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DOE OSTI2024

Low-Cost, High-Performance Carbon Fiber for Compressed Natural Gas Storage Tanks (Final Technical Report – Down Select Report)

The aim of this project is to reduce the cost of Type IV, carbon fiber (CF) composite overwrap compressed gas storage tanks by reducing the cost of CF and CF composites. The project team worked to reduce the cost of CF by exploring and testing opportunities for a low-cost alternative precursor material for CF production to supplant market-dominant and costly polyacrylonitrile (PAN). Concurrently, the team aimed to reduce the cost of the tanks at the composite level by improving the interfacial adhesion between the fibers and the matrix resin through the incorporation of low-cost nanoparticles recycled from waste materials, which would reduce the volume of costly CF required to achieve the same tank performance. At the end of the first year, the project team selected mesophase pitch as the primary precursor candidate from a field of materials based on the superior mechanical performance and cost-saving potential. During the second year, the team produced CFs derived from mesophase pitch achieving an average tensile strength of 365.6 ksi and average tensile modulus of 40.74 Msi. Facility availability for spinning and converting these fibers at greater scale has hindered scale-up demonstration, but the team has identified opportunities to conduct this work in the near term. Cost modeling shows that these mesophase pitch-derived CFs can be up to 40% less expensive than PAN-derived CFs due to the lower cost of the feedstock material, higher throughput, greater conversion yield, and lower cost spinning method and compared to PAN. Additionally, the team has demonstrated at lab-scale that nanoparticle coating CFs can significantly increase the interfacial shear strength and load transfer efficiency of CFs in a matrix. Single filament pull-out testing showed a 27% average increase in max interfacial shear strength due to this coating. A continuous method of applying these coatings to a tow of CF has been developed for scale-up. 26 m tows of coated CFs were produced using this system and formed into composite ring samples for ASTM ring burst testing. Issues with the testing protocol have limited assessment of these results. A prototype Type IV tank was designed to meet ANSI HGV2 standards, and the design criteria set out by DOE, using the CF properties developed by the team paired with a proprietary resin matrix, a polyamide liner, and aluminum end bosses. The tank weighs 153.1 kg and with a total capacity of 5.8 kg H2 (5.6 kg usable), which yields a gravimetric capacity of 1.17 kWh/kg. Cost modeling predicts that the tank will have a projected cost of $15.73/kWh. Tank performance modeling does not include considerations for fiber-matrix load transfer efficiency improvements offered by nanoparticle coating method.

08 HYDROGEN↗

DOE OSTI2025

Propylamine Functionalized Porous Fiber Sorbents with High Oxidation Stability for Direct Air Capture

Amine-based sorbents are highly effective for direct air capture (DAC) due to their excellent CO2 capture efficiency under ultra-dilute conditions. However, these sorbents can suffer degradation when exposed to combinations of heat, oxygen, and other atmospheric components, indicating a need for improved sorbent stability. In this study, we developed amidoxime functionalized polymer of intrinsic microporosity (PIM-1-AO) fibers with tethered amines, specifically tris(2-aminoethyl)amine (TAEA) and tris(3-aminopropyl)amine (TAPA), denoted as PIM-1-AO-TAEA and PIM-1-AO-TAPA, respectively. In addition, large scale sorbent fiber spinning has been successfully performed by producing meters of fibers in the lab. We demonstrated that substituting TAEA with TAPA, which has propyl chains instead of ethyl chains, reduces oxidative degradation under regeneration conditions. The findings revealed that PIM-1-AO-TAPA not only significantly outperforms PIM-1-AO-TAEA after accelerated aging process, but also outperforms any other sorbent used in DAC aged under similar conditions. Moreover, PIM-1-AO-TAPA sorbent fibers showed one of the highest amine efficiencies (0.25) considering the low amine loading (21%) coupled with robust CO2 uptake performance (1.12 mmol/g) under DAC conditions.

amine-based sorbent↗

DOE OSTI2022

Mechanical Response and Processability of Wet-Laid Recycled Carbon Fiber PE, PA66 and PET Thermoplastic Composites

