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At least 451 records · Page 25

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NASA NTRS2014

Tailorable Dielectric Material with Complex Permittivity Characteristics

A dielectric material includes a network of nanosubstrates, such as but not limited to nanotubes, nanosheets, or other nanomaterials or nanostructures, a polymer base material or matrix, and nanoparticles constructed at least partially of an elemental metal. The network has a predetermined nanosubstrate loading percentage by weight with respect to a total weight of the dielectric material, and a preferential or predetermined longitudinal alignment with respect to an orientation of an incident electrical field. A method of forming the dielectric material includes depositing the metal-based nanoparticles onto the nanosubstrates and subsequently mixing these with a polymer matrix. Once mixed, alignment can be achieved by melt extrusion or a similar mechanical shearing process. Alignment of the nanosubstrate may be in horizontal or vertical direction with respect to the orientation of an incident electrical field.

Dudley, Kenneth L.↗

NASA NTRS2013

Friction Modifier Using Adherent Metallic Multilayered or Mixed Element Layer Conversion Coatings

A process for creating conversion coatings and spin, drawing, and extrusion finishes for surfaces, wherein the conversion coatings and spin, drawing, and extrusion finishes contain potassium, phosphorus, nitrogen, and one or more non-alkaline metals and/or one or more metalloids. The process comprises forming an aqueous solution of water, phosphoric acid or sulfuric acid, ammonium hydroxide, an alkali metal hydroxide, and one or more non-alkaline metals and/or one or more metalloids. The aqueous solution forms an anti-friction multilayer conversion and/or mixed element coating or a spin, drawing, and extrusion finish on a surface when applied to the surface, either directly without the use of applied external electromotive force, or as an additive in lubricating fluids.

Schramm, Harry F.↗

DOE OSTI2018

Microstructure of titanium on complex deformation paths: Comparison of ECAP, KOBO and HE techniques

Highlights: • Method for producing CP titanium rods for medical implants is searched. • Three processing methods producing ultra-fine grain titanium are compared. • Microstructure and textures are examined and analysed. • Mechanical characteristics are determined based on microhardness and tensile tests. • Hydrostatic extrusion (HE) leads to the best properties of titanium rods for medical implants. - Abstract: In this work samples of commercial purity grade 2 titanium were severely deformed by three different extrusion techniques: equal-channel angular pressing (ECAP), extrusion through oscillating die (KOBO), and hydrostatic extrusion (HE). Resulting microstructures and mechanical properties of processed titanium samples are studied and compared with regard to potential application as a material for dental implants. The obtained results demonstrate the effect of different strain paths, involved by three applied deformation methods, on microstructure refinement, mechanical properties and textures of the studied material. Heterogeneous microstructures with bimodal grain size distributions are observed for all deformation techniques in the examined material, however differences in their internal structures and grain boundary distributions point to different grain refinement mechanisms. The fraction of ultra-fine grains is the highest in titanium deformed by HE. Also the internal grain fragmentation is the most important after HE deformation. This leads to the best mechanical and microstructural properties obtained in this type of deformation. Consequently, the HE process seems to be very interesting for production of material for medical implants.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Improving operational anodising process performance using simulation approach

The use of aluminium is very widespread, especially in transportation, electrical and electronics, architectural, automotive and engineering applications sectors. Therefore, the anodizing process is an important process for aluminium in order to make the aluminium durable, attractive and weather resistant. This research is focused on the anodizing process operations in manufacturing and supplying of aluminium extrusion. The data required for the development of the model is collected from the observations and interviews conducted in the study. To study the current system, the processes involved in the anodizing process are modeled by using Arena 14.5 simulation software. Those processes consist of five main processes, namely the degreasing process, the etching process, the desmut process, the anodizing process, the sealing process and 16 other processes. The results obtained were analyzed to identify the problems or bottlenecks that occurred and to propose improvement methods that can be implemented on the original model. Based on the comparisons that have been done between the improvement methods, the productivity could be increased by reallocating the workers and reducing loading time.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

Additive manufacturing of continuous carbon fiber-reinforced SiC ceramic composite with multiple fiber bundles by an extrusion-based technique

Due to the high cost, complex preparation process and difficulty in structural design, the traditional methods for carbon fiber-reinforced SiC ceramic composite preparation have great limitations. This paper presents a technique for the additive manufacturing multiple continuous carbon fiber bundle-reinforced SiC ceramic composite with core-shell structure using an extrusion-based technique. A conventional nozzle system was modified to print simultaneously a water-based SiC paste with continuous carbon fibers. Different levels of binder contents were investigated to optimize the stickiness, viscosity, thixotropy and viscoelasticity of the paste. After sintering, SiC whiskers were generated on the surface of fiber, which is conjectured to be due to the reaction between SiO and carbon fiber at high temperature. The continuous carbon fiber-reinforced SiC ceramic composite exhibited non-brittle fracture. In conclusion, the flexural strength of the additively manufactured Cf/SiC composites improved from 162 MPa with no fiber bundles to a maximum of 219 MPa with three fiber bundles.

