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At least 1,603 records · Page 89
All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - FY 2014 Fourth Quarterly Report

During the last quarter of FY 2014, the following technical progress has been made toward project milestones: 1) Autodesk, Inc. (Autodesk) has implemented a new fiber length distribution (FLD) model based on an unbreakable length assumption with Reduced Order Modeling (ROM) by the Proper Orthogonal Decomposition (POD) approach in the mid-plane, dual-domain and 3D solvers. 2) Autodesk improved the ASMI 3D solver for fiber orientation prediction using the anisotropic rotary diffusion (ARD) – reduced strain closure (RSC) model. 3) Autodesk received consultant services from Prof. C.L. Tucker at the University of Illinois on numerical simulation of fiber orientation and fiber length. 4) PlastiComp, Inc. (PlastiComp) suggested to Purdue University a procedure for fiber separation using an inert-gas atmosphere in the burn-off furnace. 5) Purdue University (Purdue) hosted a face-to-face project review meeting at Purdue University on August 6-7, 2014. 6) Purdue conducted fiber orientation measurements for 3 PlastiComp plaques: fast-fill 30wt% LCF/PP edged-gated, slow-fill 50wt% LCF/PP edge-gated, and slow-fill 50wt% LCF/PP center-gated plaques, and delivered the orientation data for these plaques at the selected locations (named A, B, and C) to PNNL. 7) PNNL conducted ASMI mid-plane analyses for the above PlastiComp plaques and compared the predicted fiber orientations with the measured data provided by Purdue at Locations A, B, and C on these plaques. 8) PNNL planned the project review meeting (August 6-7, 2014) with Purdue. 9) PNNL performed ASMI analyses for the Toyota complex parts with and without ribs, having different wall thicknesses, and using the PlastiComp 50wt% LCF/PP, 50wt% LCF/PA66, 30wt% LCF/PP, and 30wt% LCF/PA66 materials to provide guidance for tool design and modifications needed for molding these parts. 10) Magna Exteriors and Interiors Corp. (Magna) molded plaques from the 50% LCF/PP and 50% LCF/PA66 materials received from Plasticomp in order to extract machine purgings (purge materials) from Magna’s 200-Ton Injection Molding machine targeted to mold the complex part. 11) Toyota and Magna discussed with PNNL tool modification for molding the complex part.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Development of a MODIS-Derived Surface Albedo Data Set: An Improved Model Input for Processing the NSRDB

A significant source of bias in the transposition of global horizontal irradiance to plane-of-array (POA) irradiance arises from inaccurate estimations of surface albedo. The current physics-based model used to produce the National Solar Radiation Database (NSRDB) relies on model estimations of surface albedo from a reanalysis climatalogy produced at relatively coarse spatial resolution compared to that of the NSRDB. As an input to spectral decomposition and transposition models, more accurate surface albedo data from remotely sensed imagery at finer spatial resolutions would improve accuracy in the final product. The National Renewable Energy Laboratory (NREL) developed an improved white-sky (bi-hemispherical reflectance) broadband (0.3-5.0 ..mu..m) surface albedo data set for processing the NSRDB from two existing data sets: a gap-filled albedo product and a daily snow cover product. The Moderate Resolution Imaging Spectroradiometer (MODIS) sensors onboard the Terra and Aqua satellites have provided high-quality measurements of surface albedo at 30 arc-second spatial resolution and 8-day temporal resolution since 2001. The high spatial and temporal resolutions and the temporal coverage of the MODIS sensor will allow for improved modeling of POA irradiance in the NSRDB. However, cloud and snow cover interfere with MODIS observations of ground surface albedo, and thus they require post-processing. The MODIS production team applied a gap-filling methodology to interpolate observations obscured by clouds or ephemeral snow. This approach filled pixels with ephemeral snow cover because the 8-day temporal resolution is too coarse to accurately capture the variability of snow cover and its impact on albedo estimates. However, for this project, accurate representation of daily snow cover change is important in producing the NSRDB. Therefore, NREL also used the Integrated Multisensor Snow and Ice Mapping System data set, which provides daily snow cover observations of the Northern Hemisphere for the temporal extent of the NSRDB (1998-2015). We provide a review of validation studies conducted on these two products and describe the methodology developed by NREL to remap the data products to the NSRDB grid and integrate them into a seamless daily data set.

