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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Low Weight, High Strength Coal-Based Building Materials for Infrastructure Products (Rev.A)

Semplastics has developed, tested, and proven the viability of a new class of composite infrastructure components that use coal as the primary component. Phase I resulted in the production of brick and block components, called X-BRIX and X-BLOX, with dimensions comparable to commercially available bricks and concrete blocks, but with superior mechanical strength, lower weight, greater hardness, improved toughness, greater abrasion resistance, and greater chemical resistance than concrete. Multiple samples of full-size (16” × 8” × 8”) X-BLOX and full-size (8” × 4” × 2.5”) X-BRIX were made to demonstrate the technology, and to support the development of mortar or joining techniques. Phase I moved the coal-based composite materials technology from a current Technology Readiness Level (TRL) of 3 to TRL 5. Semplastics’ coal-based composite materials exhibit a number of high-performance characteristics, including high strength (five times the flexure strength of the best commercial brick, and more than twice the compressive strength of construction-grade concrete block), lower density (by 37 to 41%), improved mechanical durability and abrasion resistance, and resistance to chemicals, acids, salts, and chemical wastewater. These properties offer significant improvements over conventional bricks, concrete blocks, and pavers. The coal particles are completely encapsulated and bonded using a specially formulated polymer-derived ceramic (PDC) that is cured to form an “aggregate” of coal and PDC resin. This aggregate can be further processed and lightly pressed (at 10 to 50 psi) to produce a brick. After pyrolyzing (similar to the processing used to make standard clay bricks), the finished coal-based brick is significantly harder and more abrasion-resistant than regular bricks. We have produced prototype X-BRIX and X-BLOX that contain at least 55% coal by weight (71% carbon by weight, due to the controlled carbon content of the PDC) and showed their superior mechanical properties through in-house and contracted testing.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Alternate Methods for Cleaning Zirconium Plate

The United States High Performance Research Reactor Conversion Program identified the need to transition from highly enriched uranium fuel to lowly enriched uranium fuel for high power research and civil reactors. One of the fuel configurations selected for these reactors was a uranium (U) foil alloyed with 10% molybdenum (Mo). The U-10Mo fuel foil was then covered with a zirconium (Zr) interlayer and pressed into an aluminum cladding. Idaho National Laboratory prescribed a need to remove surface oxidation on the Zr prior to bonding it with U-10Mo fuel foil. To determine the best method of oxidation removal, a variety of polishing methods, including hand polishing with a diamond paste or Scotch-Brite™ pads, mechanically wet-polishing with abrasive belts, and chemical etching with hydrofluoric/nitric acid mixtures, were investigated on pre-polished Zircaloy 702 sheets purchased directly from the manufacturer. No change in surface roughness was detected using any of these methods relative to the as-received material. In fact, scanning electron microscopy detected grit from hand polishing with Amplex Grade 30 waste soluble diamond paste and Scotch-Brite™ pads. Visible staining was found, and fluorine detected via X-ray photoelectron spectroscopy on the flash etching samples. These contaminants were not seen on the as-received material. In addition to the need to remove the oxide layer on the Zr prior to co-rolling, there are concerns that the Neolube debonding agent on the co-rolling can may contaminate the Zr surface after co-rolling. The experimental results found that zirconium in contact with Neolube coated steel plates was easily cleaning with ethanol wiping after heat treated and no carbide inclusions remained on the surface. Overall, all cleaning methods tested did not significantly change the surface roughness of the plates or reduce the oxide layer present on the zirconium. Carbon was found on all the samples, before and after cleaning, except for the flash etch samples which detected fluorine instead. The insignificant changes seen in the cleaned plates relative to the as received plates question the need for cleaning prior to rolling. Further investigation in the requirements for cleaning at this step is recommended. Current methods for cleaning the surface after hot rolling with alcohol appear sufficient. After hot rolling, if Neolube does peel off the can and onto the zirconium coated foil surface, a dry abrasive or diamond paste polish is not recommended due to the chance of abrasive being embedded into the surface. However, the ability of an etchant to lift the lubricant off the zirconium surface indicates that a spot etch method could work to clean specific spots where Neolube is present, if the need arises.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Performance improvement of proton exchange membrane water electrolysis by surface modification of porous transport layers