36 MATERIALS SCIENCE↗

NASA NTRS2005

Liquid Crystalline Thermosets from Ester, Ester-Imide, and Ester-Amide Oligomers

Main chain thermotropic liquid crystal esters, ester-imides, and ester-amides were prepared from AA, BB, and AB type monomeric materials and were end-capped with phenylacetylene, phenylmaleimide, or nadimide reactive end-groups. The resulting reactive end-capped liquid crystal oligomers exhibit a variety of improved and preferred physical properties. The end-capped liquid crystal oligomers are thermotropic and have, preferably, molecular weights in the range of approximately 1000-15,OOO grams per mole. The end-capped liquid crystal oligomers have broad liquid crystalline melting ranges and exhibit high melt stability and very low melt viscosities at accessible temperatures. The end-capped liquid crystal oligomers are stable for up to an hour in the melt phase. These properties make the end-capped liquid crystal oligomers highly processable by a variety of melt process shape forming and blending techniques including film extrusion, fiber spinning, reactive injection molding (RIM), resin transfer molding (RTM), resin film injection (RFI), powder molding, pultrusion, injection molding, blow molding, plasma spraying and thermo-forming. Once processed and shaped, the end- capped liquid crystal oligomers were heated to further polymerize and form liquid crystalline thermosets (LCT). The fully cured products are rubbers above their glass transition temperatures. The resulting thermosets display many properties that are superior to their non-end-capped high molecular weight analogs.

Theodornus J Dingemans↗

NASA NTRS2005

Liquid crystalline thermosets from ester, ester-imide, and ester-amide oligomers

Main chain thermotropic liquid crystal esters, ester-imides, and ester-amides were prepared from AA, BB, and AB type monomeric materials and were end-capped with phenylacetylene, phenylmaleimide, or nadimide reactive end-groups. The resulting reactive end-capped liquid crystal oligomers exhibit a variety of improved and preferred physical properties. The end-capped liquid crystal oligomers are thermotropic and have, preferably, molecular weights in the range of approximately 1000-15,000 grams per mole. The end-capped liquid crystal oligomers have broad liquid crystalline melting ranges and exhibit high melt stability and very low melt viscosities at accessible temperatures. The end-capped liquid crystal oligomers are stable for up to an hour in the melt phase. These properties make the end-capped liquid crystal oligomers highly processable by a variety of melt process shape forming and blending techniques including film extrusion, fiber spinning, reactive injection molding (RIM), resin transfer molding (RTM), resin film injection (RFI), powder molding, pultrusion, injection molding, blow molding, plasma spraying and thermo-forming. Once processed and shaped, the end-capped liquid crystal oligomers were heated to further polymerize and form liquid crystalline thermosets (LCT). The fully cured products are rubbers above their glass transition temperatures. The resulting thermosets display many properties that are superior to their non-end-capped high molecular weight analogs.

Dingemans, Theodorous J.↗

DOE OSTI2022

Multi-process tooling for discontinuous carbon and hybrid glass fiber thermoplastics

Expensive tooling often constraints the use of composites in the design and development of automotive parts. While there is significant confidence and knowledge in sheet and bulk metals, composite processes are less understood in mass production environment. The processes used to produce composites and resulting properties are influenced by fiber length attrition, resin to fiber ratio, process waste etc. Tool designs are determined very early in the engineering process. It is cost prohibitive to build additional tools, in the event it becomes obvious a better processing method and material would be beneficial, the original decision is not easily changed. In the present work we recognize the bottleneck of tooling costs and provide an approach of multi-process tooling. The innovation of this work is the design and demonstration of a single tool for different processes namely injection, injection-compression and extrusion-compression. The materials used in this study were long and short fiber thermoplastics (LFTs and SFTs). The resulting structure-property relationships have been reported for the materials and processing methods with a battery tray (BT) tool.

