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DOE OSTI2021

Utilizing distributed acoustic sensing and ocean bottom fiber optic cables for submarine structural characterization

The sparsity of permanent seismic instrumentation in marine environments often limits the availability of subsea information on geohazards, including active fault systems, in both time and space. One sensing resource that provides observational access to the seafloor environment are existing networks of ocean bottom fiber optic cables; these cables, coupled to modern distributed acoustic sensing (DAS) systems, can provide dense arrays of broadband seismic observations capable of recording both seismic events and the ambient noise wavefield. Here, we report a marine DAS application which demonstrates the strength and limitation of this new technique on submarine structural characterization. Based on ambient noise DAS records on a 20 km section of a fiber optic cable offshore of Moss Landing, CA, in Monterey Bay, we extract Scholte waves from DAS ambient noise records using interferometry techniques and invert the resulting multimodal dispersion curves to recover a high resolution 2D shear-wave velocity image of the near seafloor sediments. We show for the first time that the migration of coherently scattered Scholte waves observed on DAS records can provide an approach for resolving sharp lateral contrasts in subsurface properties, particularly shallow faults and depositional features near the seafloor. Our results provide improved constraints on shallow submarine features in Monterey Bay, including fault zones and paleo-channel deposits, thus highlighting one of many possible geophysical uses of the marine cable network.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Asymmetric equilibrium core structures of pyramidal-II < c + a > dislocations in ten hexagonal-close-packed metals

The structures of pyramidal-II < c + a > dislocations, one of the most important defects in structural hexagonal-close-packed (HCP) metals, have not been fully characterized for many of the HCP metals in use today. Here, we employ ab initio informed phase-field dislocation dynamics to determine the minimum energy structure of pyramidal {1¯1¯22} < 11¯23 > dislocations in ten HCP metals, including Be, Co, Mg, Re, Ti, Zn, Cd, Hf, Y, and Zr. As input for the simulations, we calculate, using first-principles density functional theory, the {1¯1¯22} generalized stacking fault energy (GSFE) curves for all ten metals. From these calculations, it is found that magnetism in Co is necessary for achieving a local minimum in the GSFE curve. We observe in simulations that edge and screw character dislocations split into two partials separated by a low-energy intrinsic stacking fault. The splitting distance is shown to scale inversely with the local minimum energy normalized by the product of its shear modulus and Burgers vector. Interestingly, some HCP metals exhibit an asymmetric structure, with either unequal partial Burgers vectors or widths, in contrast to the symmetric configuration expected from linear elastic dislocation theory. We explain these structures by properties of the local maxima in their GSFE curves. Metals with larger degrees of elastic anisotropy result in dislocations with larger splitting distances than would be expected under the commonly used assumption of elastic isotropy. Furthermore, these findings on the sizes and asymmetry in the structures of pyramidal-II < c + a > dislocations are fundamental to understanding how these dislocations glide and interact or react with other defects when these metals are mechanically strained.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Linear Viscoelastic Properties of Putative Cyclic Polymers Synthesized by Reversible Radical Recombination Polymerization (R3P)