Proton exchange membrane water electrolysis (PEMWE) is a promising option for hydrogen production from a variety of energy sources. Cost-effective production of hydrogen with PEMWE requires reduction of costly precious metals as well as optimization of the components and interfaces in the cell. The interface between the platinum-coated titanium porous transport layer (PTL) and catalyst layer (CL) significantly impacts the performance of the electrolyzer cell. Here, we report on two PTL modification methods, mechanical abrasion and chemical etching, which we find improve PEMWE performance by lowering the resistance of the PTL/CL interface. The PTL surface modifications enabled performance improvements up to 77 mV at 4 A cm −2 and reduction of the high frequency resistance, demonstrating that the resistance of the PTL/CL interface is a significant factor in the cell performance. The PTL surface roughness was varied using abrasive materials ranging from 0.1 to 140 μm in grain sizes and chemical etching was found to also increase the surface roughness. The surface roughness was quantified using confocal laser microscopy and the surface oxidation was measured using X-ray photoemission spectroscopy. These results demonstrate that both increasing surface roughness and oxide removal contribute to lowering the PTL/CL interfacial resistance and increasing cell performance.

08 HYDROGEN↗
DOE OSTI2022

Industrial scale mesofluidic particle separation

Here we explore the potential of a mesofluidic separator that fits within industrial piping and is designed to remove large aspherical particles out of an abrasive slurry at fast flow rates. Mesofluidic separators have recently demonstrated separation of spherical particles at flow rates of ~1 gallon/min (gpm) (6.3.10 -5 m 3 /s). Yet, the performance of these separators at flow rates achievable within industrial piping have not been explored. Here we evaluate the permeate flowrate fraction, large particle mass fraction, and pressure drop from approximately 35-100 gpm (2.2.10-3-6.3.10-3 m 3 /s) in a three inch tube using an abrasive and modestly non-spherical slurry. Faster flow rates may be achieved with larger pumps and larger diameters. We find the permeate fraction and pressure drop both increase with flow rate, though the pressure drop remains modest. Only two feet of inserts removed 97.6±2.1% of large particles for conditions tested. Separation was demonstrated in both vertical and horizontal orientations with the horizontal orientation benefiting marginally from gravitational settling.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

A novel fiber-fretting test for tribological characterization of the fiber/matrix interface

Ceramic matrix composites exhibit excellent high temperature properties and are candidate materials for structural applications from jet engines to nuclear fuel cladding. The strength and deformation behavior of these composites are intrinsically tied to the properties of the fiber/matrix interface. This research introduces a novel technique to evaluate the fundamental friction and wear characteristics of these interfaces. A case study on SiC f /PyC/SiC m composites applies in situ fiber fretting to investigate the kinetic friction coefficient and cyclic wear characteristics of the interphase. The experimental methodology is presented in explicit detail to encourage other researchers to explore the capabilities of this technique. Additionally, testing was carried out as a function of fiber roughness, PyC thickness (≈10, 500, 1200 nm), cycle count (10, 100, 1000), and frequency (1, 5, and 10 Hz). The friction coefficient and wear behavior changed with cycle length due to a transition from adhesive to abrasive mechanisms. SEM fractography provided insights to tribological evolution from adhesive sliding to three-body abrasive wear. The structural disorder at the tribo-surface relating to graphitic content and dangling bond density was investigated using Raman spectroscopy. Properties are contextualized with comparison to uniaxial tensile behavior of the parent composite.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Selective laser melting of oxide dispersion strengthened MA956 alloy and its surface finishing by magnetic field assisted finishing

