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At least 577 records · Page 32
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Investigation of Superluminescent Diodes for Smart Lighting Systems. Final Report

The solid-state lighting ecosystem has evolved very rapidly over the last few years, with significant improvements in the technical performance of light-emitting diodes (LEDs) and the commoditization of LED-based lighting fixtures. As the performance of conventional lighting products begins to saturate, there is growing market interest in “Lighting as a Service” applications that will leverage advanced systems to impart new functionalities to lighting and improve energy efficiency, human health, and productivity. These “Smart Lighting” systems will include high-performance light sources, specialized sensors, and dynamic controls to deliver high quality, energy efficient, color tunable lighting with customized spatial light delivery and integrated visible light communication capability. To achieve these capabilities, smart lighting systems will place greater demands on the performance of light sources. Highly efficient sources with additional functionalities compared to conventional LEDs, such as small form factor, large modulation bandwidth, and spatially coherent output beams, will be required. While laser diodes have been proposed as potential sources for smart lighting systems, they also exhibit several properties that pose challenges, such as temporal coherence, extremely high spatial coherence, and ultra-narrow linewidths. To address these issues, we propose an investigation of an alternative device architecture known as a superluminescent diode (SLD). SLDs are similar in form to ridge laser diodes and share many of the same characteristics, such as stimulated emission operation, spatially coherent output, small form factor, and the potential for large modulation bandwidth. However, the operating principle for SLDs is distinct from laser diodes in that SLDs lack a strong cavity feedback mechanism, resulting in spatially coherent but temporally incoherent light output. Thus, SLDs may address the issues with laser diodes for lighting, while simultaneously maintaining some of the desirable characteristics of both laser diodes and LEDs. The objectives of this proposal are to design, grow, and fabricate blue (450 nm) SLDs on polar c-plane and nonpolar m-plane free-standing GaN substrates, and to evaluate their potential as sources in smart lighting systems through basic device characterization and detailed investigations of their efficiency droop and modulation bandwidth. The primary scientific aims of this work are to understand the fundamental role of optical gain in the superluminescent (non-lasing) regime on efficiency droop and modulation bandwidth in III-nitride emitters and to understand the effects of higher optical gain on SLD performance by comparing polar c-plane and nonpolar m-plane SLDs. The University of New Mexico (UNM) will collaborate with Sandia National Laboratories (SNL) and the Center for Integrated Nanotechnologies to design, fabricate, grow, and characterize the SLDs. UNM will perform the design and epitaxial growth, while SNL will focus on the fabrication and device characterization. The novelty of the proposed work includes the first comprehensive theoretical and experimental investigations of efficiency droop and the first investigation of modulation bandwidth in GaN-based emitters operating in the superluminescent regime. Moreover, the comparison of c-plane and m-plane SLDs will enable the first analysis of the effects of higher optical gain on the device performance. The development of high-performance GaN-based SLDs may enable efficiency gains and improved functionality in next-generation smart lighting systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Calculating Average Hot Water Mixes of Residential Plumbing Fittings Using the ANSI 301-2019 Hot Water Draw Model and National Residential Data to Estimate Hot Water Use in Showerheads and Lavatory Faucets

Available studies of hot water use percentages may not necessarily be generalized to a national level given regional differences, varying methodological approaches, and limited sample sizes. While some publicly available usage data, reports, and surveys estimate actual household usage, a lack of water use data specific to end uses make more precise savings calculations difficult. Additionally, most hot water draw models tend to focus on overall household use and may not readily estimate lavatory fixture use. However, reviewing more recent studies and standards enables the U.S. Environmental Protection Agency’s WaterSense program to update its estimates for hot water use and consumers’ corresponding energy and monetary savings to better reflect realworld conditions. This report specifically focuses on improving hot water use and savings estimates of lavatory faucets and showerheads. To estimate the hot water use of lavatory faucets and showerheads, we employed the 2015 Residential Energy Consumption Surveys (RECS) microdata alongside the ANSI 301-2019 Hot Water Draw Model. These estimates account for regional differences in hot water use, including regional cold water inlet temperatures. As a result, the refinements presented in this report are more robust, more recent, and better describe the geographic variation than previous inputs used by the WaterSense program. In addition, the approach described in this paper can be updated over time or tailored to regionally specific needs given available inputs. We conclude that hot water percentages for showers and faucets calculated using publicly available national data are close to the percentages found by regional studies and are consistent with household-level models of water use.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Residential Building Energy Efficiency Field Studies: Low-Rise Multifamily

