SEARCH · Engineering Papers

Results for “paints”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 145 records · Page 8

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Lightning Burnthrough to Containment Breach of 55-Gallon TRU Waste Drums

We investigated by arc-plasma heating the feasibility of attributing inherent lightning protection to 55-gallon DOT 7A, Type A, open head carbon steel drums made of 1.5 millimeter painted carbon steel, designed to protect Department of Energy transuranic nuclear waste. The Sandia Lightning Simulator transferred continuing current in 300 ampere (A), 400 A, and 500 A tests to achieve a 350 coulomb charge transfer and simulate cloud-to-ground lightning attachment to test coupons and 9 drums. A tungsten electrode was placed 0.75 inch from the drums. High-speed photography was recorded to observe the exterior containment breach, or "first light," seen on camera when burnthrough opened a hole in the containment. Sheet metal burnthrough occurred between 18 and 71 coulombs in lid and rolling hoop tests, but 12-gauge closure ring tests did not result in burnthrough, which suggests this feature may provide an inherent air terminal protective feature.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Tamper-Indicating Enclosures with Visually Obvious Tamper Response (Final Project Report)

Sandia National Laboratories is developing a new method for detecting penetration of tamper - indicating enclosures (TIEs). This method incorporates the use of "bleeding" materials (analogous to visually obvious, colorful bruised skin that doesn't heal) into the design of TIEs. As designed, it will allow inspectors to use simple visual observation to detect attempts to penetrate the external surfaces of a TIE, without providing adversaries the ability to repair damage. A material of this type can enhance tamper indication of current TIEs used to support treaty verification regimes. Current TIE inspections are time - consuming and rely on subjective visual assessment by an inspector, equipment such as eddy current or camera devices, or involve approaches that may be limited due to application environment. The complexities and requirements that volumetric sealing methods (or TIEs) must address are: (1) enclosures that are non - standard in size/shape; (2) enclosures that may be inspectorate - or facility - owned; (3) finding tamper attempts that are difficult and time consuming for an inspector to locate; (4) enclosures that are reliable and durable enough to survive the conditions that exist in the operating environment (including facility handling); and (5) methods that prevent adversaries from repairing penetrations. Early project R&D [1] focused on encapsulated transition metals. Due to the challenges associated with the transition metal - based approach, a mitigation approach was investigated resulting in two separate research paths — one that involves fabricating custom TIE molds that meet the specific (size and shape) needs of safeguards equipment a nd one that can be deployed as a sprayed on or painted coating to an existing TIE or surface. The "custom mold" approach is based on creating thin layers of materials that , when penetrated, expose an inner material to O 2 which causes an irreversible color change. The "in-situ coating" approach is based on applying a sensor solution containing color changing microcapsules that bleed when the microcapsule is ruptured. The anticipated benefits of this work are passive, flexible, scalable, robust , cost-effective TIEs with visually obvious responses to tamper attempts. This provides more efficient and effective monitoring , as inspectors will require little or no additional equipment and will be able to detect tamper without extensive time - consuming visual examination. Applications include custom TIEs (cabinets , equipment enclosures or seal bodies ), or spray-coating/painting onto facility-owned items, walls or structures, or circuit boards. The paper describes research and testing completed to-date on the method and integration of select system components.