Selective laser melting (SLM) is a prominent metal additive manufacturing (AM) capable of processing a myriad of engineering materials with high precision and design freedom. However, similar to other AM processes, poor surface finishing has been an omnipresent problem in SLM technology. In this study, magnetic field assisted finishing (MAF) was used to finish SLM fabricated oxide dispersion strengthened (ODS) MA956, an iron-chromium-aluminum alloy. The effect of laser processing parameters on part density and surface roughness was first studied. Using a multi-objective optimization technique, the optimal parameters to obtain the highest density and lowest surface roughness were determined. Finally, MAF was applied to the parts built with the obtained optimal SLM parameters, but without significant improvement on the surfaces of as-printed samples. Hence, the surfaces of as-printed samples were post-processed (ground) to yield better initial surface conditions prior to MAF. The effect of initial roughness, iron particles size, and abrasive size on MAF performance was studied. Initial roughness had the most dominant effect followed by abrasive size. The underlying mechanism behind the dependency on initial roughness on final surface quality was analyzed by studying the change on the surface profiles with different starting initial roughness. The initial roughness required for MAF to be effective was determined. In conclusion, using the optimal processing conditions, MAF was applied to the post-processed samples to attain the final average surface roughness (R a ) as little as 0.36 μm starting from initial average roughness (R a ) of 1.53 μm.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effects of surface treatments on ABS mechanical properties from fused filament fabrication

This paper examines the influence of surface treatments on the mechanical properties of acrylonitrile butadiene styrene (ABS) samples printed by fused filament fabrication (FFF). Prior efforts have applied brushing, painting, solvent dipping, infiltration, and vapor smoothing as post-processing surface treatments to improve the mechanical properties of FFF components. Additionally, because FFF can produce components with undesirable surface roughness, mechanical abrasion, epoxy coating, and acetone treatment may increase tensile strength by decreasing stress concentrations. Ridged surface texture may provide desirable tribological or handling properties. Based on these opportunities, this paper investigates abrasive media blasting, epoxy coating, acetone immersion, and ridged texturing surface treatments on the tensile strength and other mechanical properties of FFF ABS samples. ASTM D638-14 Type-I samples were printed, treated on all sample sides, and tested. From tensile tests, the elastic modulus, tensile strength, and fracture strain for both the untreated and treated ABS samples were calculated. For each sample, the surface finish and fracture macromorphology were observed with optical microscopy and the roughness values for the surface finish were calculated from profilometer data. Furthermore, samples were submerged in water and weighed periodically to measure mass changes due to water absorption. From surface profilometry and optical miscopy data, mechanical media blasting, epoxy coating, and immersion in all concentrations of acetone decreased surface roughness. Overall, on average, grit blasting with large beads and epoxy coating led to 2.6% and 1.2% increases in tensile strength, respectively; immersion in 40% acetone led to a 1.9% increase in tensile strength while treatment in 60% and 80% acetone decreased tensile strength by 4.9% and 1.9%, respectively. The study concludes that only grit blasting with large beads, immersion in 60% acetone, and the ridged texture significantly affected the tensile strength.

36 MATERIALS SCIENCE↗
DOE OSTI2021

The subsurface structure of abraded Al–Zn–Mg–Cu alloy

Surface abrasion has been shown to introduce heavy shear stress and produce a few hundred nanometers thick altered surface layer (ASL) on Al alloys. Such ASLs exhibit microstructural changes at room temperature and different corrosion resistance than the underlying substrate. Here, we report how sample dimensions and temperature affect the deformed subsurface microstructure evolution on an abraded Al–Zn–Mg–Cu alloy using transmission electron microscopy (TEM) and atom probe tomography. The ASL microstructure evolves differently in the bulk sample than in the thin TEM specimen. In the freshly abraded ASL, the original η'/η precipitates and grain boundaries were deformed toward the abrasion direction. After 7-day natural aging of the freshly abraded bulk sample, well-defined subgrains formed locally in the ASL, and unusual Al 2 Cu (θ) and Mg x Zn y phases precipitated at the subgrain boundaries. However, during natural aging of this TEM specimen taken from the abraded and aged bulk samples, much faster changes occurred, including the continued formation of subgrains and θ particles in the entire ASL, and the diffusion of Zn atoms out of Mg x Zn y particles to form a Zn particle. On the other hand, no obvious microstructural changes occurred in the ASL during 3-month natural aging of the TEM specimen immediately taken from the freshly abraded sample. Finally, this work advances the understanding of how Al alloy microstructures respond during and following any shear deformation, and complex and unexpected effects of sample dimensions on the behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The characterization of wear-causing particles and silica sand in particular