In recent years, the U.S. Department of Energy (DOE) has conducted a series of research studies to validate energy efficient building technologies in the field. Much of the work has focused on single-family construction, and some has also addressed commercial energy codes. The work detailed in this DOE-funded study (EE0007616) focuses on low-rise multifamily buildings (three stories or fewer above grade) in various regions of the United States, and reports on how state-level building codes are being implemented, both in terms of observed characteristics and also in terms of estimated energy impacts. Nearly 100 buildings across four states—Illinois, Minnesota, Oregon, and Washington—were sampled, which represent a range of climate types from mild temperature to very cold continental. Both common entry and outdoor entry buildings were included, and a parallel research project evaluated envelope air tightness and current still-evolving air tightness testing methods. Finally, a set of structured interviews of building designers and other relevant professionals was carried to out to gain more insight into this market. To the greatest extent possible, the methodology developed under the project for low-rise multifamily buildings mirrored the approach established by Pacific Northwest National Laboratory (PNNL) for single-family residential buildings (https://www.energy.gov/eere/buildings/downloads/residential-building-energy-code-field-study). This included the general approach to sampling, recruitment, and data collection, as well as data analysis and presentation. The range of permitting dates for the sites encompassed two energy code cycles in most regions. All states in the study had adopted a variation of the International Energy Conservation Code (IECC) for the structure of their state code. The low-rise multifamily occupancy presents a hybrid building type: most of the building’s conditioned floor area was covered by the residential chapter of the code while portions of the building (such as corridors and common spaces) fell under the commercial code chapter. The key items assessed in this work were: Building Shell—exterior wall insulation, ceiling insulation, foundation insulation, windows. Common Areas—HVAC and lighting. Living Units—lighting, ventilation. A few items were not assessed in detail, given their relative paucity in this occupancy type; these included duct leakage, pipe insulation, and hot water circulation controls. Building characteristics were collected via a combination of architectural, mechanical, electrical, and plumbing plan reviews and field inspections, and entered into a spreadsheet-based tool that was later queried to build a database. Data went through quality control both upon arrival and via a later semi-automated review and assurance process. Most of the data are presented graphically so that the reader can quickly assess compliance with the applicable energy codes (both by state and by code year). As a final step, EnergyPlus™ simulations were created for all buildings in the study to estimate both the as-found energy use intensity (EUI) and the energy and CO 2 that could be saved if features that were found to not meet code minimums were brought up to code. The savings estimates were tabulated for each of the four states in the study. The research team found that the single-family approach was largely applicable to low-rise multifamily buildings. This applies to both the data collection and the prototype EUI analysis. Most of the occupied space is living units and falls under residential energy codes, and many characteristics use similar envelope construction and relatively straightforward mechanical systems and lighting. One of the most challenging aspects of this work was to build an effective spreadsheet-based data collection instrument that could allow efficient collection of both building plan and field data. The research team is of the view that other methods could be equally effective if the work is done carefully with diligent quality control. The primary findings for the work center around the thermal envelope and mechanical systems and lighting at the sites: For thermal envelope components, the majority of buildings met or were better than the prescriptive code.This suggests that building designers and builders are aware of code requirements. In some cases, surveyed buildings were designed to qualify for energy efficiency certification programs. These buildings made up at least 20% of sampled buildings in each state. Almost all buildings met mechanical system efficiency requirements (for both living units and common areas). In some cases, sites employed systems that were considerably more efficient than required by the applicable energy code. Dwelling units had a majority of high-efficacy lighting, often in excess of the state’s residential code requirements. While high-efficacy fixtures were also typical in common areas (corridors and stairwells), lighting power densities (LPDs) in these areas were sometimes higher than levels dictated by the applicable part of the state commercial energy code. The simulation models run on a series of low-rise multifamily prototypes, informed by a composite of the field data collected, calculated annual EUIs of between 20 and 50 kBtu/ft2-yr, with the range representing the effects of both building characteristics and building location (climate zone). A detailed process (based on simulations of prototype buildings) was used to estimate the amount of avoided energy use that would occur if 100% adherence to energy codes were attained. The results indicated modest savings are attainable for items such as window thermal performance and common area lighting. The result is overall only a modest potential for additional energy savings, averaging about 10% of EUI.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

