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DOE OSTI2022

A review of the fabrication methods and mechanical behavior of continuous thermoplastic polymer fiber–thermoplastic polymer matrix composites

Abstract Thermoplastic polymer fiber–thermoplastic polymer matrix composites (PPCs or PRFPs), often recognized as self‐reinforced or single polymer composites, are potential candidates for future advanced polymer composites because of various advantages ( e.g., recyclability, formability, low‐cost, ultra‐lightweight, environmental friendliness, etc.). The manufacturability and mechanical behavior of these composites compared to conventional carbon‐/glass‐/aramid‐fiber‐reinforced polymers is of great interest to the composites community, but there are a limited number of studies in this area. To this end, this paper reviewed fabrication methods with different processing parameters and mechanical behavior of uni‐/multi‐directional thermoplastic PPCs featuring continuous thermoplastic polymer fibers from limited data in the literature. It was shown that most specific behaviors (normalized by density) of these materials in various loading conditions (e.g., quasi‐static tension/shear/flexure, tension‐tension fatigue, and out‐of‐plane impacting, etc.) are comparable to or better than glass‐/aramid‐fiber‐reinforced polymers. Particularly, the specific ductility in the foregoing conditions outperforms all the carbon‐/glass‐/aramid‐fiber‐reinforced polymers. Thermoplastic PPCs with remarkable performance can be achieved through several uncomplicated methods (e.g., film stacking, hot compaction, powder and solution impregnations, matrix infusion and injection molding, additive manufacturing, etc.), which have some similarities to the methods used for carbon‐/glass‐/aramid‐fiber‐reinforced polymers. Moreover, several opportunities and challenging problems of thermoplastic PPCs were summarized at the end of this review paper. Efficient solutions may require countless efforts in the composites community to further strengthen the performance and understanding of thermoplastic PPCs for wide applications in various engineering fields in the future.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Melt compounding of spray-dried cellulose nanofibrils/polypropylene and their application in 3D printing

Abstract Micro- and nano-scale cellulosic fillers exhibit excellent dispersion and distribution within a thermoplastic matrix during the process of melt compounding or injection molding. In this study, spray-dried cellulose nanofiber (SDCNF) powders were manufactured using a pilot-scale rotating disk atomizer spray dryer. Bleached Kraft pulp (BKP), unbleached Kraft pulp (UKP), and old corrugated cardboard pulp (OCC) fibrillated at a fines level of 90% were used as feedstock materials for spray-drying. BKP-, UKP-, and OCC- SDCNFs were compounded with polypropylene using a twin screw co-rotating extruder. Maleic anhydride grafted polypropylene (MAPP) was used as a coupling agent in the composite formulations. The tensile, flexural, and impact properties of SDCNF-filled PP composites increased at 10 wt% SDCNF loading. The presence of SDCNFs in the PP matrix resulted in faster crystallization and a 12% reduction in the degree of crystallinity of the neat PP. The coefficient of thermal expansion (CTE) of neat PP was reduced by up to 31% attributable to the presence of the SDCNFs. Application of the SDCNF-reinforced PP composites in 3D printing reduced the shrinkage rate of the printed neat PP by 39%, and the printability of the PP was significantly improved with the addition of the SDCNFs.

Materials Science↗

DOE OSTI2021

Impacts of COVID-19 related stay-at-home restrictions on residential electricity use and implications for future grid stability

“Stay-at-home” orders and other health precautions enacted during the COVID-19 pandemic have led to substantial changes in residential electricity usage. Here, we conduct a case study to analyze data from 390 apartments in New York City (NYC) to examine the impacts of two key drivers of residential electricity usage: COVID-19 case-loads and the outdoor temperature. We develop a series of regression models to predict two characteristics of residential electricity usage on weekdays: The average occupied apartment’s consumption (kWh) over a 9am-5pm window and the hourly peak demand (Watt) over a 12pm-5pm window. Via a Monte Carlo simulation, we forecast the two usage characteristics under a possible scenario in which stay-at-home orders in NYC, or a similar metropolitan region, coincide with warm summer weather. Under the scenario, the 9am-5pm residential electricity usage on weekdays is predicted to be 15% – 24% higher than under prior, pre-pandemic conditions. This could lead to substantially higher utility costs for residents. Additionally, we predict that the residential hourly peak demand between 12pm and 5pm on weekdays could be 35% – 53% higher than that under pre-pandemic conditions. We conclude that the projected increase in peak demand - which might arise if stay-at-home guidelines coincided with hot weather conditions - could pose grid management challenges, especially for residential feeders. We also note that, if there is a longer lasting shift towards work and study-from-home, utilities will have to rethink load profile considerations. The applications of our predictive models to managing future smart-grid technology are also highlighted.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Techno-economic and environmental assessment of solar-based electrical vehicles charging stations integrated with hydrogen production

