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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 505 records · Page 28
All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

Technology Demonstrator for Direct Polishing of a 50cm C/SiC Ultra Light Mirror

The NRSU portion of the contract was completed on schedule and within acceptable limits of the estimated cost. The lapping of the substrate started on schedule, and completed ahead of schedule. The polishing of the substrate was begun ahead of schedule, and was completed approximately one month ahead of schedule. It is our opinion that the substrate meets the requirements of "diffraction limited performance at 2 microns" over the measured 16 in. area. The final photos suggest that there may be edge roll-off beyond the 16 in. diameter. However, we cannot quantify this. It is our opinion that this material is suitable for use in lightweight optics as long as cladding of some type is used (Silicon, SiC, Sol-Gel, etc), as the bare material itself is too "porous" to obtain a high quality finish. We feel that this part was at the low limit of structural integrity required to mechanically polish to this level of figure requirement. Any lesser structural integrity would require some form of "non contact" figuring.

Scribner, Ken↗
DOE OSTI2023

Manufacturing Water‐Based Low‐Tortuosity Electrodes for Fast‐Charge through Pattern Integrated Stamping

Achieving high energy density and fast charging of lithium‐ion batteries can accelerate the promotion of electric vehicles. However, the increased mass loading causes poor charge transfer, impedes the electrochemical reaction kinetics, and limits the battery charging rate. Herein, this work demonstrated a novel pattern integrated stamping process for creating channels in the electrode, which benefits ion transport and increases the rate performance of the electrode. Meanwhile, the pressure applied during the stamping process improved the contact between electrode and current collector and also enhanced the mechanical stability of the electrode. Compared to the conventional bar‐coated electrode with the same thickness of 155 μm (delivered a discharge capacity of 16 mAh g −1 at the rate of 3 C), the stamped low‐tortuosity LiFePO 4 electrode delivered 101 mAh g −1 capacity. Additionally, water was employed as a solvent in this study. Owing to its eco‐friendliness, high scalability, and minimal waste generation, this novel stamping technique inspire a new method for the industrial‐level efficient roll to roll fabrication of fast‐charge electrodes.

25 ENERGY STORAGE↗
NASA NTRS2008

Making Superconducting Welds between Superconducting Wires

A technique for making superconducting joints between wires made of dissimilar superconducting metals has been devised. The technique is especially suitable for fabrication of superconducting circuits needed to support persistent electric currents in electromagnets in diverse cryogenic applications. Examples of such electromagnets include those in nuclear magnetic resonance (NMR) and magnetic resonance imaging (MRI) systems and in superconducting quantum interference devices (SQUIDs). Sometimes, it is desirable to fabricate different parts of a persistent-current-supporting superconducting loop from different metals. For example, a sensory coil in a SQUID might be made of Pb, a Pb/Sn alloy, or a Cu wire plated with Pb/Sn, while the connections to the sensory coil might be made via Nb or Nb/Ti wires. Conventional wire-bonding techniques, including resistance spot welding and pressed contact, are not workable because of large differences between the hardnesses and melting temperatures of the different metals. The present technique is not subject to this limitation. The present technique involves the use (1) of a cheap, miniature, easy-to-operate, capacitor-discharging welding apparatus that has an Nb or Nb/Ti tip and operates with a continuous local flow of gaseous helium and (2) preparation of a joint in a special spark-discharge welding geometry. In a typical application, a piece of Nb foil about 25 m thick is rolled to form a tube, into which is inserted a wire that one seeks to weld to the tube (see figure). The tube can be slightly crimped for mechanical stability. Then a spark weld is made by use of the aforementioned apparatus with energy and time settings chosen to melt a small section of the niobium foil. The energy setting corresponds to the setting of a voltage to which the capacitor is charged. In an experiment, the technique was used to weld an Nb foil to a copper wire coated with a Pb/Sn soft solder, which is superconducting. The joint was evaluated as part of a persistent-current circuit having an inductance of 1 mH. A current was induced in a loop, and no attenuation of the current after a time interval 1,000 s was discernible in a measurement having a fractional accuracy of 10(exp -4): This observation supports the conclusion that the weld had an electrical resistance <10(exp -10) omega.

