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DOE OSTI2021

Effect of process route on powder three-dimensional-printing of metal powders

The purpose of this study is to investigate the effect of two unique processing routes (solvent jetting (SJ) and binder jetting (BJ)), on the green density of printed stainless steel 316L (SS316L) and Nickel (Ni) powders. In the SJ processing route, a solvent is jetted unto the powder/binder mixture to selectively activate the binder, layer by layer. In the BJ processing route, a solution of the binder mixture is jetted onto the powder bed to selectively bind powder particles. The effects of printing parameters such as layer height, roller speed, shaker speed and nozzle temperature on the green density of printed components are investigated and compared for both processing routes. Results show that layer height and nozzle temperature affect the relative density of the printed compact for both processing routes. Slightly higher relative densities were achieved via the SJ route, with the overall highest relative density being 42.7% at 100 µ m layer height and 70% nozzle temperature for the SS316L components and 43.7% at 150 µ m layer height and 90% nozzle temperature for the Ni components, respectively. Results also show an increase in the final sintered relative density with an increase in green (printed) relative density of the solvent jetted SS316L components, with the highest relative density being 87.2%. The paper studies the influence of printing parameters on the green density of printed SS316L and Ni samples in an unprecedented effort to provide a comparative understanding of the process-property relationships in BJ and SJ of SS316L and Ni components to the additive manufacturing research community.

Engineering↗

DOE OSTI2023

Process-dependent anisotropic thermal conductivity of laser powder bed fusion AlSi10Mg: impact of microstructure and aluminum-silicon interfaces

Purpose AlSi10Mg alloy is commonly used in laser powder bed fusion due to its printability, relatively high thermal conductivity, low density and good mechanical properties. However, the thermal conductivity of as-built materials as a function of processing (energy density, laser power, laser scanning speed, support structure) and build orientation, are not well explored in the literature. This study aims to elucidate the relationship between processing, microstructure, and thermal conductivity. Design/methodology/approach The thermal conductivity of laser powder bed fusion (L-PBF) AlSi10Mg samples are investigated by the flash diffusivity and frequency domain thermoreflectance (FDTR) techniques. Thermal conductivities are linked to the microstructure of L-PBF AlSi10Mg, which changes with processing conditions. The through-plane exceeded the in-plane thermal conductivity for all energy densities. A co-located thermal conductivity map by frequency domain thermoreflectance (FDTR) and crystallographic grain orientation map by electron backscattered diffraction (EBSD) was used to investigate the effect of microstructure on thermal conductivity. Findings The highest through-plane thermal conductivity (136 ± 2 W/m-K) was achieved at 59 J/mm 3 and exceeded the values reported previously. The in-plane thermal conductivity peaked at 117 ± 2 W/m-K at 50 J/mm 3 . The trend of thermal conductivity reducing with energy density at similar porosity was primarily due to the reduced grain size producing more Al-Si interfaces that pose thermal resistance. At these interfaces, thermal energy must convert from electrons in the aluminum to phonons in the silicon. The co-located thermal conductivity and crystallographic grain orientation maps confirmed that larger colonies of columnar grains have higher thermal conductivity compared to smaller columnar grains. Practical implications The thermal properties of AlSi10Mg are crucial to heat transfer applications including additively manufactured heatsinks, cold plates, vapor chambers, heat pipes, enclosures and heat exchangers. Additionally, thermal-based nondestructive testing methods require these properties for applications such as defect detection and simulation of L-PBF processes. Industrial standards for L-PBF processes and components can use the data for thermal applications. Originality/value To the best of the authors’ knowledge, this paper is the first to make coupled thermal conductivity maps that were matched to microstructure for L-PBF AlSi10Mg aluminum alloy. This was achieved by a unique in-house thermal conductivity mapping setup and relating the data to local SEM EBSD maps. This provides the first conclusive proof that larger grain sizes can achieve higher thermal conductivity for this processing method and material system. This study also shows that control of the solidification can result in higher thermal conductivity. It was also the first to find that the build substrate (with or without support) has a large effect on thermal conductivity.

