voltage feedback from the point of common coupling as presented in this paper. To verify the effectiveness of the proposed approach, the overall system has been modeled in MATTLAB/Simulink and PLECS domain and case studies showing the successful production of low harmonic load voltages under nonideal loading condition along with other important results are presented in this paper.

dual second order generalized integrator↗
DOE OSTI2022

Internal Model-Based Active Damping Strategy for a Back-to-Back Modular Multilevel Converter System for Advanced Grid Support: Preprint

The proposed work focuses on the possibility of achieving the reduction in the size of the interfacing filter for the grid connection for a back-to-back modular multilevel converter system with the use of third order LCL filters. To achieve the same attenuation, it is possible to reduce the size of the interfacing filters by the usage of third order filters. However, this kind of filtering comes with the limitation of having sustained oscillations due to lack of damping especially during transient changes. Therefore, in this work, a methodology has been proposed based on the principle of internal model to cater for this unwanted oscillations. The third order system is modeled inside the microcontroller with the damping enabled. The error between the output from the model and the actual are compared and the error is utilized to accomplish the active damping strategy. The proposed architecture is verified via computer simulations based on MATLAB/Simulink domain and various case study results along with their discussion is presented in this paper.

dq control↗
DOE OSTI2021

Applying Utility's Advanced Grid Technologies to Improve Resiliency of a Critical Load

The US DOE Office of Electricity's Energy Storage Program's joint R&D work with the Cordova Electric Cooperative (CEC) has deployed several advanced grid technologies that are providing benefits today to Cordova Alaska's electricity users. Advanced grid technologies deployed through DoE co-funded R&D include a 1MW Battery Energy Storage System (BESS), and enhanced monitoring including Phasor Measurement Units (PMU's) to help better understand the operational impacts of the added BESS. This paper will highlight key accomplishments to-date in deploying and using advanced grid technologies, and then outline the next phase of work that will use these technologies to implement an operating scheme to reconfigure the utility's distribution system and utility resources including BESS to provide emergency back-up power to a critical load: the Cordova Community Medical Center (CCMC). This paper will include additional insights on the use of utility resources to support critical loads via case study examples by the National Rural Electric Cooperative Assoc. (NRECA).

BESS↗
DOE OSTI2022

Conceptual design of the modular detector and readout system for the CMB-S4 survey experiment

We present the conceptual design of the modular detector and readout system for the Cosmic Microwave Background – Stage four (CMB-S4) ground-based survey experiment. CMB-S4 will map the cosmic microwave background (CMB) and the millimeter-wave sky to unprecedented sensitivity, using 500,000 superconducting detectors observing from Chile and Antarctica to map over 60% of the sky. The fundamental building block of the detector and readout system is a detector module package operated at 100 mK, which is connected to a readout and amplification chain that carries signals out to room temperature. It uses arrays of feedhorn-coupled orthomode transducers (OMT) that collect optical power from the sky onto dc-voltage-biased transition-edge sensor (TES) bolometers. The resulting current signal in the TESs is then amplified by a two-stage cryogenic Superconducting Quantum Interference Device (SQUID) system with a time-division multiplexer to reduce wire count, and matching room-temperature electronics to condition and transmit signals to the data acquisition system. Sensitivity and systematics requirements are being developed for the detector and readout system over wide range of observing bands (20 to 300 GHz) and optical powers to accomplish CMB-S4’s science goals. While the design incorporates the successes of previous generations of CMB instruments, CMB-S4 requires an order of magnitude more detectors than any prior experiment. This requires fabrication of complex superconducting circuits on over 10 m2 of silicon, as well as significant amounts of precision wiring, assembly and cryogenic testing

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

Better together: Elements of successful scientific software development in a distributed collaborative community

