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At least 667 records · Page 37

Emerging Technologies for Decarbonizing Silicon Production

Abstract Silicon (Si) is an important material for alloying, solar photovoltaics, and electronics. However, current methods of producing silicon require energy consumption of around 11–13 kWh/kg Si and direct carbon emissions are 4.7–5 tons CO 2 per ton Si which conflicts with global efforts to limit climate change. In this work, we discuss several promising methods for reducing or eliminating carbon emissions from the silicon production process. Such methods include using biocarbon, integrating the current process with carbon capture and utilization/storage (CCU/CCS), metallothermic reduction, hydrogen reduction, and molten salt electrolysis. We present the positive aspects and challenges of each approach. Biocarbon coupled with CCU/CCS is the most industrially mature technology and can be carbon–neutral or -negative but is not carbon-free. Hydrogen directly reducing silicon dioxide is not thermodynamically favorable, but it may be viable to use hydrogen in conjunction with other processes to reduce emissions. Metallothermic and electrochemical methods of production are promising and have the potential to create high-purity silicon with no reduction-related carbon emissions but have only been demonstrated at lab scale. Economic viability will likely be the next determining factor for which technologies are more widely researched and implemented. Graphical Abstract

08 HYDROGEN↗

Dynamic Strength and Equation of State of Epon 828 and Diethanolamine (DEA) Polymer Epoxy Under Shock Loading

Polymers are increasingly utilized in engineering applications that can experience high loading rates, necessitating increased understanding of their response under such conditions. The tamped Richtmyer-Meshkov Instability (RMI) method was used to characterize the equation of state and dynamic strength of the polymer Epon 828 cured with Diethanolamine (DEA). Plate impact experiments that drove a uniaxial shock compression wave across a sinusoidally corrugated metal-polymer interface were performed to generate shock stresses from 4-12 GPa and strain rates of approximately 1/s in the polymer. X-ray phase contrast imaging recorded the shock motion in the polymer and subsequent interface evolution. Analysis of this data yielded the polymer equation of state and, in conjunction with numerical modeling, the dynamic strength. The equation of state was validated against one-dimensional plate impact experiments from existing literature. The dynamic strength was compared to prior data for Epon 828 and related polymers at lower strain rates and found to exhibit significant strain rate and pressure-hardening effects. The strength of the Epon 828 polymer at 10 6 1/s was found to be approximately 1.5 GPa, suggesting that it is comparable to the strength of high strength metals at these dynamic conditions.

Equation of state↗

Hybrid fiber metal composite laminate interlaminar reinforcement through metal interlocks

Aircraft and automobile industries are continually seeking high-performance and lightweight solutions. Fiber-reinforced composites in conjunction with metals are being considered in the form of hybrid materials. There is a continuous need for improvement of interfacial bonding between composite layers and metal constituents. In this study, an innovative hybrid fiber interlocking metal hooks laminate (FIMHL) system was developed in which fiber-reinforced thermoset composite, and metal sheets are mechanically bonded together using out of plane hooks stamped in the metal. Process optimization was performed to gain the full benefit of the through-thickness reinforcement. Microstructural analysis showed improved interaction between the metal hooks and the fiber layers which reduced porosity and resin richness. This was reflected in mechanical properties, as tensile and flexural strength of FIMHL was enhanced by 38.5 and 18.8%, respectively, after process optimization. Furthermore, normalized weight fraction (76.4%) properties of FIMHL also confirmed that the increase in mechanical properties of optimized panel were not only due to increased reinforcement (glass fiber + aluminum) volume fraction but also because of improved metal hooks and fibers interaction. There was no significant effect on lap shear and fracture toughness, as they depend on bend back behavior of the hooks. A bilinear traction-separation model was used to characterize mode-I interlaminar fracture toughness properties, and 4.5% variation was recorded when modeling and experimental values were compared.