The interest in recycled carbon fiber (rCF) is growing rapidly and the supply chain for these materials is gradually being established. However, the processing routes, material intermediates and properties of rCF composites are less understood for designers to adopt them into practice. This paper provides a practical pathway for rCFs in conjunction with low cost and, for the most part, commodity thermoplastic resins, namely polyethylene (PE), polyamide 66 (PA66) and polyethylene terephthalate (PET). Industrially relevant wet-laid (WL) process routes have been adopted to produce mats using two variants of WL mats, namely (a) high speed wet-laid inclined wire to produce broad good ‘roll’ forms and (b) 3DEPTM process patented by Materials Innovation Technologies (MIT)-recycled carbon fiber (RCF), now Carbon Conversions, which involves mixing fibers and water and depositing the fibers on a water-immersed mold. These are referred to as ‘sheet’ forms. The produced mats were evaluated for their processing into composites as ‘fully consolidated mats’ and ‘non-consolidated’ as-produced mats. Comprehensive mechanical data in terms of tensile strength, tensile modulus and impact toughness for rCF C/PE, C/PA66 and C/PET are presented. The work is of high value to sustainable composite designers and modelers.

compression molding↗

DOE OSTI2023

Fiber Optic Temperature Sensor System Using Air-Filled Fabry–Pérot Cavity with Variable Pressure

We report a high-resolution fiber optic temperature sensor system based on an air-filled Fabry–Pérot (FP) cavity, whose spectral fringes shift due to a precise pressure variation in the cavity. The absolute temperature can be deduced from the spectral shift and the pressure variation. For fabrication, a fused-silica tube is spliced with a single-mode fiber at one end and a side-hole fiber at the other to form the FP cavity. The pressure in the cavity can be changed by passing air through the side-hole fiber, causing the spectral shift. We analyzed the effect of sensor wavelength resolution and pressure fluctuation on the temperature measurement resolution. A computer-controlled pressure system and sensor interrogation system were developed with miniaturized instruments for the system operation. Experimental results show that the sensor had a high wavelength resolution (<0.2 pm) with minimal pressure fluctuation (~0.015 kPa), resulting in high-resolution (±0.32 ℃) temperature measurement. It shows good stability from the thermal cycle testing with the maximum testing temperature reaching 800 ℃.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Effect of Near-field Distribution on Transmission Characteristics of Fiber-fed Fabry–Perot Etalons

Fiber-fed etalons are widely employed in advanced interferometric instruments such as gravitational-wave detectors, ultrastable lasers and calibration reference for high-precision spectrographs. We demonstrate that variation in near-field distribution of the feeding fiber would deteriorate the spectrum precision of the fiber-fed Fabry–Perot etalon, especially when precision at the order of 3 × 10{sup -10} or higher is required. The octagonal fiber reinforced with double scrambler could greatly improve the steadiness and uniformness of the near-field distribution. When building wavelength calibrators for sub-m s{sup -1} precision radial-velocity instruments, the double scrambler should be considered meticulously.

47 OTHER INSTRUMENTATION↗

NASA NTRS2006

Deep Broad-Band Infrared Nulling Using A Single-Mode Fiber Beam Combiner and Baseline Rotation

The basic advantage of single-mode fibers for deep nulling applications resides in their spatial filtering ability, and has now long been known. However, and as suggested more recently, a single-mode fiber can also be used for direct coherent recombination of spatially separated beams, i.e. in a 'multi-axial' nulling scheme. After the first successful demonstration of deep (<2e-6) visible LASER nulls using this technique (Haguenauer & Serabyn, Applied Optics 2006), we decided to work on an infrared extension for ground based astronomical observations, e.g. using two or more off-axis sub-apertures of a large ground based telescope. In preparation for such a system, we built and tested a laboratory infrared fiber nuller working in a wavelength regime where atmospheric turbulence can be efficiently corrected, over a pass band (approx.1.5 to 1.8 micron) broad enough to provide reasonable sensitivity. In addition, since no snapshot images are readily accessible with a (single) fiber nuller, we also tested baseline rotation as an approach to detect off-axis companions while keeping a central null. This modulation technique is identical to the baseline rotation envisioned for the TPF-I space mission. Within this context, we report here on early laboratory results showing deep stable broad-band dual polarization infrared nulls <5e-4 (currently limited by detector noise), and visible LASER nulls better than 3e-4 over a 360 degree rotation of the baseline. While further work will take place in the laboratory to achieve deeper stable broad-band nulls and test off-axis sources detection through rotation, the emphasis will be put on bringing such a system to a telescope as soon as possible. Detection capability at the 500:1 contrast ratio in the K band (~2.2 microns) seem readily accessible within 50-100 mas of the optical axis, even with a first generation system mounted on a >5m AO equipped telescope such as the Palomar Hale 200 inch, the Keck, Subaru or Gemini telescopes.