36 MATERIALS SCIENCE↗

DOE OSTI2021

USAMP Low-Cost Mg Sheet Component Development and Demonstration Project

The overarching objective of this USAMP project was to develop and demonstrate door panels made from magnesium (Mg) sheet with a cost penalty over conventional steel stampings of no more than $\$5.50$/kg saved. The technical approach integrated experiments with advanced computational tools based on Integrated Computational Materials Engineering (ICME) methods to develop new alloy chemistries and their thermomechanical processing that promise improved formability and lower forming temperatures. A penultimate task before finally forming the stampings was to incorporate actual microstructure into models that would enable formability simulations. This approach would, for the first time, account for individual magnesium grains moving in an anisotropic fashion unlike that for aluminum or steel that have isotropic properties upon which the current simulation tools are based. In separate activities, new coatings and lubricants to facilitate forming and improved corrosion protection and joining strategies, were developed to ensure that the door could be produced with stated product requirements. A technical cost model, which included parts production, assembly, and paint for a door specifically designed for Mg sheet, showed the cost penalty to be between $\$4.26$ to $\$6.60$/kg saved, which enveloped the project’s cost targets. The cost of the coated Mg sheet was identified as the key driver for the cost penalty. The mass of the Mg-intensive door was 7.9 kg, which was 54% less than the baseline steel door.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Optimized Carbon Fiber Intermediate Development to Enable High-Volume Manufacturing of Lightweight Automotive Composites

The ongoing pursuit of improved fuel economy and reduced greenhouse gas emissions has resulted in sustained interest for lightweight materials technologies. In this context, carbon fiber composites have captured the imagination of automotive engineers due to the potential to achieve substantial mass reduction when compared to traditional steel construction. That stated, the use of carbon fiber composites in automotive has been limited for the most part to premium supercars and other derivative platforms. In these cases, manufacturing costs are less of an obstacle to implementation, and the performance benefits of carbon fiber have enabled production of structures offering more than 50% weight savings. In practice, translating these low-volume demonstrations onto high-volume vehicle platforms has remained challenging. This can be attributed to several factors, with the absence of suitable high throughput production methodologies being a key impediment. To date, structural, crash critical components have relied upon manufacturing techniques born out of the aerospace industry. This has created a disconnect between automotive production systems that are accustomed to manufacturing multiple parts per minute and the aerospace technologies that have cycle times in the order of hours. Consequently, the focus of this project is the development of manufacturing process technology for carbon fiber composites that can support a mainstream vehicle program at an assumed throughput of 100,000 vehicles per year. In practice, this translates to a part-to-part cycle time of less than 3 minutes. Project participation included contributions from a broad range of academic, industrial and national lab partners. The primary scope of work, being the development of new carbon fiber epoxy compounds that are stable at room temperature and suited to high throughput automated processing. For project management, the work streams were divided into six key areas, with the lead organization in parentheses. • Carbon fiber/epoxy materials formulation development and scale up (Dow) • Simulation of discontinuous near isotropic meso-structure intermediates (Purdue) • Simulation of mechanical performance of compression molded components (Purdue) • Meso-Scale morphological analysis and correlation with structural performance (UTK) • Paint and adhesion durability analysis (MSU) • Demonstrator part design, prototype production, and validation testing (Ford). The primary goal at the commencement of the project was development of a chopped carbon fiber sheet molding compound (SMC) that offered a three times improvement in tensile modulus over a comparable glass-based SMC. In addition to meeting mechanical performance targets, the resin kinetics were modified to achieve a processing cycle time of less than 3 minutes. Other critical-to-quality (CTQ) specifications were also stipulated to account for a broad range of materials and processing characteristics. To achieve the above, staff scientists at Dow Chemical created an extensive series of new epoxy blends for testing and validation. Throughout this development, a key challenge was attaining material performance goals without impacting processing behavior and paintability of finished components. The latter required a new internal mold release system being developed by Dow that was designed to complement the kinetics of the rapid cure epoxy. As a complement to work studies at the industrial partners, the teams from academia executed a series of analytical and experimental studies to investigate potential factors influencing CF-SMC performance. Unit cell models were developed to capture the meso-scale representations of the fiber matrix architecture. Results of this analysis and subsequent morphological investigations led to the design of a novel composite derivative comprising carbon fiber platelets embedded in an epoxy matrix; the platelet size and aspect ratio playing significant role in final composite properties. This approach was a departure from previous research in CF-SMC development whereby bulk filamentization or disassembly of the carbon fiber rovings had been considered the most effective means of achieving both fiber wet through and wet-out. As the course of the academia studies progressed, the aspect ratio of the fiber constituents was further optimized before finalizing material attributes and processing conditions. For the purposes of technology validation, the Ford team led a work stream devoted to the design, fabrication and testing of demonstration components. The carbon fiber SMC material has the potential to displace numerous stampings and castings on an automotive structure but ultimately vehicle closure applications were selected to showcase the abilities of the CF-SMC to achieve both mass reduction and business case for large complex structures. Using target properties established by the Dow staff scientists, the complete closure system for a full-size sedan decklid and a mid-size wagon liftgate were engineered. Prototypes for both applications were fabricated using production representative processing methods to allow for physical testing and performance validation of the CF-SMC structures. Following completion of a testing program that concluded with a FMVSS301 55 mph offset rear crash, the CF-SMC formulation was declared by the Ford team to have met all engineering requirements. To summarize, the joint development activities during this project led to significant technical breakthroughs and achievement of all milestones. The result was the development of a novel, tack-free carbon fiber molding compound that is suited to automated processing. This combined room temperature stability, fast cure kinetics, and internal mold release system facilitates cycle times that are conducive to high-volume production. The VORAFUSE M6400 successfully passed technology validation at Ford and is now eligible for consideration on future production commercial vehicle programs.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Photoluminescence in Tagging: A Glowing Review