Penanen, Konstantin I.↗
NASA NTRS1991

Analysis of foil bearings for high speed operation in cryogenic applications

The general objective of this project is to develop analysis tools which are required for the design of foil bearings to be used in cryogenic applications. During the second year of this project, a general analysis approach and code for journal bearings operating under steady state conditions will be completed. This will be followed by the initiation of an investigation into transient behavior of foil bearings to determine their performance in rotor systems. Foil bearings have been proposed as an alternative to rolling element bearings for use in cryogenic turbopumps in liquid propellant rocket engines. This type of bearing offers several advantages over rolling element bearings since they would use the cryogenic pump fluid for a lubricant and have structural flexibility. These bearings have the potential of high reliability and long life. The bearing surface is constructed of a 'foil' which resists deflection by a combination of bending, membrane, and elastic foundation effects. The relative motion between the rotating shaft and the foil causes pressure in the fluid film to develop. This pressure deflects the the foil surface away from the shaft. Once a full fluid film is established between the foil and the rotor shaft, contact no longer takes place and there is no subsequent wear of the surfaces. The flexible foil structure of the bearing allows it to compensate for minor tolerance and manufacturing defects. This same flexibility also has a significant effect on the dynamic performance of the rotor-bearing system.

Carpino, Marc↗
NASA NTRS2020

First Gale Western Butte Capping-Unit Compositions, and Relationships to Earlier Units Along Curiosity's Traverse

The Curiosity rover has been traversing through the clay-bearing unit (Glen Torridon; GT), approaching Greenheugh pediment, a large, fan-shaped surface surrounding the mouth of Gediz Vallis on the lower slope of Mt. Sharp. The pediment unconformably overlies the underlying bedrock, and is hence younger than units of the Mt. Sharp group. Orbital imaging of the pediment has shown it to have a slightly lower albedo and higher thermal inertia than neighboring units, to be relatively retentive of craters (e.g., erosion resistant), and to exhibit curved bedforms suggestive of lithified eolian bedforms. No diagnostic spectral signature has been observed from orbit. Recent rover positions allowed remote imaging of the contact between Greenheugh pediment and the eroded Murray formation strata below it, showing that the pediment capping material is cross-bedded and relatively thin (1-3 m), and suggesting that the pediment may have been much larger at one time. As Curiosity approached the edge of the pediment, the team investigated two buttes named Central and Western. The latter butte contains dark capping material that initially looked similar to the pediment cap, but close inspection revealed important physical differences. Here we report on compositions from ChemCam of two float rocks that appear to have rolled down from the capping unit, and on potential relation-ships to other targets along the traverse of the rover.

Wiens, R. C.↗
NASA NTRS1974

Fatigue life of high-speed ball bearings with silicon nitride balls

Hot-pressed silicon nitride was evaluated as a rolling-element bearing material. The five-ball fatigue tester was used to test 12.7-mm- diameter silicon nitride balls at maximum Hertz stresses ranging from 4.27 x 10 to the 9th power n/sq m to 6.21 x 10 to the 9th power n/sq m at a race temperature of 328K. The fatigue life of NC-132 hot-pressed silicon nitride was found to be equal to typical bearing steels and much greater than other ceramic or cermet materials at the same stress levels. A digital computer program was used to predict the fatigue life of 120-mm- bore angular-contact ball bearings containing either steel or silicon nitride balls. The analysis indicates that there is no improvement in the lives of bearings of the same geometry operating at DN values from 2 to 4 million where silicon nitride balls are used in place of steel balls.