Engineering↗

DOE OSTI2021

Effects of Wire Diameter and Filament Size on the Processing Window of Bi-2212 Round Wire

High engineering critical current density (J E of 1300 A/mm 2 at 4.2 K and 15 T) in Bi-2212 round wire has been achieved through a partial melt, overpressure heat treatment process. J E varies strongly with processing conditions, particularly the maximum heat treatment temperature (T max ). Increasing T max results in longer time in the melt (defined as the time between when Bi-2212 melts on heating and when Bi-2212 begins to form on cooling), more bridging between the filaments, lower J E , and higher ac losses. A wide processing window with a large range of T max that has a nearly constant J E is desired for processing large coils with large thermal mass and significant thermal time constants that may make precise control over the desired temperature – time profiles uncertain. Accordingly, we wanted to explore broadening the T max window by controlling the Bi-2212 powder melting or wire architecture design. In this work, we report on studies of the performance variation with T max for two production wires with a filling factor of about 20% and 85 × 18 filaments where filament size was varied by changing the wire diameter, a process which also shortens the distance between filaments. We found that wires with smaller filament diameter (9 to 11 μm) showed a peak J E at the low end of T max and also a J E that was more sensitive to T max . A J E – T max plot showed a plateau J E (4.2 K, 5 T) of ~1100 A/mm 2 between T max of 886 and 894 °C for 1.0 and 1.2 mm wires, where J E is less sensitive to the wire diameter and T max . This J E plateau range is a preferred processing window for achieving high J E in coils.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Extracting Resilience Metrics From Distribution Utility Data Using Outage and Restore Process Statistics

Resilience curves track the accumulation and restoration of outages during an event on an electric distribution grid. We show that a resilience curve generated from utility data can always be decomposed into an outage process and a restore process and that these processes generally overlap in time. We use many events in real utility data to characterize the statistics of these processes, and derive formulas based on these statistics for resilience metrics such as restore duration, customer hours not served, and outage and restore rates. The formulas express the mean value of these metrics as a function of the number of outages in the event. We also give a formula for the variability of restore duration, which allows us to predict a maximum restore duration with 95% confidence. Overall, we give a simple and general way to decompose resilience curves into outage and restore processes and then show how to use these processes to extract resilience metrics from standard distribution system data.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Analytical Study and Experimental Verification of Shear-Thinning Ink Flow in Direct Ink Writing Process

Abstract Direct ink writing (DIW) process is a facile additive manufacturing technology to fabricate three-dimensional (3D) objects with various materials. Its versatility has attracted considerable interest in academia and industry in recent years. As such, upsurging endeavors are invested in advancing the ink flow behaviors in order to optimize the process resolution and the printing quality. However, so far, the physical phenomena during the DIW process are not revealed in detail, leaving a research gap between the physical experiments and its underlying theories. Here, we present a comprehensive analytical study of non-Newtonian ink flow behavior during the DIW process. Different syringe-nozzle geometries are modeled for the comparative case studies. By using the computational fluid dynamics (CFD) simulation method, we reveal the shear-thinning property during the ink extrusion process. Besides, we study the viscosity, shear stress, and velocity fields, and analyze the advantages and drawbacks of each syringe-nozzle model. On the basis of these investigations and analyses, we propose an improved syringe-nozzle geometry for stable extrusion and high printing quality. A set of DIW printing experiments and rheological characterizations are carried out to verify the simulation studies. The results developed in this work offer an in-depth understanding of the ink flow behavior in the DIW process, providing valuable guidelines for optimizing the physical DIW configuration toward high-resolution printing and, consequently, improving the performance of DIW-printed objects.