36 MATERIALS SCIENCE↗

Geometry Optimization for Structural Reliability and Performance of a Thermoelectric Generator

The opposing requirements for the performance and reliability of a thermoelectric generator (TEG) are investigated with numerical finite element analysis simulations. The parameters that significantly influence the operational performance and structural reliability of a TEG are considered for simultaneous optimization. The design of experiments (DOE) based response surface optimization methodology in conjunction with results from finite element analysis was employed to identify optimal parameters from the structural reliability and performance (power output and efficiency) perspectives. A high temperature bismuth telluride based TEG couple was used in the studies to demonstrate the general applicability of the methodology. The response surface methodology is found to be a robust technique that can expedite the process of geometry optimization of a TE device during the research and development phase of TEG devices fabricated from new thermoelectric materials.

Karri, Naveen K.↗

Materials informatics: From the atomic-level to the continuum

We report that in recent years materials informatics, which is the application of data science to problems in materials science and engineering, has emerged as a powerful tool for materials discovery and design. This relatively new field is already having a significant impact on the interpretation of data for a variety of materials systems, including those used in thermoelectrics, ferroelectrics, battery anodes and cathodes, hydrogen storage materials, polymer dielectrics, etc. Its practitioners employ the methods of multivariate statistics and machine learning in conjunction with standard computational tools (e.g., density-functional theory) to, for example, visualize and dimensionally reduce large data sets, identify patterns in hyperspectral data, parse microstructural images of polycrystals, characterize vortex structures in ferroelectrics, design batteries and, in general, establish correlations to extract important physics and infer structure-property-processing relationships. In this Overview, we critically examine the role of informatics in several important materials subfields, highlighting significant contributions to date and identifying known shortcomings. We specifically focus attention on the difference between the correlative approach of classical data science and the causative approach of physical sciences. From this perspective, we also outline some potential opportunities and challenges for informatics in the materials realm in this era of big data.

36 MATERIALS SCIENCE↗

Exploring novel deformation mechanisms in aluminum–copper alloys using in situ 4D nanomechanical testing

Even after nearly a century of extensive use of aluminum alloys in structural applications, our understanding of such precipitation-strengthened materials is far from complete. With the advent of next generation advanced characterization techniques, our ability to probe materials in unique ways and at different length scales has established a new paradigm for devising new pathways to alloy design by engineering materials and tailoring specific properties at the nanoscale. Here, we perform in situ nanomechanical testing in conjunction with synchrotron -based hard X-ray nanotomography to capture initiation and evolution of damage in 3D in Al-Cu alloys. Precipitates in these alloys are seen to exhibit unprecedented localized deformation in compression, which is attributed to novel observations of kinking in these brittle second-phase particles, accompanied with the generation of a fine polycrystalline texture in the adjacent matrix. We observe a size-dependent transition in precipitate deformation behavior that has been thoroughly investigated using a comprehensive correlative approach.

36 MATERIALS SCIENCE↗

Modeling the role of local crystallographic correlations in microstructures of Ti-6Al-4V using a correlated structure visco-plastic self-consistent polycrystal plasticity formulation

This paper presents a multi-level crystal plasticity-based simulation framework for modeling mechanical response and microstructure evolution of Ti-6Al-4V with α-lath/lamellar microstructures. Here, the model is a correlated structure visco-plastic self-consistent (CS-VPSC) formulation linking three scales: a single crystals micro-scale, a lath/lamellar colony meso-scale, and a lath/lamellar aggregate macro-scale. A selected hardening law for the evolution of critical resolved shear stress per slip system used in CS-VPSC is phenomenological. However, it adjusts the resistances of basal and prismatic slip systems based on the geometry of slip transfer between adjacent lamellae. Consistent with experimental evidences, the resolved shear stress on the pyramidal slip planes is dependent not only on the stress in the direction of slip but also on the two orthogonal shear stress components and the three normal stress components (non-Schmid effects). Electron backscatter diffraction (EBSD) data in conjunction with a procedure relying on α→β phase transformation is used to construct paired variants of α-laths/lamellae satisfying their local crystallographic correlations. The procedure fits volume fractions of individual laths/lamellae with the experimental EBSD data and selects a distribution of habit planes between adjacent variants with respect to the loading direction. The simulation framework is applied to interpret the deformation behavior in tension and compression along two sample directions of Ti-6Al-4V fabricated via laser powder bed fusion. Moreover, the model is used to simulate texture evolution during rolling of the material to large strains. It is demonstrated that the model is capable of predicting plastic anisotropy/asymmetry and the concomitant texture evolution. While the model reveals a significant effect of habit plane inclination with respect to the loading direction on yield stress, the comparison of the data and model predictions shows that a random distribution of habit planes fits the flow response. It is further inferred that the tension-compression asymmetry arises from the non-Schmid effects.

