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DOE OSTI2025

A Novel Manufacturing Process of Lightweight Automotive Seats: Integration of Additive Manufacturing and Reinforced Polymer Composite

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2020

High Speed In-situ X-ray Imaging of 3D Freeze Printing of Aerogels

3D freeze printing (3DFP) combines drop-on-demand (DOD) inkjet printing with freeze casting to fabricate lightweight and multifunctional aerogels with customized geometries. Freeze casting is an efficient and easily implemented method capable of fabricating porous, sponge-like structures for many different applications. This process enables tailoring the microstructure of the final product (i.e., pore morphology, alignment, average size distribution, etc.) by controlling the fabrication conditions and freezing kinetics. Furthermore, its combination with DOD printing provides the capability of engineering the macrostructure without relying on a mold as reported for 3D freeze-printed aerogels made from graphene, silver nanowires, and other nanocomposites. In this paper, we performed in-situ X-ray imaging to understand the inside process dynamics in 3DFP using a commercially available colloidal silica ink. We investigated the 3DFP process with the following hierarchy: first, single droplets; then, uniform lines obtained from coalescence of droplets; and finally, three consecutive lines deposited layer by layer. With the help of X-ray imaging, the importance of the balance between material deposition and freezing rates was shown in-situ by the observation inside of the freeze front following the tip of the printed line. The effects of the substrate temperature on the elimination of undesired interfacial boundaries were also shown by the observed ice crystals penetrating from lower to upper layer.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Multifunctional Superelastic Graphene Aerogels Derived from Ambient-Dried Graphene Oxide/Camphene Emulsions

Graphene oxide (GO) emulsions have been widely adopted to fabricate lightweight graphene aerogels (GAs). However, preparing high-performance GAs from conventional GO emulsions under ambient conditions seems rather challenging because of the structural collapse caused by strong capillary forces during drying. Here, we report a new, low-cost route to prepare high-performance, multifunctional GAs by the ambient drying of GO/camphene emulsions. Benefiting from the liquid-solid and solid-gas phase transitions of camphene, highly porous GO aerogels were obtained under ambient conditions. Moreover, the thermally annealed GO aerogels exhibited excellent mechanical properties, fire resistance, thermal insulation performance, and oil adsorption capability.

ambient drying↗

DOE OSTI2017

High-Performance Flexible Supercapacitors obtained via Recycled Jute: Bio-Waste to Energy Storage Approach

In search of affordable, flexible, lightweight, efficient and stable supercapacitors, metal oxides have been shown to provide high charge storage capacity but with poor cyclic stability due to structural damage occurring during the redox process. Here, we develop an efficient flexible supercapacitor obtained by carbonizing abundantly available and recyclable jute. The active material was synthesized from jute by a facile hydrothermal method and its electrochemical performance was further enhanced by chemical activation. Specific capacitance of 408 F/g at 1 mV/s using CV and 185 F/g at 500 mA/g using charge-discharge measurements with excellent flexibility (~100% retention in charge storage capacity on bending) were observed. The cyclic stability test confirmed no loss in the charge storage capacity of the electrode even after 5,000 charge-discharge measurements. In addition, a supercapacitor device fabricated using this carbonized jute showed promising specific capacitance of about 51 F/g, and improvement of over 60% in the charge storage capacity on increasing temperature from 5 to 75 °C. Based on these results, we propose that recycled jute should be considered for fabrication of high-performance flexible energy storage devices at extremely low cost.

Science & Technology - Other Topics↗

DOE OSTI2025

A Novel Deployable Telescope Baffle Using the Kresling Origami Fold

This report introduces a novel deployable origami baffle designed for telescopes and optical systems, which reduces stray light while maintaining high compactness ratios and low weight. This design leverages the planar nature of the end caps on a cylindrical Kresling origami fold to incorporate mounting points, deployable options, and baffle vanes. The adaptable nature of origami (number of faces, origami geometrical ratios, scaling, etc.) allows the design to easily conform to system requirements, including field of view, deployed length, stowed/deployed stability points, and available volume. Geometric ratios that exhibit bistability in both the stowed and deployed states are discussed in detail, as this results in a rigid structure that maintains its desired configuration. Several designs were conceptualized, and multiple small-scale prototypes were constructed. Potential applications include camera lens hoods, lightweight astronomy telescopes, and deployable baffles for space telescopes and optical systems.

