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At least 433 records · Page 24

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DOE OSTI2025

Recycling Disassembled Automotive Plastic Components for New Vehicle Components: Enabling the Automotive Circular Economy

As the automotive industry increasingly relies on plastic components to meet fuel efficiency and emissions targets, the challenge of managing end-of-life vehicle (ELV) plastics continues to grow. Currently, more than 80% of ELV plastics in the U.S. are landfilled due to limited economic incentives and technical barriers to recycling. This study examines a mechanical recycling pathway for thermoplastic components disassembled from ELVs and assesses their usability for reintegration into new vehicle parts. Four representative materials were chosen based on material labels embedded in recovered parts and aligned with their virgin industrial equivalents: polypropylene (PP), 10% talc-filled PP (PP-T10), 20% talc-filled PP (PP-T20), and a 20% glass-/mineral-filled polyamide (PA6 + GF7 + MF13). The materials underwent shredding, drying, and injection molding before being characterized by particle size analysis, density measurement, thermal analysis (TGA, DSC), mechanical testing, and heat deflection temperature (HDT) evaluation. The results in this work indicated that minor differences in crystallinity were observed and small differences between model materials and ELV materials could have contributed to these changes. Mechanical testing revealed that neat polypropylene suffered a 15–20% reduction in stiffness and tensile strength, but talc-filled polypropylene and glass/mineral-filled nylon retained >90% of their modulus, strength, and heat deflection temperature values relative to virgin controls. Differences between virgin and ELV materials could have been attributed to use life degradation, contamination during use life, or even chemical/processing differences in model materials and ELV materials. However, these findings suggest that mechanically recycled, disassembled ELV plastics can retain sufficient structural performance to support circularity efforts in the automotive sector.

automotive recycling↗

DOE OSTI2023

A Threshold Helium Leakage Detection Switch with Ultra Low Power Operation

Detecting helium leakage is important in many applications, such as in dry cask nuclear waste storage systems. This work develops a helium detection system based on the relative permittivity (dielectric constant) difference between air and helium. This difference changes the status of an electrostatic microelectromechanical system (MEMS) switch. The switch is a capacitive-based device and requires a very negligible amount of power. Exciting the switch’s electrical resonance enhances the MEMS switch sensitivity to detect low helium concentration. This work simulates two different MEMS switch configurations: a cantilever-based MEMS modeled as a single-degree-freedom model and a clamped-clamped beam MEMS molded using the COMSOL Multiphysics finite-element software. While both configurations demonstrate the switch’s simple operation concept, the clamped-clamped beam was selected for detailed parametric characterization due to its comprehensive modeling approach. The beam detects at least 5% helium concentration levels when excited at 3.8 MHz, near electrical resonance. The switch performance decreases at lower excitation frequencies or increases the circuit resistance. The MEMS sensor detection level was relatively immune to beam thickness and parasitic capacitance changes. However, higher parasitic capacitance increases the switch’s susceptibility to errors, fluctuations, and uncertainties.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Hygrothermal Performance of Bio-Based Materials in Residential Building Wall Envelope Systems

In the United States, building envelope systems contribute approximately 28% of building energy consumption, with walls being a primary factor. As the construction industry explores new approaches to lower the energy intensity needed to manufacture materials and, in turn, reduce energy consumption, bio-based materials are gaining attention as a promising alternative. While prior studies have demonstrated that bio-based materials can decrease material energy intensity, their long-term hygrothermal behavior within a whole residential wall system is not yet fully understood. This study aims to evaluate the potential of replacing Oriented Strand Board (OSB) and drywall in residential wall systems with bio-based alternatives. The research focuses on two bio-based materials, assessing their hygrothermal performance under Chicago climate condition (Climate Zone 5). To achieve that, a series of laboratory experiments were conducted to measure key properties of the bio-based materials such as thickness, dimensions, density, thermal conductivity (as a function of temperature and humidity), moisture-dependent permeance and water vapor permeability (WVP), and sorption isotherms. These properties were then used in WUFI® simulations to predict the moisture durability of a standard residential wall system in Climate Zone 5. Results show that substituting OSB and drywall with bio-based materials can achieve acceptable moisture durability, effectively mitigating risks of mold growth and structural damage over time.