Engineering↗

DOE OSTI2026

Identifying Bounds of Inorganic Content in Solventless Processing of Hybrid Solid Electrolytes

Solid-state lithium batteries require safe, robust electrolytes to enable higher energy densities and improved safety over conventional cells. Hybrid polymer–ceramic electrolytes are a promising solution, combining the processability of polymers with the high ionic conductivity and mechanical strength of inorganic fillers. In this work, we demonstrate a solventless, UV-curing method to produce hybrid solid electrolytes using a poly(ethylene glycol) dimethyl ether (PEGDME)-based photocurable matrix incorporating Li 1.5 Al 0.5 Ge 1.5 (PO 4 ) 3 (LAGP) or Li 7 La 3 Zr 2 O 12 (LLZO) ceramic electrolyte. Inorganic filler loadings up to ∼55 wt.% could be successfully incorporated via this process which was the highest inorganic content at which the slurry remains processable and cured into a uniform film. The resulting UV-cured composite electrolytes remain flexible and exhibit room-temperature ionic conductivities on the order of 10 −4 S·cm −1 , along with notably improved lithium-ion transference numbers compared to conventional polymer electrolytes. Similar performance and processing limits were observed for both LAGP and LLZO, indicating that ceramic filler chemistry does not significantly affect the UV-curing process or the electrolyte's ion transport properties in this regime. Eliminating solvents from fabrication not only simplifies processing and mitigates environmental concerns but also enables higher solid contents that enhance mechanical strength and help suppress lithium dendrite formation. In conclusion, this scalable approach thus paves the way for manufacturing robust composite solid electrolytes for next-generation solid-state batteries (SSBs).

Batteries↗

DOE OSTI2013

Cadarache LOR (liquides organiques radioactifs) treatment by a solidification process using NOCHAR polymers

In France, two options can be considered to handle the Very Low Level Waste (VLLW) and the Low Level Waste (LLW). The first one is the incineration at CENTRACO facility and the second one is the disposal at ANDRA sites. The waste acceptance in these two channels is dependent upon the adequacy between the waste characteristics (physical chemistry and radiological) and the channel specifications. If the waste characteristics and the channel specifications (presence of significant quantities of halogens, complexing agents, organic components... or/and high activity limits) are incompatible, an alternative solution have to be identify. It consists of a waste pre-treatment process. For Cadarache LOR (Liquides Organiques Radioactifs) waste streams, two radioactive scintillation cocktails have to be treated. They are composed of a mix of organic liquids and water: for the first one, 19 % of organic compounds (xylene, mesitylene, diphenyloxazole, TBP...) and 86.9 % of water, and for the second one, 23 % of organic compounds (TBP...) and 77 % of water. They contain halogens (chlorine and fluorine), complexants agents (nitrate, sulphate, oxalate and formate) and have got αβγ spectra with mass activities equal to some 100 Bq/g. Therefore, tritium is also present. As a consequence, in order for storage acceptance at the ANDRA site, it is necessary to pre-treat the waste. An adequate solution seems to be a solidification process using NOCHAR polymers. Indeed, NOCHAR polymers correspond to an important variety of products applied to the treatment of radioactive aqueous and organic liquids (solvent, oil, solvent/oil mixing ...) and sludge through a mechanical and chemical solidification process. For Cadarache LOR, N910 and N960 respectively dedicated to the organic and aqueous liquids solidification are considered. With the N910, the organic waste solidification occurs in two steps. As the organic liquid travels moves through the polymer strands, the strands swell and immobilize the liquid. Then as the polymer-organic cure, over time, the polymer continues to collapse on the organic to create a permanent chemical bond. The N960 has the ability to absorb aqueous waste up to 100 times its own weight. It creates a strong mechanical bond which permanently traps the contamination imbedded in the aqueous liquids. Therefore, these two NOCHAR polymers seem to be able to constitute a suitable solidification matrix for a final acceptance in storage on ANDRA sites. In order to validate the solidification process using NOCHAR polymers as an acceptable solution for Cadarache LOR treatment, some solidification tests realised with N910 and N960, have been carried out for different Waste/Polymer ratios. To determine the best Waste/Polymer ratio and the optimal experimental parameters, exudation tests have been made. Indeed, the process prevents leaching and it results in the absence residual free organic or aqueous liquid which is forbidden in storage by ANDRA specifications. With these results, the obtained scientific data constitute a fundamental basis of an ANDRA agreement. As a conclusion, the aim of this study is to demonstrate that the pre-treatment by solidification using NOCHAR polymers can constitute a solution for Cadarache LOR handling and more generally, for various organic and mixed organic/aqueous waste which can not be directly acceptable at CENTRACO facility or at ANDRA storage sites. So then, this study is a solid background to demonstrate the feasibility of the waste pre-treatment by solidification with NOCHAR polymer and to encourage this process development. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2015