Parker, R. J.↗
NASA NTRS2012

Static Indentation Load Capacity of the Superelastic 60NiTi for Rolling Element Bearings

The nickel-rich, binary nickel-titanium alloys, such as 60NiTi (60Ni-40Ti by wt%), are emerging as viable materials for use in mechanical components like rolling element bearings and gears. 60NiTi is a superelastic material that simultaneously exhibits high hardness and a relatively low elastic modulus (approx.100 GPa). These properties result in the potential to endure extremely high indentation loads such as those encountered in bearings, gears and other mechanical components. In such applications, quantifying the load that results in permanent deformation that can affect component performance and life is important. In this paper, the static load capacity is measured by conducting indentation experiments in which 12.7 mm diameter balls made from the ceramic Si3N4 are pressed into highly polished, hardened 60NiTi flat plates. Hertz stress calculations are used to estimate contact stress. The results show that the 60NiTi surface can withstand an approximately 3400 kN load before significant denting (>0.6 microns deep) occurs. This load capacity is approximately twice that of high performance bearing steels suggesting that the potential exists to make highly resilient bearings and components from such materials.

DellaCorte, Christopher↗
NASA NTRS2004

Tool for Insertion of a Fiber-Optic Terminus in a Connector

A tool has been developed for the special purpose of inserting the terminus of an optical fiber in a cable connector that conforms to NASA Specification SSQ- 21635. What prompted the development of the tool was the observation that because of some aspects of the designs of fiber-optic termini and of springs, sealing rings, and a grommet inside the shell of such a connector, there is a tendency for the grommet to become damaged and detached from the sealing rings during installation. It is necessary to ensure the integrity of the grommet for proper sealing and proper functioning of the connector. The special-purpose tool provides the needed protection for the grommet. The grommet-protection tool resembles a funnel into which an axial slit has been cut (see figure). Prior to insertion, the grommet-protection tool is rolled so that one side of the slit overlaps the other side. The rolled-up grommet-protection tool is inserted in one of the connector holes that accommodate the fiber-optic termini and is pushed in until the flange (the wider of the two conical portions) of the tool becomes seated on the connector grommet. Then a special-purpose installation tool is inserted in the flange of the grommet-protection tool and pressed in until it becomes seated in the flange. This operation expands the narrower of the two conical portions of the grommet-protection tool. The installation tool is removed and the grommet-protection tool remains expanded due to the flat surfaces on the axial slit. By use of a standard contact-insertion tool, a fiber-optic terminus is inserted, through the grommet-protection tool, into the connector cavity. By use of a pair of forceps or needle-nose pliers, the grommet-protection tool is then pulled out of the cavity. Finally, the grommet-protection tool is removed from around the installed fiber-optic cable by pulling the cable through the axial slit. Unlike in some prior procedures for installing the fiber-optic termini in the connector, the procedure that involves the use of the present grommet-protection tool does not include the use of lubricants that can contaminate the interior of the connector. The grommet-protection tool is made of a fluoropolymer, taking advantage of the flexibility of such polymers and further taking advantage of the inherent slipperiness of fluoropolymers. Although the tool is designed primarily for insertion of a fiber-optic terminus, it might also be useful for extracting a previously installed fiber-optic terminus.

King, Wes↗
NASA NTRS1977

Multi-axis hand controller for the shuttle remote manipulator system

The Shuttle Remote Manipulator System, has a articulated arm of 50 ft. length with six motor-driven joints. The basic purpose is to establish physical contact with various space hardware items and maneuver these to the desired position and attitude with respect to the Orbiter, nulling out relative velocities and stabilizing the free-body system by managing residual energies. The normal operating mode is resolved-motion end-point rate control by man-in-loop command. The translational freedoms are defined so that the End Effector (EEFTR) of the arm will move in planes parallel to the principal translational planes of the Orbiter, at a rate commanded by the displacement of the Translation Hand Controller in the corresponding freedom and direction. The rotational freedoms are rate-controlled by the Rotation Hand Controller about pivot axes parallel to Orbiter roll, pitch and yaw, originating at the EEFTR reference point.