Erodants and abradants are two types of wear-causing particles (WCP). Despite their effects on the severity and rate of wear, WCP are inadequately characterized in a surprising number of publications, especially those involving impingement erosion and three-body abrasion. That shortfall makes it difficult to correlate features of WCP with the details of worn surfaces, or to develop wear models that account for those features. It is argued that the documentation of WCP should go beyond simply reporting their composition and mean particle size. In late 1985, ASTM Committee G2 on Wear and Erosion established a task group on the characterization of WCP. At that time, image analysis was slower and less sophisticated than it is today. While that ASTM task group failed to produce a consensus standard, computerized particle characterization methods were developing in fields other than tribology, fields like geoscience, heavy sand mining, materials processing, and pharmaceuticals. A notable exception to this is ferrography, which is a widely-used diagnostic for lubricated tribosystems. In the context of dry wear, it is useful to identify which features of WCP would be beneficial to document, and to identify some techniques and scales of detail appropriate to particular tribosystems. In this paper, examples are presented for the morphological and mechanical characterization of silica sand grains, as prompted by a triboanalysis of the abrasive and erosive wear of biomass pre-processing equipment. The authors propose a minimum level of documentation for WCP, one that can enrich tribosystem analysis both in laboratory tests and field studies.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Laser interference structuring of Cu for adhesive joining of HVAC equipment

Due to potential energy and cost savings benefits, adhesive joining has been recently considered for heating, ventilation, air conditioning, and refrigeration (HVAC&R) systems. HVAC adhesive bonding requires cost-effective and adequate surface preparations of adherents. Here, this article investigates the use of abrasion, traditional single-beam laser, and a laser-interference technique as surface preparations of copper surfaces. Surface morphology is characterized using scanning electron microscopy (SEM) and atomic force microscopy (AFM). Effective submicrometer peak-to-valley structuring with a periodicity of ∼2.7μ⁢m was demonstrated for laser-interference processing. Single-lap shear tests were conducted for 89 joints made with bondline thicknesses of 0.15 and 0.3 mm. Data on process variables and measured variables included open-time, bond length, maximum load, displacement at failure, shear lap strength, and failure mode. A statistical analysis was conducted on each lot to determine the lower limit with 95% confidence intervals for displacements at failure and shear lap strengths. A comparison is presented between the properties of laser-structured joints with respect to those prepared by abrasion, which is considered the baseline surface preparation technique. Based on this comparison, one single-beam laser technique and two laser-interference techniques were shown to exhibit vastly superior performance over the joints made with abraded specimens.

Sabau, Adrian S. [Oak Ridge National Laboratory (O↗
DOE OSTI2021

Investigation on nanoscale material removal process of BK7 and fused silica glass during chemical‐mechanical polishing

Abstract Understanding the nanoscale material removal process in chemical mechanical polishing (CMP) is of fundamental importance for the operation and further development of CMP. In this study, the nanoscale material removal processes of both fused silica glass and BK7 glass were investigated based on single‐pad‐asperity polishing experiments. The results indicate that the material removal characteristics are highly dependent on the composition and structure of glass materials. In the mechanically induced chemical bonding removal mode, only atoms locate near the outermost several layers can participate in the formation and breakage of interfacial bridge bonds. Moreover, the force on the abrasive particle must exceed a threshold value to induce significant removal of Si atoms from the glass substrate, because as the breakage of Si glass –O backbonds does not occur in low‐stress conditions. We reveal for the first time that the chemical and mechanical properties of the topmost layer, which is recognized as densification, hydrated, or redeposition layer, have not been significantly affected by the mechanical action of the abrasive particles when polishing in this kind of material removal mode. The results are expected to provide a deeper insight into the nanoscale material removal mechanism during glass CMP.