SU-C-304-02: Robust and Efficient Process for Acceptance Testing of Varian TrueBeam Linacs Using An Electronic Portal Imaging Device (EPID)

Purpose: The purpose of this project was to develop a process that utilizes the onboard kV and MV electronic portal imaging devices (EPIDs) to perform rapid acceptance testing (AT) of linacs in order to improve efficiency and standardize AT equipment and processes. Methods: In this study a Varian TrueBeam linac equipped with an amorphous silicon based EPID (aSi1000) was used. The conventional set of AT tests and tolerances was used as a baseline guide, and a novel methodology was developed to perform as many tests as possible using EPID exclusively. The developer mode on Varian TrueBeam linac was used to automate the process. In the current AT process there are about 45 tests that call for customer demos. Many of the geometric tests such as jaw alignment and MLC positioning are performed with highly manual methods, such as using graph paper. The goal of the new methodology was to achieve quantitative testing while reducing variability in data acquisition, analysis and interpretation of the results. The developed process was validated on two machines at two different institutions. Results: At least 25 of the 45 (56%) tests which required customer demo can be streamlined and performed using EPIDs. More than half of the AT tests can be fully automated using the developer mode, while others still require some user interaction. Overall, the preliminary data shows that EPID-based linac AT can be performed in less than a day, compared to 2–3 days using conventional methods. Conclusions: Our preliminary results show that performance of onboard imagers is quite suitable for both geometric and dosimetric testing of TrueBeam systems. A standardized AT process can tremendously improve efficiency, and minimize the variability related to third party quality assurance (QA) equipment and the available onsite expertise. Research funding provided by Varian Medical Systems. Dr. Sasa Mutic receives compensation for providing patient safety training services from Varian Medical Systems, the sponsor of this study.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2015

SU-E-P-27: Efficient Process for AccuBoost Planning and Treatment Delivery to Minimize Patient Compression Time

Purpose: To implement an efficient and robust process for AccuBoost planning and treatment delivery that can be safely performed by a single Physicist while minimizing patient’s total session time. Methods: Following a thorough commissioning and validation process, templates were created in the brachytherapy planning system for each AccuBoost applicator. Tables of individual and total nominal dwell times for each applicator as a function of separation were generated to streamline planning while an Excel-based nomogram provided by the vendor functions as a secondary verification of the treatment parameters. Tables of surface dose as a function of separation and applicator, along with concise guidance documents for applicator selection, are readily available during the planning process. The entire process is described in a set of detailed Standard Operating Procedures which, in addition to the items described above, include a verbal time-out between the primary planner and the individual performing the secondary verification as well as direct visual confirmation of applicator placement using an articulated mirror. Prior to treatment initiation, a final time-out is conducted with the Radiation Oncologist. Chart documentation is finalized after the patient is released from compression following completion of the treatment. Results: With the aforementioned procedures, it has been possible to consistently limit the time required to prepare each treatment such that the patient is typically under compression for less than 10 minutes per orientation prior to the initiation of the treatment, which is particularly important for APBI cases. This process can be overseen by a single physicist assisted by a dosimetrist and has been optimized during the past 16 months, with 180 treatment sessions safely completed to date. Conclusion: This work demonstrates the implementation of an efficient and robust process for real-time-planned AccuBoost treatments that effectively minimizes the time that the patient is under compression.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2016

WE-DE-202-03: Modeling of Biological Processes - What Happens After Early Molecular Damage?