Lippay, A. L.↗
NASA NTRSDate not supplied

To the Moon! Space Launch System Modal Testing with Video and Motion Magnification

MIT Lincoln Laboratory and NASA Marshall Space Flight Center have been collaborating on using video camera measurements and motion magnification for modal testing of large aerospace components for several years. This presentation will discuss results from the Space Launch System Integrated Modal Test (IMT) and Dynamic Rollout/Rollback Test (DRRT) in support of the Artemis I mission. During the IMT, the data collection focused on operational mode shapes. In addition, the cameras were repositioned mid-test to better understand the physics of a low-frequency torsion mode. The non-contact nature of video data capture allowed for the quick redeployment of the cameras while not causing any delay in test schedule, whereas traditional instrumentation would have required a pause in testing to attach the sensors to the test article. The motion magnification analysis was able to find the low-frequency operational mode shapes and help the test team better understand the physics of the torsion mode. Building upon the success of the IMT motion magnification work, a camera system was used during the DRRT to find operational mode shapes, if the physics of the low-frequency torsion mode remained with different boundary conditions, and relative deflection of the vehicle and ML tower during the roll. In this paper we will present operational mode shape results, discuss the physics of the torsion mode, and review experimental setup idiosyncrasies to help the community in designing video camera measurement systems.

optical↗
DOE OSTI2013

Large-scale Manufacturing of Nanoparticulate-based Lubrication Additives for Improved Energy Efficiency and Reduced Emissions

