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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

Performance Characterization of a Prototype Ultra-Short Channel Monolith Catalytic Reactor for Air Quality Control Applications

Contaminated air and process gases, whether in a crewed spacecraft cabin atmosphere, the working volume of a microgravity science or ground-based laboratory experiment facility, or the exhaust from an automobile, are pervasive problems that ultimately effect human health, performance, and well-being. The need for highly-effective, economical decontamination processes spans a wide range of terrestrial and space flight applications. Adsorption processes are used widely for process gas decontamination. Most industrial packed bed adsorption processes use activated carbon because it is cheap and highly effective. Once saturated, however, the adsorbent is a concentrated source of contaminants. Industrial applications either dump or regenerate the activated carbon. Regeneration may be accomplished in-situ or at an off-site location. In either case, concentrated contaminated waste streams must be handled appropriately to minimize environmental impact. As economic and regulatory forces drive toward minimizing waste and environmental impact, thermal catalytic oxidation is becoming more attractive. Through novel reactor and catalyst design, more complete contaminant destruction and greater resistance to poisoning can achieved leading to less waste handling, process down-time, and maintenance. Performance of a prototype thermal catalytic reactor, based on ultra-short channel monolith (USCM) catalyst substrate design, under a variety of process flow and contaminant loading conditions is discussed. The experimental results are evaluated against present and future air quality control and process gas purification processes used on board crewed spacecraft.

Perry, J. L.↗
DOE OSTI2025

Reducing waste of the hydride-dehydride process for U-6 wt% Nb spherical powders through lower impact and targeted milling

The breakdown of solid metal into powder during the hydride-dehydride process is commercially important for the formation of titanium and other metal powders. Typically, the milling of the brittle hydride powder occurs in a ball mill, where milling media impacts powder particles to break them down. The milling media can impact particles that are larger than desired, as desired, or smaller than desired, indiscriminately making all particles smaller. In this work, we investigate how to minimize waste powder production during milling using two different milling methods, planetary ball milling and milling in a sieve shaker (sieve-milling). Both processes yielded similar amounts of 20–75 μm diameter powder (the target size range); however, sieve-milling generated a significantly smaller amount of undersized waste powder. The powders were characterized by X-ray diffraction, SEM/STEM, and magnetic susceptibility. Several differences between ball milling and sieve-milling processes are discussed. We then conclude that the decreased yield of undersized powder in sieve-milling was due to a combination of lower impact energy in sieve-milling, unreacted metallic cores in the hydride flakes, and the ability to mill target particle sizes during sieve-milling. While these results are from the milling of brittle hydride powder, similar methods may be applicable to other brittle powders, including ceramics or salts.

Chemistry↗
DOE OSTI2021

Circular Economy for Building Materials

The building sector is the one of the largest consumers of raw materials and producers of waste in the United States. NREL is working to minimize waste from building construction by conducting research on new materials, construction, and building durability, as well as developing new design principles and modeling tools. These efforts are designed to help transform the "linear economy" - where materials are simply used and disposed - into a circular one.

advanced construction methods↗
DOE OSTI2026

Advancing hydrogen production: A comprehensive review of wastewater reforming techniques, feedstocks, and opportunities

Wastewater is produced across nearly all human activities and requires treatment to safeguard human health and the natural environment. Treatment of wastewater often requires a large amount of thermal energy, resulting in wasted heat after the treatment process. Because hydrocarbon reforming needs both water and heat, the integration of wastewater treatment with hydrocarbon reforming, a process that produces synthesis gas rich in hydrogen, offers an excellent opportunity to utilize this waste heat and the impurities in wastewater to produce valuable hydrogen gas, to minimize waste from industrial processes, and to integrate water treatment with the hydrogen economy. Yet, no comprehensive literature review has been conducted to examine the integration of reforming and wastewater. To address this lack, we summarize the variety of catalytic reforming techniques available in the open literature and review the current literature on wastewater reforming with these techniques. Subsequently, we conduct a review of common types of wastewater contaminants and their possible effects on reforming catalyst performance and life. Lastly, three underexamined wastewater sources are identified, namely, oilfield wastewater, geothermal water, and mining and mineral processing wastewater, and their potential for future study as a reforming feedstock is examined.