This literature review explores the options of using photoluminescence for tagging uranium fuel and zirconium cladding in order to easily and quickly associate interdicted material to its facility of origin or pathway after loss of institutional control. Photoluminescence is the spontaneous emission of radiation by a substance when excited by interaction with light. The source of photoluminescence can be from organic, inorganic, and organometallic compounds. Each luminophore, or compound responsible for luminescent properties, has individual strengths and weaknesses, depending on the intended use. Many factors can affect the brightness, lifetime, color, and detectability of luminophores, such as humidity, temperature, oxygen availability, noise from radiation–induced luminescence, and the presence of quenching substances like iron. Application of luminescent compound to the surface of an item can be done using paint, dye, thin film, thick film, or electrochemical coating. Several of the application techniques may have secondary functions such as corrosion resistance and detection, heat resistance, protective properties, and more. When considering cladding, there are various successful studies on the application of luminescent coatings on zirconium. However, significant research will be necessary to explore which luminophore and which application technique would best fit the intended use. In order to proceed with this research, a baseline of the natural luminescence of the intended base material (nuclear fuel or cladding) is necessary. While there may be issues with background noise, quenching from the environment, quenching from the substrate, signal to noise weakness, etc. the multitude of options may make photoluminescent tagging an option. In summary, this review has demonstrated that photoluminescence is a potential option to tag nuclear fuel and cladding, but additional paper–studies, testing, and research is required to understand the compatibility of luminescent tags in nuclear reactor environments, manufacturability, and detectability.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Computational and Experimental Validation of Fractal-Fin, Dimpled Solar Heat Collector

A 3 foot x 3 foot x 3 foot aluminum solar collector was manufactured using computer numerical control. The interior of the device included six triangular dimpled fins for enhanced heat transfer. The interior vertical wall on the south side was also dimpled. The solar collector working fluid was based on water, and the collector consisted solely of passive heat transfer mechanisms (no moving parts), making it ideal for off-the-grid and rural applications. Two types of heat transfer experiments were conducted. One experiment had external flat heaters attached on the top and the front side, while the other four sides were insulated. Except for the bottom surface, the second experiment had all its exterior surfaces sprayed with black solar paint to collect as much solar heat as possible. Temperature data as a function of time was collected using 14 thermocouples spread strategically throughout the solar collector. In addition, computational fluid dynamics (CFD) simulations were conducted using the dynamic Smagorinsky large eddy simulation turbulence model. The first simulation considered that both the top and front surfaces were exposed to a fixed temperature of 313.7 K (105 °F), while the remaining four surfaces were insulated. For the second simulation, all conditions were the same, except that the temperature for both heated surfaces was raised to 350 K (170.3 °F). The two temperatures are expected to bound the solar collector operational temperature during the late- Spring, Summer, and early-Fall months. The solar collector design, experimental data, CFD output, and a discussion of five manufacturing approaches and costs are documented in this report.