Linear viscoelastic properties in both melt and solution states are reported for a series of poly(3,6-dioxa-1,8-octanedithiol) (polyDODT) made by reversible radical recombination polymerization (R 3 P) under conditions designed to produce linear (LDODT), cyclic (RDODT) and linear-cyclic mixtures (LRDODT). PolyDODT is amorphous (T g < -50 °C) and highly flexible (entanglement molecular weight M e,lin ≈ 1850 g/mol for LDODT). PolyDODT’s low T g and low M e,lin enable characterization over a wide dynamic range and a wide range of dimensionless weight-average molecular weight Z w = M w /M e,lin . Measurements at temperatures from -57 °C to 100 °C provide up to 18 deades of reduced frequency, which is necessary to characterize RDODT melts with Z w from 23 to 300. The two highest molecular weight polymers in the present RDODT series have such high M w (406k and 556k g/mol) that mass spectrometry, NMR spectroscopy, and even chemical assays for chain ends are unable to rule out up to 2 mol% linear contaminant. By studying the samples in solution (using dilution to reduce Z w ) we could compare their dynamics with those of previously established high-purity polystyrene (PS) rings (limited to Z w ≤ 13.6). RDODT solutions with Z w < 15 (concentrations <5wt% for RDODT-406k and 556k) have dynamic moduli G^* that accord with LCCC-purified PS rings in terms of the frequency dependence (including the absence of a plateau), the progression of shapes of G* as a function of Z w , and the linear scaling of their zero-shear viscosity η0 with M w . The shape of G* as a function of Z w for solutions of RDODT-406k and -556k also accord with lower M w RDODT melts (which have ≤ 1.3mol% linear contaminant). Thus, measurement of the linear viscoelastic properties of appropriate concentrations of high M w (>200k g/mol) putative cyclic polymers, in which linear chains evade spectroscopic detection, may provide an alternative means (though not fully proven) of validation of sample purity. When Z w > 15 (including all seven RDODT melts and eight of their solutions), G* has a rubbery plateau. This suggests that the onset of entanglement-like behavior in rings requires 4-5-fold greater Z w than is required for linear chains. Further, the plateau moduli of RDODT samples are indistinguishable from G N o of the corresponding LDODT (melt or matched-concentration solutions). In entangled linear polymers, the observation that G N o is independent of Z w follows from limitations on lateral fluctuations due to neighboring chains becoming independent of position along a given chain. The present results for RDODT suggest that this holds for sufficiently long endless chains, too. While the RDODT have the same G N o as entangled LDODT, when Z w > 60 the terminal relaxation, if reached at all, of RDODT extends to orders of magnitude lower frequency than an entangled linear polymer of the same Z w . Consequently, the viscosity of RDODT with Z w > 60 increases with Z w much more strongly than the 3.4-power observed for entangled linear polymers. Lastly, these novel polymers, with disulfide-linked backbone and broad relaxation time distribution may prove important in relation to biodegradable elastomers and materials with exceptional low-frequency dissipation, extending at least 12 decades below the onset of the rubbery plateau.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Polymer-fiber-reinforced polymers with enhanced interfacial bonding between polypropylene fiber and polyethylene matrix

Self-reinforced composites (SRCs) consist of reinforcing fibers and a base matrix made of the same thermoplastic polymer, offering lightweight, recyclability, and sustainability benefits. However, limited research exists on composites where the reinforcing thermoplastic polymer fibers differ from the base thermoplastic matrix. Here, this study focuses on investigating the mechanical behavior of such composites and exploring different surface modification methods to enhance the fiber/matrix interfacial bonding using polypropylene fibers and a polyethylene matrix as an example. It is shown that surface treatment with a commercial adhesion promoter containing n-butyl acetate significantly improves the interfacial shear strength between polypropylene fibers and the polyethylene matrix, increasing it by 145% compared to other methods investigated. Additionally, increasing the length of the embedded polymer fiber in the matrix leads to a notable increase in specific interfacial energy. Consequently, the thermoplastic polymer-fiber-reinforced polymers (PFRPs) using surface-treated woven polypropylene fabrics and a polyethylene matrix exhibit a 20% higher tensile strength and a 65% higher toughness compared to non-treated PFRPs. This study also shows that specific mechanical properties (normalized by the composite density) of the investigated woven PFRPs are similar to those of non-treated SRCs under uni-axial tension. Particularly, their ductility outperforms carbon-/glass-/aramid-fiber-reinforced polymers by at least 6 times at a same fiber volume fraction. The investigation of such composites and the exploration of surface modification methods present important progress in the field of thermoplastic PFRPs, which serve as a solution for addressing concerns related to recyclability and sustainability.

Fiber pull-out↗

DOE OSTI2026

A Unified Photometric Redshift Calibration for Weak Lensing Surveys Using the Dark Energy Spectroscopic Instrument

The effective redshift distribution n(z) of galaxies is a critical component in the study of weak gravitational lensing. Here, we introduce a new method for determining n(z) for weak lensing surveys based on high-quality redshifts and neural-network-based importance weights. Additionally, we present the first unified photometric redshift calibration of the three leading stage-III weak lensing surveys, the Dark Energy Survey (DES), the Hyper Suprime-Cam (HSC) survey, and the Kilo-Degree Survey (KiDS), with state-of-the-art spectroscopic data from the Dark Energy Spectroscopic Instrument (DESI). We verify our method using a new, data-driven approach and obtain n(z) constraints with statistical uncertainties of the order of $σ_z$ ~ 0.01 and smaller. Our analysis is largely independent of previous photometric redshift calibrations and, thus, provides an important cross-check in light of recent cosmological tensions. Overall, we find excellent agreement with previously published results on the DES Y3 and HSC Y1 data sets, while there are some differences on the mean redshift with respect to the previously published KiDS-1000 results. We attribute the latter to mismatches in photometric noise properties in the COSMOS field compared to the wider KiDS self-organizing map-gold catalog. At the same time, the new n(z) estimates for KiDS do not significantly change estimates of cosmic structure growth from cosmic shear. Finally, we discuss how our method can be applied to future weak lensing calibrations with DESI data.

