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At least 1,657 records · Page 92

A Digital Twin Approach to Study Additive Manufacturing Processing Using Embedded Optical Fiber Sensors and Numerical Modeling

One of the major challenges for metal-powder-based additive manufacturing is measuring and mitigating residual strain induced during the manufacturing processes. This article reports distributed fiber optic sensors embedded in Inconel alloy components as experimental means to validate numerical models of additive manufacturing process. Electroplating was used to deposit a metal protective jacket onto standard telecom single-mode fibers for strain measurements, Fiber sensors were embedded in an Inconel alloy substrate using the laser engineered net shaping (LENS) process. Here by using a Rayleigh-scattering optical frequency domain reflectometer (OFDR), temperature changes, and residual strain in the metal substrate were monitored with 5 mm spatial resolution during the LENS process. Using finite element analysis, temperature and strain profiles induced by the LENS deposition processes were also numerically studied. Discrepancies between the simulated temperature and strain profiles and those measured directly were less than 10%. Results presented in this article demonstrates a digital twin approach to fuse modeling results with distributed fiber sensor measurement data to study additive manufacturing process toward design and fabrication process optimization.

36 MATERIALS SCIENCE↗

Intensity Modulated Fiber Optic Sensor: A Novel Grid Measurement Unit

This paper presents a novel approach to physical displacement-based power grid measuring via an Intensity Modulated Fiber Optic Sensor (IMFOS). An IMFOS utilizes one fiber to transmit the intensity modulation light from its Electro-Optic controller to a fiber optic probe. The power grid voltage and current can induce physical displacements in transducers via the piezoelectric effect and the Lorentz law, respectively, which then result in a distance change between the optical probe and the reflective surface of the transducers. In parallel, multiple fibers are used to collect the reflective light for electro-optic conversion. Furthermore, a National Instruments-based characterization platform is set up for performance evaluation. Here, the testing result demonstrates that the IMFOS is immune to the inherent DC and low-frequency saturation issues prevalent in conventional potential and current transformers. Finally, the IMFOS is implemented in a Universal Grid Analyzer to illustrate its applicability for phasor estimation in actual power grids.

42 ENGINEERING↗

Organometallic exposure dependence on organic–inorganic hybrid material formation in polyethylene terephthalate and polyamide 6 polymer fibers

The effect of exposure conditions and surface area on hybrid material formation during sequential vapor infiltrations of trimethylaluminum (TMA) into polyamide 6 (PA6) and polyethylene terephthalate (PET) fibers is investigated. Mass gain of the fabric samples after infiltration was examined to elucidate the reaction extent with increasing number of sequential TMA single exposures, defined as the times for a TMA dose and a hold period. An interdependent relationship between dosing time and holding time on the hybrid material formation is observed for TMA exposure PET, exhibited as a linear trend between the mass gain and total exposure (dose time × hold time × number of sequential exposures). Deviation from this linear relationship is only observed under very long dose or hold times. In comparison, amount of hybrid material formed during sequential exposures to PA6 fibers is found to be highly dependent on amount of TMA dosed. Increasing the surface area of the fiber by altering its cross-sectional dimension is shown to have little on the reaction behavior but does allow for improved diffusion of the TMA into the fiber. This work allows for the projection of exposure parameters necessary for future high-throughput hybrid modifications to polymer materials.

36 MATERIALS SCIENCE↗

Modal reduction in single crystal sapphire optical fiber

A new type of single crystal sapphire optical fiber (SCSF) design is proposed to reduce the number of guided modes via a highly dispersive cladding with a periodic array of high and low index regions in the azimuthal direction. The structure retains a “core” region of pure single crystal (SC) sapphire in the center of the fiber and a “cladding” region of alternating layers of air and SC sapphire in the azimuthal direction that is uniform in the radial direction. The modal characteristics and confinement losses of the fundamental mode were analyzed via the finite element method by varying the effective core diameter and the dimensions of the “windmill” shaped cladding. The simulation results showed that the number of guided modes were significantly reduced in the “windmill” fiber design, as the radial dimension of the air and SC sapphire cladding regions increase with corresponding decrease in the azimuthal dimension. It is anticipated that the “windmill” SCSF will readily improve the performance of current fiber optic sensors in the harsh environment and potentially enable those that were limited by the extremely large modal volume of unclad SCSF.