08 HYDROGEN↗
DOE OSTI2026

Integrating Immersive Visualization in Molten-Salt Reactor Waste Management for Experimental Design and Planning

Molten-salt reactors (MSRs) represent a promising solution for next-generation nuclear energy, offering advantages in safety, fuel efficiency, and waste minimization. However, their liquid-fueled design presents unique challenges for spent fuel management, making post-shutdown waste characterization essential for developing effective strategies. Despite this need, there is a notable absence of visualization platforms specifically tailored to the unique characteristics and analytical requirements of MSR waste management. Existing tools in the nuclear industry are primarily designed for reactor operations or generic data exploration and lack both integration with MSR-specific multiphysics frameworks and the ability to simultaneously visualize time-dependent thermal fields, chemical composition evolution, and radiation distribution patterns. To address these limitations, this paper presents an immersive virtual reality (VR) visualization platform that processes and displays high-fidelity multiphysics simulation output from the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework in real-time, using Unity. The platform visualizes MSR waste characteristics such as nuclide decay, salt cooling, and corrosion by using Exodus II output data and running on a VR headset. It includes a user-friendly interface with features such as visibility toggling, cross-sectional slicing, and time-series animation for exploring simulation data. These capabilities support experimental design, stakeholder engagement, and public communication by making complex reactor behavior more accessible and understandable. By enhancing spatial reasoning and reducing cognitive load, this immersive environment fosters more effective communication and decision-making in MSR waste management.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Unpacking Modeling Analysis for the Circular Economy

This session will cover: (1) How models simulate material recovery, recycling, product life cycles and waste management. (2) Using life cycle analysis (LCA) to measure environmental impacts across product life cycles and guide decision-making. (3) Optimizing resource use, reducing energy consumption and minimizing waste in recycling systems. (4) Evaluating EPR and other interventions through scenario analysis to make informed decisions.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS1995

NASA LaRC Hazardous Material Pharmacy

In 1993-1994 the Office of Environmental Engineering contracted SAIC to develop NASA Langley's Pollution Prevention (P2) Program. One of the priority projects identified in this contract was the development of a hazardous waste minimization (HAZMIN)/hazardous materials reutilization (HAZMART) program in the form of a Hazardous Materials Pharmacy. A hazardous materials pharmacy is designed to reduce hazardous material procurement costs and hazardous waste disposal costs. This is accomplished through the collection and reissue of excess hazardous material. Currently, a rarely used hazardous material may be stored in a shop area, unused, until it passes its expiration date. The material is then usually disposed of as a hazardous waste, often at a greater expense than the original cost of the material. While this material was on the shelf expiring, other shop areas may have ordered new supplies of the same material. The hazardous material pharmacy would act as a clearinghouse for such materials. Material that is not going to be used would be turned in to the pharmacy. Other users could then be issued this material free of charge, thereby reducing procurement costs. The use of this material by another shop prevents it from expiring, thereby reducing hazardous waste disposal costs.

Esquenet, Remy↗
NASA NTRS2013

Aerospace Fuels From Nonpetroleum Raw Materials

Recycling human metabolic and plastic wastes minimizes cost and increases efficiency by reducing the need to transport consumables and return trash, respectively, from orbit to support a space station crew. If the much larger costs of transporting consumables to the Moon and beyond are taken into account, developing waste recycling technologies becomes imperative and possibly mission enabling. Reduction of terrestrial waste streams while producing energy and/or valuable raw materials is an opportunity being realized by a new generation of visionary entrepreneurs; several relevant technologies are briefly compared, contrasted and assessed for space applications. A two-step approach to nonpetroleum raw materials utilization is presented; the first step involves production of supply or producer gas. This is akin to synthesis gas containing carbon oxides, hydrogen, and simple hydrocarbons. The second step involves production of fuel via the Sabatier process, a methanation reaction, or another gas-to-liquid technology, typically Fischer-Tropsch processing. Optimization to enhance the fraction of product stream relevant to transportation fuels via catalytic (process) development at NASA Glenn Research Center is described. Energy utilization is a concern for production of fuels whether for operation on the lunar or Martian surface, or beyond. The term green relates to not only mitigating excess carbon release but also to the efficiency of energy usage. For space, energy usage can be an essential concern. Another issue of great concern is minimizing impurities in the product stream(s), especially those that are potential health risks and/or could degrade operations through catalyst poisoning or equipment damage; technologies being developed to remove heteroatom impurities are discussed. Alternative technologies to utilize waste fluids, such as a propulsion option called the resistojet, are discussed. The resistojet is an electric propulsion technology with a powered thruster to vaporize and heat a propellant to high temperature, hot gases are subsequently passed through a converging-diverging nozzle expanding gases to supersonic velocities. A resistojet can accommodate many different fluids, including various reaction chamber (by-)products.