Vaidya, Uday↗

DOE OSTI2016

Modeling Co-Extruded Cathodes for High Energy Lithium-Ion Batteries

Utilizing an existing macro-homogeneous porous electrode model developed by John Newman, this talk presents the potential energy density gains that can be realized in lithium-ion battery electrodes fabricated with co-extrusion (CoEx) technology. CoEx uses carefully engineered fluidic channels to cause multiple streams of dissimilar fluids to impart shape to one another. The result is a high-speed, continuous deposition process that can create fine linear structures much smaller than the smallest physical feature within the printhead. By eliminating the small channels necessary for conventional extrusion and injection processes, CoEx is able to deposit highly loaded and viscous pastes at high line speeds under reasonable operating pressures. The CoEx process is capable of direct deposition of features as small as 10 μm with aspect ratios of 5 or greater, and print speeds > 80 ft/min. We conduct an analysis on two-dimensional cathode cross-sections in COMSOL and present the electrochemical performance results, including calculated volumetric energy capacity for Lithium Nickel Manganese Cobalt Oxide (NMC) co-extruded cathodes, in the presence of a lithium metal anode, polymer separator and ethylene carbonate–diethyl carbonate (EC:DEC) liquid electrolyte. The impact of structured electrodes on cell performance is investigated by varying the physical distribution of a fixed amount of cathode mass over a space of dimensions which can be fabricated by CoEx. By systematically varying the thickness and aspect ratio of the electrode structures, we present an optimal subset of geometries and design rules for co-extruded geometries. Modeling results demonstrate that NMC CoEx cathodes, on the order of 125-200 µm thick, can garner an improvement in material utilization and in turn capacity through the addition of fine width electrolyte channels or highly conductive electrode regions. We also present initial experimental results on CoEx NMC cathode structures.

25 ENERGY STORAGE↗

NASA NTRS1983

Stress-corrosion behavior of aluminum-lithium alloys in aqueous environments

The stress corrosion susceptibility of two powder metallurgy (P/M) alloys, Al-Li-Cu and Al-Li-Cu-Mg two mechanically attrited (M/A) alloys, Al-Li-Cu and Al-Li-Mg; and two wrought, ingot alloys, X-2020 and AA7475, are compared. Time-dependent fracture in an aqueous sodium chloride environment under alternate immersion condition was found to vary significantly between alloys. The stress corrosion behavior of the two powder metallurgy processed alloys was studied in detail under conditions of crack initiation, static crack growth, and fatigue crack growth. A variety of stress corrosion tests were performed including smooth surface, time-to-failure tests; potentiostatic tests on smooth surfaces exposed to constant applied strain rates; and fracture mechanics-type tests under static and cyclic loads. Both alloys show surface pitting and subsequent intergranular corrosion. Pitting is more severe in the magnesium-bearing alloy and is associated with stringer particles strung along the extrusion direction as a result of P/M processing.

Pizzo, P. P.↗

NASA NTRS1984

Stress-corrosion behavior of aluminum-lithium alloys in aqueous salt environments

The stress corrosion susceptibility of two powder metallurgy (P/M) alloys, Al-Li-Cu and Al-Li-Cu-Mg; two mechanically attrited (M/A) alloys, Al-Li-Cu and Al-Li-Mg; and two wrought, ingot alloys, X-2020 and AA7475, are compared. Time-dependent fracture in an aqueous sodium chloride environment under alternate immersion condition was found to vary significantly between alloys. The stress corrosion behavior of the two powder metallurgy processed alloys was studied in detail under conditions of crack initiation, static crack growth, and fatigue crack growth. A variety of stress corrosion tests were performed including smooth surface, time-to-failure tests; potentiostatic tests on smooth surfaces exposed to constant applied strain rates; and fracture mechanics-type tests under static and cyclic loads. Both alloys show surface pitting and subsequent intergranular corrosion. Pitting is more severe in the magnesium-bearing alloy and is associated with stringer particles strung along the extrusion direction as a result of P/M processing.