36 MATERIALS SCIENCE↗

Feature Extraction for Pipeline Defects Inspection Based Upon Distributed Acoustic Fiber Optic Sensing Data

Fiber-optic distributed acoustic sensing (DAS) is becoming an increasingly important tool for real-time monitoring of energy and civil infrastructure structural health such as pipelines. We present a systematic theoretical study of the potential for DAS to be directly coupled with guided ultrasonic waves typically used in conventional acoustic non-destructive evaluation (NDE) methods for real-time pipeline health monitoring. We are referring to this innovative new NDE technique as ultrasonic guided wave and optical fiber sensor fusion. In the practical application of DAS coupled with guided ultrasonic waves, the structural design of (1) the specific guided waves excited, (2) the physical installation of the acoustic transducers and the fiber optic sensors, and (3) the functional performance specifications (gauge length, sensitivity, Etc.) of fiber optic DAS have an important influence on overall capabilities of the monitoring system. Meanwhile, physics-based analysis of acoustic waves is still a challenge due to the complex nature of the Lamb wave when it propagates, scatters, and disperses in the presence of structural defects. In this work, we simulate carbon steel pipes relevant for oil and gas pipeline applications with diameters of approximately 6-12” and wall thickness of 0.5” as the objects to be monitored. By establishing and implementing these capabilities, we seek to pursue an in-depth study on structural parameter optimization of DAS network, measurement range, and signal processing with an ultimate goal of increasing the sensitivity and efficacy of DAS to defect identification for various modes of corrosion expected in practice. To study the characteristics of scattered acoustic waves and performance of DAS for defect identification, we simulated the response of DAS for multiple pipe structures, defect types, and DAS sensor network configuration using finite element software Ansys, then the properties of signal response are extracted to construct defect-sensitive features. The raw data simulated, and the associated features extracted can ultimately be utilized as annotated training data to benchmark various designs for DAS applications, guided acoustic excitation sources, and learning model parameters to enhance early detection of potentially problematic defects.

Pipeline Defects Inspection, Fiber-optic sensors, ↗

Evaluation of a real-time BeO ceramic fiber-coupled luminescence dosimetry system for dose verification of high dose rate brachytherapy

Purpose: The authors evaluate the capability of a beryllium oxide (BeO) ceramic fiber-coupled luminescence dosimeter, named radioluminescence/optically stimulated luminescence (RL/OSL) BeO FOD, for dosimetric verification of high dose rate (HDR) treatments. The RL/OSL BeO FOD is capable of RL and OSL measurements. Methods: The RL/OSL BeO FOD is able to be inserted in 6F proguide needles, used in interstitial HDR treatments. Using a custom built Perspex phantom, 6F proguide needles could be submerged in a water tank at 1 cm separations from each other. A second background fiber was required to correct for the stem effect. The stem effect, dose linearity, reproducibility, depth-dose curves, and angular and temperature dependency of the RL/OSL BeO FOD were characterised using an Ir-192 source. The RL/OSL BeO FOD was also applied to the commissioning of a 10 mm horizontal Leipzig applicator. Results: Both the RL and OSL were found to be reproducible and their percentage depth-dose curves to be in good agreement with those predicted via TG-43. A combined uncertainty of 7.9% and 10.1% (k = 1) was estimated for the RL and OSL, respectively. For the 10 mm horizontal Leipzig applicator, measured percentage depth doses were within 5% agreement of the published reference calculations. The output at the 3 mm prescription depth for a 1 Gy delivery was verified to be 0.99 ± 0.08 Gy and 1.01 ± 0.10 Gy by the RL and OSL, respectively. Conclusions: The use of the second background fiber under the current setup means that the two fibers cannot fit into a single 6F needle. Hence, use of the RL is currently not adequate for the purpose of in vivo brachytherapy dosimetry. While not real-time, the OSL is shown to be adequate for in vivo brachytherapy dosimetry.