Many scientific disciplines rely on computational methods for data analysis, model generation, and prediction. Implementing these methods is often accomplished by researchers with domain expertise but without formal training in software engineering or computer science. This arrangement has led to underappreciation of sustainability and maintainability of scientific software tools developed in academic environments. Some software tools have avoided this fate, including the scientific library Rosetta. We use this software and its community as a case study to show how modern software development can be accomplished successfully, irrespective of subject area. Rosetta is one of the largest software suites for macromolecular modeling, with 3.1 million lines of code and many state-of-the-art applications. Since the mid 1990s, the software has been developed collaboratively by the RosettaCommons, a community of academics from over 60 institutions worldwide with diverse backgrounds including chemistry, biology, physiology, physics, engineering, mathematics, and computer science. Developing this software suite has provided us with more than two decades of experience in how to effectively develop advanced scientific software in a global community with hundreds of contributors. Here we illustrate the functioning of this development community by addressing technical aspects (like version control, testing, and maintenance), community-building strategies, diversity efforts, software dissemination, and user support. We demonstrate how modern computational research can thrive in a distributed collaborative community. The practices described here are independent of subject area and can be readily adopted by other software development communities

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

PIP-II 800 MeV Proton Linac Beam Pattern Generator

The PIP2 IT Beam Pattern Generator is the system that synchronizes beam injection and the RF systems between the PIP2 LINAC to the Booster. The RF frequencies of these two accelerator systems are not harmonically related. Synchronization is accomplished by controlling two MEBT Beam Choppers, which select 162.5MHz beam bunches from the LEBT and RFQ to produce an appropriate reduced beam bunch pattern that enables bucket-to-bucket transfer to the Booster RF at 46.46MHz (84th harmonic). This chopping pattern also reduces the beam current to an average of 2mA over the Booster injection, matching the Linac nominal beam current. The BPG also generates the RF frequency/phase reference which the Booster will phase lock to during injection. The BPG is fully programmable, allowing for arbitrary beam patterns with adjustable timing parameters, having a fine adjustment resolution of 38ps. The latter is accomplished using digital signal processing techniques. This paper discusses the design of the BPG, its construction, test results, and operational experience after being integrated into the PIP2 IT test accelerator and concludes with a discussion of the system’s performance and future plans.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Distributed fiber sensing systems for 3D combustion temperature field monitoring in coal-fired boilers using optically generated acoustic waves (Final Report)