Palaszewski, Bryan A.↗
NASA NTRS2013

Aerospace Fuels from Nonpetroleum Raw Materials

Recycling human metabolic and plastic wastes minimizes cost and increases efficiency by reducing the need to transport consumables and return trash, respectively, from orbit to support a space station crew. If the much larger costs of transporting consumables to the Moon and beyond are taken into account, developing waste recycling technologies becomes imperative and possibly mission enabling. Reduction of terrestrial waste streams while producing energy and/or valuable raw materials is an opportunity being realized by a new generation of visionary entrepreneurs; several relevant technologies are briefly compared, contrasted and assessed for space applications. A two-step approach to nonpetroleum raw materials utilization is presented; the first step involves production of supply or producer gas. This is akin to synthesis gas containing carbon oxides, hydrogen, and simple hydrocarbons. The second step involves production of fuel via the Sabatier process, a methanation reaction, or another gas-to-liquid technology, typically Fischer- Tropsch processing. Optimization to enhance the fraction of product stream relevant to transportation fuels via catalytic (process) development at NASA GRC is described. Energy utilization is a concern for production of fuels whether for operation on the lunar or Martian surface, or beyond. The term "green" relates to not only mitigating excess carbon release but also to the efficiency of energy usage. For space, energy usage can be an essential concern. Other issues of great concern include minimizing impurities in the product stream(s), especially those that are potential health risks and/or could de-grade operations through catalyst poisoning or equipment damage; technologies being developed to remove heteroatom impurities are discussed. Alternative technologies to utilize waste fluids, such as a propulsion option called the resistojet, are discussed. The resistojet is an electric propulsion technology with a powered thruster to vaporize and heat a propellant to high temperature, hot gases are subsequently passed through a converging-diverging nozzle expanding gases to supersonic velocities. A resistojet can accommodate many different fluids, including various reaction chamber (by-)products.

Palaszewski, B. A.↗
DOE OSTI2022

Exploring Secondary Markets to Improve Circularity: A Comparative Case Study of Photovoltaics and Hard-Disk Drives

Each year renewable energy generation increases notably with solar panel installations, but these panels have a limited lifespan and will produce between 2 and 4 million metric tons of waste by 2040. Similarly, there are currently between 20 to 70 million hard-disk drives (HDDs) reaching end-of-life (EOL) annually. The circular economy (CE) strives to recycle and reuse materials that are rare and expensive to obtain, minimizing waste. However, studying the potential circularity of photovoltaics (PV) and HDDs requires various data, for instance, on the maturity of the secondhand markets. In this context, the objective of the present study is to identify the current state of secondhand PV and HDD markets. After conducting a literature review, an automated data collection process was set up for that purpose. The analysis of the literature and collected data assess the maturity of the secondhand PV modules and HDDs markets and highlight differences between them.

agent-based modelling↗
DOE OSTI2023

DOE-VFP; Surface Engineered Multifunctional Zeolite Composite for Photodegradation of Per- and Polyfluoroalkyl substances (PFAS) in Aqueous Medium

Per- and Polyfluoroalkyl substances (PFAS) are widely used compounds proven to bioaccumulate and result in detrimental health effects. On October 18, 2021 the United States Environmental Pollution Agency (EPA) released a strategic roadmap to address PFAS that includes the investment in effective research that accelerates cleanup. Existing water treatment technologies for PFAS removal are based on adsorptive removal, are commonly single-use and result in pollutant-laden waste, leading to costly disposal processes. Here we proposed the development of a zeolite-TiO 2 composite for removal and degradation of PFAS. The composite is advantageous as it can be easily integrated into water treatment facilities, is multifunctional, and minimizes waste through regeneration. We studied the adsorptive capacity of zeolites 13X, 3A, 4A and 5A for an anionic PFAS surrogate, methyl orange (MO). Zeolite 3A showed the highest adsorptive capacity, followed by 4A, 5A, and 13X when incubated with 15 ppm MO for 3 hours. Depositing Au-nanospheres on the zeolites surface reduced MO adsorption for all zeolites. We also investigated the photodegradation capacity of TiO 2 , Fe 2 O 3 , Au-TiO 2 , and Au-Fe 2 O 3 , ranking their performance as TiO2 > Fe2O3 > Au-TiO 2 > Au-Fe 2 O 3 under 254 nm light in a 10 ppm MO solution. Our results highlight the favorable adsorption of small pore size zeolites for PFAS surrogates and the potential of TiO2 as a photocatalyst for PFAS degradation. We can further study and integrate the composite's components at our home institution. Other notable achievements of our VFP team includes the submission of two funding proposals, two poster presentations and one invited talk thus showcasing our progress.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Hazardous Waste Management Progress Report [SB14]