With the growing interest in adopting both commercial and residential electric vehicles (EVs) utilizing green renewable energy, the techno-economic assessment of EV charging stations with solar energy is a critical aspect of the transition to sustainable transportation. However, battery storage capacity for variable solar energy production is becoming increasingly less cost-effective due to the higher Lithium price. Complementing solar energy production and battery storage, the potential of combining green hydrogen fuel energy integration with solar energy for EV charging stations can provide a sustainable alternative to reach carbon-free transportation. This research aims to assess the technical and economic viability of grid-connected Photovoltaic (PV)-based EV charging stations across Kentucky based on existing EV load profiles. The study considers different PV system sizes, locations, orientations, and the impact of net metering policies and electricity tariffs on the profitability of the PV systems. Further, using excess PV energy, Lithium-Ion batteries will be charged, which will be assessed considering the techno-economic and environmental impacts of green EV charging stations. To further enhance green renewable energy production, we also investigated the feasibility of on-grid PV-based EV charging stations with Lithium-Ion batteries charged during low tariff periods. In comparison with these scenarios, we studied the potential benefits of integrating green hydrogen energy production using excess solar energy with and without governmental incentives. Furthermore, we assess the environmental impact of these green EV charging stations across Kentucky. Our study indicates that EV stations across Kentucky have similar techno-economic feasibility with insignificant deviation in the levelized cost of electricity, payback period, and PV energy fraction with/without Li-Ion batteries. However, with green hydrogen production, the marginal H 2 production cost indicates the first scenario (on-grid PV energy charging) is the most significant, roughly 10 USD/Kg, which is similar to 1.5 times higher than the second (charging during low-tariff periods) and the third scenarios (power grid to satisfy the demand deficit - approximately 6.5 USD/Kg). From the environmental perspective, the second scenario would be a good option for either hybrid EV/H 2 or EV charging stations in Kentucky, factoring in the hydrogen production cost and the carbon footprint.

08 HYDROGEN↗

DOE OSTI2023

Creating an Advanced Sensor Network to calculate real-time, mass-weighted flue gas composition and air heater leakage of a coal-fired utility boiler under dynamic operating conditions

Utilization of renewable energy sources to minimize the environmental impact of energy production has changed the way utility boilers operate, requiring frequent load cycling between full load and partial loads as low as 30%. Dynamic operation of coal-fired utility boilers significantly reduces boiler efficiency when compared to steady state at full load. Data-driven plant optimization has shown success with coal-fired utility boilers under dynamic operating conditions. The purpose of this work was to create an Advanced Sensor Network (ASN) to provide more extensive real-time data to inform dynamic plant optimization of Net Unit Heat Rate (NUHR). The ASN consists of gas sampling grids in the convective pass of the boiler and downstream of the air heater. These sampling grids allow for quantification of spatial variation of flue gas within the boiler and calculation of mass-weighted composition of flue gas through the combination of composition, velocity, and temperature measurements. The comparison of O 2 between the inlet and outlet of the air heater is used to calculate air leakage in real time. Flue gas composition and air heater leakage are both important factors in boiler efficiency and NUHR. Further, the results of this work support the value of mass-weighted averages for determining flue gas composition accurately. The measurements from the ASN show increased composition stratification during dynamic operation, with an average standard deviation 38% higher than observed during steady-state operation. Air heater leakage was also observed to increase from 2.8% to 5.1% following a load change. Prior to the installation of the ASN, these data would not have been available for dynamic control. These real-time data will be leveraged to calculate and optimize for NUHR during dynamic operation in future work.

