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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Regolith, rock and fluid distributions at the Upper Colorado River Basin via a multicomponent seismic imaging approach

In October 2018, we conducted an exploratory seismic survey of the East River Watershed Function Science Focus Area, near Crested Butte, CO. Our survey goals were to map seismic bedrock, regolith and sediment properties and relate them to geomorphic and hydrologic processes. We acquired ~12 km of seismic data along roads with a 72-channel, 1.25m spaced streamer, an average shot spacing of 2.5m and an average acquisition rate of 3 km/day. We also obtained ~3km of planted geophone data with geophone and shot spacing between 2.5 and 5 meters and an acquisition rate of 0.5 km/day. Vp results show a sharp transition between regolith and bedrock along hillslopes suggesting a similarly abrupt change in porosity. Vp anisotropy in the Mancos Shale is observable in the lower reaches of the watershed, but is absent in regions near crystalline intrusions where contact metamorphism has likely modified pore structure within the shale. Alluvium thickness varies along the river axis from 0 to > 20 meters reflecting variations in depositional processes as function of stream gradient. We show that when strong discontinuities at the regolith base are present, inhomogeneous waves that travel along subsurface interfaces are generated and can be measured on vertical component geophones. We present a summary manuscript in the report appendix.

58 GEOSCIENCES↗
DOE OSTI2021

A Publicly Available, Annotated Dataset for Naturalistic Driving Study and Computer Vision Algorithm Development

Oak Ridge National Laboratory developed and implemented a data collection effort to create a dataset for use in evaluating and testing algorithms for analyzing driver behavior under controlled settings for support of the Federal Highway Administration’s Exploratory Advanced Research Program. This collection is called the ORNL Naturalistic Driving Study Sample (ONDSS). The dataset is designed to emulate aspects of the Second Strategic Highway Research Project (SHRP2), which contained a massive naturalistic driving study (NDS) with over 3000 drivers between 2010 and 2013 using their personal vehicles, with over 4300 person-years of data collected [HANKEY].

42 ENGINEERING↗
DOE OSTI2021

A HPC Theory-Guided Machine Learning Cyberinfrastructure for Communicating Hydrometeorological Data Across Scales

High-resolution predictions of hydrometeorological variables are critical for supporting hydropower generation decisions and flood control at hydroelectric power plants. Traditional climate and hydrologic models rely on the numerical simulation of detailed physical processes. Therefore, running these simulations is time-, labor-, and computation-intensive. Improving the spatial and temporal resolution in these modeling outputs could lead to cubic increases in both the simulation time and computational demands, rendering high-resolution hydrometeorological predictions expensive and impractical. Many past studies apply the super resolution (SR) technique to downscale climate models using deep learners. However, deep learners are deemed “black-boxes,” as their derivation processes from low-resolution outputs to high-resolution outputs are often hidden. Their results are difficult for domain scientists to interpret and validate. Thus, there is a need for an exploratory machine learning approach that can partially integrate domain-specific theory and knowledge into the data-driven mapping process between simulation outputs of different spatial scales. The domain-specific theory and knowledge can be incorporated into the data model through an inductive approach in which process-related environmental variables are used and analyzed as key drivers (i.e., environmental surrogates) to reflect the complex physical processes. Many of these variables, such as land use land cover, soil types, topography, digital elevation, air temperature, and various watershed characteristics, can be directly measured through sensors or remote sensing techniques. Additionally, SR applications that can downscale hydrological and hydrodynamics models to efficiently produce high-resolution (1 m) flood depth grids are still rare. Since the flood depth grid can be used to support critical decisions for flood control operation at hydroelectric power plants, it is crucial to enable an SR-based capability for interpolating high-resolution flood inundation maps.

13 HYDRO ENERGY↗
DOE OSTI2021

Technology Innovation Pathways for Distributed Wind Balance-of-System Cost Reduction

This exploratory analysis characterizes the balance-of-system (BOS) cost reduction opportunity for small, commercial, medium, and large distributed wind systems. To do this, we used the National Renewable Energy Laboratory’s (NREL’s) Land-based Balance of System Systems Engineering (LandBOSSE) model (Eberle et al. 2019). This model calculates the capital expenditures (CapEx) associated with installation and the system components (e.g., foundation and electrical infrastructure) other than the rotor nacelle assembly and tower. Then, building on the cost reduction potential assessment, we provide a more qualitative evaluation of prospective technology innovation concepts that may enable realization of those cost reductions for distributed wind systems.