14 SOLAR ENERGY↗
DOE OSTI2017

Interim Report on Mixing During the Casting of LEU-10Mo Plates in the Triple Plate Molds

LEU-10%Mo castings are commonly produced by down blending unalloyed HEU with a DU-12.7%Mo master-alloy. This work uses process modeling to provide insight into the mixing of the unalloyed uranium and U-Mo master alloy during melting and mold filling of a triple plate casting. Two different sets of situations are considered: (1) mixing during mold filling from a compositionally stratified crucible and (2) convective mixing of a compositionally stratified crucible during mold heating. The mold filling simulations are performed on the original Y-12 triple plate mold and the horizontal triple plate mold.

36 MATERIALS SCIENCE↗
DOE OSTI2017

LDRD Final Report: Advanced Hohlraum Concepts

Indirect drive inertial confinement fusion (ICF) experiments to date have mostly used cylindrical, laser-heated, gas-filled hohlraums to produce the radiation drive needed to symmetrically implode DT-filled fusion capsules. These hohlraums have generally been unable to produce a symmetric radiation drive through the end of the desired drive pulse, and are plagued with complications due to laser-plasma interactions (LPI) that have made it difficult to predict their performance. In this project we developed several alternate hohlraum concepts. These new hohlraums utilize different hohlraum geometries, radiation shields, and foam materials in an attempt to improve performance relative to cylindrical hohlraums. Each alternate design was optimized using radiation hydrodynamic (RH) design codes to implode a reference DT capsule with a high-density carbon (HDC) ablator. The laser power and energy required to produce the desired time-dependent radiation drive, and the resulting time-dependent radiation symmetry for each new concept were compared to the results for a reference cylindrical hohlraum. Since several of the new designs needed extra laser entrance holes (LEHs), techniques to keep small LEHs open longer, including high-Z foam liners and low-Z wires at the LEH axis, were investigated numerically. Supporting experiments and target fabrication efforts were also done as part of this project. On the Janus laser facility plastic tubes open at one end (halfraums) and filled with SiO 2 or Ta 2 O 5 foam were heated with a single 2w laser. Laser propagation and backscatter were measured. Generally the measured propagation was slower than calculated, and the measured laser backscatter was less than calculated. A comparable, scaled up experiment was designed for the NIF facility and four targets were built. Since low density gold foam was identified as a desirable material for lining the LEH and the hohlraum wall, a technique was developed to produce 550 mg/cc gold foam, and a sample of this material was successfully manufactured.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2017

Initial Computational Study of a New Multi-Hole Hohlraum (the "Midraum")

Existing cylindrical hohlraums with two oppositely positioned laser entrance holes (LEHs) have multiple constraints. Their goal is to produce radiation sources distributed over the sky, as visible from the spherical implosion capsule, with most of the deposition near the zeroes of the fourth Legendre polynomial in cosine of the polar angle. This requires some of the laser light to propagate across the hohlraum to positions near the hohlraum symmetry plane. The ratio of case spherical radius to capsule spherical radius should exceed 3 so that the light doesn’t pass through over-dense ablator plasma. Radiation transport can smooth higher radiation modes. For capsules that demand long pulse lengths, hohlraum walls can blow in and change the position where light is absorbed. This changes the radiation symmetry in a time dependent fashion. This affects both P2 and P4. This wall motion can be reduced by introducing fill gas into the hohlraum. The gas provides back pressure and tamps the wall motion. Adding the fill gas comes at some cost. It leads to increased absorption of laser light along the path. The fill gas adds heat capacity to the system, ultimately requiring more laser energy to meet the radiation flux goals, both in total and particularly in the amount of radiation coming from the vicinity of the capsule waist. Given the existing beam pointing at NIF energy from the outer beams must be transferred into the inner beams. Cross beam energy transport (CBET) is accomplished via a plasma instability. This transfer is not perfectly predictable. In addition, the higher intensity required to make up for the losses along the long path can lead to stimulated backscatter as well as the generation of suprathermal electrons. The inner beams will pass through the plasma ablated from the capsule toward the end of the pulse. Heating this plasma acts as another parasitic loss. In addition, the light passing through the turbulent blow-off can be refracted in unpredictable directions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