This project was funded under the Department of Energy (DOE) Lab Call on Nanomanufacturing for Energy Efficiency and was directed toward the development of novel boron-based nanocolloidal lubrication additives for improving the friction and wear performance of machine components in a wide range of industrial and transportation applications. Argonne's research team concentrated on the scientific and technical aspects of the project, using a range of state-of-the art analytical and tribological test facilities. Argonne has extensive past experience and expertise in working with boron-based solid and liquid lubrication additives, and has intellectual property ownership of several. There were two industrial collaborators in this project: Ashland Oil (represented by its Valvoline subsidiary) and Primet Precision Materials, Inc. (a leading nanomaterials company). There was also a sub-contract with the University of Arkansas. The major objectives of the project were to develop novel boron-based nanocolloidal lubrication additives and to optimize and verify their performance under boundary-lubricated sliding conditions. The project also tackled problems related to colloidal dispersion, larger-scale manufacturing and blending of nano-additives with base carrier oils. Other important issues dealt with in the project were determination of the optimum size and concentration of the particles and compatibility with various base fluids and/or additives. Boron-based particulate additives considered in this project included boric acid (H 3 BO 3 ), hexagonal boron nitride (h-BN), boron oxide, and borax. As part of this project, we also explored a hybrid MoS 2 + boric acid formulation approach for more effective lubrication and reported the results. The major motivation behind this work was to reduce energy losses related to friction and wear in a wide spectrum of mechanical systems and thereby reduce our dependence on imported oil. Growing concern over greenhouse gas emissions was also a major reason. The transportation sector alone consumes about 13 million barrels of crude oil per day (nearly 60% of which is imported) and is responsible for about 30% of the CO 2 emission. When we consider manufacturing and other energy-intensive industrial processes, the amount of petroleum being consumed due to friction and wear reaches more than 20 million barrels per day (from official energy statistics, U.S. Energy Information Administration). Frequent remanufacturing and/or replacement of worn parts due to friction-, wear-, and scuffing-related degradations also consume significant amounts of energy and give rise to additional CO 2 emission. Overall, the total annual cost of friction- and wear-related energy and material losses is estimated to be rather significant (i.e., as much as 5% of the gross national products of highly industrialized nations). It is projected that more than half of the total friction- and wear-related energy losses can be recovered by developing and implementing advanced friction and wear control technologies. In transportation vehicles alone, 10% to 15% of the fuel energy is spent to overcome friction. If we can cut down the friction- and wear-related energy losses by half, then we can potentially save up to 1.5 million barrels of petroleum per day. Also, less friction and wear would mean less energy consumption as well as less carbon emissions and hazardous byproducts being generated and released to the environment. New and more robust anti-friction and -wear control technologies may thus have a significant positive impact on improving the efficiency and environmental cleanliness of the current legacy fleet and future transportation systems. Effective control of friction in other industrial sectors such as manufacturing, power generation, mining and oil exploration, and agricultural and earthmoving machinery may bring more energy savings. Therefore, this project was timely and responsive to the energy and environmental objectives of DOE and our nation. In this project, most of the boron-based materials with known and potential anti-friction and -wear properties have been manufactured as colloidal additives and tested for their effectiveness in controlling friction and wear. Unlike other anti-friction and -wear additives, which consist of zinc, molybdenum, sulfur, phosphorus, and even chlorine, lubricious boron compounds considered in this project are made of boron, oxygen, nitrogen, and hydrogen, which are more environmentally benign. Among others, boric acid is a natural mineral (known in mineralogy as "sassolite"). Based on our earlier exploratory research, it was found to offer the best overall prospect in terms of performance improvements, environmental friendliness, and ease of manufacturing and, hence, cost effectiveness. Hexagonal boron nitride and borax also offered good prospects for improving the tribological properties of lubricated sliding surfaces. Boron oxide particles were found to be rather hard and somewhat abrasive and, hence, were not considered beyond the initial screening studies. In our bench-top tribological evaluation, we also demonstrated that those additives which worked well with engine oils could work equally well with very common gear oils. When added at appropriate concentrations, such gear oils were found to provide significant resistance to micropitting and scuffing failures in bench-top tribological test systems. Their traction coefficients were also reduced substantially and their scuffing limits were improved considerably. Such impressive tribological behavior of boron-based additives may have been due to their high chemical affinities to interact with sliding contact surfaces and to form slick and protective boundary films. Indeed, our surface studies have confirmed that most of the boron-based nanoparticulate additives prepared in our project possess a strong tendency to form a boron-rich boundary film on sliding contact surfaces. It is believed that the formation of such slick and highly durable boundary films is perhaps one of the fundamental reasons for their superior anti-friction, -wear, and -scuffing performance. Boron-based additives developed under this project have shown potential to reduce or replace the uses of environmentally unsafe sulfur- and phosphorus-bearing anti-wear and friction additives, such as zinc dialkyl dithiophosphate (ZDDP) and molybdenum dialkyl dithiocarbamate (MoDTC), in current lubricating oils. Because ZDDP and MoDTC were suspected of adversely impacting the performance of after-treatment catalysts in current engines, the Environmental Protection Agency (EPA) and other regulatory agencies are demanding that the concentrations of these catalysts in current oils be curtailed drastically. The boron-based nano-additives developed in this project may help reduce the use of ZDDP and MoDTC additives and, hence, help ease the poisoning effects on after-treatment catalysts. When used as lubricity additives, these boron additives can chemically interact with sliding or contacting surfaces and form a protective and slick boundary film, which can, in turn, help reduce friction and wear and increase resistance to scuffing. In the cases of traditional anti-friction and -wear additives mentioned, such protective boundary films result from phosphorus, sulfur, and other elements in the additive package, and again they have been under increased scrutiny in recent years, mainly because of their adverse effects on after-treatment devices. Overall, the boron-based nano-additive technology of this project was shown to hold promise for a broad range of industrial and transportation applications where lower friction and higher resistance to wear and scuffing are needed. Due to more stringent operating conditions of modern machinery, rolling, rotating, and sliding components have been failing to meet the projected lifetimes, mainly because of failures related to mechanical wear, corrosion, and scuffing. The novel boron-based additive technology developed under this project may help such machine components to function reliably by cutting down the friction and wear losses and by increasing resistance to scuffing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Non-Contact Eddy Current Method for Assessing Proton Conductivity in Nafion Membranes

Accurate measurement of proton conductivity in Proton Exchange Membranes (PEMs) is vital for fuel cell performance and durability. This study explores eddy current testing as a non-destructive, non-contact and high-rate quality control (QC) method for measuring Nafion membrane proton conductivity, with potential for high-volume manufacturing applications.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2000