36 MATERIALS SCIENCE↗

Heteroepitaxy of FCC-on-FCC systems of large misfit

Here, to understand the effects of lattice mismatch on heteroepitaxial growth, we have studied the equilibrium structure and orientation relationships (ORs) of FCC films grown epitaxially on FCC substrates, using molecular dynamics simulations in conjunction with embedded atom method potentials. Three film/substrate systems have been investigated, namely: Ag on Cu, Ag on Ni and Pb on Al. These systems cover a significant range of lattice mismatch, from 12.6% for Ag/Cu to 21.8% for Pb/Al. For each system, the ORs of films on six different substrate orientations, namely: (100), (511), (311), (211), (322) and (111), have been investigated. Films on these susbstrates cover a gradual transition from the oct-cube orientation relationship, which occurs only on (100) substrates, to the heterotwin orientation relationship, which often occurs on (111) substrates. It is found that the resulting ORs vary systematically with substrate orientation, but that the pattern of variation is almost identical for all three systems, and therefore largely independent of mismatch. However, the manner in which mismatch is accommodated does depend on the magnitude of mismatch. Simulations point to an important role for edge-to-edge matching and defects such as stacking faults. An analysis of these results in terms of transformation strains highlights the distinction between the ORs, which are largely independent of mismatch, and the local interfacial structure, which changes directly with mismatch.

36 MATERIALS SCIENCE↗

High performance high-power textured Mn/Cu-doped PIN-PMN-PT ceramics

Piezoelectric ceramics with combinatory soft and hard characteristics are highly desired for high-power applications. However, it remains grand challenge to achieve simultaneous presence of hard (e.g. high coercive field, E c ; high mechanical quality factor, Q m ) and soft (e.g. high piezoelectric constant, d; high electromechanical coupling factor, k) piezoelectric properties in piezoelectric ceramics since the mechanism controlling the hard behavior (pinned domain walls) will significantly reduce the soft behavior. Here, we address this grand challenge and demonstrate <001> textured MnO 2 and CuO co-doped Pb(In 1/2 Nb 1/2 )O 3- Pb(Mg 1/3 Nb 2/3 )O 3- PbTiO 3 (PIN-PMN-PT) ceramics exhibiting ultrahigh combined soft and hard piezoelectric properties (d 33 = 713 pC N –1 , k 31 = 0.52, Q m ≈950, E c = 9.6 kV cm –1 , tan δ = 0.45%). The outstanding electromechanical properties are explained by considering composition/phase selection, crystallographic anisotropy and defect engineering. Phase-field model in conjunction with high resolution electron microscopy and diffraction techniques is utilized to delineate the contributions arising from intrinsic piezoelectric response, domain dynamics, and local structural heterogeneity. Furthermore, these results will have significant impact in the development of high-power transducers and actuators.

36 MATERIALS SCIENCE↗

Kinetics and evolution of solid-state metal dealloying in thin films with multimodal analysis

Thin-film solid-state metal dealloying (thin-film SSMD) is an emerging technique that uses self-organization to design nanostructured thin films. The resulting 3D bicontinuous nanostructures are promising for a wide range of applications, such as catalysis and energy storage. In this work, we prepared thin films by SSMD using Ti-Cu as the parent alloy and Mg as the solvent. Using a multimodal approach, we combined synchrotron X-ray spectroscopy, diffraction, and high-resolution electron-based spectroscopy and imaging to study their morphological, structural, and chemical evolution. The processing-structure relationship was analyzed as a function of parent alloy composition and dealloying temperature and time. Morphological transitions from globular, to lamellar, to bicontinuous structures, in conjunction with a ligament size evolution, were identified as functions of the parent alloy composition. The dealloying rate increased with increasing concentration of interdiffusing elements (dissolving component) in the parent alloy. The parting limit, a dealloying compositional threshold, was systematically analyzed and determined to be 30%–40%. The order of crystalline phase formation is CuMg 2 , Cu 2 Mg, and Ti; the Ti phase first shows self-reorganization during dealloying, separate from the crystallization process. The coarsening in thin-film SSMD was identified and not entirely self-similar; in addition to the increase of ligament size over time, the formation of larger globular ligaments were also observed. This work furthers our fundamental understanding of thin-film SSMD and nanostructured thin-film design, where the thermodynamic and kinetic effects differ from the bulk counterparts. The fact that dealloying and diffusion outpaces the crystallization and new phase formation also offers opportunities to utilize thin-film SSMD in certain alloy systems in which deleterious intermetallic phases need to be suppressed, that may not be possible in the bulk geometry.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