Pizzo, P. P.↗

DOE OSTI2020

Mechanical Characterization of High-Temperature Carbon Fiber-Polyphenylene Sulfide Composites for Large Area Extrusion Deposition Additive Manufacturing

Additive manufacturing (AM) is evolving from rapid prototyping to production of structural components. The widespread application of AM demands a high level of mechanical performance from these components, and it is therefore essential to improve feedstock material in order to meet these mechanical expectations. However, compared to traditional manufacturing techniques, the mechanical properties of AM materials and their resulting components are not well understood. In this study, we investigated the processability, microstructure, and mechanical performance of twin-screw compounded short carbon fiber reinforced polyphenylene sulfide (PPS) pellets as a feedstock material for big area AM (BAAM). The performance of the AM components was compared to that of traditional processing methods, namely injection molding (IM) and extrusion-compression molding (ECM). It was found that the AM composites exhibited 118% lower tensile strength and 55% lower tensile modulus when compared to traditional injection molding composite specimens; however, AM composites exhibited comparable properties to ECM composites. This response was attributed to highly aligned fibers in IM and AM samples. However, the AM composites contained porosity (15.5% volume), which reduced their mechanical properties in comparison to ECM composites. Finally, the IM process showed the maximum amount of fiber attrition with minimum porosity (0.007% volume), while the ECM process exhibited the least fiber attrition with 4.3% volume porosity.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Invertible neural networks for real-time control of extrusion additive manufacturing

Material extrusion additive manufacturing (AM) has enabled an elegant fabrication pathway for a vast material library. Nonetheless, each material requires optimization of printing parameters generally determined through significant trial-and-error testing. To eliminate arduous, iteration-based optimization approaches, many researchers have used machine learning (ML) algorithms which provide opportunities for automated process optimization. Here, in this work, we demonstrate the use of an ML-driven approach for real-time material extrusion print-parameter optimization through in-situ monitoring of printed line geometry. To do this, we use deep invertible neural networks (INNs) which can solve both forward and inverse, or optimization, problems using a single network. By combining in-situ computer vision and deep INNs, the printing parameters can be autonomously optimized to print a target line width in 1.2 s. Furthermore, defects that occur during printing can be rapidly identified and corrected autonomously. The methods developed and presented in this work eliminate user-intensive, time-consuming, and iterative parameter discovery approaches that currently limit accelerated implementation of extrusion-based AM processes. Furthermore, the presented approach can be generalized to provide real-time monitoring and optimization pathways for increasingly complex AM environments.

36 MATERIALS SCIENCE↗

DOE OSTI2022

In Situ Microstructure Characterization of Potassium Di-Phosphate (KDP) Densification during Cold Sintering

In order for ceramic additive manufacturing (AM) to achieve its full potential, it is increasingly important to develop a more rigorous understanding of fundamental phenomena that govern the kinetics and thermodynamics of ceramic AM processes. In the case of additive build processes, such as direct ink write and ceramic extrusion, methods for densifying the resulting green-body product need to be considered to complement the efficiencies of ceramics AM, itself. One densification route, at least for monolithic components, built layer-by-layer, is offered by the recently developed cold sintering process, whereby high-density final product is achieved through addition of a small amount of liquid solvent and application of modest uniaxial compressive stress at relatively low temperature. In situ small-angle X-ray scattering methods and X-ray diffraction have been applied to characterize and quantify the pore morphology evolution during cold sintering for a model system: potassium di-phosphate, KH 2 PO 4 (KDP). It is shown that both temperature and applied stress affect the densification rate, but stress has a stronger effect on the evolving morphology. A regime with an approximate linear densification rate can be identified, yielding an effective densification activation energy of ≈90 kJ/mol.

36 MATERIALS SCIENCE↗

NASA NTRS2016

Bladed Terrain on Pluto: Possible Origins and Evolutions

Pluto's Bladed Terrain (centered roughly 20 deg N, 225 deg E) covers the flanks and crests of the informally named Tartarus Dorsa with numerous roughly aligned blade-like ridges oriented approx. North-South; it may also stretch considerably farther east onto the non-close approach hemisphere but that inference is tentative. Individual ridges are typically several hundred meters high, and are spaced 5 to 10 km crest to crest, separated by V-shaped valleys. Many ridges merge at acute angles to form Y-shape junctions in plan view. The principle composition of the blades themselves we suspect is methane or a methane-rich mixture. (Methane is spectroscopically strongly observed on the optical surfaces of blades.) Nitrogen ice is very probably too soft to support their topography. Cemented mixtures of volatile and non-volatile ices may also provide a degradable but relief supporting "bedrock" for the blades, perhaps analogous to Callisto. Currently we are considering several hypotheses for the origins of the deposit from which Bladed Terrain has evolved, including aeolian disposition, atmospheric condensation, updoming and exhumation, volcanic intrusions or extrusions, crystal growth, among others. We are reviewing several processes as candidate creators or sculptors of the blades. Perhaps they are primary depositional patterns such as dunes, or differential condensation patterns (like on Callisto), or fissure extrusions. Or alternatively perhaps they are the consequence of differential erosion (such as sublimation erosion widening and deepening along cracks), variations in substrate properties, mass wasting into the subsurface, or sculpted by a combination of directional winds and solar isolation orientation. We will consider the roles of the long-term increasing solar flux and short periods of warm thick atmospheres. Hypotheses will be ordered based on observational constrains and modeling to be presented at the conference.