14 SOLAR ENERGY↗

DOE OSTI2021

Low-Cost Magnesium Alloy Sheet Component Development and Demonstration Project

The overarching objective of this USAMP project was to develop and demonstrate door panels made from magnesium (Mg) sheet with a cost penalty over conventional steel stampings of no more than $5.50/kg saved. The technical approach integrated experiments with advanced computational tools based on Integrated Computational Materials Engineering (ICME) methods to develop new alloy chemistries and their thermomechanical processing that promise improved formability and lower forming temperatures. A penultimate task before finally forming the stampings was to incorporate actual microstructure into models that would enable formability simulations. This approach would, for the first time, account for individual magnesium grains moving in an anisotropic fashion unlike that for aluminum or steel that have isotropic properties upon which the current simulation tools are based. In separate activities, new coatings and lubricants to facilitate forming and improved corrosion protection and joining strategies, were developed to ensure that the door could be produced with stated product requirements. A technical cost model, which included parts production, assembly, and paint for a door specifically designed for Mg sheet, showed the cost penalty to be between 4.26 USD to 6.60 USD/kg saved, which enveloped the project’s cost targets. The cost of the coated Mg sheet was identified as the key driver for the cost penalty. The mass of the Mg-intensive door was 7.9 kg, which was 54% less than the baseline steel door.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Wastewater Recycling Using a Hygroscopic Cooling System

This project by the Energy & Environmental Research Center (EERC), Baltimore Aircoil Company (BAC), and Great River Energy (GRE) evaluated the concept of recycling wastewater at a coal-fired power plant using a hygroscopic cooling system, which is an evaporative cooling technology analogous to conventional cooling towers, except that sparingly soluble dissolved solids are precipitated and removed as waste solids instead of purging them with a liquid blowdown stream. This technology can maximize the use of plant makeup water by obtaining useful evaporative cooling from wastewater while minimizing the volume of wastes needing disposal. Experimental activities were conducted in two phases, a laboratory-based evaluation of the properties of wastewater from the host site, GRE’s Coal Creek Station near Underwood, North Dakota, and a field test of a small pilot hygroscopic cooling system at the host site power plant. Findings from the laboratory study informed the design of the pilot system and the system’s field test performance served as the basis for a techno-economic analysis (TEA) of the hygroscopic recycling concept. At the preferred operating conditions identified during the TEA, the wet-bulb approach temperature of the tower was 7.3°C (13°F) and the volume of blowdown produced by the plant was reduced to 5.4% of its incoming volume. Waste solids produced during field testing were classified as nonhazardous waste based on the measured hazardous element content and evaluation of their leaching potential. However, to qualify as a solid for landfill disposal i.e., as determined by the U.S. Environmental Protection Agency’s paint filter test, it appears that a dewatering step beyond hydrocyclone separation is needed. The baseline levelized cost of wastewater disposal (LCWD) for hygroscopic wastewater recycling was estimated to be $\$ $3.69–$\$ $3.72 per m3 of plant blowdown. Capital cost was estimated to contribute over 54% to the LCWD, and parameters that impact capital cost such as the heat exchange coil material of construction and the tower’s wet-bulb approach temperature were identified as having the greatest impact on overall LCWD. A LCWD estimate prepared for the same application but using thermomechanical brine evaporation was almost 40% higher than that calculated for hygroscopic cooling, despite recovering distilled-quality water for reuse, while the LCWD for disposal-only, deep well injection was estimated to be 30% lower compared to hygroscopic wastewater recycling.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Design of Transition-Metal/Zeolite Catalysts for Direct Conversion of Coal-derived CO 2 to Aromatics