An assessment of the utility of multirate time integration for the modeling of laser powder bed fusion

Finite element simulation of the laser powder bed fusion process is made challenging by the inherently multiscale nature of the process. When using the typical global time stepping techniques, slowly-evolving regions of the domain receive the same numerical treatment as the regions with the highest temperature rates. The current work details the implementation and evaluation of an implicit multirate method which is able to advance different regions of the domain with distinct time steps, depending on their current solution rate. Previous work indicates that this representation of the temporal scales of the problem can lead to significant reductions in wall clock run time, and it is shown herein that multirate time integration, when used with a uniform process-scale mesh, can result in speedups of approximately 19, 42, and 87 times, for domains with edge lengths of approximately 1 mm, 2 mm, and 5 mm, respectively. When used in conjunction with $\ h$-refinement (limited to two levels of refinement), the resulting speedups (taken relative to the uniform mesh) are around 28, 85, and 665 times. The method is demonstrated to converge as indicated by the literature, and its use with an AM-Bench domain is demonstrated.

42 ENGINEERING↗

Custom-form iron trifluoride Li-batteries using material extrusion and electrolyte exchanged ionogels

Custom-form factor batteries fabricated in non-conventional shapes can maximize the overall energy density of the systems they power, particularly when used in conjunction with energy dense materials (e.g., Li metal anodes and conversion cathodes). Additive manufacturing (AM), and specifically material extrusion (ME), have been shown as effective methods for producing custom-form cell components, particularly electrodes. However, the AM of several promising energy dense materials (conversion electrodes such as iron trifluoride) have yet to be demonstrated or optimized. Furthermore, the integration of multiple AM produced cell components, such as electrodes and separators, along with a custom package remains largely unexplored. In this work, iron trifluoride (FeF 3 ) and ionogel (IG) separators are conformally printed using ME onto non-planar surfaces to enable the fabrication of custom-form Li-FeF 3 batteries. Further, to demonstrate printing on non-planar surfaces, cathodes and separators were deposited onto cylindrical rods using a 5-axis ME printer. ME printed FeF 3 was shown to have performance commensurate with FeF 3 cast using conventional means, both in coin cell and cylindrical rod formats, with capacities exceeding 700 mAh/g on the first cycle and ranging between 600 and 400 mAh/g over the next 50 cycles. Additionally, a ME process for printing polyvinylidene fluoride-co-hexafluoropropylene (PVDF-HFP) based IGs directly onto FeF 3 is developed and enabled using an electrolyte exchange process. In coin cells, this process is shown to produce cells with similar capacity to cells built with Celgard separators out to 50 cycles, with the exception that cycling instabilities are observed during cycles 8–20. When using printed and exchanged IGs in a custom cylindrical cell package, 6 stable high-capacity cycles are achieved. Overall, this work demonstrates approaches for producing high-energy-density Li-FeF 3 cells in coin and cylindrical rod formats, which are translatable to customized, arbitrary geometries compatible with ME printing and electrolyte exchange.