methane↗

NASA NTRS2016

Bladed Terrain on Pluto: Possible Origins and Evolutions

Pluto’s Bladed Terrain (centered roughly 20°N, 225°E) covers the flanks and crests of the informally named Tartarus Dorsa with numerous roughly aligned blade-like ridges oriented ~North-South; it may also stretch considerably farther east onto the non-close approach hemisphere but that inference is tentative. Individual ridges are typically several hundred meters high, and are spaced 5 to 10 km crest to crest, separated by Vshaped valleys. Many ridges merge at acute angles to form Y-shape junctions in plan view. The principle composition of the blades themselves we suspect is methane or a methane-rich mixture. (Methane is spectroscopically strongly observed on the optical surfaces of blades.) Nitrogen ice is very probably too soft to support their topography. Cemented mixtures of volatile and non-volatile ices may also provide a degradable but relief supporting “bedrock” for the blades, perhaps analogous to Callisto. Currently we are considering several hypotheses for the origins of the deposit from which Bladed Terrain has evolved, including aeolian disposition, atmospheric condensation, updoming and exhumation, volcanic intrusions or extrusions, crystal growth, among others. We are reviewing several processes as candidate creators or sculptors of the blades. Perhaps they are primary depositional patterns such as dunes, or differential condensation patterns (like on Callisto), or fissure extrusions. Or alternatively perhaps they are the consequence of differential erosion (such as sublimation erosion widening and deepening along cracks), variations in substrate properties, mass wasting into the subsurface, or sculpted by a combination of directional winds and solar isolation orientation. We will consider the roles of the long-term increasing solar flux and short periods of warm thick atmospheres. Hypotheses will be ordered based on observational constrains and modeling to be presented at the conference.

Nitrogen ice↗

DOE OSTI2019

Effect of Post-processing Annealing on Crystallinity Development and Mechanical Properties of Polyphenylene Sulfide Composites Printed on Large-format Extrusion Deposition System

This work investigates the effect of annealing on structure development and mechanical properties of parts printed on a large-format extrusion additive manufacturing system using short carbon fiber reinforced polyphenylene sulfide (PPS). PPS, being a semi-crystalline polymer, offers the potential to alter the mechanical properties of parts with changes in crystallinity. Annealing PPS at temperatures above the glass transition and below the melting point for long hours can enhance crystallinity in the material, thereby improving the mechanical properties. However, high temperature polymers such as PPS can also undergo reactions (branching and/or crosslinking) when annealed in an oxidative environment, which further influence crystallization. This work reports the effect of annealing on the changes in crystallinity, possibility of chemical reactions taking place, melt rheological properties and thermo-mechanical properties of the chosen PPS grades.

Kishore, Vidya↗

DOE OSTI2023

Friction Extrusion: Solid-State Metal Synthesis and Recycling in Sustainable Manufacturing

Friction extrusion (FE) is a novel solid-state process for synthesis and recycling of metals and alloys. The novelty of FE is that it utilizes the frictional heating and extensive plastic deformation intrinsic in the process to stir, mechanically alloy, consolidate, and convert powders, chips, and other recyclable feedstock metals into a usable product form of highly engineered materials. FE represents a potentially transformational sustainable manufacturing technology. Being a solid-state process, it eliminates the energy-intensive melting and solidification steps, which are necessary in the conventional metal recycle and synthesis processes. Therefore, FE is a highly energy-efficient, practically zero-emission, and economically competitive process. Here, in this work, the concept and configuration of FE are introduced, the energy-saving advantage of FE is analyzed, the feasibility of FE is demonstrated with synthesizing Al alloys, and the results of some metallographic and mechanical properties studies are presented. A prognosis of the friction extrusion technology is outlined.

36 MATERIALS SCIENCE↗