Lange, J. U. [American Univ., Washington, DC (Unit↗

DOE OSTI2025

Lensing Without Borders: Measurements of galaxy-galaxy lensing and projected galaxy clustering in DESI DR1

We present Galaxy-Galaxy Lensing measurements obtained by cross-correlating spectroscopically observed galaxies from the first data release of the Dark Energy Spectroscopic Instrument (DESI) with source galaxies from the Hyper Suprime-Cam Subaru Strategic Survey, the Kilo-Degree Survey, the Sloan Digital Sky Survey, and the Dark Energy Survey. Specifically, we measure the excess surface mass density $ΔΣ$ and tangential shear $γ_\mathrm{t}$ for the Bright Galaxy Sample and Luminous Red Galaxies measured within the first year of observations with DESI. To ensure robustness, we test the measurements for systematic biases, finding no significant trends related to the properties of the \acrshort{desi} lens galaxies. We identify a significant trend with the average redshift of source galaxies, however, this trend vanishes once we apply shifts to the Hyper Suprime-Cam Subaru Strategic Survey redshift distributions that are also favored by their fiducial cosmology analysis. Additionally, we compare the observed scatter in the measurements with the theoretical covariance and find excess scatter, driven primarily by small-scale measurements of $r\leq 1 \, \mathrm{Mpc}/h$; measurements on larger scales are consistent at the $2\,σ$ level. We further present the projected clustering measurements $w_p$ of the galaxy samples in the the first data release of DESI. These measurements, which will be made publicly available, serve as a foundation for forthcoming cosmological analyses.

Heydenreich, S. [Lick Observ.] (ORCID:000000027273↗

DOE OSTI2021

Towards ternary binders involving limestone additions — A review

The review summarises literature to examine the transition from portland limestone cement system to composite ternary binder systems involving limestone. Interest in limestone addition as an ideal component in multicomponent binder systems has surged as evident from the large volume of literature published in the recent past. A ternary blended system, with co-substitution of limestone, has the potential to complement the reaction of the supplementary cementitious materials (SCMs). The direct addition of limestone powder helps to attain higher substitution levels of portland cement clinker, improve early age properties, and supplement SCM's reactivity. However, the dilution of hydrates could hamper the long-term benefits. In this review, the interaction of fine limestone is classified and elaborated under two broad umbrellas: physical and chemical interactions. The physical interactions can manifest in three ways, namely, filler action, shearing action and improved packing, which alters reaction rate and extent at early ages. The chemical interactions also modify the reaction kinetics and phase assemblage due to nucleation of C-S-H on calcite surfaces, preservation of the ettringite phase and formation of carboaluminates. Two different forms of carboaluminate hydrates — hemicarboaluminate and mono-carboaluminate can be present in the hydrate matrix depending on the balance between carbonate ions and aluminates in the pore solution. Several factors such as replacement level, particle size, choice of SCM, its reactivity and reactive aluminates content, sulphate levels, curing temperature, and duration of curing can control the carboaluminate formation, reaction degree of SCMs and chemical interaction from limestone additions. A combination of physical and chemical effects makes fine limestone a potential material for co-substitution with aluminosilicate based SCMs, mainly fly ash, slag, and calcined clay. In this review, the factors affecting limestone-SCM composites are summarised based on a detailed literature survey. The effects of SCM-limestone cement composites on hydration kinetics, reaction chemistry, the reactivity of SCMs, the stability of hydrated phases, and contribution to the physical structure development and macroscopic properties by evaluating hydration and mechanical properties are discussed. The importance of AFm (Al{sub 2}O{sub 3}–Fe{sub 2}O{sub 3}-mono) phases in various deterioration mechanisms in concrete and their influence on performance characteristics in different exposure environment is critically appraised.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Beta-dependent Properties of Solar Wind Current Sheets at 1 au