Multiscale Modeling of CO 2 Migration and Trapping in Fractured Reservoirs with Validation by Model Comparison and Real-Site Applications (Final Technical Report)

This report documents the accomplishments achieved during the project titled “Multiscale Modeling of CO 2 Migration and Trapping in Fractured Reservoirs with Validation by Model Comparison and Real-Site Applications” funded by the US Department of Energy, Office of Fossil Energy. The objectives of the project were to develop modeling capabilities for predicting CO 2 and brine migration in fractured reservoirs during geologic carbon storage and to investigate the feasibility of carbon storage in fractured reservoirs using the newly developed modeling capabilities. To achieve these objectives new mass transfer functions were developed to adapt existing dual-continuum approaches – a commonly used approach in hydrocarbon reservoir modeling – to the CO 2 -brine system. In the dual-continuum approach the undisturbed rock matrix and the fractures are modeled as two separate continua, which are coupled through mass exchange of CO 2 and brine between the two continua. Mass transfer functions represent the mass exchange between fractures and the rock matrix, without requiring highly resolved numerical grids of individual fractures, thus allowing large modeling domains relevant to geologic carbon storage questions (tens of meters to hundreds of kilometers). Mass transfer functions for the exchange of both free-phase CO 2 and brine between fractures and rock matrix were developed for both the injection phase and the post-injection phase. During the injection phase the fractures are filled with CO 2 , while the rock matrix is initially filled with brine. Therefore, a mass transfer function was developed that is based on vertical displacement of brine by CO 2 in the rock matrix due to gravitational forces. Once CO 2 injection ceases and CO 2 migrates away from the direct vicinity of the injection site, the fractures will begin to re-fill with brine, while the rock matrix will have high CO 2 saturations. For these conditions a mass transfer functions was developed that is based on spontaneous imbibition, as the pore spaces in the rock matrix are much smaller than in the fractures. For formations with low permeability or high capillary entry pressure of the rock matrix, free-phase CO 2 may not be able to enter the rock matrix. However, free-phase CO 2 at the interface between fractures and rock matrix can dissolve into brine resident in the rock matrix. Therefore, additional mass transfer functions were developed based on aqueous-phase diffusion of CO 2 through the rock matrix. These mass transfer functions are based on existing solutions for diffusion and were expanded to be applicable to a variety of block shapes relevant to dual-continuum modeling. Implementations of the newly developed mass transfer functions showed that they give accurate results when compared to highly resolved models. In addition to developing new transfer functions, a new vertically-integrated dual-continuum modeling framework was developed. This development takes advantage of fast vertical segregation of CO 2 and brine in the fractures due to the density difference between CO 2 and brine and the high permeability of the fractures. Therefore, a vertically-integrated vertical equilibrium model for the fractures is coupled with a vertically-distributed model for the rock matrix. The newly developed approach significantly reduces the computational effort, but is only accurate for fracture permeabilities of 100 mD or higher. Finally, the newly developed models were applied to real and hypothetical geologic carbon storage sites to investigate the feasibility of using fractured reservoirs for carbon storage. The general results were, that storage of CO 2 – both as free-phase and dissolved – is feasible, but that storage capacities are likely lower than in unfractured systems. While the high permeability of the fractures reduces the injection pressure (or permits higher injection rates), fast migration of CO 2 may limit the overall storage volume, because CO 2 may escape laterally with not enough of the rock matrix being swept for effective storage.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2019

Preliminary Analysis of Species Partitioning in the DWPF Melter - Sludge Batch 7b