Wang, Lin↗
DOE OSTI2022

Characterization of Saltstone Grout Line Samples

During a prestart recirculation operation in the Saltstone Processing Facility (SPF), operations staff noticed hardened scaling falling into the hopper. As a result, SPF operators and Saltstone Engineering decided to postpone operation and conduct a process room hopper cleanout. During the cleanout effort personnel noted greater than normal buildup of damp solid material in the transfer line. A borescope investigation was conducted and confirmed buildup was present throughout the transfer line to the downstream valves. Savannah River National Laboratory personnel were asked to characterize the scale material and samples collected from the saltstone grout line and provide recommendations and/or further guidance as to whether additional corrosion testing is needed for useful equipment operating life information. Based on the samples characterized results, the plug material contained only the 60:40 slag:fly ash saltstone. Portland cement in the original 10:45:45 Portland cement:slag:fly ash mix may result in a less abrasive slurry compared to the 60:40 slag:fly ash mix because the slag is > 95 % crushed angular, sharp edged glass. Saltstone grout erosion and corrosion testing of A36 carbon steel is needed to determine if the 60:40 mix is more abrasive and corrosive for A36 carbon steel than the 10:45:45 mix.

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

GEN3D Experimental and Numerical Development of GEN3 Durability Models

Understanding of the high temperature durability of particles and the materials that contain them is critical to next generation of concentrating solar power (CSP) technology. Here we studied the durability of particles and their containment materials under extreme UV cycling, thermal cycling, and in low-speed high temperature mechanical wear situations. The optical stability of seven candidate particles has been determined following exposure to the high temperature conditions present in a generation 3 particle-based CSP technology. Particle solar weighted absorptance and emittance measured periodically during 10,000 high solar irradiance exposure cycles and up to 400 hours of isothermal aging has been documented. The particle aging due to repeated exposure to concentrated solar flux represented the 30-year lifetime of a power plant. Models were fit to the absorptivity and emissivity data following the isothermal aging provides the projected optical degradation of the particles as a function of temperature. Mechanical wear was studied through the use of custom developed wear testing facilities for measuring high temperature impact wear, abrasion wear, and particle attrition. Additionally, a novel technique for measuring the high temperature mechanical properties of single particles was developed. Through these tests it was observed that high nickel alloys generally showed lower wear than comparable iron based steels, particularly at elevated temperatures of 800°C. Mechanical wear at these temperatures is a highly complex phenomenon combining both mechanical wear and oxidation. Additionally, the containment materials wear rates are influenced by the particles (both hardness and roundness), making the wear mechanisms complex. The initial wear test conducted in the abrasion test rig revealed a substantial amount of oxide materials in the particle bed after testing (in relative to later tests), and substantially more wear, likely indicating a need for concern in startup operation of particle facilities to not incur high wear from the presence of oxides. Particle attrition experiments have only been conducted for a single material but increase size distribution, reduction in circularity, and particle diameter is observed. Efforts to develop predictive models was limited due to a testing campaign that prioritized testing materials for particle pathway developers over building a comprehensive design of experiments. The results discussed in this report inform future CSP developers and researchers further de risking the technology and assisting in its future development. ParticleBased CSP development provides a path to dispatchable solar power generation with storage at a price competitive in the current energy market. Lowering the cost of CSP technology provides a carbon free power generation solution that can assist in the transition from fossil fuels to renewable sources of electricity.