We utilize plasma turbulence in interplanetary coronal mass ejections as a natural laboratory to analyze more than 4600 current sheets observed over a broad range of electron and proton beta values, 10 −2 ≲ β e ≲ 10 and 10 −3 ≲ β p ≲ 10. The analysis shows that the shear angle Δθ and the thickness λ CS of the current sheets depend on both electron and proton beta. Specifically, the dependencies on electron beta are Δθ ≈ 12.6° $β^{0.41}_{e}$ and, λ CS /λ p ≈ 1.9 $β^{0.26}_{e}$ where λ p is the local proton inertial length. We argue that the beta dependence of the shear angle is an intrinsic feature of solar wind turbulence arising from the natural correlation between turbulence intensity and plasma beta. In contrast, the beta dependence of current sheet scales is likely a general characteristic of plasma turbulence. According to recent theory, current sheets formed in turbulence are disrupted by the electron tearing instability once their thickness is smaller than a critical scale. We demonstrate that normalizing the thickness of current sheets by this critical scale eliminates the dependence on beta across the entire range of plasma beta. This observation not only supports the theory suggesting that current sheets mediate the transition from the inertial to the kinetic cascade through the electron tearing instability, but also demonstrates the plausibility of similar processes in astrophysical plasma. The presented results also indicate that the theory may be applicable beyond its formal limits, m e /m i ≪ β ≪ 1.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2021

Design and Analysis of an Advanced Three-Point Bend Test Approach for Miniature Irradiated Disk Specimens

Candidate tungsten armor materials in a magnetic confinement fusion device must be able to withstand thermal variation that leads to internal stresses caused by the impinging heat load. In addition, the thermomechanical properties of these materials are degraded by irradiation-induced defect accumulation. Fission reactor–based irradiation data are used to predict the fusion neutron damage and property change. This study examines the motivation and design of a custom-designed three-point bend test for neutron-irradiated disk specimens that are 3 mm in diameter to be able to define the flexural strength of advanced tungsten materials, alloys, and composites—and to the extent that embrittlement occurs after neutron irradiation. The theory provided shows a calculation for the flexural deflection and shear deflection due to the small-geometry constraints. A finite element deformation analysis is performed to evaluate the mechanical stress field of disk bend specimens. The stress values above 80% of the maximum stress are concentrated in 2.4 mm of the 3.0-mm length of the centerline across the tungsten disk diameter. A bend test fixture has been designed and fabricated to enable testing of these specimens with precisely engineered tolerance and minimal machine compliance. This fixture will be able to be placed inside a universal testing frame at elevated temperatures for the mechanical property evaluation of future neutron-irradiated disk specimens.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Microstructural and material property changes in severely deformed Eurofer-97

Severe plastic deformation changes the microstructure and properties of steels, which may be favourable for their use in structural components of nuclear reactors. In this study, high-pressure torsion (HPT) was used to refine the grain structure of Eurofer-97, a ferritic/martensitic steel. Electron microscopy and X-ray diffraction were used to characterise the microstructural changes. Following HPT at room temperature to a maximum shear strain of 230, the average grain size reduced by a factor of ~30, with a marked increase in high-angle grain boundaries. Dislocation density also increased by more than one order of magnitude. The thermal stability of the deformed material was investigated via in-situ annealing during synchrotron X-ray diffraction. This revealed substantial recovery between 450 K – 800 K. Irradiation with 20 MeV Fe-ions to ~0.1 dpa caused a 20% reduction in dislocation density compared to the as-deformed material. However, HPT deformation prior to irradiation only had a minor effect in mitigating the irradiation-induced reductions in thermal diffusivity and surface acoustic wave velocity of the material. Microstructural and material property changes are dominated by deformation compared to irradiation. In light of this, the benefits of using HPT to improve the irradiation resistance of Eurofer-97 are limited. These results provide a multi-faceted view of the changes in ferritic/martensitic steels due to severe plastic deformation, and how these changes can be used to alter material properties.

ion-irradiation↗

DOE OSTI2020

Adhesion Capabilities of Permanent Foaming Fixatives for Deactivation and Decommissioning Activities - 20308