The goal of the work described in this report is to provide additional off-gas carryover data from the Defense Waste Processing Facility (DWPF) melter to support the estimation of off-gas carryover rates from the Low Activity Waste (LAW) melter at the Hanford Site. Of particular interest is to determine the volatility of technetium-99 (Tc-99), which is a key isotope of concern for disposal and is a significant challenge to retain in glass in the Hanford waste treatment flowsheet. Since the DWPF melter is not equipped with routine offgas monitoring and/or sampling capabilities, the off-gas carryover data had to be extracted using component mass balance of the measured feed and pour stream (PS) glass compositions under time-averaged melter operating conditions over the duration of one canister-filling cycle, typically 20-25 hours. The method was first tested using the Sludge Batch 6 (SB6) PS sample data taken while Canister #3472 was being filled on 12/20/2010, approximately three months after the (argon) glass bubblers were installed. The method was tested again using the SB7a PS sample data taken while Canister #3619 was being filled on 8/5/2011 with the glass bubblers in operation.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Modeling Hydrodynamic Instabilities and Mix in National Ignition Facility Hohlraums

Radiation hydrodynamics modeling of hohlraum experiments on the National Ignition Facility has shown a chronic overprediction of hohlraum performance compared to experiment. Depending on the particular experiment, up to several hundred kilojoules of laser energy must be artificially subtracted from the simulations in order to match experimentally measured quantities like the time of peak neutron production (bang time). Fine-scale hydrodynamic mixing of the high-Z hohlraum wall with the low-Z hohlraum gas, an effect omitted in current hohlraum simulations, has long been hypothesized as possible source of some of this degradation. A preliminary computational assessment using a spherical hohlraum model has been made. It shows that the wall-gas interface is both unstable during certain phases of the experiment and has the potential for turbulent mixing of the gas and wall material, depending on the hohlraum gas fill and pulse shape. The same simulations also indicate that mixing at this interface can delay the simulated bang time by up to 140 ps with high gas fills but appears negligible for low gas fills.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

Microphysics Studies of Hohlraum Dynamics (LDRD 17-ERD-060 Final Report)

The goal of this project was demonstrate the feasibility and utility of modeling the effects of kinetic physics in gas-filled hohlraums using high-fidelity simulation tools. We have successfully achieved this goal. In our work, we have found that hybrid particle-in-cell simulations (Thoma et al. 2017, Higginson et al. 2019a) utilizing quasi-neutral, fluid electrons and kinetic ions are powerful tools to understand the kinetic physics of interpenetration and mix relevant to low-gas-fill (near-vacuum) hohlraums. We have benchmarked the code, Chicago, against OMEGA laser experiments designed to mimic conditions found in hohlraums; the code was able to reproduce data from x-ray imaging and Thomson Spectra resolved over both time and space. The experiments highlighted kinetic-ion effects such increased penetration depth that were only able to be resolved with a kinetic model. We have run preliminary simulations with Chicago of full-scale hohlraum experiments that include laser raytracing, equation-of-state and ionization, radiation transport, and accurate experimental geometries. Continuation of this work will predictive hohlraum models at low-gas-fill and identify the better regimes of hohlraum design with the potential for improved coupling and capsule symmetry.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Thermal Instability in the Manufacturing of Wind Turbine Blade Spar Caps – Phase 2

As the wind turbine industry continues to develop, the technology surrounding the design, development, and manufacturing of blades requires advancement as well. Wind turbine blades continue to increase in size, increasing the cost and time associated with manufacturing. Simulation driven manufacturing cycle design is required for the industry to maintain manufacturing schedules and optimize the manufacturing process. A recent effort to reduce the cycle time of wind blade spar caps encountered a recurring manufacturing defect during the exotherm and curing of the resin system after filling in the vacuum-assisted resin transfer molding (VARTM) process. Thermal waves developed in sections of the spar cap resulting in unacceptable part tolerances, requiring the parts to be thrown out. The first phase of this IACMI project focused on characterizing the fabric and epoxy system used in manufacturing and simulating the manufacturing process to determine the root cause of the thermal waves. The second phase of this project refined and validated the manufacturing simulations. The simulation workflow was then used to analyze multiple cure cycle options to determine if the thermal waves would appear. The estimated filling time from the filling simulation was shown to match well to experiment, and the temperature history from the curing simulation lined up well with experiment. This indicates that these simulations could be used to evaluate future curing cycles to be used with manufacturing. It is recommended that the distortion simulation work be completed for this project, as it would allow for further manufacturing cycle evaluation through the prediction of stresses and strains in the part. This could provide indicators of defects like the thermal waves seen in manufacturing earlier.