This project introduces a lab-scale, stand-alone process to produce aromatics from CO 2 . Besides reducing the amount of coal-derived CO 2 emission, this process can provide new approaches to produce valuable chemicals such as benzene, toluene, and xylene (BTX). These chemicals are the starting material in various industries such as pharmaceuticals, polymers, paints, and coatings. The focus of the project is on developing a suitable reaction configuration, feed composition, and catalyst combination that leads to high aromatics selectivity and CO 2 conversions. To achieve these objectives, computational catalysis will accompany hands-on experiments to provide insights to potential transition metals or alloys that may serve as optimal active sites for different steps of the reaction mechanism, such as reduction of CO 2 and dehydration (in the case of alcohol intermediates) and oligomerization (in the case of paraffins or olefins) of intermediate hydrocarbons.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

SRPPF Aqueous Recovery System Sorbent Testing

This study details preliminary testing of 7 inorganic sorbents for the solidification of the surrogate SRPPF aqueous recovery system liquid excess material of 4M sodium nitrate. Sorbents were subject to various mixing methods to incorporate sodium nitrate solution including static, rotating, and in situ paddle mixing. Paddle mixing was found to be the most effective mixing technique, while simple static tests were also successful, though only for some of the sorbents. Setting tests were performed to ensure that the sorbent sequestered the liquid without release through a conical paint filter. Recommended set times ranged from near immediate to 7 days. The set mixtures were investigated further using ultra-centrifugal liquid release testing, thermogravimetric analysis, and visual microscopy to understand the mechanism by which the sorbent sequestered the liquid. Most sorbents seem to incorporate liquid by sorbing it onto and into the sorbent particles, while Drierite ® , anhydrous calcium sulfate, created a crystal structure that bound the surrogate liquid. Overall, four sorbents are recommended for continued testing: Aquaset II, Aquaset IIG, Drierite ® , and Spill-X-A.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Enhancing Lifetime and Reducing Costs for Fish Diversion Netting Structures (Abstract)

This effort will focus on technology transfer and commercialization of antifouling coatings with an enthusiastic and engaged industrial team. Environmental requirements and operational demands call for a nontoxic coating/paint to prevent fouling on fish passage guidance netting at hydropower facilities. For example, one netting customer estimated the capital cost for compliance at $\$12$ million to $\$15$ million. This project will build partnerships between PNNL and private companies to optimize, demonstrate, mature, and commercialize a novel PNNL-developed technology that addresses this critical coating need of the hydropower industry. This effort will support modification of existing coatings for application to flexible netting structures. Industrial partners include commercial coating development specialist (Lorama), hydrophobic material manufacturer and paint developer (Dry Surface Technologies), aquatic applications specialists (Prometheus Innovations and River Connectivity Systems), and hydropower netting producer (Pacific Netting Products). Engagement with the U.S. Army Corps of Engineers (USACE) and Bureau of Reclamation (BOR), two hydropower operators, throughout the project will provide expertise and field test sites that will provide crucial proof of real-world performance data (additional details provided in Teaming section). Taylor Shellfish Farms will provide organisms and fouling expertise as well as a perspective of potential broader impacts for the blue economy. Sample netting will demonstrate performance in a range of environments for key hydropower applications. PNNL will work with industrial partners to overcome commercialization barriers as well as resolving any manufacturing or regulatory issues. This Phase 1 effort is focused on technology optimization for application to fish passage guidance netting and technology validation as verified by independent testing (through USACE, BOR, Taylor Shellfish and Prometheus Innovations). Through this effort, SLIC will be demonstrated for netting applications at technology readiness level (TRL) 5. The field test data will allow optimization of SLIC formulation and performance which is key to enabling technology transfer of a mature proven technology to industry and production of a viable commercial product specifically focused for hydropower needs.