25 ENERGY STORAGE↗

Soil sealing by algae: An alternative to plastic pond liners for outdoor algal cultivation

Commercial production of algal biofuels is currently limited by high capital costs, particularly costs of synthetic pond liners that minimize seepage of cultivation fluids, salts, and nutrients into the subsurface beneath outdoor algae cultivation facilities. Even some profitable nutraceutical companies bear the high costs of pond liners. However, studies of animal waste holding ponds and aquaculture facilities have shown that underlying soils can effectively “self-seal”, potentially eliminating the need for plastic liners. Here, we explored the potential for self-sealing with algae to provide an alternative to synthetic pond liners in unlined algae cultivation ponds. Laboratory-scale soil column experiments were used to investigate soil clogging by algae, a topic rarely discussed in the literature. Columns composed of fine sand, loamy sand, and loam soil displayed reductions in saturated hydraulic conductivity of the entire soil column of up to two orders of magnitude in response to infiltration by the alga Scenedesmus dimorphus suspended in algal culture nutrient solution at a density of 5 × 10 8 cells L –1 . Scanning electron microscope imaging showed a dense algal layer on the surface of each soil column, thickly coating mineral grains with algal material and filling pore spaces. The algal coating was absent in samples at >3 cm depth in the soil columns, and measurements of chlorophyll content also confirmed that algal cells were mostly confined to the soil surface. In this study, the application of an algal suspension contributed significantly to soil sealing. In conclusion, this new application of biological sealing technology should be studied further to determine its utility and durability as an alternative to plastic liners, perhaps in conjunction with soil compaction to achieve hydraulic conductivities beneath algal production ponds that are protective of groundwater quality.

59 BASIC BIOLOGICAL SCIENCES↗

Model for radiation damage-induced grain subdivision and its influence in U 3 Si 2 fuel swelling

Here, the swelling mechanisms of U 3 Si 2 from neutron irradiation under reactor conditions are not unequivocally known. The limited experimental evidence that is available suggests that the main driver of the swelling in this material would be fission gases accumulation at crystalline grain boundaries. The steps that lead to the accumulation of fission gases at these locations are multiple and complex. However, gradually, the gaseous fission products migrate by diffusion. Upon reaching a grain boundary, which acts as a trap, the gaseous fission products start to accumulate, thus leading to formation of bubbles and hence to induced swelling. Therefore, a quantitative model of swelling requires the incorporation of phenomena that increase the presence of grain boundaries and decrease grain sizes, thus creating sites for bubble formation and growth while concurrently deceasing the distance from gas species formation to gas accumulation sites. It is assumed that grain boundary formation results from the conversion of stored energy from accumulated dislocations into energy for the formation of new grain boundaries. This work attempts to develop a quantitative model for grain subdivision in U 3 Si 2 based on the above mentioned phenomena to quantitatively corroborate the presence of such a mechanism. Then the model is used in conjunction with swelling codes to evaluate the total swelling of a fuel pellet during its lifetime in the I 2 S-LWR reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Neutron thermalization in nuclear graphite: A modern story of a classic moderator

Graphite has been of great interest since the dawn of the nuclear era. In this work, we will focus on the thermal neutron scattering of two types of nuclear graphite that have different microstructures, namely, the historic PGA which has a very anisotropic medium-grained needle coke, and the new G347A which is a near-isotropic fine-grained graphite. We report the results of room temperature inelastic neutron scattering measurements for the scattering function, double differential scattering cross-section, and phonon density of states. The obtained results are discussed in conjunction with results extracted from first-principles lattice dynamics simulations of crystalline graphite, using the incoherent approximation and by also including the coherent-one phonon contribution. Excellent agreements have been found between the measured and calculated scattering functions and phonon densities of states. The inclusion of the coherent-one phonon scattering shows a significant improvement of the calculated scattering functions, double differentials, and inelastic scattering cross-sections. We also highlight the physical concerns about the current thermal neutron scattering ENDF/B-VIII of nuclear graphite library and its corresponding phonon density of states. This work aims to provide a new presentation of neutron thermalization by graphite and offers a new set of high quality experimental and computational data for consideration.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Casimir–Polder energy for axially symmetric systems