17 WIND ENERGY↗
DOE OSTI2022

HFTS-2 (Final Report)

This report delves into the research program, identified tasks, various studies, observations, results, and conclusions under the Hydraulic Fracturing Test Site (HFTS-2) project. This test site is located in Loving County close to the Texas, New Mexico border. The program targeted the Wolfcamp formation in Delaware Basin. The aim of the project was to improve our understanding of hydraulic fracturing processes to not only optimize unconventional resource development in US Basins but to minimize environmental footprint as well. Various new diagnostic technologies were demonstrated at this site, including distributed acoustic microseismic, high resolution strain using Rayleigh frequency band (DSS-RFS), and in-fill proppant logging tool. Significant conclusions from this study include: 1) lateral and vertical fracture growth mapping as well as proppant transport behavior, 2) Use of DSS-RFS as a diagnostic tool to understand cluster level behavior, 3) Validation of proppant log, both at core scale as well as in-fill well implementation, and 4) New modeling tools to map far-field strain response using distributed strain sensing data. Specifically, far-field fracture distribution is influenced by linear fracture corridors defined by the stress-state as well as clustering behavior influenced by spatio-temporal effects. Depletion impacts on new stimulation was demonstrated and technically quantified. Significant vertical fracture height growth was observed. However, our understanding is limited by available gauge data availability. Numerical strain modeling techniques have been developed and demonstrated to help understand observed strain response behavior. Finally, proppant log has been further validated as a useful tool to map propped zones within the SRV. It has also shown very strong correlation with observed drawdown behavior at this test site. This report will detail many of these studies as well as technical results and conclusions from said studies. These include general subsurface characterization work, completion designs as implemented, studies looking at fracture geometry, high resolution microseismic study including source mechanisms, advanced DSS-RFS studies including drainage characterization, core characterization results, proppant analysis (core and in-fill child well), geochemistry, etc.

02 PETROLEUM↗
DOE OSTI2023

Scoping Thermal Response Calculations of RNS Waste During Transport to and Disposal at the WIPP

Sandia National Laboratories (SNL) was contracted by the United States Department of Energy Environmental Management (DOE-EM), Los Alamos Field Office to perform mechanical and thermal scoping calculations as part of a study seeking to understand the ignitability risk of the Remediated Nitrate Salts (RNS) waste drums during transportation from the Waste Control Specialists (WCS) facility to Waste Isolation Pilot Plant (WIPP) and permanent disposal of the waste at WIPP. The scoping thermal simulations described in this report pertain to thermal calculations performed with a packaging system consisting of one Standard Waste Box (SWB) loaded with drums placed inside a Standard Large Box 2 (SLB2). During transportation, the SLB2 is inside Transuranic Package Transporter Model III (TRUPACT-III), which provides the third layer of the packaging. Once at the WIPP, it is assumed the SLB2 is extracted from the TRUPACT-III and maintained above ground, and then subsequently placed underground for permanent disposal. In these proposed configurations, the space between the SLB2 and the SWB is always filled by a layer of insulation consisting of air-filled glass microbubbles except for the bottom which rests directly on the SLB2. The thermal scoping calculations described in this report specifically address whether the introduction of external heat inputs, combined with the contributions from the internally generated radiolytic decay heat and chemical reactions, lead to an unstable thermal state during the time of its movement and placement in the permanent disposal location. The external heat inputs are of two forms: 1) ambient thermal irradiation (e.g., solar and ambient storage/disposal temperatures) and 2) accident-induced fire. Three scoping calculation scenarios were derived as representative, conservative scenarios: 1A) TRUPACT-III transient transportation, 1B) SLB2 48-hour outdoor storage with solar radiation, and 2) fully-engulfing fire during SLB2 handling or emplacement following a steady-state analysis in a 38 °C environment. All the simulated scenarios are conservative relative to the operational conditions expected for handling the waste package during transportation and placement in the WIPP underground disposal unit. The predictions obtained from simulating the three exposure scenarios revealed that adding the SLB2 and the air-filled glass microbubbles to the transport and storage/disposal configurations provides additional thermal protection of the drums beyond what the SWB provides alone, both during long-term above ground insolation and underground during a fire accident. Under the current transportation/storage/disposal concepts, the degree of protection provided by the packaging concept is sufficient to prevent the waste from being ignitable. The simulation results demonstrate that there is adequate margin to safely transport and place the RNS waste from WCS to the WIPP under the current operational concept.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Effects of Structure and Filler on Mechanical Properties of Direct Ink Write Pads