Effect of Roller Profile on Cylindrical Roller Bearing Life Prediction

Four roller profiles used in cylindrical roller bearing design and manufacture were analyzed using both a closed form solution and finite element analysis (FEA) for stress and life. The roller profiles analyzed were flat, tapered end, aerospace, and fully crowned loaded against a flat raceway. Four rolling-element bearing life models were chosen for this analysis and compared. These were those of Weibull, Lundberg and Palmgren, Ioannides and Harris, and Zaretsky. The flat roller profile without edge loading has the longest predicted life. However, edge loading can reduce life by as much as 98 percent. The end tapered profile produced the highest lives but not significantly different than the aerospace profile. The fully crowned profile produces the lowest lives. The resultant predicted life at each stress condition not only depends on the life equation used but also on the Weibull slope assumed. For Weibull slopes of 1.5 and 2, both Lundberg-Palmgren and Iaonnides-Harris equations predict lower lives than the ANSI/ABMAJISO standards. Based upon the Hertz stresses for line contact, the accepted load-life exponent of 10/3 results in a maximum Hertz stress-life exponent equal to 6.6. This value is inconsistent with that experienced in the field.

Poplawski, Joseph V.↗
DOE OSTI2018

Dynamic simulation of powder packing structure for powder bed additive manufacturing

Here, powder packing structure is a critical parameter of powder bed-based additive manufacturing (AM). Experimental characterization of powder is typically limited to measuring bulk properties, whereas many numerical models of AM powder packing are based on geometrical consideration without accounting for particle-to-particle interactions. In the present paper, the powder packing dynamics is simulated using a discrete element method (DEM)-based model that solves the mechanical contact forces and moments between individual particles. As DEM uses explicit time integration, a main challenge in modeling dynamics of metallic powder packing is the need for extremely fine time increment size (e.g., in the order of 1 ns for a 10-μm-diameter particle). The effect of mass scaling, employed for speeding up the calculation, on the simulation results is examined in a test case of powder particles packed inside a box container. The calculated packing density for two different particle size distributions is validated against independent literature data for laser powder bed AM with AISI 316L stainless steel powder. The sensitivity of key input parameters (e.g., friction coefficient) is further evaluated in this test case. The powder packing model is then applied to a practical situation of binder jet AM involving rolling of multiple layers of IN718 powder particles onto a powder bed, for which the calculated packing density is also validated with independent literature data.

42 ENGINEERING↗
NASA NTRS1988

The simulation of the alternate turbopump development high pressure oxygen and fuel turbopumps for the space shuttle main engine using the Shaberth computer program

The Space Shuttle Main Engine (SSME) is basically comprised of a combustion chamber and nozzle, high and low pressure oxygen turbopumps and high and low pressure fuel turbopumps. In the current configuration, the high pressure fuel (HPTFP) and high pressure oxygen turbopumps (HPOTP) have experienced a history of ball bearing wear. The wear problem can be attributed to numerous factors including the hydrodynamic axial and radial loads caused by the flow of liquid oxygen and liquid hydrogen through the turbopump impellers and turbine. Also, friction effects between the rolling elements, races, and cage can create thermally induced bearing geometry changes. To alleviate some of the current configuration problems, an alternate turbopump development (ATD) was proposed. However, the ATD HPOTP and HPTFP are constrained to operate interchangeably with the current turbopumps, thus, the operation conditions must be similar. The ATD configuration features a major change in bearings used to support the integrated shaft, impeller, and turbine system. A single ball and single roller will replace the pump-end and turbine and duplex ball bearings. The Shaft-Bearing-Thermal (SHABERTH) computer code was used to model the ATD HPOTP and ATD HPFTP configurations. A two bearing model was used to simulate the HPOTP and HPFTP bearings and shaft geometry. From SHABERTH, a comparison of bearing reaction loads, frictional heat generation rates, and Hertz contact stresses will be attempted with analysis at the 109 percent and 65 percent power levels.

Mcdonald, Gary H.↗
NASA NTRS1964

Dynamic Model Investigation of the Landing Characteristics of a Manned Spacecraft