Radiation therapy for the treatment of cancer has been established as a highly precise and effective way to eradicate a localized region of diseased tissue. To achieve further significant gains in the therapeutic ratio, we need to move towards biologically optimized treatment planning. To achieve this goal, we need to understand how the radiation-type dependent patterns of induced energy depositions within the cell (physics) connect via molecular, cellular and tissue reactions to treatment outcome such as tumor control and undesirable effects on normal tissue. Several computational biology approaches have been developed connecting physics to biology. Monte Carlo simulations are the most accurate method to calculate physical dose distributions at the nanometer scale, however simulations at the DNA scale are slow and repair processes are generally not simulated. Alternative models that rely on the random formation of individual DNA lesions within one or two turns of the DNA have been shown to reproduce the clusters of DNA lesions, including single strand breaks (SSBs), double strand breaks (DSBs) without the need for detailed track structure simulations. Efficient computational simulations of initial DNA damage induction facilitate computational modeling of DNA repair and other molecular and cellular processes. Mechanistic, multiscale models provide a useful conceptual framework to test biological hypotheses and help connect fundamental information about track structure and dosimetry at the sub-cellular level to dose-response effects on larger scales. In this symposium we will learn about the current state of the art of computational approaches estimating radiation damage at the cellular and sub-cellular scale. How can understanding the physics interactions at the DNA level be used to predict biological outcome? We will discuss if and how such calculations are relevant to advance our understanding of radiation damage and its repair, or, if the underlying biological processes are too complex for a mechanistic approach. Can computer simulations be used to guide future biological research? We will debate the feasibility of explaining biology from a physicists’ perspective. Learning Objectives: Understand the potential applications and limitations of computational methods for dose-response modeling at the molecular, cellular and tissue levels Learn about mechanism of action underlying the induction, repair and biological processing of damage to DNA and other constituents Understand how effects and processes at one biological scale impact on biological processes and outcomes on other scales J. Schuemann, NCI/NIH grantsS. McMahon, Funding: European Commission FP7 (grant EC FP7 MC-IOF-623630)

60 APPLIED LIFE SCIENCES↗

DOE OSTI2018

Effect of Barothermal Processing on the Solid-State Formation of the Structure and Properties of 16 at % Si–Al Hypereutectic Alloy

We describe barothermal processing (hot isostatic pressing) of a 16 at % Si–Al binary alloy for 3 h at a temperature of 560°C and pressure of 100 MPa for 3 h, in combination with measurements of heat effects during cooling. The results demonstrate that this processing leads to the fragmentation of the silicon structural constituent and ensures a high degree of homogenization of the as-prepared alloy. Heat treatment of the 16 at % Si–Al alloy at 560°C and a pressure of 100 MPa leads to a thermodynamically driven enhanced silicon dissolution, up to ~10 at %, in the aluminum matrix, resulting in the formation of a supersaturated solid solution, which subsequently decomposes during cooling. We analyze the complete porosity elimination process, which makes it possible to obtain a material with 100% relative density. According to differential barothermal analysis, microstructural analysis, and scanning and transmission electron microscopy data, barothermal processing of the 16 at % Si–Al alloy produces a bimodal size distribution of the silicon phase constituent: microparticles 3.6 μm in average size and nanoparticles down to ~1 nm in diameter. The Al matrix has been shown to contain a high density of edge dislocations. Barothermal processing reduces the thermal expansion coefficient and microhardness of the hypereutectic alloy. We conclude that solid-state barothermal processing is an effective tool for completely eliminating microporosity from the 16 at % Si–Al alloy, reaching a high degree of homogenization, and controlling the microstructure of the alloy, in particular by producing high dislocation density in the aluminum matrix.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Stochastic representation and conditioning of process-based geological model by deep generative and recognition networks

Accurate and realistic geological modeling is the core of oil and gas development and production. In recent years, process-based methods are developed to produce highly realistic geological models by simulating the physical processes that reproduce the sedimentary events and develop the geometry. However, the complex dynamic processes are extremely expensive to simulate, making process-based models difficult to be conditioned to field data. In this work, we propose a comprehensive generative adversarial network framework as a machine-learning-assisted approach for mimicking the outputs of process-based geological models with fast generation. The main objective of our work is to obtain a continuous parametrization of the highly realistic process-based geological models which enables us to calibrate the models and condition the models to data. Numerical results are presented to illustrate the capability of our proposed methodology.