17 WIND ENERGY↗
DOE OSTI2021

Shocked Transport: Experiments to Study Dynamic Particle Behavior under Varying Volume Fraction Conditions

Shocks interacting with densely-packed porous media is common in volcanic eruptions or in engineering applications such as ordinance. Large-scale, exploratory experiments have been performed by Frost and collaborators examining the behavior of a bed of particles subjected to a detonation wave. The detonation replaces the central explosive with a high-density, high-temperature gas that propagates outward. A shock wave travels through the particle bed, followed by a contact discontinuity between the shocked air and the explosive products. In the early times, the detonation wave causes many of the particles to collide and compact with each other. As the particles disperse, the experiments demonstrate a series of large-scale jets or fingers that form in the advancing particle front.

42 ENGINEERING↗
DOE OSTI2021

Evaluating Offshore Infrastructure Integrity

Drilling in the offshore environment involves a complex network of infrastructure including pipelines, platforms, rigs, subsea installations, ports, and terminals. Government and industry partners have developed this network over many decades and it remains a critical part of the United States (U.S.) energy portfolio. Many of the major components of this system have been designed with a 20- to 30-year lifespan, yet consistent and growing energy demands support the need to extend the design life of existing infrastructure or repurpose it for secondary needs (i.e. enhanced oil recovery, carbon storage, and new wells). As a result, a growing portion of the offshore infrastructure in the U.S. is approaching or has exceeded its original design life. A critical step in ensuring the continued safe and effective operation of offshore infrastructure is developing a comprehensive understanding of the state of offshore infrastructure and the factors that effect it. The purpose of this project is to assess the current state of existing infrastructure and identify the factors involved in infrastructure degradation through the development and application of big data analytics, machine learning, and advanced spatio-temporal analysis. The project leverages existing data at NETL and combines it with new information on offshore oil and gas structures and the ambient offshore environment in an effort to identify patterns associated with infrastructure integrity. Building on the identified trends and patterns, this project incorporates exploratory analytics and spatial analysis tools in conjunction with machine learning and statistical models to characterize the condition of existing platforms in the offshore environment and predict their risk of failure.

02 PETROLEUM↗
DOE OSTI2021

Geo Thermal Cloud: Cloud Fusion of Big Data and Multi-Physics Models using Machine Learning for Discovery, Exploration, and Development of Hidden Geothermal Resources

The project is motivated by the challenges, risks, and costs associated with geothermal exploration and production. Many processes and parameters impacting geothermal conditions are poorly understood. Diverse datasets are available to help characterize subsurface geothermal conditions (public and proprietary; satellite, airborne surveys, vegetation/water sampling, geological, geophysical, etc.). Yet, it is not clear how to properly leverage these datasets for geothermal exploration due to an incomplete understanding of how physical processes impacting subsurface geothermal conditions are represented in these observations. Recent advancements in machine learning (ML) provide great promise to resolve these issues. The tremendous challenges and risks of geothermal exploration and production bring the demand for novel ML methods and tools that can (1) analyze large field datasets, (2) assimilate model simulations (large inputs and outputs), (3) process sparse datasets, (4) perform transfer learning (between sites with different exploratory levels), (5) extract hidden geothermal signatures in the field and simulation data, (6) label geothermal resources and processes, (7) identify high-value data acquisition targets, and (8) guide geothermal exploration and production by selecting optimal exploration, production, and drilling strategies. Our goals and work under Phases 1 and 2 (as proposed) of this project address all these needs.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Sticky roots--implications of widespread, cryptic, viral infection of plants in natural and managed ecosystems for soil carbon processing in the rhizosphere