Direct ink write (DIW) is an extrusion-based additive manufacturing (AM) technique that enables superior repeatability, property tuning, and material customization compared to conventional manufacturing techniques. In this research, DIW is used to print silicone foams that must accommodate the thermal expansion of other parts. This expansion requires the material to compress and subsequently recover. Thus, a key performance metric is reducing “compression set” or deformation retained after the material is compressed. For this study, a silicone resin was compounded with a getter material, 1,4 bis(phenylethynyl)benzene (DEB) mixed with carbon-supported palladium (Pd) and printed in a variety of lattice structures. The effects of the filler and print structure on compression set were evaluated. In these experiments, 0.5-inch diameter coupons were compressed to 75% their original height for 22 hours at 70 °C, and the change in height calculated at intervals between 30 minutes and 24 hours post-decompression. The unfilled pad with skin layers had the best compression set at 0.7% ± 0.1%, followed by the unfilled pad with no skins at 1.5% ± 0.1%. As the number of filled layers increased, compression set performance degraded. The pad with filled skin layers and all filled layers had a compression set of 7.0% ± 0.3%. Additionally, the reaction extent of DEB was found to increase compression set, possibly due to the diffusion of DEB to the surface at elevated temperatures. Imaging reveals extensive crystallization at the surface. These investigations show that a non-reinforcing filler will increase compression set but that print structure can mitigate this effect.

36 MATERIALS SCIENCE↗
DOE OSTI2024

ILAW Container Cost Reduction and Optimization Study

This study, performed on behalf of Washington River Protection Solutions (WRPS), examines the potential for making cost savings for the Immobilized Low Active Waste (ILAW) containers over the mission life of the Waste Treatment and Immobilization Plant (WTP). it builds on earlier study assessments 24590-LAW-RPT-M-01-001 Rev 0 ILAW Product Container Specifications Optimization Study and DOE/ORP-2013-02 Rev 0 Decision Analysis of Low-Active Waste Container Finishing Handling System Alternatives. The WTP design and installed equipment has evolved over an extended period ~20 years. Consequently, some of the existing requirements relating the ILAW containers may no longer be applicable under current mission plans where the glass filled containers are placed into the Integrated Disposal Facility (IDF) rather than stacked in an engineered purpose-built ventilated store as originally envisioned. The study team reviewed available WTP project reference documents to establish the functions the container must perform and assign requirements against each of these functions. With the assumptions that some of the existing WTP contract restrictions would not necessarily apply to the subsequent facility operations contract the container requirements were reviewed to identify those which were ‘hard constraints‘, imposed by regulatory requirements. Initially each of these hard constraints were reviewed, evaluated and documented to see if they precluded the use of an alternate less expensive material of construction, carbon steel, to the existing 304 L stainless steel in the current container specification. That review did not generate any fatal flaws for a change in material of construction to carbon steel allowing the study team to examine the impacts of material cost savings, potential changes to the design and requirements and impacts on interfaces of the containers with the existing WTP process equipment from container receipt, transfers, glass filling, cooling and export. In addition, a change in container target fill level was evaluated and qualitative, and quantitative where feasible, impacts to the container fabrication process assessed. Lastly, additional follow on development or testing activities to support the use of carbon steel were assessed and a recommended path forward with a ROM cost and timescale developed.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Enabling Next Generation Reaction Injection Molding (RIM) for Lightweight Structures