60 APPLIED LIFE SCIENCES↗

Radiation Hardness of Scintillation Detectors Based on Organic Plastic Scintillators and Optical Fibers

Scintillation detectors (SD) based on organic plastic scintillators and optical fibers are basic detectors at all modern accelerators and in astrophysics and neutrino physics experiments. In recent years, interest in SD has significantly increased due to the upcoming major upgrade of the LHC and the construction of new accelerators NICA, FAIR, FCC, etc. At the same time, requirements on the stability and reliability of SD operation under new conditions have become stricter, and their fulfillment largely depends on radiation hardness of scintillators, optical fibers, and photodetectors. The review presents the results of the radiation hardness investigations of various scintillators, optical fibers (scintillating, as well as wavelength-shifting and clear), and optical glues used to increase light collection from scintillators by fibers. The influence of various factors (dose, dose rate, type of radiation, scintillator materials, and fluors) on light output, light collection, and transmittance of the irradiated materials and their recovery is considered. Aging of scintillators caused by environmental effects (temperature, humidity) irrespective of radiation is also briefly considered.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Study of the formation, stability, and X-ray emission of the Z-pinch formed during implosion of fiber arrays at the Angara-5-1 facility

Results from experimental studies on the implosion of arrays made of kapron fibers coated with different metals (Al, In, Sn, and Bi) are presented. It is shown that the power, total energy, and spectrum of radiation emitted by the imploding array depend on the number of metallized fibers and the mass of the metal layer deposited on them but are independent of the metal characteristics (density, atomic number, etc.). Analysis of frame X-ray images shows that the Z-pinches formed in the implosion of metallized kapron fiber arrays are more stable than those formed in wire arrays and that MHD perturbations in them develop at a slower growth rate. Due to the lower rate of plasma production from kapron fibers, the plasma formed at the periphery of the array forms a layer that plays the role of a hohlraum wall partially trapping soft X-ray emission of the Z-pinch formed in the implosion of the material of the deposited metal layer. The closure of the anode aperture doubles the energy of radiation emitted in the radial direction.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

The Importance of Carbon Fiber to Polymer Additive Manufacturing

Additive manufacturing holds tremendous promise in terms of revolutionizing manufacturing. However, fundamental hurdles limit mass adoption of the technology. First, production rates are extremely low. Second, the physical size of parts is generally small, less than a cubic foot. Third, while there is much excitement about metal additive manufacturing, the major growth area is in polymer additive manufacturing systems. Unfortunately, the mechanical properties of the polymer parts are poor, limiting the potential for direct part replacement. To address this issue, we describe three benefits of blending carbon fiber with polymer additive manufacturing. First, development of carbon fiber reinforced polymers for additive manufacturing achieves specific strengths approaching aerospace quality aluminum. Second, carbon fiber radically changes the behavior of the material during deposition, enabling large scale, out-of-the-oven, high deposition rate manufacturing. Finally, carbon fiber technology and additive manufacturing complement each other. Merging the two manufacturing processes enables the construction of complex components that would not be possible otherwise.

additive manufacturing↗

Global Carbon Fiber Composites Supply Chain Competitiveness Analysis

This study identifies key opportunities in the carbon fiber supply chain where the United States Department of Energy's Office of Energy Efficiency and Renewable Energy resources and investments can help the United States achieve or maintain a competitive advantage. The report focuses on four application areas--wind energy, aerospace, automotive, and pressure vessels--that top the list of industries using carbon fiber and carbon fiber reinforced polymers and are also particularly relevant to EERE's mission. For each of the four application areas, the report addresses the supply and demand trends within that sector, supply chain, and costs of carbon fiber and components, all contributing to a competitiveness assessment that addresses the United States' role in future industry growth. This report was prepared by researchers at Oak Ridge National Laboratory and the University of Tennessee for the Clean Energy Manufacturing Analysis Center.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Global Carbon Fiber Composites Supply Chain Competitiveness Analysis

This analysis identifies key opportunities in the carbon fiber supply chain where resources and investments can help advance the clean energy economy. The report focuses on four application areas — wind energy, aerospace, automotive, and pressure vessels — that top the list of industries using carbon fiber and carbon fiber reinforced polymers. For each of the four application areas, the report addresses the supply and demand trends within that sector, supply chain, and costs of carbon fiber and components.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Testing of Sapphire Optical Fiber and Sensors in Intense Radiation Fields When Subjected to Very High Temperatures

The primary objective of this project was to determine the optical attenuation and signal degradation of sapphire optical fibers & sensors (temperature & strain), in-situ, operating at temperatures up to 1500°C during reactor irradiation through experiments and modeling. The results will determine the feasibility of extending sapphire optical fiber-based instrumentation to extremely high temperature radiation environments. This research will pave the way for future testing of sapphire optical fibers and fiber-based sensors under conditions expected in advanced high temperature reactors.