42 ENGINEERING↗

DOE OSTI2013

X-ray micro-tomography investigation of the foaming process in the system of waste glass–silica mud–MnO{sub 2}

In case of foamed lightweight aggregates (LWAs), porosity is introduced by the addition of a foaming agent to the glassy matrix, which degasses at an elevated temperature, so that the resulting gases remain trapped inside the glassy structure. The efficiency of action of MnO{sub 2} as a foaming agent in waste glass and waste glass/silica mud systems was studied. Samples were fired at different temperatures and with different dwelling times at a certain temperature, and the development of porosity was investigated by means of X-ray micro-tomography. It was found that, with the prolongation in dwelling times, the number of pores decreased, while, on the other hand, the volume of these pores increased, and that the addition of silica mud increases the foaming temperature and slows down the foaming process. - Highlights: • Preparation of lightweight aggregate from waste glass, silica sludge, and MnO{sub 2} • DTA/TG investigation of MnO{sub 2} • Characterization of pore-forming process by means of X-ray micro-tomography (μcT)

36 MATERIALS SCIENCE↗

DOE OSTI2014

Matrix phased arrays for the inspection of CFRP-components

Lightweight components are increasingly used in different industrial sectors such as transportation, energy generation and automotive. This growing field includes different types of CFRP-structures, hybrid materials and glued components showing - compared to their pure metallic counterparts- a significant more complicated structure in terms of internal interfaces and anisotropy of material parameters. In this work we present the use of matrix phased array to increase the amount of obtained information to enhance the inspection quality. We used different types of carbon materials such as 6 mm thick uni- and bidirectional prepreg specimens containing impact damages. The latter were introduced with different energy levels ranging from 1.3 to 7.2 J. By scanning a 2.25 MHz matrix array with 6 × 10 elements above the prepreg surface and using different angels of incidence a complete 3D-image was generated which allows the detection of defects as small as 1mm in a depth of 4 mm. A comparison with conventional approaches show that the signal-to-noise ratio can be highly increased. This enables us to visualize the region of damage within the impact zone, clearly showing the cone-like damage distribution along increasing material depth. The detection quality allows the estimation of the opening angles of the cone shaped damage, which can be used for further evaluation and quantitation of energy dependent impact damages.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2016

Final Report: Self-Consolidating Concrete Construction for Modular Units

This report focuses on work completed on DE-NE0000667, Self-Consolidating Concrete for Modular Units, in connection with the Department of Energy Nuclear Energy Enabling Technologies (DOE-NEET) program. This project was completed in the School of Civil and Environmental Engineering at the Georgia Institute of Technology, with Westinghouse Corporation as the industrial partner. The primary objective of this project was to develop self-consolidating concrete (also termed “self-compacting concrete” or SCC) mixtures so that concrete placement can be made into steel plate composite (SC) modular structures without the need for continuous concrete placement. As part of the research, SCC mixtures were developed and validated to ensure sufficient shear capacity across cold-joints, while minimizing shrinkage and temperature increase during curing to enhance concrete bonding with the steel plate construction found in modular units. The SCC mixtures developed were able to carry shearing forces across the cold-joint boundaries. This “self-roughening” was achieved by adding a tailored fraction of lightweight aggregate (LWA) to the concrete mix, some of which raised to the surface during curing, forming a rough surface on which subsequent concrete placements were made. The self-roughening behavior was validated through three sets of structural tests. Shear friction on small-scale specimens with cold joints was assessed using varying fractions of LWA and with varying amounts of external steel plate reinforcement. The results show that the shear friction coefficient, to be used with the provisions of ACI 318-14, Section 22.9, can be taken as 1.35. Mid-scale beam tests were completed to assess the cold-joint capacity in both in-plane and out-of-plane bending. The results showed that the self-roughened joints performed as well as monolithic joints. The final assessment was a full-scale test using a steel composite module supplied by Westinghouse and similar in construction to the steel composite modules being assembled at the Vogtle and V.C. Summer plant expansions. The final test showed that the roughened cold-joint showed excellent shear and flexural capacity, and substantial ductility, when used in conjunction with steel composite construction.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Computational discovery of ultra-strong, stable, and lightweight refractory multi-principal element alloys. Part I: design principles and rapid down-selection