Plants strongly influence soil properties through rhizodeposition, in which exudates diffuse from roots, additional secretions are actively released, and root cells are sloughed into the soil. This contribution by plants of carbon compounds belowground is at the core of soil health, water holding capacity, and the soil carbon storage that pulls carbon dioxide out of the atmosphere. Once in soil, organic matter can bind with minerals such as iron hydroxides, where it can be protected from microbial attack for millenia, preserving very large terrestrial soil carbon pools. However, those same compounds contributed by roots to soil may also destabilize the long-term protective associations of SOM with minerals, making that soil organic matter (SOM) more vulnerable to microbial attack and decomposition. Plant roots thus influence both the buildup and breakdown of soil carbon pools. DOE’s E3SM Land Model (ELM) includes a representation of soil carbon storage on minerals, but the potential vulnerability of SOM–mineral associations to effects of rhizodeposition is not yet represented in ELM. To begin testing for this effect of rhizodeposition on soil carbon storage and decomposition, we worked to develop a novel approach during this TES Exploratory project DE-SC0019142 – we harnessed the power of plant viral infection. We examined whether plant virus infection can serve as a tool to intensify rhizodeposition at the root surface, and therefore possibly intensify mobilization of SOM from minerals making it visible to our analytical techniques. Viral infection is widespread in terrestrial ecosystems; 25-70% of plants have virus infection, yet the influence of such infection on root traits and terrestrial soil carbon dynamics remains largely unexplored. We used two plant hosts: the annual Avena sativa (oats) and the genetically tractable, model grass Brachypodium distachyon. These grasses were infected with the broad host range virus Barley Yellow Dwarf Virus (BYDV) via aphids (Rhopalosiphum padi). BYDV infects at least 150 grass species in agricultural and natural ecosystems, and in previous experiments, oats infected with BYDV had roots that were very sticky to the touch, strongly suggesting that infection altered rhizodeposition. We developed this new experimental approach mostly in a one virus (Barley Yellow Dwarf Virus)–one plant (Avena sativa) system. (Several effects of infection in a Brachypodium-BYDV system were similar in nature to effects on Avena sativa, but were more variable.) In the BYDV-Avena system, we developed protocols for consistently infecting target plants (and avoiding infection of control plants) using aphid caging on leaves. We measured that infected plants exhibited reduced photosynthesis, plant (including root) biomass, and root:shoot ratio, as well as simplified root system architecture. We established procedures for sampling the organic compounds carried specifically in phloem (vascular tissue) of leaves and roots, using aphid stylectomy. We used FTICR-MS, Orbitrap GC-MS, and LC-MS/MS to analyze organic compounds in phloem, liquid around roots of plants grown hydroponically, and pore water around roots in soil, and found differences in the compounds in solution bathing roots when infected and uninfected plants were grown hydroponically. Finally, we synthesized isotopically-labeled mineral–organic matter (MAOM) associations in the lab and developed assays using them in solution and in soil. Assays quantified the extent and rate of mineralization of labeled MAOM that was mobilized by functionally distinct rhizodeposits and then attacked by microbes. Two mechanisms for MAOM mobilization emerged, with distinct dynamics. During “direct” mobilization, rhizodeposits such as the strong ligand oxalic acid could drive rapid dissolution of minerals, mobilizing MAOM. During “indirect” mobilization, rhizodeposits such as the simple sugar glucose did not attack minerals directly but instead intensified microbial activity, which led to mobilization via changes in e.g. pH, Eh, and microbial metabolite production (Li et al. 2021). Mechanistic understanding derived from these data and our ongoing experiments using these techniques will inform future development of ELM. Plant roots not only contribute newly fixed organic compounds to soils, but also root activities can drive mineralization of the carbon and nutrients mobilized off minerals via “indirect” or “direct” mechanisms. Using viral infection as a new tool, ongoing combined experimentation and modeling will explore the strength and larger-scale significance of the cascade of processes from rhizodeposition to MAOM mobilization for soil carbon storage and nutrient cycling in terrestrial ecosystems. And if viral infection leads quite generally to “sticky roots”, our perception of the potential importance of prevalent virus infection in terrestrial landscapes will be transformed.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Structure-preserving numerical discretizations for domains with boundaries