SR19016 - Characterization of AM Materials for SRTE Service

This project addresses several issues and challenges for the use of AM produced components in the tritium facility. It will evaluate the effect of low level hydrogen and tritium exposure on the mechanical and chemical characteristics of Arcam A2X Electron Beam Powder Bed Fusion Produced (EPBF) Ti-6AI-4V by printing tensile samples and testing them in the as printed, machined, and hydrogen exposed conditions. Hydrogen uptake will be measured using an Eltra Hydrogen-Oxygen- Nitrogen analyzer. Hydride response will be measured using a Seiffert's apparatus and determining the effects of various surface treatments on the hydriding susceptibility. Tools, fixtures, and other objects will be deigned and printed for use in the AM lab and tritum facility and for other groups that support the tiritum mission.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Safety Review Board review of explosive pressing initiation event

On June 30, 2020, a 0.87 gram PETN charge being pressed in the Rapid Prototyping Facility (RPF), unexpectedly initiated, resulting in destruction of the pressing fixture but no injuries or facility damage. In response, the Safety Review Board (SRB) met on Aug. 13, 2020 and Oct. 1, 2020 to review information collected following the incident, consider likely direct causes, and form recommendations.

42 ENGINEERING↗
DOE OSTI2021

Robustness and Validation of Model and Digital Twins Deployment

For digital twins (DTs) to become a central fixture in mission critical systems, a better understanding is required of potential modes of failure, quantification of uncertainty, and the ability to explain a model’s behavior. These aspects are particularly important as the performance of a digital twin will evolve during model development and deployment for real-world operations.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Impact Testing and Analysis of Modified Metal Slugs

This report summarizes initial results from a series of gun experiments which were conducted at the DICE facility. The target of these experiments was a modified metal slug composed of a tantalum/tungsten alloy (Ta-10W). The general geometry of the slug was a right circular cylinder with a through-hole cut normal to the cylinder's axis. In all experiments, hardened steel impactors were used, the desired impact velocity was 200 m/s, the slug was preheated to a target temperature of 175° C, photon doppler velocimetry (PDV) was used to measure the projectile velocity before and after impact, and the impact event was recorded with high-speed video. In two of the impacts the slug was oriented perpendicular to the projectile, while in the remaining two it was tilted 8° from normal. Initial high-speed speed video results showed slug failure in the tilted impact case, while the slug survived normal impacts. Recovery fixtures were used to preserve impacted slugs for future postmortem analysis. Discussions are included regarding improvements to potential future experiments involving these slugs.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2021

Controlled Pyroshock Test Transients Can Be Used To Better Match Operational Shock Transients and Reduce Artificial Pyroshock Test Failures [Slides]

Shock analysis is typically done via SRS (shock response spectrum). Oftentimes shock analysis is not performed because most loads specifications only supply SRS requirements with no representative shock transients that can be used for analysis. SRS analysis is too conservative. There is no structural dynamics involved as all modes are assumed to have peak responses simultaneously and in-phase with each other. It is possible that all other loads and combination of loads show the design to be good, whereas SRS analysis (1000 g’s are involved) results may require redesign. Multiple shock transients can satisfy a SRS, yet most loads documents don’t provide a representative shock transient that could be used for shock analysis. Shock testing is less common than harmonic and random vibration testing. Engineers typically go into shock tests with very little knowledge of what to expect. A pass/fail type of approach with very little engineering done to prepare for the test or to control the type of shock transient is used. Most engineers will not model the shock test fixture due to lack of knowledge about the details of the test setup. Shock analysis and testing is often an open loop type situation with no test setup modeling, no test correlation, and no control over the test shock transient. In this work, if we can create applied test force transient that comes close to matching calculated force transient then a more reasonable acceleration transient will be created at the test reference accelerometer that better matches operational shocks.