14 SOLAR ENERGY↗
DOE OSTI2024

Examining Graphite Degradation in Molten Salt Environments: A Chemical, Physical, and Material Analysis

Molten-salt reactors (MSRs) are Generation IV nuclear reactors that use liquid salt as a coolant and/or fuel. In several MSR designs, graphite serves as a moderator and/or reflector. However, due to limited experimental data and operational experience, our understanding of graphite behavior in molten salt environments remains incomplete. This report aims to identify the degradation mechanisms of nuclear graphite in MSRs, detail the mechanisms of each factor, and provide an initial assessment of their impact on the structural integrity of graphite components. This assessment is based on an extensive literature review and insights from subject matter experts. Furthermore, given the limited data, a modeling strategy using existing Grizzly software is proposed for a more thorough analysis where appropriate. Additionally, it presents mitigation strategies where applicable. The report covers physical degradation mechanisms such as infiltration, erosion, and abrasion, as well as chemical degradation mechanisms including fluorination, intercalation, corrosion, and oxidation. Molten salt can infiltrate the porous structure of graphite, leading to several detrimental effects. Entrapment of fissile products within the graphite pores can cause radiation damage and could pose challenges in the handling and disposal of contaminated components. The differential thermal expansion between the infiltrated salt and graphite, along with internal stress from pressurized molten salt and volumetric heating, can compromise the structural integrity of graphite. To mitigate these effects, employing ultra-fine graphite grades and applying sealants and coatings are effective strategies. A computational model based on coupled solid mechanics and heat transfer phenomena could be used to predict the internal stresses using Grizzly software. In pebble-bed MSRs, graphite fuel pebbles can cause abrasion against reactor components due to friction and wear. The severity of wear is influenced by various factors such as temperature, environment, and the presence of lubricants. Tribological studies reveal that higher temperatures and molten salt environments, such as FLiBe, significantly reduce wear rates compared to dry conditions. Additionally, the chemical composition of the salt can further optimize graphite's tribological performance. Long-term wear effects can be modeled by incorporating surface defects into the geometry and predict stresses under thermal and radiation effects using Grizzly software. Chemical degradation of graphite in a molten salt environment can occur through fluorination and intercalation. Fluorination can occur via replacement of hydrogen or oxygen atoms, or at the active sites, but does not cause structural degradation. Intercalation, on the other hand, can lead to exfoliation, where layers of graphite separate and peel away, damaging the graphite. Protective coatings can enhance graphite's resistance to intercalation. Graphite generally exhibits good chemical stability in molten salt environments, though it can corrode under specific conditions, particularly in the presence of impurities or oxidants. Studies have shown that protective coatings, such as plasma-sprayed partially stabilized zirconia (PSZ), can effectively prevent such degradation. Corrosion behavior varies significantly with different graphite grades and coating applications, underscoring the need for detailed studies on uncoated and coated graphite to understand and mitigate corrosion mechanisms in MSRs. Research indicates that the presence of oxidants and impurities can accelerate graphite degradation in molten salts, making it essential to explore acceptable impurity limits. Oxidation is another critical degradation mechanism, leading to weight loss and structural damage due to the formation of CO and CO 2 from the reaction of carbon atoms with oxygen. This process creates new porosity and compromises graphite's integrity. While extensive research on graphite oxidation has been conducted for gas-cooled reactors, studies specific to MSRs are limited. Findings from the coal industry suggest that molten alkali metal salts can significantly accelerate graphite oxidation, a hypothesis worth exploring for fluoride salts in MSRs. Understanding oxidation behavior in MSRs is vital for developing protective measures. The analysis of post-irradiated graphite from the MSRE experiment demonstrated exceptional chemical compatibility with molten fluoride salt, suggesting that the extent of chemical attack on graphite largely depends on the salt's infiltration capability. Therefore, the use of ultra-fine grade graphite could help mitigate chemical degradation effects. Existing oxidation modeling capabilities in Grizzly, which use reaction-diffusion equations to model graphite-air interactions, could be adapted to simulate the chemical degradation effects of graphite in molten salt environments.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Wear Mechanism Analysis of a New Rotary Shear Biomass Comminution System