This SAND report documents Exploratory Express LDRD Project 223790, "Structure-preserving numerical discretizations for domains with boundaries", which developed a method to incorporate consistent treatment of domain boundaries and arbitrary boundary conditions in discrete exterior calculus (DEC) for arbitrary polygonal (2D) and tensor-product structure prism (3D) grids. The new DEC required the development of novel discrete exterior derivatives, boundary operators, wedge products and Hodge stars. This was accomplished through the use of boundary extension and the blending of known 2D operators on the interior with 1D operators on the boundary. The Hodge star was based on the Voronoi Hodge star, and retained the limitation of a triangular circumcentric primal or dual grid along with low-order accuracy. In addition to the new DEC, two related software packages were written: one for the study of DEC operators on arbitrary polygonal and polyhedral grids using both symbolic and numerical approaches and one for a (thermal) shallow water testbed using TRiSK-type numerics. Immediately relevant (already funded, through CANGA) followup work is the development of a high-order, geometrically flexible Hodge star and structure-preserving, high-order, oscillation-limiting transport operators (using WENO) for n-forms on arbitrary 2D and 3D grids. This will provide all of the machinery required for a high-order version of TRiSK with boundaries on arbitrary 2D and tensor-product 3D grids, which is applicable to both the atmospheric (CRM in E3SM-MMF) and oceanic (MPAS-O) components of E3SM.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Hospice Landscape Report

In July 2018, CMS requested assistance from Oak Ridge National Laboratory (ORNL) to provide expert data science support aimed at developing algorithms for data mining of medical data for operational and payment purposes. The project is intended to be exploratory: work is aimed at alleviating challenges associated with improper payments, specifically audit methodologies and targeting and changes to risk scores. Project goals include developing new, sophisticated methods for audit targeting and improved profile– payment error correlations, specifically focused on Medicare Part C, the program under which MAOs provide health care services to beneficiaries. ORNL conducted RADV analyses against RAPS and EDS data as well as a hospice landscape analysis per a January 2015 dataset that included Medicare beneficiaries who were in hospice in 2017 and 2018. Ongoing work under this project also involves development of predictive models for RADV investigations and hospice landscape.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Demineralization of Carbon Black Derived from End-of-Life Tires

The research carried out in this exploratory research demonstrates an energy and cost-efficient method to purify carbon black recovered from waste tires for recycling back into tires or rubber products. Compared to conventional methods, the methods explored demonstrate improvements in product purity by 40%-60%, a reduction in water requirements by 50%, reduction in processing costs by 80%-90%, and processing/embodied energy by 70%-95%. A techno-economic feasibility analysis of a pilot scale operation shows that these new demineralization methods explored in this work are potentially economically viable. Further development and implication of this technology would help enable cleanup of waste tires and recycling of tires. The work carried out in this study has been successful in demonstrating a new processing method to produce recycled carbon black (rCB) with drastically improved economic viability and impacts.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Exploring Explicit Uncertainty for Binary Analysis (EUBA)

Reverse engineering (RE) analysts struggle to address critical questions about the safety of binary code accurately and promptly, and their supporting program analysis tools are simply wrong sometimes. The analysis tools have to approximate in order to provide any information at all, but this means that they introduce uncertainty into their results. And those uncertainties chain from analysis to analysis. We hypothesize that exposing sources, impacts, and control of uncertainty to human binary analysts will allow the analysts to approach their hardest problems with high-powered analytic techniques that they know when to trust. Combining expertise in binary analysis algorithms, human cognition, uncertainty quantification, verification and validation, and visualization, we pursue research that should benefit binary software analysis efforts across the board. We find a strong analogy between RE and exploratory data analysis (EDA); we begin to characterize sources and types of uncertainty found in practice in RE (both in the process and in supporting analyses); we explore a domain-specific focus on uncertainty in pointer analysis, showing that more precise models do help analysts answer small information flow questions faster and more accurately; and we test a general population with domain-general sudoku problems, showing that adding "knobs" to an analysis does not significantly slow down performance. This document describes our explorations in uncertainty in binary analysis.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Intentional Uranium Tagging for Material Provenance and Pathway Forensics (LA19-Intentional-Forensics-NDD3Bb): Final Project Report