Florida International University's Applied Research Center and the Department of Energy's Savannah River National Laboratory are examining various mechanical properties of intumescent rigid polyurethane foams in order to be used as a permanent foaming fixative. Intumescent polyurethane foams are favored more than non-intumescent polyurethane foams due to their ability to mitigate flame and smoke propagation when exposed to a fire. As a consequence, this ability, known as intumescing, will allow fire personnel ample time to arrive at a scene. Due to sites being dormant for many decades before the final decontamination stages, the likelihood of a fire remains high. Adhesion properties will ensure quality immobilization performance. The analysis consisted of evaluating tensile adhesion strengths on a variety of commercial-off-the-shelf polyurethane (PU) foams. The foams consisted of intumescent and a combination of flexible and rigid foams. The goal was to down select the rigid foams out of the group in terms of tensile adhesion performance. The ensuing analysis was to conduct shear adhesion testing on the rigid foams in an operational volume with one of the rigid foams being intumescent. This approach helped down select the intumescent rigid foam in an adhesion and operational sense. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Higher harmonic non-linear flow modes of charged hadrons in Pb-Pb collisions at $\sqrt{s_{\mathrm{NN}}}$ = 5.02 TeV

Anisotropic flow coefficients, v n , non-linear flow mode coefficients, χ n,mk , and correlations among different symmetry planes, ρ n,mk are measured in Pb-Pb collisions at $\sqrt{s_{NN}}$ = 5.02 TeV. Results obtained with multi-particle correlations are reported for the transverse momentum interval 0.2 < p T < 5.0 GeV/c within the pseudorapidity interval 0.4 < |η| < 0.8 as a function of collision centrality. The v n coefficients and χ n,mk and ρ n,mk are presented up to the ninth and seventh harmonic order, respectively. Calculations suggest that the correlations measured in different symmetry planes and the non-linear flow mode coefficients are dependent on the shear and bulk viscosity to entropy ratios of the medium created in heavy-ion collisions. The comparison between these measurements and those at lower energies and calculations from hydrodynamic models places strong constraints on the initial conditions and transport properties of the system.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

The effect of ink ball milling time on interparticle interactions and ink microstructure and their influence on crack formation in rod-coated catalyst layers

This work investigates the influence of ballmilling (sometimes also referred to as jar roller milling) time on cathode catalyst layer (CL) inks and electrode properties using formulations and coating methods relevant for industrial manufacturing. Four CL inks with the same composition were milled for 24, 48, 72, or 96 h. Rheological investigation of these inks showed a reduction of elastic moduli and steady-shear viscosity with continuous ink milling, which is correlated to a decrease in particle-particle interactions as well as formation of smaller agglomerates. Optical microscopy (OM) analysis of the fabricated electrodes revealed a trend in surface crack formation; formulations milled for 24 h contained the lowest average surface crack area percentages of 0.370% at heavy-duty loadings of ~0.300 mg Pt cm -2 , compared to 2.418% for the ink milled for 96 h. Further characterization of the CL through transmission electron microscopy (TEM) imaging showed a decrease in the mean agglomerate and pore size with milling time. Furthermore, these smaller electrode features were consistent with reduced fracture resistance and, hence, development of larger stresses during drying. Our results highlight the need to consider ink processing as an important component in defect-free CL manufacturing.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2021

Predicting orientation-dependent plastic susceptibility from static structure in amorphous solids via deep learning

It has been a long-standing materials science challenge to establish structure-property relations in amorphous solids. Here we introduce a rotationally non-invariant local structure representation that enables different predictions for different loading orientations, which is found essential for high-fidelity prediction of the propensity for stress-driven shear transformations. This novel structure representation, when combined with convolutional neural network (CNN), a powerful deep learning algorithm, leads to unprecedented accuracy for identifying atoms with high propensity for shear transformations (i.e., plastic susceptibility), solely from the static structure in both two- and three-dimensional model glasses. The data-driven models trained on samples at one composition and a given processing history are found transferrable to glass samples with different processing histories or at different compositions in the same alloy system. Our analysis of the new structure representation also provides valuable insight into key atomic packing features that influence the local mechanical response and its anisotropy in glasses.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Stress-induced high- T c <?em> superconductivity in solid molecular hydrogen