Abstract Refractory metal-based multi-principal element alloys (MPEAs) are compelling materials for high-temperature (1000–2000 K) structural applications. However, only a minuscule fraction of their vast and heterogeneous compositional design space has been explored, leaving many potentially interesting alloys undiscovered. In this two-part work, a large region of the 11-element Al-Cr-Fe-Hf-Mo-Nb-Ta-Ti-V-W-Zr design space is computationally explored to identify refractory MPEAs with simultaneously high yield strength or specific yield strength and body-centered cubic (BCC) solid solution stability. In Part I , two case studies illuminate key factors and considerations in the yield strength versus phase stability tradeoff, provide guidelines for narrowing the expansive design space, and identify many candidates predicted to be stronger than refractory MPEAs reported to date, with BCC phase stability. Our findings indicate that medium entropy ternary alloys can outperform alloys with more elements and highlight the importance of exploring regions away from the equiatomic center of composition space.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Design and Production for Maximum Structural Efficiency With Respect to Fiber Orientation With Increased Understanding of Hybrid Fiber Flow Behavior

Discontinuous fiber-reinforced thermoplastic composites have gained considerable attention in automotive, aerospace, and other industries, due to their high-rate of production combined with their ability to attain complex and intricate shapes. Among other high-rate thermoplastic manufacturing processes, injection-molding is one of the most common manufacturing methods due to fast production and high surface finishing of complex geometries. Fiber orientation in discontinuous fiber composites plays a pivotal role in determining the mechanical, electrical, and thermomechanical properties, underscoring the necessity to comprehend fiber orientation in injection molded parts. Among different fiber types, glass and carbon fibers are most common in the composite industries. The recent trend of hybrid composites comprising both glass fiber (GF) and carbon fiber (CF) is also gaining importance in the automotive industry. Hybrid fiber options allow designers to optimize the balance between glass and carbon fibers by leveraging the high durability and low cost of GF while the strength and lightweight properties of CF. Consequently, comparing the fiber oriented distribution (FOD) of injection molded composites containing GF, CF, and a hybrid of GF/CF is critical to investigating the local mechanical properties of intricate structures for high-end applications. In Phase I of this project, FOD in injection-molded panels with respect to distance from the gate was analyzed using X-ray computed tomography (X-CT) for GF, CF, and hybrid CF/GF (CGF) reinforced nylon 66. To understand the reason behind the FOD with different fiber types, computational fluid dynamics (CFD) and rheology were performed. Samples were extracted at three locations: near the gate, center, and opposite end. Thickness of the layers of typical skin-shell-core type FOD varies with fiber type and location. GF achieved flow direction alignment (in shell) earlier than viscous CF and CGF near the gate, whereas CF showed the highest flow-direction alignment at the center due to shear induced orientation. At the opposite end, GF experienced more backflow than others indicating faster mold filling owing to its lower viscosity. Hybrid CGF exhibited GF-dominated center and CF-dominated end region. The numerical model used to obtain FOD and rheological predictions for the CF and GF composites served to corroborate the trends observed in the experimental trials. The FOD responses across fiber types and location were reflected in their longitudinal and transverse properties. Only GF showed higher longitudinal modulus over transverse modulus near the gate attributed to rapid alignment, whereas CF and CGF exhibited opposite trend. However, fountain flow enhanced the longitudinal modulus over transverse modulus with the distance for all, particularly for CF. This study offers insights into mold filling behavior of different fibers which are critical in optimizing injection molding conditions for tailored final properties.

36 MATERIALS SCIENCE↗

DOE OSTI2020

3D Printing of Liquid Crystal Elastomer Foams for Enhanced Energy Dissipation Under Mechanical Insult

Polymer foams are an essential class of lightweight materials used to protect assets against mechanical insults, such as shock and vibration. Two features are important to enhance their energy absorption characteristics: the foam structure and the matrix phase mechanical behavior. This study investigates novel approaches to control both of these features to enhance the energy absorption capability of flexible lattice foams. First, we consider 3D printing via digital light processing (DLP) as a method to control the foam mesostructure across a suite of periodic unit cells. Second, we introduce an additional energy dissipation mechanism in the solid matrix phase material by 3D printing the lattice foams with polydomain liquid crystal elastomer (LCE), which undergo a mechanically induced phase transition under large strains. This phase transition is associated with LC mesogen rotation and alignment and provides a second mechanism for mechanical energy dissipation in addition to the viscoelastic relaxation of the polymer network. Here, we contrast the 3D printed LCE lattices with conventional, thermomechanically near-equivalent elastomer lattice foams to quantify the energy-absorbing enhancement the LCE matrix phase provides. Under cyclic quasi-static uniaxial compression conditions, the LCE lattices show dramatically enhanced energy dissipation in uniaxial compression compared to the non-LCE equivalent foams printed with a commercially available photocurable elastomer resin. The lattice geometry also plays a prominent role in determining the energy dissipation ratio between the LCE and non-LCE foams. We show that when increasing the lattice connectivity, the foam deformation transitions from bending-dominated to stretching-dominated deformations, which generates higher axial strains in the struts and higher energy dissipation in the lattice foam, as stretching allows greater mesogen rotation than bending. The LCE foams demonstrate superior energy absorption during the repeated dynamic loading during drop testing compared with the non-LCE equivalent foams, demonstrating the potential of LCEs to enhance physical protection systems against mechanical impact.