This report summarizes the outcomes of a 3-year NA-22 exploratory project to research the feasibility of tagging uranium materials, especially nuclear fuels, for nuclear nonproliferation purposes. The experimental focus was on metallic uranium forms under prospective surface and bulk tagging manufacturing and detection scenarios. This study showed that a large number of tags (drawn from an even larger menu of options) could be successfully imparted and detected in both as-built and degraded conditions. These results pave the way for additional R&D studies of surface and bulk tagging of metallic forms of uranium.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2022

Integration of Omics into a New Comprehensive Rate Law for Competitive Terminal Electron-Accepting Processes in Reactive Transport Models: Application to N, Fe, S, and Contaminant Transformations in Stream and Wetland Sediments

Surface waters represent important sources of alternate energy and drinking water in the United States, and characterizing the biogeochemical processes that affect surface water quality is relevant to the DOE-BER mission. Sediment biogeochemical processes regulate the release of carbon (C), nutrients, and contaminants to surface waters and thus influence water quality. Sediment biogeochemical processes are dynamic and affected by the deposition and remobilization of solid material and changes in environmental conditions driven by water discharge variations. Wetlands are important natural filters of surface waters which may either trap, metabolize, or mobilize nutrients and contaminants. Despite their importance, biogeochemical processes regulating nutrient and contaminant release and C transformation in stream and wetland sediments cannot be predicted accurately by current mathematical models. These reactive transport models largely rely on detectable changes in geochemical conditions to activate metabolic processes, do not accurately account for the competition between microbial processes, and poorly constrain effects of hydrological perturbations on biogeochemical processes. In this BER-SBR exploratory project, metagenomic and geochemical signatures were combined to identify microbially-mediated redox processes in anaerobic stream and wetland sediments from the Savannah River Site (SRS, ANL SFA) and East Fork Poplar Creek (EFPC, ORNL SFA) that play important roles in C, uranium (U), and mercury (Hg) transformations. In addition, sediment incubations were conducted to examine the competition between anaerobic respiration processes Finally, new rate laws were developed for reactive transport models that rely on complementary metagenomic and geochemical signatures to identify the underlying anaerobic microbial processes in stream and wetland sediments, describe the competition between the dominant metabolic processes involved in nutrient release and U and Hg mobilization, and more accurately quantify carbon transformation and the response of microbial processes to changes in redox conditions associated with hydrological forcing. These rate laws were optimized in batch reactors with SRS wetland sediments, where iron and sulfate reduction dominate. Anaerobic carbon remineralization processes followed the expected thermodynamic sequence of microbial respiration with depth in both sediments, except that geochemical signals indicated that sulfate reduction was inactive in EFPC sediments and moderate in SRS wetland sediments. Estimates indicated that microbial iron reduction contributed to at least half of the production of reduced iron in these sediments. Incubations demonstrated that nitrate reduction, denitrification, and dissimilatory nitrate reduction to ammonium were active in the natural EFPC sediment and activated upon nitrate amendment in these nitrate-rich sediments. In turn, these processes were outcompeted by the addition of either iron oxides or sulfate as alternative terminal electron acceptors. Although geochemical products of sulfate reduction were not detected in the incubations, the abundance of sulfate reduction genes increased with depth in the sediment and was equally more pronounced in treatments amended with either iron oxides or sulfate. Simultaneously, anaerobic sulfide oxidizing bacteria coupling sulfide oxidation to DNRA (and not conventional denitrification) were apparently enriched over time, regardless of the treatments. These findings indicate that sulfate reduction is important in freshwater stream sediments and probably catalyzed by a cryptic sulfur cycle involving nitrogen species, in which the sulfur products from sulfate reduction are immediately removed by side reactions and not detectable by geochemical measurements alone. Similar experiments in SRS sediments, however, demonstrated little interaction between nitrogen and sulfur cycling microorganisms. Sulfate reduction was impacted by the addition of more thermodynamically favorable electron acceptors, suggesting either that iron-reducing microorganisms outcompeted sulfate-reducing microorganisms for organic substrate, depleting the stock of electron donor available for sulfate reduction, or that the cryptic sulfur cycle was shunted by the precipitation of FeS generated as a result of the abiotic reduction of iron oxides by dissolved sulfide. A diagnostic modeling exercise was conducted to further investigate the competition between terminal electron accepting processes. As conventional kinetic models typically do not account for cryptic cycles and used inaccurate formulations to describe competition between microbial communities, new metabolic rate laws were developed that explicitly express the electron acceptor-specific enzyme of each energetically favorable metabolic process based on gene abundance detected in the incubations. The model was tested with the sediment slurry incubation data to determine whether substrate competition could explain the decrease in sulfate reduction observed in the presence of iron oxide competitor. The model was able to reproduce geochemical concentrations really well in each treatment once the model was calibrated with the unamended control, suggesting that microbial competition was indeed driven by thermodynamic considerations. Overall, carbon remineralization processes and rates will be reproduced much more realistically with the new metabolic rate laws.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