Replacing metal components in trucks, trailers, and buses with lightweight polymer composites is challenging due to high temperatures and complex manufacturing. The Reaction Injection Molding (RIM) process using Dicyclopentadiene (DCPD) resin offers a solution by producing robust parts with excellent stiffness, impact strength, and resistance properties. Simulations are essential for optimizing this process, predicting defects, and improving quality. However, most commercial software is tailored for thermoplastics, requiring thermoset users to generate their own datasets. In this project, a material data card for DCPD was developed to perform RIM simulations. Design of Experiments (DOE) was used to identify key factors affecting filling, curing, and warpage, aiming to minimize cycle time and defects. The simulations explored varying injection gate parameters (size, location, number) and process conditions (mold/resin temperature, injection/curing pressure). Results showed that gate design significantly impacts filling behavior and defects. A single central gate provided balanced flow with fewer defects, while two corner gates led to more defects. Additionally, lower injection pressure increased filling time, while higher mold temperature accelerated curing but led to more warpage. This optimization framework aims to enhance DCPD part performance and promote sustainable manufacturing by reducing waste and energy consumption. This research has been performed in collaborations with McClarin Composites. The research outcome has been submitted to the Journal of Manufacturing Processes.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Calibration of the Nonlinear Viscoelastic SPECtacular Model for 828-CTBN/DEA/GMB and 828/Z/AlOx

Nonlinear viscoelastic model calibrations are developed for two filled epoxies: an adduct of Epon 828 DGEBA and CTBN cross-linked with diethanolamine (DEA) filled with glass microballoons, called 828-CTBN/DEA/GMB, and Epon 828 DGEBA cross-linked with Ancamine Z and filled with alumina, called 828/Z/AlOx. The thermo-mechanical responses of these materials are represented using the SPECtacular constitutive model, an extension of the Simplified Potential Energy Clock (SPEC) model. The model couples

Cundiff, Kenneth Noel [Sandia National Laboratorie↗
DOE OSTI2018

Experimental Study on Performance Enhancement of Evacuated Tube by Constant Heat Flux Mode

The evacuated tube collector with U shape copper absorber tube is considered for the analysis. The experimental investigation is conducted on parabolic trough collector with U shape tube as absorber tube. The effect of the sudden fluctuations in the solar radiation on the performance of the collector is reduced by means of evacuated tube collector filled with thermic fluids. The analysis is performed with different thermic fluids such as dowtherm, therminol66, glycol water and ethylene glycol, are filled in the annular space between inner glass tube and U shape copper absorber tube. The experimentation is carried out at various mass flow rates from 20 to 100 LPH with the step-up flow rate of 20 LPH. A comparative study is carried out on various parameters such as effect of mass flow rate over instantaneous efficiency, useful heat gain and work input, etc. The characteristic curve of cylindrical parabolic trough collector (PTC) is also discussed. Experimental results show that, ethylene glycol gives better efficiency over mass flow rate and therminol66 gives best power heat ratio. Heat transfer mediums and its properties [specific heat capacity, thermal conductivity and dynamic viscosity] for all specified heat transfer fluids are also discussed. The results obtained with various specified heat transfer fluids filled in the annulus space of evacuated tube are compared with plain evacuated tube. It is observed that there is significant enhancement of overall instantaneous collection efficiency of the parabolic trough collector.

14 SOLAR ENERGY↗
DOE OSTI2015

Multilayer Coextrusion of Polymer Composites to Develop Organic Capacitors

Multilayer coextrusion is applied to produce a tape containing layers of alternating electrical properties to demonstrate the potential for using coextrusion to manufacture capacitors. To obtain the desired properties, we develop two filled polymer systems, one for conductive layers and one for dielectric layers. We describe numerical models used to help determine the material and processing parameters that impact processing and layer stability. These models help quantify the critical ratios of densities and viscosities of the two layers to maintain stable layers, as well as the effect of increasing the flow rate of one of the two materials. The conducting polymer is based on polystyrene filled with a blend of low-melting-point eutectic metal and nickel particulate filler, as described by Mrozek et al. (2010). The appropriate concentrations of fillers are determined by balancing measured conductivity with processability in a twin screw extruder. Based on results of the numerical models and estimates of the viscosity of emulsions and suspensions, a dielectric layer composed of polystyrene filled with barium titanate is formulated. Despite the fact that the density of the dielectric filler is less than the metallic filler of the conductive phase, as well as rheological measurements that later showed that the dielectric formulation is not an ideal match to the viscosity of the conductive material, the two materials can be successfully coextruded if the flow rates of the two materials are not identical. A measurable capacitance of the layered structure is obtained.

36 MATERIALS SCIENCE↗