We develop a formalism suitable for studying Maxwell’s equations in the presence of a medium that is axially symmetric, in particular with respect to Casimir–Polder interaction energies. As an application, we derive the Casimir–Polder interaction energy between an electric δ-function plate and an anisotropically polarizable molecule for arbitrary orientations of the principal axes of polarizabilities of the molecule. We show that in the perfect conductor limit for the plate the interaction is insensitive to the orientation of the polarizabilities of the molecule. We obtain the Casimir–Polder energy between an electric δ-function sphere and an anisotropically polarizable molecule, again for arbitrary orientations of the principal axes of polarizabilities of the molecule. We derive results when the polarizable molecule is either outside the sphere, or inside the sphere. We present the perfectly conducting limit for the δ-function sphere, and also the interaction energy for the special case when the molecule is at the center of the sphere. Our general proposition is that the Casimir–Polder energy between a dielectric body with axial symmetry and a unidirectionally polarizable molecule placed on the axis with its polarizability parallel to the axis gets non-zero contribution only from the m=0 azimuth mode. This feature in conjunction with the property that the m=0 mode separates into transverse electric and transverse magnetic modes allows the evaluation of Casimir–Polder energies for axially symmetric systems in a relatively easy manner.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

A dual promotional effect of doping tantalum (Ta) in atomically dispersed Ru/CeO 2 catalyst toward CO 2 methanation: Enhanced associative adsorption of CO 2 and activation of H 2

Precisely controlling the product selectivity in CO 2 hydrogenation through rational catalyst design presents a promising approach to mitigate environmental and energy-related challenges, though it remains a significant scientific hurdle. Herein, the CH 4 selectivity of 0.5 wt% Ru loaded catalysts at 250 °C was effectively shifted from approximately 35 % to 100 % through the incorporation of Ta dopant into the CeO 2 support. The EXAFS spectra in conjunction with CO DRIFTS experiment indicated the presence of atomically dispersed Ru particles anchored on the Ta-doped CeO 2 surface. A higher oxidized CeO 2 surface was evidenced in the presence of Ta dopant. The presence of Ta dopant also improved the dispersion of Ru species and their interaction with the support. Most importantly, the Ru/Ta-CeO 2 catalyst exhibited a pronounced capacity for associative CO 2 -adsorption under atmospheric pressure at 50 °C. An improved H 2 activation was also observed under CO 2 hydrogenation conditions. This novel finding of the dual promotional effect of Ta carries a significant impact in the field of CO 2 capture and utilization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Impact of fuel and engine operating conditions on efficiency of a heavy duty truck engine running compression ignition mode using energy and exergy analysis

Gasoline compression ignition using a single gasoline-type fuel for direct/port injection has been shown as a method to achieve low temperature combustion with low engine-out NO x and soot emissions and high indicated thermal efficiency. However, key technical barriers to achieving low temperature combustion on multi-cylinder engines include the air handling system (limited amount of exhaust gas recirculation) as well as mechanical engine limitations (e.g. peak pressure rise rate). In light of these limitations, high temperature combustion with reduced amounts of exhaust gas recirculation appears more practical. Previous studies by the authors demonstrated that utilizing port and direct injection of E85 gasoline simultaneously resulted in the best performance and the highest brake thermal efficiency of 47.1%, which was 1.2% higher compared to diesel baseline. For further efficiency improvement, a better understanding of energy and exergy loss mechanisms is required. As such, in this work first and second law thermodynamics analysis were applied to experiments with gasoline compression ignition at an engine speed of 1038 rpm and brake mean effective pressure of 1.4 MPa on a 12.4 L multi-cylinder heavy-duty diesel engine. The impact on the efficiency, losses, and irreversibility with respect to various parameters such as fuel, injection strategy, intake condition, and port injected water mass was quantified. The peak efficiency of ideal cycles and the combined efficiency with a waste heat recovery system were also estimated in this study to assess opportunities for further efficiency gains. It was found that the combustion irreversibility was dominated by the combustion temperature rather than the fuel structure. Despite its highest brake thermal efficiency, E85 gasoline generated the highest exergy destruction due to its lowest combustion temperature. For the same reason, retarding the combustion phasing or adopting a port and direct injection strategy increased the exergy destruction. The combustion duration loss was more notable than the phasing loss and was affected by both the combustion duration and shape of heat release profile. Water port injection increased the exhaust energy, but the available energy dropped significantly attributed to the decrease in the exhaust temperature, rendering waste heat recovery ineffective. The second law analysis serves as a helpful tool in conjunction with the first law analysis to explore pathways to maximize engine efficiency.

33 ADVANCED PROPULSION SYSTEMS↗