COVID-19 Data Curation Effort: An Initial Analysis of the Data

During the COVID-19 pandemic of 2020, major case reporting outlets quickly coalesced around two or three primary vendors. Johns Hopkins University and The New York Times were among the more prominent, and all were of great value to the nation, particularly during the uncertain early stages of the pandemic. They primarily focused on three major attributes: number of new cases, deaths, and recovery. Recognizing that many states were reporting very detailed data sets (e.g., hospital beds) at a county level or finer, the ORNL Pandemic Modeling team embarked on a major data curation effort from March to June 2020 for the purpose of capturing this wealth of detailed data. The challenge of curating this data was daunting. The number of attributes reported by the states grew on almost on a weekly basis. States were routinely shifting their web tool strategies away from easily parsable HTML-based formatting to new Tableau and ArcGIS content. This growth in the sheer number of attributes, combined with the unpredictable shifts in data format, meant an aggressive and agile combination of automated scripting and manual scraping was required to capture new daily streams. Further, the team had to scale up staff and widen its approach for capture and storage. As a result, the team collected more than 11 million data points. Following the close of this data collection effort on June 30 th , 2020, the team embarked on a major effort to appraise what had been collected, including an inventory list, spatial completeness, temporal completeness, scale and geographic characteristics, and a determination. A report on this matter was submitted on September 15 th , 2020, titled “DOE COVID-19 Data Curation Effort: Overview of Data Collection Coverage”. Over 2000 unique attributes had been netted over a wide range of spatial scales, including state, county, zip codes, health regions, and census blocks. Over 11 million individual data points were collected across these attributes, and spatial coverage (in total) included all 50 states and multiple territories. What became apparent in the process is that in the absence of any data standards, many states reported a wide variety of unique attributes that were not always compatible with attributes reported in other states. As time continued, states began adding new attributes and offering finer grain detail in some older attributes. This meant that not all data streams existed for the entire time period; in fact, the number tended to increase dramatically towards the end. Often, states would begin an attribute series and then stop altogether. These highly variable and uncertain conditions illuminated the need for harmonization approaches that would reconcile and conflate changing attribute names and detail over time. For example, grouping racial data reported as either Black or African American, depending on the state, into a single harmonized attribute. These choices would make a within-state analysis possible during the time period and lead to potential between-state analytics later on. This was almost entirely a manual decision process, requiring some subjective decision-making at times, to prevent a fragmented, short-lived collection of time series fragments that would offer few insights into trends, patterns, and correlates. This report imports harmonized data for state and county into the World Spatio-Temporal Analytics and Mapping Project (WSTAMP). WSTAMP is a major space-time analysis and visualization tool developed at ORNL for the National Geospatial-Intelligence Agency specifically for this kind of exploratory analysis. WSTAMP offers a rich analytical and graphical environment consisting of a wide range of analytics. These include time series plots, statistical summaries, data mining techniques, trend and pattern detection, and hypothesis generation.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

STEM imaging of irradiation induced defects in Eurofer97 steel variants irradiated in the EUROfusion collaboration