42 ENGINEERING↗

DOE OSTI2021

Effect of Background Electrolyte Composition on the Interfacial Formation of Th(IV) Nanoparticles on the Muscovite (001) Basal Plane

Understanding the impact of actinide nanoparticle (NP) formation is important to assess radionuclide mobility in the environment. We combined surface X-ray diffraction (SXRD) and in situ AFM to investigate the previously reported unusual electrolyte effects on Th uptake on mica. At low [Th] (0.1 mM), interfacial structures show a broad Th electron density (~50 Å). A linear decrease of Th uptake with decreasing hydration enthalpy of the electrolyte cation (Li+, K+, NH4+, and Cs+) indicates a competitive effect between Th and the electrolyte cation. Na+ is a clear outlier from this trend. In situ AFM imaging confirms the results. Particles show a vertical size of ~1–2 nm and larger lateral dimensions of ~10–20 nm, which is typical for particles formed at interfaces (heterogeneous nucleation). At high [Th] = 1 and 3 mM, all investigated electrolytes (ACl, A = Li+, Na+, K+) show similar Th uptake, indicating a much smaller impact of electrolyte composition. The interfacial structures are dominated by a high Th loading at a distinct distance (~6.5 Å) from the surface. Therefore, the main retention mechanism at high [Th] is suggested to be the sorption of Th NPs aggregated from Th oligomers present in solution (homogeneous nucleation).

Neumann, J↗

DOE OSTI2024

Residential Water Heating Demand Side Management (DSM) - South Africa

The electricity crisis in South Africa has deteriorated significantly, with the country experiencing frequent and prolonged rolling blackouts. These outages have severe economic repercussions, leading to decreased growth and productivity. Demand Side Management (DSM), particularly focusing on electric water heaters due to their significant energy consumption and peak demand contribution, is identified as a key strategy. The study aims to assess opportunities for DSM programs targeting water heating to reduce energy consumption and peak demand. It entails developing a bottom-up simulation model to establish a baseline scenario of water heating electricity load demand in 2023 and 2033, identifying technologies for energy reduction, estimating the impacts of a selected number of measures and providing recommendations to inform policy makers.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Investigation of an Intermittent Binary Control Strategy for Distributed Aerodynamic Control Devices for Load Alleviation in Wind Turbine Blades

A study was conducted of an intermittent binary control strategy for trailing edge flaps and leading edge spoilers installed on wind turbine blades for the purpose of load alleviation. Cost estimation models were developed for the systems to predict overall impact on levelized cost of energy over the lifecycle of the turbine system. Aeroelastic simulations of turbines with the control strategy implemented showed improved levelized cost for some, but not all cases.

17 WIND ENERGY↗

DOE OSTI2025

Aeroelastic Modelling of Large Wind Turbines: Towards a Unified OpenFAST-SEAHOWL Approach

In recent years, the scale of wind turbines has significantly increased to maximize energy capture for a given site (particularly offshore), presenting new challenges in terms of structural design and dynamics. As towers grow taller and blades grow longer, flexion and torsion of the latter have a non-negligible impact on the behavior and performance of the turbine in terms of overall loads, power production, and control. When representing large-scale wind turbines numerically to capture these important effects, particular attention must therefore be given to the level of fidelity for representing each structural component, as well as the coupling scheme used between them to keep simulations accurate, stable, and efficient. To address this issue, we combine here the two following tools: (1) OpenFAST, the reference whole-turbine simulation tool from NREL with standalone modules covering each physics and the choice between loose coupling and a new tight coupling scheme for structural dynamics, and (2) SEAHOWL, the whole-turbine simulation tool from TotalEnergies with monolithic coupling of structural dynamics through Project Chrono and partitioned coupling for multiphysics interactions.

17 WIND ENERGY↗

DOE OSTI2026

Pilot Development Progress to Demonstrate Electric Thermal Energy Storage (ETES) Using Low-Cost Particles