13 HYDRO ENERGY↗

DOE OSTI2022

Design of Transition-Metal/Zeolite Catalysts for Direct Conversion of Coal-derived CO 2 to Aromatics

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2023

Perspectives on the status of fusion energy research and near term directions [Slides]

Over the past few years, nearly five billion dollars of private investments from private industry sparked excitement for accelerating the development of fusion energy technologies. Driving these investments are various technical advances in research such as those at facilities such as JET, EAST, NIF, etc. At the same time, the Office of the President, in the spring of 2022, announced a commitment to fusion energy development as part of its strategy to combat climate change. With the goal of a pilot power plant by the 2040s, the research strategy shifted to public private partnerships as a means for the government to support the lofty goal of shorten the deployment time of fusion energy technologies. The rapid change in strategy created a quickly changing research landscape with many potential opportunities. In this presentation, I will attempt to paint a picture of the current state of fusion energy, highlight major challenges, and provide insights into some near-term opportunities for LANL.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Hidden in Plain Sight: How Interior Furnishings Management Can Help Los Alamos National Laboratory Meet the United States Department of Energy's Sustainability Goals [Capstone Project]

In the last three years, LANL has purchased over $50 million in new interior products with a focus on sustainable building and high-quality interior furnishings, carpet, and paint. Purchasing interior products that focus on sustainable manufacturing, however, is only the beginning of properly operating and maintaining an interior space over its useable life. Sustainable commercial furniture, if well maintained and warrantied, can last well beyond the accounting depreciation of the asset, ultimately saving taxpayer dollars. Given DOE’s recently announced built environment sustainability goals, now is the time to look at interior products as an important part of the overall sustainability plan for LANL’s green building initiatives. The scope of this thesis provides an environmentally sustainable O&M process for the procurement, use, and proper decommissioning of interior products. The thesis also provides environmental and financial data to assist with LANL’s overall DOE Matrix milestones, currently due in 2030.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Laser Driven Hydrothermal Processing (LDHP) for Rapid Dissolution of Glassy Nuclear Debris

Discovered in 2009 on the SLAB laser system at LLNL, Laser-Driven Hydrothermal Processing (LDHP) both spalls and transiently dissolves a wetted surface (e.g., rock, concrete, paint) when that surface is struck by a laser beam pulse under specific conditions. Previous projects have explored the application of LDHP to expediting sample dissolution for post-detonation nuclear forensics. Early results were very promising, indicating that this method could decrease material dissolution time by a factor of 10 or more. However, the large and complicated lasers previously used are impractical for this application. Under the R^3 venture we aimed to benchmark the LDHP capabilities of turn-key commercial off-the-shelf (COTS) lasers, and to establish how this process could be integrated into an analytical workflow for nuclear forensic analysis. We demonstrated that geological rock standards could be quickly processed into fine powder by LDHP followed by complete acid digestion in 15 minutes, without elemental fractionation that would skew analytical results. We determined that the COTS laser can be used for LDHP that could potentially reduce dissolution time for solid nuclear debris samples in post detonation nuclear forensics. One downside to this approach, however, is that the laser interactions are different with every material, so extensive method validation would be required for all likely material compositions. The LDHP processing rates of several materials were tested and determined to be favorable in the beginning with significant slowdown due to particulate scattering. This could be mitigated either by stopping and centrifuging the sample at specific intervals, or through design of a continuous solvent flow through mechanism.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Degradation and Upcycling of Poly(acrylic) Acid (PAA)

Poly(acrylic acid) (PAA) is a superabsorbent polymer (SAP) widely used in food, paint, textiles, and household products, such as absorbent hygiene products. Specifically, disposable diaper waste comprises a large majority of hygiene waste, in which 80% is landfilled and 20% is incinerated. This proposal describes new methods to valorize PAA to mitigate pollution and risk of large-scale release, dispersion, and accumulation of PAA into aquatic and terrestrial environments. The first strategy builds upon photoredox catalysis to oxidize PAA, which will allow for subsequent cleavage to PAA into valuable chemical feedstocks with intriguing functional groups that can readily undergo further transformations. Moreover, in conjunction with RAFT polymerization, photoredox catalysis would also lead to preparation of new graft block polymers to serve as pH-sensitive drug delivery vehicles. The second strategy invokes electrocatalysis, which can access different intermediates compared to photoredox catalysis. This method would lead to refunctionalization and repurpose of PAA into hydrogels and zwitterionic polymers that can find utilities in ion exchange, water treatment, soil conditioning, paper reinforcement, pigment retention, shampoo formulation, and drug delivery.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Testing a Hazmatpac Can with Locking Ring as a Secondary Shipping Container for Radium-224/Lead-212 Generators