3D printing↗

DOE OSTI2019

Crush Strengths of Stainless Steel Honeycomb for Packaging

Honeycomb structures are used as energy absorbers to dissipate kinetic energy. Their low density to high axial strength and inexpensive cost make them ideal for the energy absorption application. Mechanical properties of lightweight materials are well known compared to more dense materials like stainless steel. Determines the viability of using 304 Stainless Steel honeycomb in future SRNL radioactive material packages. Using a combination of the material properties and testing procedures both static and dynamic crush strength of stainless steel honeycomb will be determined. Both static and dynamic crush strengths of stainless steel honeycomb need to be quantified because strain rate plays a role in the material strength. The stainless steel honeycomb being tested will be cut into sections of about 2.0 inches in width, 2.3 inches in length and 2.5 inches in height. The cell size of the material is 0.25 in and the ribbon thickness 0.003 in. The material has a yield strength of 48 ksi and an ultimate strength of 103.2 ksi, with an elastic modulus of 29,300 ksi. Compression testing to determine the static crush strength will use an Instron compression test machine. This Instron machine uses a 20 ksi capacity load cell, while recording data at varying low strain rates. Dynamic impact testing will involve dropping a 43.8 lb impactor from a height around 5 feet onto the stainless steel honeycomb. The honeycomb structure will be on a rigid surface and the impactor will be dropped via a quick release hook. Dynamic crush strength is determined from the weight of the impactor, height of the drop and difference in height of the honeycomb after the drop.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Stiff and strong, lightweight bi-material sandwich plate-lattices with enhanced energy absorption

Plate-based lattices are predicted to reach theoretical Hashin–Shtrikman and Suquet upper bounds on stiffness and strength. However, simultaneously attaining high energy absorption in these plate-lattices still remains elusive, which is critical for many structural applications such as shock wave absorber and protective devices. In this article, we present bi-material isotropic cubic + octet sandwich plate-lattices composed of carbon fiber-reinforced polymer (stiff) skins and elastomeric (soft) core. This bi-material configuration enhances their energy absorption capability while retaining stretching-dominated behavior. We investigate their mechanical properties through an analytical model and finite element simulations. Our results show that they achieve enhanced energy absorption approximately 2–2.8 times higher than their homogeneous counterparts while marginally compromising their stiffness and strength. When compared to previously reported materials, these materials achieve superior strength-energy absorption characteristics, making them an excellent candidate for stiff and strong, lightweight energy absorbing applications.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Electrically and magnetically dual-driven Janus particles for handwriting-enabled electronic paper

In this work, we describe the synthesis of novel electrically and magnetically dual-driven Janus particles for a handwriting-enabled twisting ball display via the microfluidic technique. One hemisphere of the Janus particles contains a charge control agent, which allows the display color to be controlled by applying a voltage and superparamagnetic nanoparticles, allows handwriting by applying a magnetic field to the display. We fabricated a twisting ball display utilizing these Janus particles and tested the electric color control and handwriting using a magnet. As a result, the display was capable of permitting handwriting with a small magnet in addition to conventional color control using an applied voltage (80 V). Handwriting performance was improved by increasing the concentration of superparamagnetic nanoparticles and was determined to be possible even when 80 V was applied across the electrodes for 4 wt. % superparamagnetic nanoparticles in one hemisphere. This improvement was impossible when the concentration was reduced to 2 wt. % superparamagnetic nanoparticles. The technology presented in our work can be applied to low-cost, lightweight, highly visible, and energy-saving electronic message boards and large whiteboards because the large-size display can be fabricated easily due to its simple structure.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2019

Materials for Automotive Lightweighting

Reducing the weight of automobiles is a major contributor to increased fuel economy. The baseline materials for vehicle construction, low-carbon steel and cast iron, are being replaced by materials with higher specific strength and stiffness: advanced high-strength steels, aluminum, magnesium, and polymer composites. We find that the key challenge is to reduce the cost of manufacturing structures with these new materials. Maximizing the weight reduction requires optimized designs utilizing multimaterials in various forms. This use of mixed materials presents additional challenges in joining and preventing galvanic corrosion.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Innovative large overbraided carbon fiber composite beams in historical Friendship Bell Pavilion