single mode fibers↗

NASA NTRS2006

Measurement of Spatial Filtering Capabilities of Single Mode Infrared Fibers

Spatial filtering is necessary to achieve deep nulls in optical interferometer and single mode infrared fibers can serve as spatial filters. The filtering function is based on the ability of these devices to perform the mode-cleaning function: only the component of the input field that is coupled to the single bound (fundamental) mode of the device propagates to the output without substantial loss. In practical fiber devices, there are leakage channels that cause light not coupled into the fundamental mode to propagate to the output. These include propagation through the fiber cladding and by means of a leaky mode. We propose a technique for measuring the magnitude of this leakage and apply it to infrared fibers made at the Naval Research Laboratory and at Tel Aviv University.

infrared↗

NASA NTRS2017

Fiber Optic Temperature Sensors in TPS: Arc Jet Model Design & Testing

Techniques for using fiber optics with Fiber Bragg Gratings (FBGs) have been developed by IFOS Corp. for use in thermal protection systems (TPS) on spacecraft heat shield materials through NASA Phase 1 and 2 SBIR efforts and have been further improved in a recent collaboration between IFOS and NASA that will be described here. Fiber optic temperature sensors offer several potential advantages over traditional thermocouple sensors including a) multiplexing many sensors in a single fiber to increase sensor density in a given array or to provide spatial resolution, b) improved thermal property match between sensor and TPS to reduce heat flow disruption, c) lack of electrical conductivity.

sensors↗

NASA NTRS2017

SiC Fibers and SiCf/SiC Ceramic Matrix Minicomposites Damage Behavior

Silicon Carbide based Ceramic Matrix Composites (CMCs) are attractive materials for use in high-temperature applications in the aerospace industry. Performance and durability of CMCs depend on the properties of its constituents such as fibers and matrix. Therefore, CMCs constituents limitations and damage mechanisms are discussed and characterized in representative simulated application conditions and dominant damage mechanisms are identified at elevated temperatures. In this work, the initiation and evolution of damage in Hi-Nicalon type S fiber-reinforced minicomposites with different interphases thicknesses from different manufacturers were investigated employing several nondestructive evaluation techniques such as acoustic emission, electrical resistance and microscopy. Moreover, the tensile creep behavior of single Hi-Nicalon Type S SiC fibers were tested and characterized and creep parameters were extracted. Fibers creep tests were performed in air or vacuum at 1200-1482 C under high stresses. Creep parameters was then used in understanding load sharing and lifing of ceramic matrix minicomposites. Future work plans will be reviewed.

SiC fibers↗

NASA NTRS2018

Bit Error Rate Performance on Passive Alignment in Free Space Optical Links Using Large Core Fibers

A 20-meter free-space optical link (FSOL) is proposed for data transmission between external ISS payload sites and the main cabin at a target rate of 10 Gbps (gigabits per second). Motion between a payload site and the main cabin is predicted to cause up to 5 cm in lateral misalignment and 0.2 degrees of angular misalignment. Due to the harsh environment of space it is advantageous to locate the optical transceivers inside the spacecraft or in a controlled environment. With the optical components and transceivers in separate locations, a fiber optic cable will be required to carry light between the two. In our past work we found that the use of large-core fibers provide an increased misalignment tolerance for such systems and could eliminate the need for active control of the optics. In that work, it was shown that a 105 ïm core diameter fiber optic cable offered a viable low SWaP (size, weight, and power) solution for the ISS application; however, the effects of modal dispersion were not investigated. This paper will present bit error rate performance of the FSOL using these large-core fibers.