47 OTHER INSTRUMENTATION↗

Fast Fiber-Coupled Imaging Devices

HyperV Technologies Corp. has successfully designed, built and experimentally demonstrated a full scale 1024 pixel 100 MegaFrames/s fiber coupled camera with 12 or 14 bits, and record lengths of 32K frames, exceeding our original performance objectives. This high-pixel-count, fiber optically-coupled, imaging diagnostic can be used for investigating fast, bright plasma events. In Phase 1 of this effort, a 100 pixel fiber-coupled fast streak camera for imaging plasma jet profiles was constructed and successfully demonstrated. The resulting response from outside plasma physics researchers emphasized development of increased pixel performance as a higher priority over increasing pixel count. In this Phase 2 effort, HyperV therefore focused on increasing the sample rate and bit-depth of the photodiode pixel designed in Phase 1, while still maintaining a long record length and holding the cost per channel to levels which allowed up to 1024 pixels to be constructed. Cost per channel was 53.31 dollars, very close to our original target of $50 per channel. The system consists of an imaging "camera head" coupled to a photodiode bank with an array of optical fibers. The output of these fast photodiodes is then digitized at 100 Megaframes per second and stored in record lengths of 32,768 samples with bit depths of 12 to 14 bits per pixel. Longer record lengths are possible with additional memory. A prototype imaging system with up to 1024 pixels was designed and constructed and used to successfully take movies of very fast moving plasma jets as a demonstration of the camera performance capabilities. Some faulty electrical components on the 64 circuit boards resulted in only 1008 functional channels out of 1024 on this first generation prototype system. We experimentally observed backlit high speed fan blades in initial camera testing and then followed that with full movies and streak images of free flowing high speed plasma jets (at 30-50 km/s). Jet structure and jet collisions onto metal pillars in the path of the plasma jets were recorded in a single shot. This new fast imaging system is an attractive alternative to conventional fast framing cameras for applications and experiments where imaging events using existing techniques are inefficient or impossible. The development of HyperV's new diagnostic was split into two tracks: a next generation camera track, in which HyperV built, tested, and demonstrated a prototype 1024 channel camera at its own facility, and a second plasma community beta test track, where selected plasma physics programs received small systems of a few test pixels to evaluate the expected performance of a full scale camera on their experiments. These evaluations were performed as part of an unfunded collaboration with researchers at Los Alamos National Laboratory and the University of California at Davis. Results from the prototype 1024-pixel camera are discussed, as well as results from the collaborations with test pixel system deployment sites.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Use of Fiber Optic Distributed Acoustic Sensing for Measuring Hydraulic Connectivity for Geothermal Applications