Palani, Hevar [ORNL] (ORCID:0000000220211994)↗

DOE OSTI2026

Development and Validation of Low-Cost, High-Reflectance Composite CSP Facets: SIPS Final Report

This work investigates the various challenges associated with developing heliostat structural composite facets using 1 mm glass mirrors. Such facets are desirable for Concentrating Solar Power because 1 mm glass mirrors provide an absolute increase in reflectivity of 2-3 % over the industry standard of 4 mm glass mirrors. Prototypes of paraboloid composite facets with 1 mm glass mirrors were constructed that have a root mean square slope error on the order of 2 mrad while achieving greater than 96% reflectivity. These facets were constructed using a low-quality aluminum mold and a bill of materials that show potential to achieve cost parity with existing 4 mm glass mirrors supported by structural steel. The facets produced were able to survive up to 50 mm hail ball impacts and were robust against accelerated environmental cycling designed to expose durability concerns. Further work is needed to develop a scalable and cost-effective manufacturing process with a similar bill of materials.

14 SOLAR ENERGY↗

DOE OSTI2020

Study of Additive Manufacturing Application to Geothermal Technologies

Geothermal reservoir characterization, field construction, and reservoir operations are very technology intensive activities that contribute significantly to the cost of delivering electricity produced from geothermal resources. Many geothermal technologies, such as downhole tools and drilling equipment, have unusual material, design, and manufacturing considerations dictated by the harsh geothermal environment and extreme aspect ratios required for deployment in a borehole. An additional challenge that faces geothermal applications is the low tool production volume needed to support the industry. Whereas tens of thousands of Oil & Gas wells are drilled and completed in the U.S. annually, there are typically only tens of geothermal wells that are drilled and completed. If a tool typically used in Oil & Gas applications cannot be directly used for geothermal, then the cost associated with making the tool suitable for geothermal is often prohibitive. There is therefore a much smaller inventory of technologies available to geothermal as compared to Oil & Gas and the level of efficiency and sophistication associated with field practice suffers accordingly. A number of advanced manufacturing methods, such as additive manufacturing, have received increased R&D as well as commercial attention in recent years because of their ability to rapidly prototype complex parts. Additive manufacturing in particular provides an opportunity to increase the technology available to the geothermal industry by either reducing fabrication costs associated with complex components or enabling economic production of low volume parts where specialized tooling is often required. Additional potential benefits of additive manufacturing include increased design freedom to make higher performing parts that cannot be made conventionally, the ability to integrate components into assemblies without joining operations, and the ability to economically fabricate variations on design in cases, such as casting molds, where there are large up-front costs associated with tooling. We have recently completed a study that investigated technology needs, representative use cases, manufacturability, and a techno-economic framework for comparing conventional to additive manufacturing methods for geothermal applications. This paper will provide an overview of this recent effort, describe the different elements of the assessment, and summarize the key takeaways related to both the feasibility of using additive manufacturing for geothermal technology applications as well as the potential benefits and impacts.

Polsky, Yarom↗

DOE OSTI2020

Resilient, untethered soft robot

A pneumatically powered, fully untethered mobile soft robot is described. Composites consisting of silicone elastomer, polyaramid fabric, and hollow glass microspheres were used to fabricate a sufficiently large soft robot to carry the miniature air compressors, battery, valves, and controller needed for autonomous operation. Fabrication techniques were developed to mold a 0.65 meter long soft body with modified Pneumatic network actuators capable of operating at the elevated pressures (up to 138 kPa) required to actuate the legs of the robot and hold payloads of up to 8 kg. The soft robot is safe to handle, and its silicone body is innately resilient to a variety of adverse environmental conditions including snow, puddles of water, direct (albeit limited) exposure to flames, and the crushing force of being run over by an automobile.