Free Space Optical Link↗

NASA NTRS2018

Bit Error Rate Performance on Passive Alignment in Free Space Optical Links Using Large Core Fibers

Optical Bit Error Rate Testing↗

NASA NTRS2023

Leveraging Automated Fiber Placement Computer Aided Process Planning Framework for Defect Validation and Dynamic Layup Strategies

Process planning represents an essential stage of the Automated Fiber Placement (AFP) workflow. It develops useful and efficient machine processes based upon the working material, composite design, and manufacturing resources. The current state of process planning requires a high degree of interaction from the process planner and could greatly benefit from increased automation. Therefore, a list of key steps and functions are created to identify the more difficult and time-consuming phases of process planning. Additionally, a set of metrics must exist by which to evaluate the effectiveness of the manufactured laminate from the machine code created during the Process Planning stage. Layup strategies, in addition to dog ears, stagger shifts, steering constraints, and starting points, represented the group of functions labeled as process optimization and ranked the highest in terms of priority for automation. The laminates resulting from the selected parameters are evaluated through the occurrences of principal defect metrics such as fiber gaps, overlaps, angle deviation and steering violations. This document presents an automated software solution to the layup strategy and starting point selection phase of process planning. A series of ply scenarios are generated with variations of these ply parameters and evaluated according to a set of metrics entered by the Process Planner. These metrics are generated through use of the Analytical Hierarchy Process (AHP), where relative importance between each of the fiber features are defined. The ply scenarios are selected which reduce the overall fiber feature scores based on the defects the Process Planner wishes to minimize.

HiCAM↗

DOE OSTI2013

Fiber Optic Picosecond Laser Pulse Transmission Line for Hydrogen Ion Beam Profile Measurement

We present a fiber optic laser pulse transmission line for non-intrusive longitudinal profile measurement of the hydrogen ion (H-) beam at the front-end of the Spallation Neutron Source (SNS) accelerator. The 80.5 MHz, 2.5 ps, multi-killowatt optical pulses are delivered to the accelerator beam line through a large mode area polarization maintaining optical fiber to ensure a high measurement stability. The transmission efficiency, output laser beam quality, pulse jitter and pulse width broadening over a 100-ft fiber line are experimentally investigated. A successful measurement of the H- beam microbunch (~130 ps) profile is obtained. Our experiment is the first demonstration of particle beam profile diagnostics using fiber optic laser pulse transmission line.

fiber optic↗

DOE OSTI2017

Upcoming Irradiation of Ultrasonic and Fiber Optic Sensors in the MITR

Fiber optic and ultrasonic technologies offer the potential for high accuracy and resolution in-pile measurement of a range of parameters, including geometry changes, temperature, crack initiation and growth, gas pressure and composition, and microstructural changes. These technologies, which have performed successfully in out-of-pile tests, have not been well qualified in a test reactor environment. The uncertainty of successful operation of instruments at this level of development has typically been a significant barrier to in-core deployment. Many Department of Energy-Office of Nuclear Energy (DOE-NE) programs are exploring the use of these technologies to provide enhanced sensors for irradiation testing. For example, the ability of small diameter ultrasonic thermometers (UTs) to provide a temperature profile in candidate metallic and oxide fuel would provide much needed data for validating new fuel performance models. The National Scientific User Facility (NSUF) is sponsoring a project to evaluate the performance of promising temperature sensors based on ultrasound and on fiber optics during an upcoming irradiation test in the Massachusetts Institute of Technology Research Reactor (MITR). Several types of thin-wire metallic waveguide ultrasonic thermometers will be tested along with fiber optic temperature sensors using regenerated Fiber-Bragg Grating technology. Additionally, samples of several new optical materials which are potentially much more radiation tolerant than commonly used materials, such as silica, will be included and analyzed post-irradiation. The irradiation is a collaborative effort between researchers from Idaho National Laboratory, the French Alternative Energies and Atomic Energy Commission, the University of Pittsburgh, the Massachusetts Institute of Technology, and AFO Research, Inc.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2013