In this project, we have developed and tested three kinds of fiber optic sensing systems for real time monitoring of temperature variations within an industrial scale boiler furnace. The fiber optic sensing systems target spatial and temporal distributions of high temperature profiles in a boiler furnace in fossil power plants. The reconstructed temperature profile will provide critical input for the control mechanisms to optimize the combustion process. This temperature profile will address the essential problem for fossil power plants in achieving higher efficiency and fewer pollutant emissions. Acoustic pyrometer systems have been used to reconstruct temperature field of power plant boilers based on measuring TOF (times-of-flight) of sound waves along some straight paths in a 2D cross-section of the boiler. In this project, optically generated acoustic signals from a fiber optic sensing system have replaced the acoustic signals generated from an electrical transducer. A 3D reconstruction algorithm replaced the previous 2D model. In this project, three kinds of fiber optic sensing systems have been developed and tested. They are fiber optic sensing system I, fiber optic sensing system II (Distributed Sensing System I) and fiber optic sensing system III (Distributed Sensing System II). For fiber optic sensing system I, the fiber optic ultrasound generator acts as a signal generator. A microphone, hydrophone or other electronic devices serve as a signal receiver. In this system, there are one generator and one receiver. Distance test, water temperature test, air temperature test, air temperature reconstruction, and GE ISBF pilot test were performed by Fiber optic sensing system I. The fiber optic sensing system I successfully detected temperature in all these tests. We got 2D temperature reconstruction results by using the fiber optic sensing system I and it matched the reference data. The fiber optic sensing system I successfully survived in GE ISBF boiler environment (480 °F). For fiber optic sensing system II (Distributed Sensing System I), it is an all optical ultrasound system. The fiber optic ultrasound generator acts as a signal generator. Fiber Bragg Grating (FBG) and Fabry-Perot (FP) sensor act as a signal receiver. In this system, there is one generator and one receiver. Aluminum plate temperature test, furnace high temperature test, and GE ISBF pilot test were performed by the fiber optic sensing system II. Fiber optic sensing system II successfully detected the temperature in all these tests. The fiber optic sensing system II successfully survived at up to 700 °C furnace environment and 320 °C GE ISBF boiler environment. For fiber optic sensing system III (Distributed Sensing System II), it is also an all optical ultrasound system. The fiber optic ultrasound generator acts as a signal generator. Multiple FP fiber sensors act as signal receivers. In this system, there is one generator and three receivers. Three GE ISBF pilot tests were performed by fiber optic sensing system III. The fiber optic sensing system III survived in the cold flow tests in GE’s ISBF pilot test facility. However, we didn’t get high temperature data by using this system since the nanosecond laser issues. During the period of the project, test trials, data simulation and algorithm optimization was performed successfully. For real time temperature field construction, the sampling rate must be fast enough to capture the field variations. The technology of Code-division multiple access (CDMA) is well studied which could allow parallel multiplexing, even if signals overlap in time or frequencies. Moreover, it has been known that extending the length of signal significantly improves SNR. For acoustic signals, these multiplexing techniques have also been widely used, mainly for sonar and acoustic communications. The CDMA modulation technique has been proposed and studied to guarantee high network throughput, low channel access delay and low energy consumption. We have studied the temperature field reconstruction using Gaussian Radial Basis Functions (GRBF)-based approximation approach. Reconstruction of 3D temperature field using Neural Networks with measured TOF and known propagation paths is feasible. 2D and 3D temperature field reconstruction simulation results are achieved. The milestone status is shown in Table 1. We finished milestone 1-8 and milestone 10. For milestone 9, we did three pilot tests by using the fiber optic sensing system III (Distributed Sensing System II) at GE Power. However, due to the failure of the ns laser, we did not get the temperature results. We conducted some additional tasks that were not originally proposed: 1) We fabricated a fiber optic sensing system I and did a pilot test based on this system. 2) In the proposal, we proposed two pilot tests at GE Power. In reality, we finished at least seven pilot tests at GE Power. GE Power has made a lot of efforts for supporting the pilot tests. 3) We got a simulation results based on CDMA. In summary, most of the tasks have been accomplished. The outcome of this project removed a few barriers that hinder the achievement of the final product of the distributed sensing systems. With the successful accomplishment of this project, a prototype of the fiber optic sensing system can be fabricated to attract more interests from companies and other funding agencies.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Carbon Cycling, Environmental & Rural Economic Impacts of Collecting & Processing Specific Woody Feedstocks in Biofuels

Woody biomass will be an essential feedstock for a large-scale cellulosic biofuel industry. The life cycle carbon accounting for the production of biofuels from woody feedstocks is complex and has engendered significant controversy. Issues such as below ground carbon, carbon debt, varied regional forest practices, multiple parallel forest product lines, and development of realistic counterfactual scenarios all contribute to the complexity. DOE funded CORRIM to develop comprehensive and definitive lifecycle inventories and assessments on the production of fuels from woody feedstocks. CORRIM brought together expertise in forest practices, short rotation woody crops, bioconversion of woody biomass, process modeling, and life cycle assessment to successfully accomplish this goal. The CORRIM team has developed data on forest productivity, fuel usage, and fuel production for six regionally specific forest systems. These six forest systems include three current commercial systems; southern pine plantations, Douglas-fir plantations, naturally regenerated Northeastern (NE) spruce/fir, and three ‘short rotation woody crops’, poplar, eucalyptus and willow, which are at different stages of demonstration in the US. The fuel production systems include cellulosic ethanol and bio-oil based hydrocarbons. The project was successfully reviewed at the BETO Program review in March 2015, 2017, and 2019 and has resulted currently in 19 publications and reports and 35 presentations at both national and international conferences, with more in the pipeline. See publications and presentations for links to each document. Finally, and most importantly, CORRIM has gone beyond the scope of the original DOE proposal to work closely with GREET at Argonne National Laboratory (ANL) to incorporate all the life cycle data and scenario models into their modeling system. GREET is the most widely used and definitive information source for evaluating lifecycle carbon emissions for fuels. The incorporation of CORRIM data from this project guarantees the results of the research will be extensively used and widely disseminated. Technical process improvements and policy relevant accomplishments are detailed in the relevant programmatic sections in the full report including citations therein. Highlights are summarized here for easy reference.