42 ENGINEERING↗

DOE OSTI2020

Method of fabricating rigid radiation reflectors

A rigid radiation reflector is fabricated from a powdered material transparent to light in a wavelength band extending from approximately 0.2 micrometers to at least 8 micrometers. The powdered material is dispersed in a liquid wherein the powdered material is at least 95% insoluble in the liquid. The resulting mixture is molded under pressure at room temperature and then sintered to generate a porous solid. The porous solid is cooled to room temperature. A surface of the porous solid is then coated with a light-reflecting metal.

Youngquist, Robert C.↗

DOE OSTI2021

Improvements to the Powder Processing of near-Final Shape alnico Magnets

Alnico permanent magnets (PMs), a recent PM system of interest as an attractive rare earth-free PM alternative, have advantageous high operating temperature and magnetic saturation with the potential for utilization in electric machines, e.g. interior-PM motors found in electric vehicles, if current directional solidification methods can be replaced by a true mass production approach. Recently, two unique alnico compositions, termed Full-Co and Co-lean, with improved coercivity, were gas atomized, compression molded, and vacuum sintered (4h at 1240°C) to high densities of 97.8% and 99.3%, respectively. However, the Co-lean remained fine grained isotropic magnets and the Full-Co grains were not textured, lowering magnetic strength in spite of attempts to grow large textured grains by a stress-biased solid state grain alignment method to convert them to high energy anisotropic magnets. It was hypothesized that oxidation during de-binding in air left many prior particle boundary oxides within the sintered microstructure that hindered grain growth and texturing during the stress-biased texturing procedure and prevented the desired abnormal grain growth (AGG). Here we explored a vacuum de-binding step that was linked (in-place) to vacuum sintering and found that the Co-lean exhibited faster uniform grain growth that doubled the average grain size (40 μm to 80 μm). Linked vacuum de-binding and sintering of Full-Co produced some AGG after only 1 h of 1240°C sintering. A new direction for promoting AGG (and stress-biased texturing) in alnico is being explored that utilizes a fundamental analysis of systems with second phase particles that either inhibit or boost grain growth. This effort explores the influence of vacuum de-binding linked to a series of lower sintering temperatures at a fixed time (4h) to see if oxide particle size and volume fraction can be changed to promote AGG conditions in alnico. Surprising qualitative results indicate that AGG may be promoted for vacuum sintering at less than 1200°C.

Rinko, Emily↗

DOE OSTI2021

Inkjet-Based 3D Printing: From Quantum Dots to Steel Tools

Inkjet-based additive manufacturing (AM) technologies are highly versatile among manufacturing processes due to their ability to shape any material in powder or ink form. The two inkjet-based AM technologies are binder jetting and material jetting, and as each of their names suggest, the former uses inkjet to deposit binder into the actual build material and the latter uses inkjet to deposit the actual build material. With each of these technologies comes unique opportunities in the form of embedding functional components within the build, creating material gradients within parts by selectively layering feedstocks, shaping non-weldable materials, and creating low-cost tooling with conformal cooling channels. Dr. Amy Elliott at Oak Ridge National Laboratory has explored a variety of materials and approaches with inkjet-based manufacturing technologies, focusing on industry-relevant applications such as injection molding tooling and mining drills.

Elliott, Amy↗

DOE OSTI2021

Air Dehumidification using Ionic Liquid-Based Fiber Bundle Membrane Contactor

Air dehumidification is essential since excess moisture in the buildings causes discomfort to the occupants, encourages the production of air pathogens such as mold or mildew, and causes corrosion and rotting that degrade building materials. Existing moisture removal processes are mainly focused on condensation and desiccant (liquid or solid) techniques with direct contact between air and desiccant. However, these methods are energy-intensive, or desiccant might be lost or cause corrosion in the process. The main objective of this study is to investigate an ionic liquid-based liquid desiccant absorber based on a membrane fiber bundle. The novel system consists of membrane contactors containing bundles of 10,000 polypropylene fibers. The fiber bundles have 0.3 micron diameter, with ionic liquid flowing inside, and air flowing outside. The fibers provide a high contact area among phases: 1.4 m2 contact surface area in a 0.00015 m3 volume. The ionic liquid as a sorbent stipulates the selectivity for air, prevents the loss of solvent in the operation due to negligible volatility, provides fast diffusion due to low viscosity compared to common ionic liquids, and has high affinity and solubility in water. The dehumidification capacity of the membrane technology was experimentally investigated. The experimental results show that the ionic-liquid based membrane system can effectively remove excess moisture from the air. The novel fiber bundle dehumidification system has a system volume of 0.00798 m3 (7.98 L) and active heat and mass transfer surface area of 8.4 m2. It achieved an average dehumidification of 320 ± 25 W with a volumetric air flowrate of 3.1 m3/min (108 ft3/min).