42 ENGINEERING↗
DOE OSTI2021

Criticality Accident Alarm System Shielding Benchmark: Integral Experiment Request 498, Critical Engineering Decision 2 Report

A workable design to perform a CAAS benchmark experiment is detailed herein. Key dimensions, materials, source intensity levels, and detectors are listed in this report. Sensitivity to 21 perturbations was determined to be acceptable. The next step will be for NCSP management to determine whether procurement should occur and if the experiment should proceed. The perturbation study suggests that the room return shield cavity radius and runout should be maintained to within a millimeter, the room return shield should be positioned carefully (perhaps with a laser range finder), and that the detectors should be mounted in a lightweight fixture such as aluminum, so their positioning is assured. Using a 3D scanner or photogrammetry to record part shapes may be beneficial. Further work is also needed to verify source reproducibility.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Sandia National Laboratories FY21 Progress Report

The Energetic Neutrons campaign led by Sandia National Laboratories (SNL) had a successful year testing electronic devices and printed circuit boards (PCBs) under 14 MeV neutron irradiation at OMEGA. During FY21 Sandia’s Neutron Effects Diagnostics (NEDs) and data acquisition systems were upgraded to test novel commercial off-the-shelf and Sandia-fabricated electronic components that support SNL’s National Security mission. The upgrades to the Sandia platform consisted of new cable chains, sample mount fixtures and a new fiber optics platform for testing optoelectronic devices.

42 ENGINEERING↗
DOE OSTI2022

Testing, Characterization, and Modeling of the Resonant Plate Test Environment

The resonant plate shock test is a dynamic test of a mid-field pyroshock environment where a projectile is struck against a plate. The structure undergoing the simulated field shock is mounted to the plate. The plate resonates when struck and provides a two sided shock that is representative of the shock observed in the field. This test environment shock simulates a shock in a single coordinate direction for components looking to provide evidence that they will survive a similar or less shock when deployed in their operating environment. However, testing in one axis at a time provides many challenges. The true environment is a multi-axis environment. The test environment exhibits strong off-axis motion when only motion in one axis is desired. Multiple fixtures are needed for a single test series. It would be advantageous if a single test could be developed that tests the multi-axis environment simultaneously. In order to design such a test, a model must be developed and validated. The model can be iterated in design and configuration until the specified multi-axis environment is met. The test can then execute the model driven test design. This report discusses the resonant plate model needed to design future tests and the steps and methods used to obtain the model. This report also details aspects of the resonant plate test discovered during the process of model development that aids in our understanding of the test.

42 ENGINEERING↗
DOE OSTI2021

High Temperature Irradiation-Resistant Thermocouple Qualification (Test Results Report)

This is a qualification report for the high-temperature irradiation-resistant thermocouple (HTIR-TC) developed by Nuclear Energy Enabling Technologies Advanced Sensors and Instrumentation program. Utilizing the Advanced Gas Reactor (AGR) 5/6/7 test conducted in the Advanced Test Reactor (ATR) at Idaho National Laboratory, the HTIR-TCs measured temperatures upwards of 1500°C during accident conditions. The HTIR TCs are thus qualified to perform and withstand an 18-month refueling cycle typical of nuclear power plants at the normal operating temperature, with a drift of less than ±1%. The HTIR-TC is also qualified for incorporating into a test fixture during new fuels tests.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Enhanced Light Outcoupling from OLEDs Fabricated on Novel Low-Cost Patterned Plastic Substrates of Varying Periodicity