The Department of Energy (DOE) is the owner and part operator of multiple facilities in Northern California. The facilities include those located at Lawrence Livermore National Laboratory (LLNL), Lawrence Berkeley National Laboratory (LBNL), Sandia National Laboratories/California (SNL/CA) and SLAC National Accelerator Laboratory (SLAC) among other sites. Through their operations, the facilities generate hazardous waste and, thereby, are subject to the requirements of Chapter 31 of the Title 22 California Code of Regulations, Waste Minimization. The Northern California sites are primarily research and development facilities in the areas relating to national security, high-energy physics, engineering, bioscience and environmental health and safety disciplines. As mentioned above these DOE facilities are primarily research and development facilities. The hazardous wastes generated may be associated with operations that range in size from small, bench scale R&D to major maintenance and operations waste streams. Therefore, even though this document breaks down the waste streams based on California Waste Codes (CWC), the quantities of waste within one waste code category could be from many different locations and dissimilar processes. Because of the nature of the work at the sites, it is not economically feasible to try to implement source reduction measures for every process that generates a portion of the waste stream. This document identifies the processes that generate the major portion of the waste within an identified major waste stream and reports on progress made toward source reduction. In accomplishing the mission, it is DOE’s goal to eliminate waste generation and emissions giving priority to those that may present the greatest risk to human health and the environment.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

The Evaluation of Chemical Decontamination for Contaminated Carbon Steel Scrap by Multiphase Treatment Process - 20249

There is a significant growth in the field of decommissioning of nuclear facilities due the fact that for a lot of them their end of life is nearing. In Taiwan, the government plans to steadily reduce the dependence on nuclear power and moves gradually towards a nuclear-free homeland. Therefore, the development of decommissioning technology becomes the significant issue for the next coming years. The decommissioning of a nuclear power plant is a long process and practical work including radiological surveys, decontamination, dismantling, and the subsequent waste management. Chemical decontamination is an important task in the decommissioning of nuclear power plants and is usually performed by circulating the chemical solution in selected systems or full systems in order to reduce dose levels. However, the decontamination of segmented metal parts is also considered to reduce the contamination to such levels that they may be disposed of at a lower classification or be unconditionally released, and it helps to achieve the goal of waste minimization and provide a more economical cost for disposal management. Chemical decontamination technology is used to remove the contaminated oxides deposited on the surface of metals by dissolving them with chemical mechanisms, such as chelation, acidic or alkaline dissolution, redox reaction and so on. Carbon steel is the major material used in systems and pipelines in the nuclear power plant, thus it is also commonly selected as the target to be decontaminated in the decommissioning process. In this study, the effectiveness of chemical decontamination is evaluated by using multiphase treatment process including the reduction and the oxidation steps. In the step of redox reaction, the oxidation state of the substance is very important. Especially metals of some oxidation states show solubility in water, which has a decisive influence on the chemical decontamination. The experiment of decontamination of metal scraps is carried out by the immersion method within a chemical solution. The relative operation parameters such as temperature, pH, and concentration of the chemical solution are recorded to demonstrate the effect of the decontamination process. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Extraction, purification, and reuse of dyes from coloured polyester textiles

The removal of dyes from coloured textile waste represents a sustainable approach to textile recycling, enabling the recovery of valuable chemical, and material resources that would otherwise be discarded. Up to 40% of the greenhouse gas emissions from textiles originate from dye production, making efficient recycling of dyes a major opportunity for curbing emissions and minimizing waste in both textile manufacturing and recycling. Here, in this study, we demonstrate a process for the extraction, purification, and reuse of mixed dyes from polyester textiles using bio-based, non-hazardous solvents selected on the basis of computational predictions for polyester and dye solubilities. Extracted dyes are purified to individual compounds using counter-current chromatography and analysed via liquid chromatography-mass spectrometry. Post-extraction characterization of the extracted dyes and polymer substrate confirms dye colour retention and polyester fabric property preservation. Dye recycling is demonstrated by redyeing colour-free fabrics with the recovered dyes. We further show a potential process configuration for dye removal using a flow-through reactor packed with a textile substrate. The proposed dye removal process produces reusable, recyclable dyes, and dye-free fabrics, thus facilitating textile recycling.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Tritiated Water Disposition Strategies