A Hazmatpac can, paint can style shipping container with locking ring, was tested for use as an alternative shipping configuration for shipment of radium- 224 /lead- 212 generators. 224 Ra ( t 1/2 = 3.63 d) decays by alpha emission to radon-220 ( t 1/2 = 55.6 s). The potential for the radioactive radon gas to escape the generator column and the shipping container is of particular concern for the safe delivery of 224 Ra/ 212 Pb generators to customers. The purpose of this study was to evaluate whether the Hazmatpac can is a suitable shipping configuration, capable of containing the radon gas that may escape the generator column during transit. A 17.3 mCi 224 Ra/ 212 Pb generator was built and packaged into a Hazmatpac can. The can was smeared by a Radiological Control Technician (RCT) every day for seven days to analyze for radioactive contamination on the outside of the can. Over the course of the study, no radioactive contamination was found on the outside of the can. Therefore, the Hazmatpac can was approved as an alternative shipping configuration for shipment of 224 Ra/ 212 Pb generators.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Next Generation Co-Molded One-Piece Automotive Parts

The purpose of this project was to determine the feasibility of co-molding Class A Sheet Molding Compound (SMC), structural SMC, and continuous fiber prepreg materials to produce a single piece co-molded automotive part, such as a hood. The combination of the three molding materials and the incorporation of selective design features (ribs, flanges, corrugations) was expected to eliminate the need for inner reinforcement panels, significantly reducing tooling costs and simplifying the manufacturing process. A multi-material solution would also result in significant weight savings. The scope of this project included the material characterization of the three materials, development of cure and flow simulation models, and validation of the models against parts molded with different combinations of the materials on an 11”x11” plaque tool with rib features. The intent of this project was to apply the learnings obtained from co-molding a part with simplified geometry to a Phase 2 project that would produce a single piece hood, co-molded with the same materials. Resins from INEOS Composites were provided to IDI to produce SMC and continuous fiber prepregs. Purdue University and INEOS Composites characterized the rheological and curing behavior of the different materials as well as the mechanical properties of the co-molded parts. This data was used by Purdue University to create simulation models. Models were created to predict both flow patterns and predict mechanical properties of different laminate constructions in and around the ribs. Michigan State University - Corktown validated Purdue’s models by co-molding the three materials in different combinations on a tool containing rib features provided by Century Tool. The co-molded parts were evaluated against the simulation models by Purdue, Corktown and INEOS. The project team demonstrated the following: • The ability to obtain a cohesive co-molded structure made up of Class A SMC, Structural SMC, and continuous fiber prepreg. • The ability to obtain a co-molded part with a Class A surface • Modeling of flow and fiber orientation • Modeling to predict mechanical properties of multi-material co-molded structures The predicted flow behavior and fiber orientation from simulations were then compared with the molded samples. Exact local orientation state was difficult to compare between microscopy and flow simulation, but captured general trends. Multi-material flow behavior was generally modeled well with SMC materials, but the introduction of woven material sheets requires further model development. Purdue compared the predicted versus actual mechanical properties, and INEOS Composites evaluated the surface appearance of unpainted and painted co-molded parts. The models developed by Purdue demonstrated that the mechanical properties can be predicted for parts with varying material configurations. The resulting models can be applied to future co-molded part design, tooling design, and molding conditions.

36 MATERIALS SCIENCE↗