The rapid growth of future energy demand increases the need to economically store electrical energy over durations up to several days in long-duration energy storage (LDES) applications. LDES can reduce the grid stress for improving the resilience of the grid. The integration of renewable power and storage has several significant and positive impacts including expanding the renewable energy portion of electricity generation, meeting peak-load demand, and coordinating supply and demand. Several energy storage approaches including mechanical, chemical and electrochemical methods are currently deployed or under development. However, LDES requirements pose unique challenges for scalability, energy capacity, and cost. Thermal energy storage (TES) has the ability to store a large capacity of energy with improved site flexibility compared to incumbent LDES technologies (i.e., pumped hydro) and has attracted significant interest. Our development in TES technology using solid particles as the storage medium has shown feasibility and potential in serving LDES purposes. Particle TES has various advantages over commercialized molten nitrate salt TES and has emerged as a promising storage technology originating from Generation 3 concentrating solar power (CSP) development. Stable, inexpensive silica sand produced in the Midwestern U.S. was identified as a suitable storage medium and has been validated through lab heating and cycling tests. We have successfully developed particle TES for bidirectional electric energy storage to broaden the applications for TES beyond CSP technologies and into standalone electric-thermal energy storage (ETES) systems. Key component designs and performance were verified with prototype testing and model simulations. The ETES system uses high-temperature, low-cost particle thermal energy storage coupled with a unique pressurized fluidized bed heat exchanger that supports a high-efficiency, air-Brayton combined power cycle. At times of low energy demand or high renewable production, an electric particle heater heats large quantities of solid particles to high temperatures in excess of 1100 degrees C. The particles are stored in internally insulated silos. At times of high electricity demand, the hot particles are gravity-fed through the heat exchanger where stored thermal energy is transferred to the power cycle working fluid to drive the gas turbine power generation system, thereby converting the thermal energy back into electricity for the grid. The cold particles leaving the heat exchanger are returned to the storage silos by a well-insulated particle conveyor. This ETES technology using particle TES can be sited anywhere and is predicted to be economic and efficient. Moreover, this ETES technology could be co-located with a retired coal or gas plant to leverage existing power generation and grid infrastructure. Our work has focused on the development of each of the key components (e.g., the electric particle heater, particle storage silos, and the particle-to-gas pressurized fluidized bed heat exchanger) through conceptual designs, prototype testing, and computational modeling. These developments demonstrate technological feasibility and are an important step towards the next phase of development of this promising LDES technology. This presentation will show the progress in developing a pilot demonstration of the ETES system on a commercially relevant scale.

25 ENERGY STORAGE↗

DOE OSTI2023

Recycled Glass Polypropylene Composites from Transportation Manufacturing Waste

In recent years there has been growing interest in developing recycling technologies for composites manufacturing scrap, process waste and end-of-life parts. The focus of this work was to establish processing routes and mechanical property bounds for glass-polypropylene (PP-GF) scrap from the production of parts for truck trailers, automobiles, and rail cars. This study considered PP-GF scrap and demonstrated extrusion-compression molding (ECM) as a viable route for the closed-loop manufacture of composite parts. The results were promising in terms of the strength and modulus retention of the PP-GF recyclate. The tensile strength and modulus was the highest for 50% and 66% recycled content, compared with 100% and 83% recycle content. The flexural strength and modulus of the 100% and 83% recycled compositions was higher than the 66% and 50% recycled content, respectively. The impact energy absorption of the PP-GF recyclate at at all fiber loadings was superior in absorbing energy compared with the incumbent (benchmark) plywood. This work is useful to designers seeking to incorporate recycled materials in their products.

Vaidya, Uday↗

NASA NTRS1983

Parametric tip effects for conformable rotor applications

A research study was initiated to systematically determine the impact of selected blade tip geometric parameters on aeroelasticity conformable rotor performance and loads characteristics. The model articulated rotors included baseline and torsionally soft blades with interchangeable tips. Seven blade tip designs were evaluated on the baseline rotor and three tip designs were tested on the torsionally soft blades. The designs incorporated a systematic variation in three geometric parameters: sweep, taper, and anhedral. The rotors were evaluated in the NASA Langley Transonic Dynamics Tunnel at several advance ratios, lift and propulsive force values, and tip Mach numbers. Based on the test results, tip parameter variations generated significant rotor performance and loads difference for both baseline and torsionally soft blades. Azimuthal variation of elastic twist generated by the tip parameters strongly correlated with rotor performance and loads, but the magnitude of advancing blade elastic twist did not correlate.

Mantay, W. R.↗

NASA NTRS1987

In-situ thermal cycling in SEM of a graphite-aluminum composite

In situ SEM observations of a graphite-aluminum composite (unidirectional P100 graphite-fiber-reinforced 6061 aluminum MMC plates) were used to measure displacements within the graphite fiber relative to the interface between the graphite fiber and the aluminum matrix during thermal cycling. Specimens were thermally cycled from room temperature to 300 C or 500 C in a SEM chamber and then cooled to room temperature. The obtained shear strains within the fiber were then related to anomalous values of measured residual stresses and to the impact on the composite coefficient of expansion and potential damage under thermal fatigue loading. The shear mechanism was proposed as a source of temperature limits on the low coefficient of expansion of these composites, as well as a potential source of thermal fatigue degradation.