09 BIOMASS FUELS↗
DOE OSTI2020

Energy Efficient Thermoplastic Composite Manufacturing

The objective of the project was to establish an effective and affordable method to lay-up and consolidate/join large thermoplastic composite aerospace structure with cycle times measured in minutes rather than hours. Composite airplane designs have proven efficient and effective however future potential product production rates are challenging what the current systems can efficiently produce due to material lay-down constraints and extended thermal cycle times. The ability to lay-up then rapidly heat, consolidate, and cool large complex composite structures plus very accurately tool them (i.e. matching CTE of composite materials) along with very precise thermal control is a difficult challenge. Current systems such as autoclave processing of thermoset materials require long cycle times due to method of heating and the large associated thermal masses. These extended cycle times inhibit the ability to meet higher rate production scenarios due to the need for multiple sets of equipment and tools. Thermoplastic composite materials were used to facilitate more rapid cycle times via the elimination of a need for a cure dwell at temperature. Also, utilized induction heating along with smart susceptors to enable the quick cycle times needed while providing precise intrinsic thermal control. The intrinsic control of the induction heating process via the smart susceptors along with the use of laser assisted fiber placement were the key innovations areas developed. The ability to rapidly heat and then precisely control the temperature of the consolidation component was paramount to the success of this project. It is this unique processing attribute coupled with the thermoplastic material characteristics along with rapid lay-up methods that are novel and advantageous. While many requirements and influencing factors decide the materials and processes utilized for future airplane construction, the forecast of accelerated production rates and the recent performance successes of composites in airplane construction provide an opportunity for this processing technology to have significant influence. During the course of this project a number of key accomplishments were completed. They are as follows: The needed laser assisted fiber placement capabilities have been developed and validated on a component of meaningful scale and complexity. Subsequently, a thermoplastic preform of the part scale-up part design was laser assisted fiber placed and made availalbe for consolidation. An induction consolidation system was sized, designed, and fabricated resulting in the full capability to consolidate the scale-up component. The tool for induction consolidating of the scale-up component was designed and fabricated. An aluminum pressure bladder was welded and formed for use as the pressurization membrane to perform the needed application of pressure on the part at temperature to achieve consolidation. The induction consolidation system consisting of the restraint, induction power supply, induction tool with integrated induction coils and smart susceptor liners, along with the aluminum bladder were successfully used to consolidate a large thermoplastic skin. The capability of accomplishing rapid heat-up rates and cool down rates for consolidation of large thermoplastic skins with precise thermal control and even pressure application at the consolidation temperature was validated. The general conclusion is that the use of induction consolidation with smart susceptors is an effective method to rapidly and efficiently consolidate large thermoplastic composite components and enable affordable high rate manufacturing of composites. More specific conclusions generated by this project are as follows: A restraint type induction consolidation system provides an affordable option over the standard press when using the induction consolidation processing method. Aluminum bladders can be formed to the complex shapes needed and supply uniform pressure for consolidation and co-consolidation of thermoplastic composite materials. Straightforward modifications can be made to existing fiber placement robotic systems to enable their use for thermoplastic lay-up applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