Remote Fiber Laser Cutting System for Dismantling Glass Melter - 13071

Since 2008, the equipment for dismantling the used glass melter has been developed in High-level Liquid Waste (HLW) Vitrification Facility in the Japanese Rokkasho Reprocessing Plant (RRP). Due to the high radioactivity of the glass melter, the equipment requires a fully-remote operation in the vitrification cell. The remote fiber laser cutting system was adopted as one of the major pieces of equipment. An output power of fiber laser is typically higher than other types of laser and so can provide high-cutting performance. The fiber laser can cut thick stainless steel and Inconel, which are parts of the glass melter such as casings, electrodes and nozzles. As a result, it can make the whole of the dismantling work efficiently done for a shorter period. Various conditions of the cutting test have been evaluated in the process of developing the remote fiber cutting system. In addition, the expected remote operations of the power manipulator with the laser torch have been fully verified and optimized using 3D simulations. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Time Constants for Optical Fiber Temperature Sensing using a Thermal Resistance Approach

Optical fibers are immune to electromagnetic interference, have no moving parts, no applied voltages, no special environmental conditions, and they are extremely small (100's of microns in diameter). The U.S. Department of Energy is interested in extending this technology to extremely high temperature radiation environments for the purposes of developing in-pile instrumentation for the restart of TREAT (Transient Reactor Test Facility). TREAT is an air-cooled, thermal, heterogeneous test reactor facility that was designed to evaluate reactor fuels and structural materials under conditions that simulate various types of transient overpower and under-cooling conditions that may be postulated to occur in a nuclear reactor. Spatially distributed temperature measurements can be made using an Optical Backscatter Reflectometer (such as, model 4600, manufactured by Luna Innovations, Inc.), coupled to single-mode optical fiber that is placed in an in-pile nuclear reactor testing facility. In-pile temperature sensing for the TREAT reactor will need to have a fast response to temperature changes, since the reactor pulse will be on the order of 100 msec. The sensors must also be robust enough to be installed in the testing facility; this requires the fibers to be in a protective capillary tubing that is made of a tough material, such as stainless steel. The temperature response of the fiber will be delayed by the capillary tubing. This paper discusses the characterization and modeling of the thermal time constants of the sensors. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2017

Optimization of Silica Optical Fiber for High Temperature, Radiation Environments

The Department of Energy and Idaho National Laboratory are restarting the TREAT (Transient Reactor Test facility) reactor and are interested in updating the reactor's instrumentation regarding the analysis of the test fuel. Optical fibers' ability to make distributed temperature measurements coupled with its small footprint makes optical fiber a viable candidate to monitor fuel performance in the TREAT reactor. In addition to TREAT reactor, the U.S. Department of Energy and nuclear reactor companies like TerraPower have shown interest in using distributed optically based instrumentation for nuclear instrumentation in Next-Gen reactors. The work presented in this paper focuses on optimizing commercial silica optical fiber so that it can survive the temperatures and radiation fluences of the TREAT reactor and Next-Gen reactors. Temperatures in the TREAT reactor can spike to around 900 - 1000 C and so the goal of this work is to optimize optical fiber to survive these temperatures.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Pilot-Scale Validation of Distributed Optical Fiber Sensors for Underground Pipeline Monitoring

Distributed fiber optic sensing is a cutting-edge technology that has found extensive applications in the monitoring of Ensuring the safety, integrity, and operational efficiency of underground product pipelines is vital for maintaining the nation’s critical infrastructure. Monitoring parameters such as hoop strain, pressure, and acoustic vibrations is key to detecting potential leaks, intrusions, or structural issues. Distributed optical fiber sensor (DOFS) systems provide a compelling solution for continuous, real-time monitoring over long distances. This paper details the development and pilot-scale implementation of DOFS systems for underground pipeline monitoring, evolving from a proof-of-concept stage. Multiple custom-designed DOFS interrogator units—such as optical frequency-domain reflectometry (OFDR), Brillouin optical time-domain analysis (BOTDA), and multimodal interferometer-based fiber acoustic sensors—were employed to measure key parameters like hoop strain, pressure, and acoustic vibrations. The underground product pipeline's outer diameter is 30 inches, the wall thickness is 1.28 inches, and the 3-foot depth. The fiber deployment strategies, and sensing data acquisition methods for these systems are discussed. The results demonstrate the effectiveness of DOFS in detecting hoop strain, temperature changes, and acoustic vibrations, showcasing their potential for real-time monitoring and enhancing pipeline safety.

distributed fiber sensing↗