Tritium, a radioactive isotope of hydrogen, is typically confined within one or more confinement barriers. Tritium readily reacts with oxygen to form tritiated water or can exchange with protium or deuterium atoms in water to create tritiated water which is around 10,000 times more toxic than elemental tritium. Primary tritium confinement systems can create small volumes of highly tritiated water. Secondary confinement systems, like inert gloveboxes, will produce larger volumes of lower concentration tritiated water. Much larger volumes of tritiated water of very low tritium content are produced by tritium permeation/diffusion. Tritium from inside primary and secondary confinement barriers will diffuse from these systems into cooling water systems. Closed loop, recirculating cooling water systems will slowly accumulate tritium and create concentrations which exceed drinking water (or permitted discharge) concentrations. The cooling water systems designed as series of interconnected cooling loops that can slowly transfer tritium from one cooling loop to another cooling loop through heat exchangers. These large volumes of tritiated water may be above federal discharge limits and also lack convenient disposition pathways. This document will discuss tritiated water management strategies from the perspective of large volume, low tritium concentrations that exceed drinking water or permitted discharge limits. Applicable US regulatory requirements for a Molybdenum-99 (Mo-99) production facility concerning tritiated water are also cited. Tritiated water disposition options, based on typical waste minimization strategies will guide dispositions options. A Case Study example is presented to illustrate the pros and cons of several disposition options. The report does not recommend any particular disposition pathway but discusses strategies to be explored by a producer to guide selection of processes which best fits the needs of a particular waste stream.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

SB14 Source Reduction Evaluation Review and Plan for the DOE California Sites

The Department of Energy (DOE) is the owner of multiple facilities in Northern California. The facilities include Lawrence Livermore National Laboratory (LLNL), Lawrence Berkeley National Laboratory (LBNL), Sandia National Laboratories/California (SNL/CA) and SLAC National Accelerator Laboratory (SLAC) among other sites. Through their operations, the facilities generate hazardous waste and, thereby, are subject to the requirements of Chapter 31 of the Title 22 California Code of Regulations, Waste Minimization. The Northern California sites are primarily research and development facilities in the areas relating to national security, high-energy physics, bioscience and the environment.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Opportunities to Implement Solutions to Achieve Remedial Action Objectives in Consideration of Stakeholder Interests - 20365