Ten exploratory variants of Eurofer97 reduced activation ferritic martensitic (RAFM) steel were irradiated in HFIR to ~2.94 – 32.4 dpa, 300±30 °C as a part of the EUROfusion collaboration. The irradiations were performed in rabbit capsules. ES21-22 capsule were used for irradiating SS-J3 tensile samples while M4CVN bend bar samples were irradiated in ES31-35 capsules. The mechanical properties and multi-length scale characterization of the microstructures of these ten steels, designated as H, I, P, J, K, L, M, N, O, P and reference E, in the nonirradiated form was reported in "Mechanical properties and microstructure characterization of unirradiated Eurofer-97 steel variants for the EUROfusion project, ORNL/SPR-2018/882," while their irradiated properties and some microstructure analysis was reported in "Post-irradiation examination of Eurofer97 steel variants irradiated to 2.5 dpa, ~300 °C in HFIR for the EUROfusion program, ORNL/SPR-2020/1440." Here, additional microstructures using TEM/STEM and STEM-EDX of the irradiated steels is presented. Characterization was performed at the Low Activation Materials Development and Analysis (LAMDA) laboratory.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Low-Cost Preform and Molding Processes

The entry cost for prototyping a composite component for manufacture using automated, high rate processes is prohibitively expensive in many cases, especially for small business, where tooling costs may be several $100k. Discussions with industry also indicate that many small companies, tier 1 and 2 suppliers, have an interest to mold composite parts but do not want to deal with the capital cost, material handling issues, and labor associated with dry fiber preforming operations. While the molders may locate near the end user for logistics reasons, it may be more cost effective for the performer to remain regional and invest in capital equipment to support preform automation, thus keeping costs to a minimum. This project was designed to explore and demonstrate several options to meet these industry needs. Dry fiber preforming approaches were evaluated which allow for low pressure resin infusion, single sided tooling options such a vacuum assisted resin transfer molding (VARTM) or low pressure resin transfer molding (RTM-light). Unlike sheet molding compound, SMC compression molding where typical molding pressures of 1000 psi are required to push material into the desired location; positioning of a dry fiber preform into the desired location on the tool allows for low molding pressures of 10-50 psi. Lower molding pressures allow for use of low cost, additive fabrication of polymeric tooling. Polymeric tooling is suitable for rapid part prototyping and limited production. Dry fiber preforming approaches evaluated included use of commercial chopped strand mat, robotic chopper gun deposition, and continuous fiber preform augmentation using tailored fiber placement (TFP). Use of chopped strand mat does not require a robotic deposition method, however a cutting table is generally required and there is typically 20-30% scrap generation. While various fiber areal weights are available, the preform is not readily optimized for minimal fiber use or weight savings. In contrast, a robotic chopper gun approach allows for localized deposition where fiber is required to meet structural requirements. The robotic method is highly automated and minimizes fiber scrap, however the capital cost of the equipment and engineering labor for programming can result in higher preform cost compared to chopped strand mat in certain cases depending on preform complexity. Dry fiber preforming using the robotic chopper gun method allows for creation of three dimensional forms. This approach may be ideal for molding in-house, or if the preforms stack together densely to allow for efficient shipping. Applications evaluated for this program considered trade-off between fabrication of a fully 3D preform versus production of a flat preform which is designed to readily drape into the final desired shape. Such a preform design greatly simplifies robotic programming and requires no specialized tooling. The flat preforms are easily stacked and shipped to the final molding location. Flat preforms are much easier to augment with TFP continuous fiber to provide local reinforcement. The demonstration and evaluation of these preforming and tooling methods were completed on three component applications. The first application was a battery box cover for an electric vehicle which was highly three dimensional. The second demonstrator article was comprised of complex contours and was used to demonstrate the use of TFP and RTM-light molding process. The third demonstration article was the roof of an operator’s cab for large construction equipment. The roof is relatively flat however it is comprised of complex changes in thickness which clearly demonstrate the advantage of robotic chopper gun approach as compared to using numerous preform layers of chopped strand mat. The cost trades for the various preforming methods are summarized to help guide the reader as to preforming method considerations. Finally, these demonstrations all used glass fiber roving. A fourth, exploratory task was added to evaluate the ability to make preforms using Zoltek’s carbon fiber split tow roving. We were able to adapt the chopper gun to make flat preforms for laminate testing, but further development effort would be required to make suitable preforms.

36 MATERIALS SCIENCE↗