Investigations were made to study the water-landing and certain grounds-surface landing characteristics of a Gemini spacecraft model. The water landing experiments were made by simulating paraglider and parachute letdowns with two 1/6- scale model configurations. Parameters included various combinations of attitude, horizontal speed, vertical speed, and landing skids extended and retracted. Investigations were made in calm water and in waves. The paraglider landings at horizontal speeds of 63 feet per second (19.8 m/sec) which resulted in a noseover or tumbling shortly after initial water contact. The maximum longitudinal acceleration of the model in calm water was about 14g units, and the maximum angular acceleration was 66 radians per second squared. In the parachute landings with the heat shield forward, the model skidded along the water surface on the heat shield. Parachute landings with the small end forward resulted in behavior similar to that of the paraglider landings. The ground-surface landings were made with a 1/3-scale model by simulating a parachute letdown with braking rockets, which were fired prior to touchdown to dissipate vertical velocity. In these landings, control of timing and aligning the rockets on the model was very critical, and violent behavior resulted when either rocket alignment or timing was in error. In the landings that were correctly controlled, the model either remained upright or slowly rolled over on its side.

EXPERIMENTS↗
DOE OSTI2012

Energy Saving Glass Lamination via Selective Radio Frequency Heating

This project focused on advancing radio-frequency (RF) lamination technology closer to commercial implementation, in order to reduce the energy intensity of glass lamination by up to 90%. Lamination comprises a wide range of products including autoglass, architectural safety and innovative design glass, transparent armor (e.g. bullet proof glass), smart glass, mirrors, and encapsulation of photovoltaics. Lamination is also the fastest growing segment of glass manufacturing, with photovoltaics, architectural needs, and an anticipated transition to laminated side windows in vehicles. The state-of-the-art for glass lamination is to use autoclaves, which apply heat and uniform gas pressure to bond the laminates over the course of 1 to 18 hours. Laminates consist of layers of glass or other materials bonded with vinyl or urethane interlayers. In autoclaving, significant heat energy is lost heating the chamber, pressurized air, glass racks, and the glass. In RF lamination, the heat is generated directly in the vinyl interlayer, causing it to heat and melt quickly, in just 1 to 10 minutes, without significantly heating the glass or the equipment. The main purpose of this project was to provide evidence that low energy, rapid RF lamination quality met the same standards as conventionally autoclaved windows. The development of concepts for laminating curved glass with RF lamination was a major goal. Other primary goals included developing a stronger understanding of the lamination product markets described above, and to refine the potential benefits of commercial implementation. The scope of the project was to complete implementation concept studies in preparation for continuation into advanced development, pilot studies, and commercial implementation. The project consisted of 6 main tasks. The first dealt with lamination with poly-vinyl butyral (PVB) interlayers, which prior work had shown difficulties in achieving good quality laminates, working with Pilkington North America. The second task dealt with a study of current lamination processes in the various laminate industries, and development of concepts for integrating RF lamination into new or existing processes. The third task explored the use of a non-destructive technique for analyzing laminate adhesion with the University of Illinois at Urbana-Champaign. The fourth task focused on developing concepts for curved glass lamination using RF lamination. The fifth and sixth tasks together comprised an analysis of laminate product markets, ranking for applicability and commercialization potential, and the development of commercialization strategies for those products. In addition, throughout the project as new experimental data and conventional process data were obtained, the benefits analysis of RF lamination was refined. The goals of the project described above were achieved, positioning RF lamination for the next stage growth envisioned in the original Industrial Grand Challenge proposal. Working with Pilkington North America, lamination of flat autoglass with PVB was achieved, meeting all 16 stringent industry tests. In particular, PVB laminates made with RF lamination passed environmental tests including the high temperature, 120 C bake test, without significant formation of bubbles (defects). The adhesion of PVB to glass was measured using the pummel method. Adhesion values ranging from 1 to 7 out of 10 were obtained. The significant process parameters affecting the environmental and adhesion performance were identified through a designed experiment. Pre-lamination process variables including PVB storage humidity and the de-airing process (vacuum or nip rolling) were significant, as well as the level of pressure applied to the laminate during the RF process. Analysis of manufacturing with RF lamination equipment, based on the processes developed indicated that 3 RF presses could replace a typical auto-industry autoclave to achieve equal or greater throughput with possibly less capital cost and smaller footprint. Concepts for curved lamination identifying castable molds for prototyping were developed, which allowed Ceralink to obtain commitment to begin curved tooling development. The project significantly helped to advance RF lamination past the feasibility and novelty stage and into the realm of commercial acceptance as a viable alternative to autoclaves. The demonstration of autoclave-quality autoglass produced in just 1 minute with RF lamination, with validation by Pilkington, has fueled industry motivation to seriously consider RF lamination. The industry and other contacts and outreach made in the study of laminate markets (including 3 technical publications and 5 conference presentations), has resulted in a recent surge in RF lamination activity.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2012