Turnaoglu, Tugba↗

DOE OSTI2019

Adaptive Water-Resistive Barrier for Building Envelopes

Excessive moisture transport into building enclosures can lead to elevated moisture levels in wall cavities and associated damage. Such conditions can also produce increased energy consumption. Currently, architects and builders are limited to using static membranes as water-resistive barriers that exhibit a single vapor permeance irrespective of environmental conditions. Membranes with a high permeance may allow moisture ingression under hot and humid ambient conditions, while membranes with a low permeance may not allow wall cavities to dry out when moisture accumulates within them.An electrostatically actuated, dual permeance membrane previously demonstrated for protective apparel is under development for use as a water-resistive barrier for building envelopes. When outdoor temperature and relative humidity are high as detected by sensors, the membrane exhibits low permeance (~0.5 perms) to inhibit water vapor ingression into the building enclosure; but when humidity in the wall cavity is high, the membrane exhibits high permeance (~50 perms) to facilitate water vapor egression to the outside. The membrane changes state by electrostatic actuation using a very low current electrical power supply.In order to quantify the benefits of a dual permeance water-resistive barrier, WUFI® hygrothermal modeling simulations were completed comparing the adaptive membrane to conventional fixed permeance membranes relative to inhibiting mold growth for various US climates and several wall constructions. The WUFI® code was modified to accommodate switching the permeance of the adaptive membrane between low and high permeance states for several humidity setpoint control strategies. The effect of liquid water leakage into the wall cavity was also considered.This report summarizes the initial steps in development of dual permeance, electrostatically actuated water-resistive barriers focusing on the results of hygrothermal model simulations of these adaptive structures and testing of subscale adaptive structures to demonstrate the capability of the technology to achieve the preferred permeance levels suggested by the modeling.

Trentacosta, Joseph↗

DOE OSTI2021

Helical superconducting undulator for 3rd and 4th generation of synchrotron light source and FELs

A helical superconducting undulator includes a cylindrical magnetic core through which a bore hole allows the passage of charged particles. A single superconducting wire wraps the magnetic core guided by helical flights and cylindrical protrusions, to create interleaved helical windings on the magnetic core. An electrical current may be supplied to the superconducting wire to generate a periodic helical magnetic field in the bore. The helical superconducting undulator also includes a strong-back enclosure that acts as an epoxy mold during epoxy impregnation, a structural support to ensure straightness of the undulator after epoxy impregnation, and assists in cooling and thermal control of the magnetic core and superconducting wire during device operation.

Gluskin, Efim↗

DOE OSTI2022

Methods, systems, and apparatuses for in-line variably porous surfaces

Variably porous panels and panel assemblies incorporating shape memory alloy components along with methods for actuating the shape memory alloys are disclosed to predictably alter the porosity of a substrate surface, with the shape memory alloy maintained in an orientation relative to the panel that is in-plane with a mold-line of the panel outer surface.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Rapid manufacturing of tailored preforms

A method for rapid manufacturing of three dimensional discontinuous fiber preforms is provided. The method includes the deposition of a polymeric material containing fibers on a surface to form a tailored charge for compression molding. The reinforced polymeric material may be a thermoplastic or a reactive polymer with viscosity low enough to allow flow through an orifice during deposition, yet high enough zero shear viscosity to retain the approximate shape of the deposited charge. The material can be deposited in a predetermined pattern to induce the desired mechanical properties through alignment of the fibers. This deposition can be performed in a single layer or in multiple layers. The alignment is achieved passively by shear alignment of the fibers or actively through fiber orientation control or mixing. The fibers can be of the desired material, length, and morphology, including short and long filaments.