The International Friendship Bell Pavilion located in the City of Oak Ridge, Tennessee symbolizes the spirit of the peace and friendship shared by the city of Oak Ridge and city of Naka, Japan. The Bell Pavilion features an 8000-pound bronze cast bell along with futuristic materials and advanced manufacturing technologies. The team has developed innovative overbraided carbon fiber arched beams in conjunction with the bronze bell. Carbon fiber was utilized in these beams because of its lightweight, strong, stiff, and durable characteristics. A sandwich design used a high-performance foam core, overbraided with triaxial carbon fibers. This is the world’s largest overbraided composite structure for parks and recreation. For the first time in such an application, 17 free floating, 33-foot (10 m) long arched carbon fiber composite beams cantilever from a central concrete-steel superstructure over the bronze bell. The arc radius of the bottom of each beam is uniquely different giving an appearance of an open dome when standing underneath the structure.

Parks and Recreation↗

DOE OSTI2019

Development of a Planar Focusing Collector for CSP

In the field of the concentrating solar power (CSP) technology, the parabolic trough is a common choice for a solar collector. Parabolic troughs are highly reflective curved mirrors that take incident sunlight and focus it onto a line-shaped receiver that runs down the center of troughs. The receivers are generally heat-absorbing pipes containing a heat transfer fluid that delivers the collected thermal energy to steam turbines or engines for generating electricity. However, parabolic troughs are constrained by wind loads and cost of materials and support structure. The goal of this project was to develop a planar focusing collector (PFC) that would serve as an alternative to the parabolic trough. An ideal PFC is ultrathin (less than a few microns) and lightweight, and could be manufactured in a manner that is scalable and low cost. Furthermore, these features would be attractive to CSP technology because of the potential to reduce cost and complexity of installation and maintenance. The work pursued in this project attempted to actualize the PFC concept by utilizing advances in the emerging area of metasurfaces, which rely on the nanopatterning of surfaces to control the amplitude and phase of light at length scales smaller than an optical wavelength. Academic pursuits of metasurface technology predominately employ electron-beam lithography (EBL) for fabrication because the technique offers highly reliable nanopatterning of surfaces with a spatial resolution of ~10 nm. However, due to the techno-economic constraints of the DOE’s SunShot program, particularly cost-effective scalability, the use of EBL was avoided in this project. Rather, fabrication approaches that lend themselves to scalable manufacturing by way of stamping or imprinting were favored. Ultimately, the tradeoffs with using such methods was the larger feature size—on the order of ~150 um critical dimension—resulting in poorer control of light compared to structures fabricated by EBL. A summary of our 2-year investigation on this topic is presented herein. We begin by presenting highlights of our 1 st -year efforts using plasmonics, i.e., metallic nanostructures, as the building block for our PFC. The limitations in this approach are subsequently summarized. We then review the strategy we employed during the final year of our project, in particular utilizing insulating or dielectric materials as the light controlling medium. We round out the report discussing the results of our findings from using this approach. The report is relatively self-contained in that and no prior knowledge of optics or nanotechnology is assumed and technical jargon is kept at a minimum.

14 SOLAR ENERGY↗

DOE OSTI2015

Fracture, failure and compression behaviour of a 3D interconnected carbon aerogel (Aerographite) epoxy composite

Aerographite (AG) is a mechanically robust, lightweight synthetic cellular material, which consists of a 3D interconnected network of tubular carbon [1]. The presence of open channels in AG aids to infiltrate them with polymer matrices, thereby yielding an electrical conducting and lightweight composite. Aerographite produced with densities in the range of 7–15 mg/cm 3 was infiltrated with a low viscous epoxy resin by means of vacuum infiltration technique. Detailed morphological and structural investigations on synthesized AG and AG/epoxy composite were performed by scanning electron microscopic techniques. Our present study investigates the fracture and failure of AG/epoxy composites and its energy absorption capacity under compression. The composites displayed an extended plateau region when uni-axially compressed, which led to an increase in energy absorption of ~133% per unit volume for 1.5 wt% of AG, when compared to pure epoxy. Preliminary results on fracture toughness showed an enhancement of ~19% in K IC for AG/epoxy composites with 0.45 wt% of AG. Furthermore, our observations of fractured surfaces under scanning electron microscope gives evidence of pull-out of arms of AG tetrapod, interface and inter-graphite failure as the dominating mechanism for the toughness improvement in these composites. These observations were consistent with the results obtained from photoelasticity experiments on a thin film AG/epoxy model composite.

36 MATERIALS SCIENCE↗