A new biomass comminution system, Crumbler rotary shear, was developed to process fuel-grade biomass. The rotary shear is more efficient than the traditional hammer mill in comminuting high-moisture biomass and producing more uniform particles with minimal fines. However, the milling unit experiences significant wear in processing dirty woodchips. This study investigated the wear mechanisms of the rotary shear system based on analysis of the minerals carried by woodchips and characterization of actual worn components. Abrasive wear was found to be the dominant effect, and localized adhesive wear (material transfer), microfracture (chipping), and plastic deformation were additional effects. Connections have been made between the wear progression of key cutting components and the particle size change of biomass extrinsic minerals. On the basis of the wear mechanism understanding, mitigations based on advanced tool materials and optimized tool geometric designs are being developed for improving the tool life and cutting efficiency.

09 BIOMASS FUELS↗
DOE OSTI2020

Material Characterization-Based Wear Mechanism Investigation for Biomass Hammer Mills

Biomass, as harvested, is composed of inorganic compounds both intrinsically and extrinsically and can be abrasive. The present study investigates the wear modes and mechanisms of two types of blades of hammer mills used in biomass size reduction (impacting the particle size and distribution) and densification (impacting the size, shape, and density). The dominant wear modes for the stage 1 steel blades are determined to be erosive and polishing wear. For the stage 2 blades with a carbide weld overlay, the main wear mechanisms are erosion and fracture. Partial replacement of Co by Fe in the outer layer of the carbide grits, likely induced by diffusion during high-temperature welding, has been correlated to the observed microcracking. Finally, the microcracking is believed to weaken the grit strength and fracture toughness to make the overlay prone to fracture and erosion due to repetitive contact with the inorganic contents in chopping biomass.

42 ENGINEERING↗
DOE OSTI2025

Annual and sub-seasonal dynamics of a rapidly eroding permafrost coastline along the Beaufort Sea in northern Alaska

Drew Point, an unlithified ice-rich permafrost coastline along the Alaskan Beaufort Sea, is among the most rapidly eroding Arctic coastlines, with an average erosion rate of 19 m/yr from 2007 to 2019. We use 16 high-resolution remote sensing datasets (satellite, airborne, and UAV imagery) to analyze erosion mechanisms (thermal abrasion and denudation) in relation to environmental forcings along a 1.5 km stretch of coastline during the 2018 and 2019 open water seasons. In a striking contrast, 2019 exhibited the highest mean erosion rate (34.5 m) within the 2007–2019 record, while 2018 had the second lowest (11.2 m). Block failure contributed to sub-seasonal erosion rates 6 to 21 times higher than thermal denudation, with staggered block fall timing, lag responses post-storm, and non-storm block collapse influencing overall erosion magnitude and timing. To quantify wind effects, we developed wind sums, a metric combining cumulative wind speed and directional data that can be used as a proxy for integrated storm intensity capable of incorporating lagged responses that correlated strongly with erosion at sub-seasonal and annual scales. Our findings emphasize the dominant role of wind during periods of open water and air temperature during the thaw season in driving permafrost coastline erosion dynamics, while highlighting the importance of spatiotemporally high-resolution datasets for understanding Arctic coastal change dynamics.

Alaska Beaufort Sea Coast↗
DOE OSTI2020

Identification of Critical Process Parameters for Knife Milling and Alternative Communication Strategies

An assessment of knife milling operations was performed to identify parameters that require consideration to model wear and degradation of knife blades. A quality-by-design (QbD) paradigm was followed to identify material and feedstock attributes, and processing parameters that impact the quality attributes of the blades used in the comminution of biomass into forms compatible with downstream operations. Based on analytical and experimental observations of knife and tool wear, a QbD model is proposed that considers three wear mechanisms (erosion, abrasion, and gouging) to predict volumetric wear of knife blades and sharpness. These factors, if properly applied, provide a science-based approach to predict the mechanical efficiency of the mill as a function of feedstock properties, knife blade material properties, and processing parameters (feed rate, speed, and design parameters).

09 BIOMASS FUELS↗