OLEDs continue to make strides in display applications, but their commercial utilization in solid-state lighting (SSL) is lagging. An ongoing challenge, in particular for manufacturing, is the need for enhanced efficiency and hence the necessity to increase in an inexpensive approach the extraction of the light generated inside the OLED into the forward (viewing) hemisphere. In conventional OLEDs fabricated on a transparent flat anode coated on glass, the external quantum efficiency (EQE) is only ~20%. About 50% of the light is lost to internal waveguiding in the high refractive index (RI) organic + ITO anode layers and to surface plasmon polaritons (SPPs) at the organic/metal cathode interface. Another ~30% of the light is externally waveguided in the substrate to its edges. While extraction of the externally waveguided light is commonly addressed by adding a microlens array (MLA) or a scattering layer at the substrate’s air-side, light outcoupling increases by only ~1.6-1.7x (vs up to 2.5x in improving from ~20% to ~50%). The use of a hemispherical lens or an index matching fluid (IMF) at the substrate/photodetector (PD) interface increases the outcoupling by at least 2x; these approaches however, are not viable industrially, and even a MLA is sometimes undesirable due to its non-planar, scattering structure. In multi-stack tandem OLEDs, where the metal cathode is far from the emitting zone(s), the impact of photons loss to SPPs decreases. Our project addressed the ~50% loss to the internally waveguided light and SPPs. We evaluated OLEDs fabricated on patterned or planarized plastic substrates manufactured in a cost-effective approach compatible with a roll-to-roll (R2R) process. The OLEDs were either (i) patterned to various degrees depending on the pitch a and height or depth h of the pattern features or (ii) planar, with a pattern buried under a flat high RI planarization layer. We demonstrated that the outcoupling from green patterned OLEDs reaches ~50% by mitigating plasmon–related loss and internal waveguiding, even without the addition of a MLA, a hemispherical lens, or IMF. Simulations conducted in parallel with the experimental effort demonstrated how diffraction by conformally corrugated OLEDs increases the outcoupling to >60%. Structures with varying pitch values were also simulated indicating that combining domains of varying pitch could increase outcoupling to 55-60%. Experimentally, we additionally assessed the role a and h in determining not only the OLED efficiencies, but also their structural properties, i.e., the uniformity and conformality throughout the OLED stack. As planar OLEDs are preferred over corrugated devices, we studied different patterns in plastic substrates that were planarized by a high RI formulation. Planar green OLEDs on such structures showed enhanced efficiencies with EQEs larger than 60% with the addition of an IMF (to extract the substrate mode) at the substrate/Si PD interface. White OLEDs showed EQEs of 45.5%. Plastic substrates are currently less attractive than glass substrates due to drawbacks such as permeability to water vapor and oxygen, and in some cases thermal instability. Plastic substrates however, are flexible and easy to handle unlike thin flexible glass, and once transparent thin barrier films are available, they will become more attractive; they are already of interest in medical applications. Importantly, as it is easy to generate various patterns in different plastic materials, they provide excellent means for assessing and optimizing enhancing extracting structures. Such structures can also be transferred to glass substrates with some process modifications. The technical effectiveness and economic feasibility of the project lie in the patterning of the extracting plastic substrates in an approach that is scalable to R2R manufacturing. R2R processes are of drastically lower-cost than batch or single-unit fabrication. The patterned plastic can be a part of an integrated substrate either plastic or glass, which includes also a MLA or a planar layer with embedded scattering particles, as well as a conductive metal mesh/electrode design. SSL is environmentally-friendly and as OLED SSL becomes more efficient it will reduce electricity consumption, and hence lighting cost, as well as produce less expensive attractive lighting fixtures. Our university-industry collaboration is hence of major benefit to the public as it demonstrates the feasibility of manufacturing optimized extracting substrates for highly efficient OLEDs for SSL in a future R2R process, which would drastically reduce the manufacturing cost and increase production in the USA. Moreover, newly developed methods by our team allow low-cost roll manufactured substrates to be transferred to flexible or rigid glass substrates, which solves the plastic substrate barrier issues, and when combined with device encapsulation will increase the OLEDs’ environmental stability.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Taongi: An Obscure Atoll on the International Stage

Taongi is a microscopic dot in the vast expanse of the Pacific Ocean. Comprised of ten small islands, the atoll has never been permanently inhabited. The ancient Melanesians who settled the Marshallese Archipelago bypassed Taongi because the atoll was too dry to sustain a permanent settlement. Despite its seeming insignificance, Taongi has been a fixture in international affairs since its European discovery in 1526, including being at the center of a simmering feud between Los Alamos and the University of California Radiation Laboratory (UCRL).