58 GEOSCIENCES↗

DOE OSTI2024

High-Throughput Computing: Case Study of Medical Image Processing Applications

HPC is designed for large-scale simulations using monolithic codes of tightly coupled processes highly optimized to deliver decreased time to solution. Medical image processing is not a traditional field of HPC. Similar to AI applications, medical image processing parses large datasets, typically multiple times, to support a variety of studies for classification, diagnosis or monitoring purposes. The convergence of AI, HPC and Big Data encouraged more fields using image processing to transition to HPC. However, not all applications benefit from the same optimizations. In this paper we focus on high throughput medical image processing applications that analyze a huge dataset of small MRI images and that require HPC systems to decrease the time of parsing the entire dataset and not individual MRIs. We show in this research the performance of running SLANT, an image processing application for a whole brain segmentation, on large-scale systems and highlight performance limitations. We present optimizations prioritizing throughput that exhibit a 3.5x speed-up on the Summit Supercomputer that can be used as a baseline for building a high-throughput execution framework for other HPC systems.

Predescu, Maria↗

DOE OSTI2025

Modeling a High-Temperature Electrochemically Driven Water-Gas-Shift Process Using a Mixed-Conducting Membrane without External Electrical Power

This paper develops a model to predict and interpret the performance of an elevated-temperature, electrochemical, membrane-assisted, water-gas-shift process. The process uses separated feed streams of H 2 O and CO to produce separated streams of H 2 and CO 2 , without an external electrical power source. The dense ceramic membrane is mixed ionic-electronic-conducting (MIEC) gadolinium-doped ceria (GDC) and the porous composite electrodes are Ni-YSZ. At elevated temperature, GDC conducts both oxygen ions and small polarons. The present process uses chemical potential to drive the process. Electrochemical oxidation of CO proceeds within the composite anode and H 2 O reduction proceeds within the composite cathode. At high temperature (e.g., T > 700 °C), GDC has significant electronic leakage in the form of a reduced-cerium small polaron, which supports the charge-transfer reactions. In a typical electrolyzer or fuel cell, this leakage is significantly problematic. However, the present process depends on the leakage current to complete the electrochemical circuit. Model development and validation is based on measured material properties and reactor performance. Potential applications include using CO-rich blast-furnace off gases in steel processing, producing separated streams of H 2 and CO 2 .

Zhu, Huayang↗

DOE OSTI2022

Idaho National Laboratory Data Acquisition And Processing System

The INLDAS data acquisition and processing system is designed to develop prototype measurements and real-time processing techniques. The INLDAS hardware and firmware currently consists of National Instruments • NI-DAQmx 14.1 • cDAQ-9184 • 9205 • 9211 INLDAS can perform of standard data acquisition functions as well as novel functions and real-time processing algorithms. There are 3 acquisition modes to choose from: • Continuous mode runs when the user hits start, processing data and logging it to file • SWTrigger mode waits for one or more predefined triggers before acquiring data. It will buffer data as well, so it can record data that happened shortly before the trigger • Wakeup mode waits on predefined timers. When a time goes off, it acquires a preset amount of data There are also 3 Data Processing Modes • Normal mode does no processing besides the rolling average • FFT Mode Performs an FFT on incoming data every time the time window has elapsed • STFFT mode