Solid molecular hydrogen has been predicted to be metallic and high-temperature superconducting at ultrahigh hydrostatic pressures that push current experimental limits. Meanwhile, little is known about the influence of nonhydrostatic conditions on its electronic properties at extreme pressures where anisotropic stresses are inevitably present and may also be intentionally introduced. In this report we show by first-principles calculations that solid molecular hydrogen compressed to multimegabar pressures can sustain large anisotropic compressive or shear stresses that, in turn, cause major crystal symmetry reduction and charge redistribution that accelerate bandgap closure and promote superconductivity relative to pure hydrostatic compression. Our findings highlight a hitherto largely unexplored mechanism for creating superconducting dense hydrogen, with implications for exploring similar phenomena in hydrogen-rich compounds and other molecular crystals.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2025

Magnetic geometry effects on turbulent density fluctuations in Wendelstein 7-X

Line-integrated density fluctuation measurements from the core of the optimised stellarator Wendelstein 7-X (W7-X) are studied in the context of magnetic field geometry changes. The amplitude as well as the spectral distribution of fluctuations is affected by varying the magnetic field configuration. Weaker turbulent fluctuations are observed in configurations with higher rotational transform and lower magnetic mirror depth. Simulations with the gyrokinetic codes stella and GENE-3D are used to investigate the role of magnetic geometry for the experimental observations. The stabilising effect of the high rational transform configuration is reproduced by simulations and can be associated with stronger shaping of the magnetic field. This leads to increased finite Larmor radius and local shear effects, which limit the toroidal extent of ion temperature gradient (ITG) modes. For W7-X configurations with higher magnetic mirror depth, gyrokinetic theory and simulations predict weaker fluctuations, since they are closer to having the maximum-J property, which has a stabilising effect on trapped-electron mode and ITG. The opposite trend is observed experimentally, which can therefore not be explained by geometry effects on turbulence alone.

Wendelstein-7X↗

DOE OSTI2020

Indirectly probing the structural change in ion-irradiated Zr-Based metallic glasses from small scale mechanical tests

Ion irradiation was applied to tailor the structural heterogeneities in Zr-based metallic glasses at room temperature. Experimental methods of X-ray diffraction, nanoindentation, and micropillar compression were conducted to examine the irradiation effects on their structural and mechanical property changes. It is found that the irradiated materials retained amorphous structure after room-temperature Ni ion irradiation. The reduction of elastic modulus and hardness measured by nanoindentation indicated the irradiation-induced mechanical degradation. A unified statistic model was employed to quantitatively predict the density and strength of irradiation defects, although their specific structural and physical nature is not explicitly included in this model. The transition of non-intersecting shear bands to multiple intersecting shear bands was observed on compression tests of irradiated micropillars with the increase of irradiation dose. Furthermore, the analysis of the displacement excursion of micropillar compression tests indicated a different deformation mode from the unirradiated state. These results from nanoindentation pop-in and micro-pillar compression tests suggested that irradiation eventually leads to a new state with different types and characteristics of structural heterogeneities from violent displacement cascades and non-equilibrium energy deposition/dissipation processes, which also proves ion irradiation as an effective method to tune the structure and mechanical properties of metallic glasses.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Copper carbon composite wire with a uniform carbon dispersion made by friction extrusion

Copper-carbon composites are a group of materials with excellent mechanical, electrical, thermal, and tribological properties. However, bulk size copper-carbon composites made by the traditional manufacturing processes, like rolling or extrusion, fall short of reaching some of these properties predicted by theory or demonstrated only by samples at centimeter scale or smaller. The two main challenges to the successful scaling-up are: 1) to uniformly disperse carbon in the metal matrix; 2) to avoid degradation due to oxidation or reaction from overheating. In this work, we first demonstrate friction extrusion as a new method to make bulk-size void-free copper-carbon composite wires with homogenized carbon dispersion. Three different carbon varieties, graphite powder, graphene nanopowder, and carbon nanotubes, were added to the copper matrix with the concentration ranging from 0.5 wt% to 15 wt%. Special tooling, processing parameters, and procedures were developed, especially for high carbon content samples. Ten-fold reductions of both copper grain size and carbon particle size were achieved and attributed to the high shear deformation. Energy dispersive X-ray spectrometry indicates the carbon powder was refined to a sub-micron level and uniformly dispersed in the copper matrix. Compared with that of pure copper, the thermal capacity of the composite wire increases by 30 % while density reduces by 29 %.

Friction extrusion, Metal matrix composite, Graphe↗