58 GEOSCIENCES↗
DOE OSTI2022

A Cybersecurity Threat Profile for a Connected Lighting System

In anticipation of improved energy performance and cost savings, cities and building owners are increasingly considering “smart lighting initiatives” that aim to convert their collection of simple luminaires (i.e., lighting fixtures) into an intelligent connected lighting system (CLS) capable of remotely monitoring energy consumption and fault conditions, and possibly implementing adaptive lighting schemes. The U.S. Department of Energy (DOE) has set an national goal of tripling the energy efficiency and demand flexibility of the buildings sector by 2030, relative to 2020 levels 1. It is forecast that connected lighting systems can contribute to that goal by delivering 125 TWh of annual energy savings by 2035 2, equivalent to the annual output of 50 typical (500 MW) power plants. However, these energy savings and the DOE goal are put at significant risk if connected technologies are not adopted due to real or perceived cybersecurity concerns. Connected IoT devices such as these have historically been rife with vulnerabilities which sometimes put security considerations secondary to functionality and operability. What are the cybersecurity threats that will impact these systems, as formerly banal luminaires transition into intelligent connected devices that collect information about themselves, their surrounding environment, and possibly us? In this paper we analyze a threat profile performed on a fault-detection use case for streetlights. A threat profile establishes security requirements, justifies security measures, yields actionable controls, and effectively communicates risk to stakeholders. This effort provides critical information for making threat-based decisions to increase security at a reasonable cost, and can effectively be used by development teams, software architects, and managers to make cybersecurity a part of their ongoing culture of awareness, training, and prevention. This leads to more secure systems and better-understood security. On-premise, cloud, and hybrid architectures with different authentication mechanisms were modeled and later categorized using the Microsoft STRIDE framework. An analysis of the recommended controls for each threat was performed to determine which controls could and should be put in place by manufacturers or third-party suppliers, and which controls need to be left up the end-user to implement. Fifty-seven threats were identified. Among our key findings: (1) 65% (37/57) of the threats did not involve the luminaires, but rather the other components needed to communicate with and manage them; (2) 63% (36/57) of the threats could have been mitigated through manufacturer-implemented defensive techniques or “controls”; and (3) 23% (13/57) of the threats were dependent on the network configuration. Recommendations based on the results of this work are made to key stakeholder groups. Notably, lighting technology developers are advised to address all threats that can be reasonably controlled with baked-in technology solutions (e.g., encryption or authentication controls), and employ some form of secure supply chain management and tracking where other parts (e.g., sensors, microprocessors) of a luminaire must also be built and manufactured with the proper security controls in place. Developers should also review threats involving assets not developed in-house to understand how connectivity with other devices will affect their product during system operation and determine if a compensating control for a defense-in-depth strategy will be needed. Finally, those interested in deploying CLS should compare the differences between cloud and on-premise models to determine which is more suitable for their needs and the abilities of their security team.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Rapid, Approximate Multi-Axis Vibration Testing [Slides]

Sequential single-axis testing provides a poor approximation of service environments. Multi-axis vibration tests are not yet standard practice. How good do multi-axis tests need to be to replace single-axis testing in practice? Is the simplest possible multi-axis test close to single-axis testing in test quality? Can single-axis testing techniques provide a sufficient rapid approximation to a multi-axis test? How much can we improve multi-axis test quality by optimizing passive test fixture hardware instead of adding active excitation sources?

42 ENGINEERING↗
DOE OSTI2022

Solid Phase Processing of Lead-Free Brass with Carbon Additives

Currently, “lead-free” brass alloys (like C27450/C27451/C6930), used extensively in drinking water fixtures and automotive, electrical, and electronic applications contain maximum 0.25% lead to maintain mechanical performance and machinability. Adding graphite to brass as an alternative to lead, using casting, powder metallurgy, and extrusion methods, has been explored previously. However, all these methods have proven to be energy-, time-, and resource-intensive, while not enabling performance equivalent to that of C36000 brass. In this project, we developed a one-step approach using friction extrusion and ShAPE to make lead-free brass/graphite components such as wires, rods and tubes with mechanical performance equivalent to commercial lead-free brass alloys. Manufacturing temperatures were maintained ~550-730 °C with feed rates ranging between 4 – 25 mm/min. Results show larger grains at the center of the rods and wires with smaller grains developing at the edges. Graphite particles were sheared in the direction of extrusion with higher strains observed towards the edges. Hardness of the brass/graphite samples was over 25% higher than that of the corresponding brass-only samples (rods and wires), also friction extruded. Our results show that the sub-micron graphite plays an important role in limiting process temperature and restraining grain growth during friction extrusion, thus reducing grain size in composites.

36 MATERIALS SCIENCE↗