Advanced methods in reservoir characterization are required to effectively harness geothermal energy from fractured high-temperature, high-pressure crystalline rock. It is critical to determine sufficient fluid connection between injection and production wells to enhance sweep efficiency and optimize the lifetime of the reservoir. A technology is needed that can monitor hydraulic connectivity in real time at any depth in the reservoir, throughout the lifetime of the reservoir. GeoMechanics Technologies, in collaboration with California State University, Long Beach (CSULB) and Silixa LLC, working in cooperation with the Department of Energy, Small Business Innovation Research through DOE SBIR Grant No: DE-SC-0017744, conducted a Phase I research project to investigate the use of fiber optic Distributed Acoustic Sensing (DAS) to improve geothermal reservoir characterization. Fiber optic DAS technology uses inter-well pressure sensing in response to periodic injection to determine hydraulic connectivity in fractured geothermal reservoirs. Fiber optic technology is capable of withstanding high temperatures and pressures typical of geothermal reservoirs. This tool would provide nearly continuous pressure monitoring along the length of the wellbore, providing knowledge into hydraulic pathways even where perforations do not exist. Real-time hydraulic monitoring can be performed without interrupting normal field operations. Also, measurements can be obtained throughout the lifetime of the well, ideally accounting for any changes in operations or reservoir configurations or thermally induced changes in permeability. The objective of this research effort was to develop and document an innovative tool that can be used for geothermal reservoir characterization. GeoMechanics Technologies and partners investigated and documented the use of fiber optic DAS for measuring the hydromechanical response caused by fractures in a reservoir and how that correlates to reservoir connectivity. For this Phase I project, numerical simulations, laboratory testing, and a field demonstration were performed to further validate the effectiveness of DAS technology for detecting formation hydraulics. This report summarizes the project activities. The main significant findings are: 1. From the numerical simulations using conceptual models, it is concluded that a high permeability zone inside a reservoir shows a different strain pattern along vertical monitoring lines away from the injection, when inducing low frequency pressure pulses. 2. The order of magnitude of strain observed at a distance of 100 ft from the injection well ranged from nanostrain to microstrain. Such strains are detectable with DAS tools currently available to industry. 3. Laboratory experiments stressed the importance of cable design and layout in the field, making calibration on site necessary for each application individually. 4. Field comparison highlighted the operational conditions that play a role in adding noise to the DAS measurement, where temperature effects for this type of application are also considered as noise to the strain measurements. 5. The analyses conducted to date provide motivation for further research, development and application of this technology, combined with field testing.

15 GEOTHERMAL ENERGY↗

Carbon Fiber Prepreg Recycling- Automated Perform Manufacturing Equipment (Final Technical Report)

Discontinuous fiber composites have a compelling business case as related to light metals such as aluminum and magnesium machined or die cast components. DFC’s have been in commercial production using carbon fiber/epoxy prepreg for both commercial aircraft and for military applications for a number of years and their usage is expanding into automotive and consumer goods components. Reasons for this include significantly lower cost as compared to continuous fiber composites easier design and understanding of the material by metal traditionalists, higher degree of part complexity with relatively simple and low cost molds when compared to high-pressure die casting, and potential for near zero waste. IACMI’s 10-year goals of reduction in carbon fiber reinforced plastics manufacturing cost by 25%, reduction in their embodied energy by 50%, and recyclability of 95% can all be advanced through robust recycling. With recycling We have shown that a 15% contribution in manufacturing cost reduction is feasible, that a significant reduction in embodied energy (over 90% for the recycled fraction) is achievable, and that when combined with primary pyrolysis recycling, the 95% target can be met. Large-scale application of advanced composites began with the aerospace industry, and CRTC’s location in Washington State provided access to a waste stream of nearly 900 tonnes/year that was going to landfill. As the aerospace industry has automated parts production, their material forms have become significantly easier to recycle, and some evidence of this exists for the future automotive and wind turbine components as well. CRTC decided to focus on re-purposing the carbon fiber/epoxy aerospace scrap streams through materials reformatting and reuse, and not on primary recycling (pyrolysis mainly) as this technology is commercially available. The main reasons for this were that it offers a route to effective use of the most widely available and consistent feedstock called edge-trim, as well as allows creation of complex and low-cost parts using rapid and cost-effective compression molding technologies. The reasons also include leading the way for potential automotive pre-preg recycling as the combination of roughly 85% virgin pre-preg and 15% recycled pre-preg directly supports IACMI’s goals and enables significant part cost reduction and a path to zero-waste composite manufacturing at the OEMs or Tier 1’s. The purpose of the project was to develop equipment and technology to transform continuous fiber pre-preg in roll forms into smaller chip-format DFC feedstock, and to determine impacts on moldability and performance based on lessons learned along the path. The availability of scrap from pre-preg manufacturers was a significant value to the program even though the aerospace pre-preg is designed to be autoclave molded thus has handling, tackiness, and processing factors that are not ideal for DFCs. The scope of the project was to develop a Phase 1 system that could identify and resolve some of the major hurdles, determine where to focus effort on building a commercial-scale Phase 2 system, and develop technology for handling a wide variety of incoming scrap materials to produce the most usable product. A chopping system was developed and reduced to practice via an experimental approach that enabled all forms of scrap coming from the pre-preg manufacturers and some forms of the scrap coming from OEM production lines to be very effectively re-purposed. The systems that were developed were not considered to be production robust but rather identified and resolved some of the major technical hurdles, and demonstrated the path towards effective full-scale commercialization.