Energy Saving Glass Lamination via Selective Radio Frequency Heating

This project focused on advancing radio-frequency (RF) lamination technology closer to commercial implementation, in order to reduce the energy intensity of glass lamination by up to 90%. Lamination comprises a wide range of products including autoglass, architectural safety and innovative design glass, transparent armor (e.g. bullet proof glass), smart glass, mirrors, and encapsulation of photovoltaics. Lamination is also the fastest growing segment of glass manufacturing, with photovoltaics, architectural needs, and an anticipated transition to laminated side windows in vehicles. The state-of-the-art for glass lamination is to use autoclaves, which apply heat and uniform gas pressure to bond the laminates over the course of 1 to 18 hours. Laminates consist of layers of glass or other materials bonded with vinyl or urethane interlayers. In autoclaving, significant heat energy is lost heating the chamber, pressurized air, glass racks, and the glass. In RF lamination, the heat is generated directly in the vinyl interlayer, causing it to heat and melt quickly, in just 1 to 10 minutes, without significantly heating the glass or the equipment. The main purpose of this project was to provide evidence that low energy, rapid RF lamination quality met the same standards as conventionally autoclaved windows. The development of concepts for laminating curved glass with RF lamination was a major goal. Other primary goals included developing a stronger understanding of the lamination product markets described above, and to refine the potential benefits of commercial implementation. The scope of the project was to complete implementation concept studies in preparation for continuation into advanced development, pilot studies, and commercial implementation. The project consisted of 6 main tasks. The first dealt with lamination with poly-vinyl butyral (PVB) interlayers, which prior work had shown difficulties in achieving good quality laminates, working with Pilkington North America. The second task dealt with a study of current lamination processes in the various laminate industries, and development of concepts for integrating RF lamination into new or existing processes. The third task explored the use of a non-destructive technique for analyzing laminate adhesion with the University of Illinois at Urbana-Champaign. The fourth task focused on developing concepts for curved glass lamination using RF lamination. The fifth and sixth tasks together comprised an analysis of laminate product markets, ranking for applicability and commercialization potential, and the development of commercialization strategies for those products. In addition, throughout the project as new experimental data and conventional process data were obtained, the benefits analysis of RF lamination was refined. The goals of the project described above were achieved, positioning RF lamination for the next stage growth envisioned in the original Industrial Grand Challenge proposal. Working with Pilkington North America, lamination of flat autoglass with PVB was achieved, meeting all 16 stringent industry tests. In particular, PVB laminates made with RF lamination passed environmental tests including the high temperature, 120°C bake test, without significant formation of bubbles (defects). The adhesion of PVB to glass was measured using the pummel method. Adhesion values ranging from 1 to 7 out of 10 were obtained. The significant process parameters affecting the environmental and adhesion performance were identified through a designed experiment. Pre-lamination process variables including PVB storage humidity and the de-airing process (vacuum or nip rolling) were significant, as well as the level of pressure applied to the laminate during the RF process. Analysis of manufacturing with RF lamination equipment, based on the processes developed indicated that 3 RF presses could replace a typical auto-industry autoclave to achieve equal or greater throughput with possibly less capital cost and smaller footprint. Concepts for curved lamination identifying castable molds for prototyping were developed, which allowed Ceralink to obtain commitment to begin curved tooling development. The project significantly helped to advance RF lamination past the feasibility and novelty stage and into the realm of commercial acceptance as a viable alternative to autoclaves. The demonstration of autoclave-quality autoglass produced in just 1 minute with RF lamination, with validation by Pilkington, has fueled industry motivation to seriously consider RF lamination. The industry and other contacts and outreach made in the study of laminate markets (including 3 technical publications and 5 conference presentations), has resulted in a recent surge in RF lamination activity.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