Smith, JamesA↗

DOE OSTI2016

Development and Characterization of a High-Solids Deacetylation Process

Dilute-acid pretreatment has proven to be a robust means of converting herbaceous feedstock to fermentable sugars. However, it also releases acetic acid, a known fermentation inhibitor, from acetyl groups present in the biomass. A mild, dilute alkaline extraction stage was implemented prior to acid pretreatment to separate acetic acid from the hydrolysate sugar stream. This step, termed deacetylation, improved the glucose and xylose yields from enzymatic hydrolysis and ethanol yields from fermentation of the sugars relative to the control experiments using dilute-acid pretreatment of native corn stover without deacetylation. While promising, deacetylation as it was historically practiced is conducted at low solids loadings, and at fixed conditions. Thus, many questions have been left unanswered, including the relationship between sodium hydroxide and solids loading, and acetate and xylan solubilization, as well as the impact of temperature and residence time on the process efficacy. A central composite experiment was designed to evaluate the impact of solids loading, sodium hydroxide loading, reaction time and temperature during deacetylation on the acetate and xylan solubilization of corn stover. Using the ANOVA test, it became apparent that neither of the responses was significantly impacted by the solids loading, while the reaction time was a minor factor - the responses were largely driven by reaction temperature and the sodium hydroxide loading. Based on the results, we successfully demonstrated the ability to transition the low-solids (10 % w/w) deacetylation process to a higher-solids process (30 % w/w) with minimal impact on the ability to extract acetate from biomass. Conditions were selected to minimize xylose loss during deacetylation, while also removing 70 % of acetyl groups. The impact of selected conditions on the enzymatic hydrolysis and fermentation was further investigated. In conclusion, evaluation of the whole-process impact demonstrated that despite the upfront reduction in carbohydrate loss during deacetylation, the overall process sugar yields were depressed by the high-solids, low alkali process relative to the historical control. Consequently, ethanol titers were reduced, though strong fermentation performance was still observed, indicating that 70 % acetate removal is sufficient to depress acetic acid concentrations to a level that does not substantially inhibit ethanol fermentation by rZymomo nas.

09 BIOMASS FUELS↗

DOE OSTI2023

Processing Temperature Effect on Failure Behavior of Unidirectional Thermoplastic Polymer-fiber-reinforced Polymers (PFRPs)

This study aimed to examine the influence of processing temperature on the mechanical and morphological characteristics of unidirectional (UD) thermoplastic polymer-fiber-reinforced polymers (PFRPs), utilizing UHMWPE-polymer-fiber-reinforced HDPE composites as an example. To achieve this objective, UD thermoplastic PFRPs were produced through filament winding and hot pressing techniques, employing five distinct processing temperatures within the range spanning from the melting onset temperature of the polymer matrix to the melting peak temperature of the reinforcing polymer fiber. By conducting the uni-axial tensile tests on the UD UHMWPE-polymer-fiber-reinforced HDPE composites fabricated at different processing temperatures, it was shown that the optimal longitudinal tensile properties of the composites, comparable with glass-fiber-reinforced thermoset or thermoplastic polymers (GFRPs or GFRTPs) can be achieved when the processing temperature does not significantly exceeds the melting onset temperature of the reinforcing polymer fiber. However, when the processing temperature exceeds this threshold, the mechanical properties of the composites are significantly reduced, as evidenced by the transition in the failure morphology from the presence of significant splitting cracks to the occurrence of plastic necking due to the complete melting of the reinforcing polymer fibers in a composite. Particularly, the ductile behavior of the optimal thermoplastic PFRPs investigated in this study is superior than that of carbon-fiber-reinforced thermoset or thermoplastic polymers (CFRPs or CFRTPs) and even GFRPs and GFRTPs. This study not only provides valuable insights into the proper fabrication of high-performance thermoplastic PFRPs but also offers useful experimental data that can aid in the validation and development of computational models, particularly those related to processing modeling.

Qiao, Yao↗

DOE OSTI2018

Data from Increasing Ethanol Yield through Fiber Conversion in Corn Dry Grind Process

Conversion of corn fiber to ethanol in the dry grind process could increase ethanol yields, reduce downstream processing costs and improve overall process profitability. This work investigates the in-situ conversion of corn fiber into ethanol (cellulase addition during simultaneous saccharification and fermentation) during dry grind process. Addition of 30 FPU/g fiber cellulase resulted in 4.6% increase in ethanol yield compared to the conventional process. Use of excess cellulase (120 FPU/g fiber) resulted in incomplete fermentation and lower ethanol yield compared to the conventional process. Multiple factors including high concentrations of ethanol and phenolic compounds were responsible for yeast stress and incomplete fermentation in excess cellulase experiments.

Conversion↗