Kunc, Vlastimil↗

DOE OSTI2022

What does it take to “see” air leakage through a building envelope?

Unwanted air leakage in buildings can cause health and comfort issues for the building occupants and contribute to rot and mold growth in building materials. Leakage also contributes to unnecessary energy consumption ~4 quads (1172 TWh) per year in the buildings sector in the United States. Finding and repairing leaks through the building envelope can improve the energy efficiency, comfort, air-quality, and moisture durability of the building stock. Typical methods of locating air leakage, such as infrared imaging or smoke tracing, rely on concurrent blower door operation which also measures the total leakage rate of the building. These methods can be disruptive to occupants and can’t measure the contribution of individual leaks to prioritize sealing efforts. ORNL is working on a refraction-based fluid flow imaging technique that can measure the leakage rate of individual leaks from the outside of the building. The working principle of this device is based on the refraction of light caused by the exfiltration because there is a small difference in density between the exfiltration and ambient air. We will discuss the operation of the air leak detector and key variables that affect its performance. We will also present preliminary results showing the visualization capability of this new air leak detector under different conditions. Experiments were completed with different claddings, air temperatures, and lighting conditions.

Boudreaux, Philip↗

DOE OSTI2023

System and method of making a crankshaft with alternate materials

A crankshaft for an internal combustion engine is provided. The crankshaft comprises at least four main journals aligned on a crankshaft axis of rotation defining a centerline. The crankshaft further comprises at least three pin journals. Each pin journal is disposed about a respective pin journal axis and positioned between the main journals. Each of the pin journals is joined to a pair of crank arms. Each pair of crank arms is joined to a respective main journal. Each of the main journals, pin journals, and crank arms is made of a first metallic material. Each crank arm has an over-molded counterweight metallurgically bonded thereto. Each counterweight is disposed opposite a respective pin journal relative to the centerline for balance and stability. Each counterweight is made of a second metallic material. The crankshaft has a weight ratio of the second metallic material to the first metallic material of between 0.20 to 0.50.

Klemstine, David C.↗

DOE OSTI2022

Thin Triples Expand the Affordable High-Performance Window Options For Retrofit

Sales of high-performance triple-pane windows make up only a small fraction (~3%) of total window sales in the United States with relatively stagnant market growth over the past 20 years. High costs have been the most commonly cited barrier to adoption. The emergence of thin triples that can fit into the glazing pocket of existing double pane windows has the potential to revolutionize the high-performance window market in particular the retrofit market by enabling glass only upgrades for situations where the frames are still in good condition. The retrofit market has other unique challenges not found in new construction that can be solved or reduced by thin triple pane windows. Insert replacements are often pursued instead of full frame replacement, in retrofits, this method reduces the net free area of a window and can turn an egress window into one that no longer meets the net free area requirements for egress. Thin frames minimize such occurrences. However, these thin frames can often not accommodate the weight of a traditional triple pane, thin triples can bring high performance to this situation. Thicker frames can also increase retrofit labor costs because the interior drywall and/or trim molding needs to be cut back to accommodate a thicker frame while thin triples can fit into frames that match the thickness of the existing window. This paper presents information about field test experiences the highlight these retrofit advantages from experiencing the challenges associated with retrofitting a thick frame as well as the supply chain, purchasability, material and labor costs, and real-world energy and non-energy performance associated with the IGU only replacement method.

window retrofits, thin triple-pane windows, high p↗

DOE OSTI2023

Coating composition embodiments for use in investment casting methods

Disclosed herein are embodiments of a coating composition for use in investment casting. The coating composition embodiments provide a solidified coat that can be as a mold for casting castable materials and that is easily removed from the casted material using water. The coating composition embodiments disclosed herein are reusable and are non-toxic and exhibit high thermal stability.

Cluff, Kyle↗