Cheong, Y. M.↗

NASA NTRS1990

Fundamental aspects of and failure modes in high-temperature composites

Fundamental aspects of and attendant failure mechanisms for high temperature composites are summarized. These include: (1) in-situ matrix behavior; (2) load transfer; (3) limits on matrix ductility to survive a given number of cyclic loadings; (4) fundamental parameters which govern thermal stresses; (5) vibration stresses; and (6) impact resistance. The resulting guidelines are presented in terms of simple equations which are suitable for the preliminary assessment of the merits of a particular high temperature composite in a specific application.

Chamis, Christos C.↗

NASA NTRS1998

Architectural Optimization of Digital Libraries

This work investigates performance and scaling issues relevant to large scale distributed digital libraries. Presently, performance and scaling studies focus on specific implementations of production or prototype digital libraries. Although useful information is gained to aid these designers and other researchers with insights to performance and scaling issues, the broader issues relevant to very large scale distributed libraries are not addressed. Specifically, no current studies look at the extreme or worst case possibilities in digital library implementations. A survey of digital library research issues is presented. Scaling and performance issues are mentioned frequently in the digital library literature but are generally not the focus of much of the current research. In this thesis a model for a Generic Distributed Digital Library (GDDL) and nine cases of typical user activities are defined. This model is used to facilitate some basic analysis of scaling issues. Specifically, the calculation of Internet traffic generated for different configurations of the study parameters and an estimate of the future bandwidth needed for a large scale distributed digital library implementation. This analysis demonstrates the potential impact a future distributed digital library implementation would have on the Internet traffic load and raises questions concerning the architecture decisions being made for future distributed digital library designs.

Biser, Aileen O.↗

NASA NTRS2006

Shearography NDE of NASA COPV

1. 21 Composite Over-wrapped Pressure Vessels (COPV) consisting of Kevlar Space Shuttle Fleet Leaders and Graphite COPV were inspected at NASA WSTF, NM from Sept. 12 through Sept 16. 2. The inspection technique was Pressurization Shearography, tests designed to image composite material damage, degradation or design flaws leading to stress concentrations in the axial or hoop strain load path. 3. The defect types detected consisted of the following: a) Intentional impact damage with known energy. b) Un-intentional impact damage. c) Manufacturing defects. 4. COPV design features leading to strain concentrations detected include: a) Strain concentrations at bosses due to fiber closure pattern. b) Strain concentrations in body of COPV due to fiber wrap pattern. c) Strain concentrations at equator due to liner weld/fiber lay-up.

Newman, John W.↗

NASA NTRS2016

Applications of Advanced Nondestructive Measurement Techniques to Address Safety of Flight Issues on NASA Spacecraft

Advanced nondestructive measurement techniques are critical for ensuring the reliability and safety of NASA spacecraft. Techniques such as infrared thermography, THz imaging, X-ray computed tomography and backscatter X-ray are used to detect indications of damage in spacecraft components and structures. Additionally, sensor and measurement systems are integrated into spacecraft to provide structural health monitoring to detect damaging events that occur during flight such as debris impacts during launch and assent or from micrometeoroid and orbital debris, or excessive loading due to anomalous flight conditions. A number of examples will be provided of how these nondestructive measurement techniques have been applied to resolve safety critical inspection concerns for the Space Shuttle, International Space Station (ISS), and a variety of launch vehicles and unmanned spacecraft.

Prosser, Bill↗

NASA NTRSDate not supplied

Applications of Advanced Nondestructive Evaluation (NDE) and Structural Health Monitoring (SHM) Techniques to Address Safety of Flight Issues on NASA Spacecraft

Advanced NDE and SHM techniques are critical for ensuring the reliability and safety of NASA launch vehicles and spacecraft. NDE techniques such as infrared thermography, THz imaging, x-ray computed tomography and backscatter x-ray are used to detect indications of damage in spacecraft components and structures. Additionally, sensor and measurement systems are integrated into spacecraft to provide SHM to detect damaging events that occur during flight such as debris impacts during launch and assent or from micrometeoroid and orbital debris, or excessive loading due to anomalous flight conditions. A number of examples will be provided of how these NDE and SHM techniques have been applied to resolve safety critical inspection concerns for the Space Shuttle, International Space Station (ISS), and a variety of launch vehicles and unmanned spacecraft.

Advanced Nondestructive Evaluation (NDE)↗