36 MATERIALS SCIENCE↗

Materials Development and Advanced Process Simulation for Additive Manufacturing with Fiber-Reinforced Thermoplastics (Final Technical Report)

DuPont, Local Motors, and the Composites Manufacturing and Simulation Center (CMSC) at Purdue worked together to advance process simulation capabilities for Additive Manufacturing (AM) and develop printable short fiber reinforced semi-crystalline engineering thermoplastics suitable for vehicle components. DuPont provided one candidate thermoplastic material, which was evaluated against the following three criteria: 1) Printability using extrusion additive manufacturing processes. 2) Suitability for vehicle applications based on mechanical coupon screening tests. 3) Predictive capability of process simulations. Indiana Manufacturing Institute provided modeling and simulation technology and access to Purdue’s lab scale AM printer. Local Motors provided mechanical property requirements and printed demonstration prototype components using their Thermwood Large Scale Additive Manufacturing (LSAM) printer. To meet the performance and cost requirements of the automotive industry, high fiber content semi-crystalline engineering materials are required. Printing experience and property data for a 50% by weight short glass fiber reinforced material were gathered. Further, material properties required for simulating the printing process with the glass-fiber reinforced material were characterized. Knowledge was acquired with regards to the processability and performance of this thermoplastic material. Predictions of part deformation and crystallinity level were verified against experimental observations. Any significant results other than verification of simulation, e.g., novel material identified here would be impactful.

36 MATERIALS SCIENCE↗

Continuous Fiber Bath Treatments at Pilot Scale: A Novel Testbed System

The technical demands on high performance textiles continues to expand, and the research community has answered the call with innovative fiber bath treatments for enhanced properties and sizings for improved composites. However, little translation to greater scale has been demonstrated. To fill this gap, a novel, multifunctional system has been developed to explore polymer fiber treatment methods, the deployment of nanoadditive coatings and other sizings, and smart processing methods at the pilot scale. Continuous tows of fibers can be passed through a temperature-controlled, crossflow bath with an immersion residence time exceeding 2 hours. The modular system is resistant to corrosive solutions, includes additional inline stations for washing and drying after processing, is equipped with a bevy of sensors, pumps, and valves monitored and controlled by a LabView program, and can be fully contained in a standard lab fume hood. This new testbed system, when coupled with high fidelity materials characterization methods, will enable rapid evaluation of new fiber treatment methods at pilot-scale.

36 MATERIALS SCIENCE↗

Filament Formation and Melt Spinning of Coal-Based Mesophase Pitch for Carbon Fiber Production

High-performance carbon fibers excel as high specific strength and modulus materials, and are utilized in composites applications ranging across aerospace, automotive, energy, infrastructure, and sports equipment sectors. Compared to PAN-based carbon fiber, mesophase pitch-based carbon fiber has lower tensile strength but provides a higher modulus, higher thermal conductivity, and a lower cost potential. However, challenges in stable, continuous melt spinning processing are a serious limiting factor. Unlike typical melt spinning of long, linear chain polymers, mesophase pitch is a comprised of relatively shorter polycyclic aromatic hydrocarbons which form a liquid crystal. In its ‘green’ or ‘as-spun’ state, the fibers are very fragile. Moreover, its temperature of processing is quite high, often approaching 400ºC. Complex flow dynamics combined with short length and time scale heat transfer render its melt spinning a formidable processing challenge. Improved understanding of the root causes for nascent filament breakage and spinning instabilities are needed. This work aims to determine fundamental phenomena that govern mesophase pitch filament formation by comparison of required draw force and uninterrupted spinning minutes with applied draw down ratio. The effect of perturbations on spinning stability are analyzed using capillary rheometry, microscopy of elongating filaments, and filtration.

01 COAL, LIGNITE, AND PEAT↗