A case study in the implementation of a soils excavation and removal project conducted at a Formerly Utilized Sites Remedial Action Program (FUSRAP) Maywood Superfund Site (FMSS) vicinity property; an active commercial business, in a densely populated area, with significant operational, technical and, logistical constraints that were expected to limit areas that could be remediated. The United States Army Corps of Engineers-led (USACE) team successfully navigated complex overlapping stakeholder interests to achieve a more efficient and complete removal of contaminated soils and debris while minimizing unnecessary excess costs to the Government. This paper centers on FUSRAP activities at the FMSS vicinity property located at 149-151 Maywood Avenue, Maywood, Bergen County, New Jersey. For most of its FUSRAP history, this ∼109,000 square meter (27-acre) property housed a now-demolished ∼26,000 square meter (6.5-acre) warehouse operated by Sears Logistics Services, a unit of the Sears Roebuck Company (Figure 2). Sears ended its property lease and vacated the warehouse in December 2016. Given that long history and for the purposes of this paper, the property will be referred to as the 'Sears property' or simply 'the property.' The Sears property is approximately 109,000 square meters (27-acres) and is currently zoned for commercial use. The property is bound to the north and northwest by 100 West Hunter Avenue (the Stepan Company), to the northeast by 205 Maywood Avenue, to the east by Maywood Avenue, to the south by 23 West Howcroft Road, and to the west by businesses on NJ Route 17 and the NJ Route 17 roadway. Until December 2016, the property housed a warehouse and distribution center operated by Sears Logistical Services. On-site structures were demolished by the property owner in 2017. The warehouse covered the north section of the property along the Stepan Company property line. A railroad spur from the adjacent property now known as the Maywood Interim Storage Site (MISS) ended at the northeast corner of the warehouse. Wetlands were located east of the warehouse; the rest of the property was covered with paved parking lots and grassed areas. During remediation at the property, opportunities frequently arose where the project team was able to coordinate effectively with stakeholders to sequence remediation activities to facilitate removal of otherwise inaccessible soils and identify opportunities for materials reuse when supported by residual radiological and chemical levels. Some specific opportunities include: - remediating individual truck loading dock bays to maintain tenant operations; - working along a busy highway and in a utility corridor containing a 30-inch high pressure gas main; - remediating Lodi Brook and associated wetlands requiring bypass pumping and other diversionary structures to maintain local community stormwater drainage; - protecting during remediation and supporting access to facilitate tenant/owner maintenance of critical fire protection and water supply system service lines buried in contaminated soils and necessary for safe warehouse operations; and - coordinating with stakeholders to ensure non-radiological contaminants of concern for the site (unaffiliated with FUSRAP) were addressed by the responsible party in a manner that maximized benefit to all parties while supporting an efficient overall site remediation program. Once the property was vacant and the warehouse structure and radiologically non-impacted above-grade structures were demolished, the project identified an opportunity to significantly reduce the volume of waste associated with the foundation of the former warehouse, a foundation suspected of being partially constructed in radiologically contaminated soils. The project developed and implemented supplemental radiological verification survey and sampling strategies based on radiological cross-contamination risk potential with process flow-charts and screening-level based decision points; a program that classified saw-cut sections of concrete based on observed residual surface radioactivity conditions using a combination of gamma sensitive sodium-iodide scans and beta sensitive Geiger-Muller direct measurements. The proposed approach was reviewed with stakeholders with feedback, including consideration of applicable State of New Jersey Site Remediation Program criteria and guidance before implementation. Once classified, additional sampling was performed at frequencies driven by screening. The sampling methods, stockpile sampling frequencies, criteria and, approach to data evaluation were developed in consideration of existing site cleanup standards, regional background ranges, State of New Jersey radiological remediation program guidance, and specific stakeholder input With the property remediation and survey efforts nearly completed, it is relevant to examine retrospectively the objectives, assumptions and limitations in the remedial design (i.e., what was planned) versus what was able to be accomplished through effective teaming. Benefits to other environmental remediation site programs include better understanding of how to work effectively with stakeholders to achieve win-win outcomes, and approaches to site remediation, waste minimization and materials reuse that were successful in their overall outcomes. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2003

Using Diffusion Bonding in Making Piezoelectric Actuators

A technique for the fabrication of piezoelectric actuators that generate acceptably large forces and deflections at relatively low applied voltages involves the stacking and diffusion bonding of multiple thin piezoelectric layers coated with film electrodes. The present technique stands in contrast to an older technique in which the layers are bonded chemically, by use of urethane or epoxy agents. The older chemical-bonding technique entails several disadvantages, including the following: It is difficult to apply the bonding agents to the piezoelectric layers. It is difficult to position the layers accurately and without making mistakes. There is a problem of disposal of hazardous urethane and epoxy wastes. The urethane and epoxy agents are nonpiezoelectric materials. As such, they contribute to the thickness of a piezoelectric laminate without contributing to its performance; conversely, for a given total thickness, the performance of the laminate is below that of a unitary piezoelectric plate of the same thickness. The figure depicts some aspects of the fabrication of a laminated piezoelectric actuator by the present diffusion- bonding technique. First, stock sheets of the piezoelectric material are inspected and tested. Next, the hole pattern shown in the figure is punched into the sheets. Alternatively, if the piezoelectric material is not a polymer, then the holes are punched in thermoplastic films. Then both faces of each punched piezoelectric sheet or thermoplastic film are coated with a silver-ink electrode material by use of a silkscreen printer. The electrode and hole patterns are designed for minimal complexity and minimal waste of material. After a final electrical test, all the coated piezoelectric layers (or piezoelectric layers and coated thermoplastic films) are stacked in an alignment jig, which, in turn, is placed in a curved press for the diffusion-bonding process. In this process, the stack is pressed and heated at a specified curing temperature and pressure for a specified curing time. The pressure, temperature, and time depend on the piezoelectric material selected. At the end of the diffusion-bonding process, the resulting laminated piezoelectric actuator is tested to verify the adequacy of the mechanical output as a function of an applied DC voltage.

Sager, Frank E.↗