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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Development of city buildings dataset for urban building energy modeling

Urban building energy modeling (UBEM) is becoming a proven tool to support energy efficiency programs for buildings in cities. Development of a city-scale dataset of the existing building stock is a critical step of UBEM to automatically generate energy models of urban buildings and simulate their performance. This study introduces data needs, data standards, and data sources to develop city building datasets for UBEM. First, a literature review of data needs for UBEM was conducted. Then, the capabilities of the current data standards for city building datasets were reviewed. Moreover, the existing public data sources from several pioneer cites were studied to evaluate whether they are adequate to support UBEM. The results show that most cities have adequate public data to support UBEM; however, the data are represented in different formats without standardization, and there is a lack of common keys to make the data mapping easier. Finally, a case study is presented to integrate the diverse data sources from multiple city departments of San Francisco. The data mapping process is introduced and discussed. It is recommended to use the unique building identifiers as the common keys in the data sources to simplify the data mapping process. Furthermore, the integration methods and workflow are applied to other U.S. cities for developing the city-scale datasets of their existing building stock, including San Jose, Los Angeles, and Boston.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Divergence of stable isotopes in tap water across China

Stable isotopes in water (e.g., δ2H and δ18O) are important indicators of hydrological and ecological patterns and processes. Tap water can reflect integrated features of regional hydrological processes and human activities. China is a large country with significant meteorological and geographical variations. This report presents the first national-scale survey of Stable Isotopes in Tap Water (SITW) across China. 780 tap water samples have been collected from 95 cities across China from December 2014 to December 2015. (1) Results yielded the Tap Water Line in China is δ2H = 7.72 δ18O + 6.57 (r2 = 0.95). (2) SITW spatial distribution presents typical "continental effect". (3) SITW seasonal variations indicate clearly regional patterns but no trends at the national level. (4) SITW can be correlated in some parts with geographic or meteorological factors. This work presents the first SITW map in China, which sets up a benchmark for further stable isotopes research across China. This is a critical step toward monitoring and investigating water resources in climate-sensitive regions, so the human-hydrological system. These findings could be used in the future to establish water management strategies at a national or regional scale. Title: Divergence of stable isotopes in tap water across China Authors: Zhao, SH; Hu, HC; Tian, FQ; Tie, Q; Wang, LX; Liu, YL; Shi, CX Source: SCIENTIFIC REPORTS, 7 10.1038/srep43653 MAR 2 2017

58 GEOSCIENCES↗
DOE OSTI2023

High-bandwidth density silicon photonic resonators for energy-efficient optical interconnects

The growth of artificial intelligence applications demands ever larger and more complex deep learning models, dominating today's—and tomorrow's—data center and high-performance computing systems. While traditional electronics are failing to keep pace with application demands, silicon photonic (SiPh) interconnects have emerged as a necessary technology to support these systems. SiPh-driven wavelength-division multiplexing (WDM) offers a particularly promising path toward supporting incredibly high-aggregate link bandwidth in a compact and efficient form factor. One of the basic building blocks of these integrated WDM interconnects is the SiPh resonator. Their inherent wavelength selectivity and compact footprint allow for efficient data transmission multiplexed across dozens of carrier wavelengths. Used as add-drop (AD) filters, SiPh resonators are critical to constructing integrated tunable wavelength-selective optical circuit switches as well as for demultiplexing the different carrier wavelengths toward independent wavelength-insensitive photodiodes in a dense wavelength-division multiplexing receiver. Resonators in the all-pass (AP) configuration are widespread as well, allowing for wavelength-selective modulation to drive aggregate link bandwidths far beyond the individual channel data rate. Unlike SiPh Mach–Zehnder modulators (MZM), resonant modulators can be driven using low, complementary metal-oxide-semiconductor drive voltages, allowing for tight co-integration between photonic integrated circuits, fabricated with larger process node technologies, and electronic integrated circuits, designed to exploit the advantages of the latest node. To push toward practical peta-scale interconnects, a comprehensive review of SiPh resonators is required, addressing bottlenecks and design constraints at both the architecture and device levels. We first describe the predominant integrated link architectures and identify their limits. We then discuss the device-level design considerations that can be made for both AD and AP configuration resonators to overcome the system level limits with novel resonator device designs. Analytical models and numerical simulation of resonators are validated by experimental measurement of devices fabricated in a commercial 300-mm foundry, showing a clear path toward volume manufacturing. The demonstrated resonant modulators and filters support the feasibility of increasing the aggregate bandwidth of resonator-driven SiPh interconnects into the peta-scale regime.

42 ENGINEERING↗
DOE OSTI2020

Multi-Model and Multi-Scale Global Sensitivity Analysis for Identifying Controlling Processes of Complex Systems

An environmental model consists of multiple process level sub-models, and each sub-model represents a process that is key to the operation of the simulated system. Global sensitivity analysis methods have been widely used to identify important processes for system model development and improvement. The existing methods of global sensitivity analysis only consider parametric uncertainty, and are not capable of handling model uncertainty caused by multiple process models that arise from competing hypotheses about one or more processes. To address this problem, this project develops a new method to probe model output sensitivity to competing process models by integrating model averaging methods with variance-based global sensitivity analysis to address uncertainty in process models and parameters. The new method yields three process sensitivity indices. The first one is called first-order process sensitivity index, and it is derived as a single summary measure of relative process importance. Evaluating the index is computationally expensive, because it relies in a Monte Carlo scheme that requires thousands and even millions of model executions. To reduce computational cost, this project develops a computationally efficient, quasi Monte Carlo method, and this method is presented in Chapter 2 of this report with and a numerical example for demonstration. The numerical example shows that the results of the quasi Monte Carlo method are substantially close to those of the full Monte Carlo method, but the computational cost of the quasi Monte Carlo method is only 0.7% of that of the full Monte Carlo method. The second index is called total-effect process sensitivity index, and it measures interactions between different processes. Therefore, this sensitivity index includes the first-order process sensitivity index, and can be used to identify influential processes. On the other hand, the total-effect process sensitivity index can also be used to screen non-influential processes. This is demonstrated by two numerical examples using the Sobol-G* functions and groundwater flow models that consider recharge process, geological process, and snowmelt process. The numerical examples shows that the total-effect process sensitivity index is more informative than the first-order process sensitivity. The derivation of the process sensitivity index and the numerical examples are discussed in Chapter 3. Chapter 4 presents two computationally efficient methods for screening non-influential processes to exclude them from further investigation. The two methods are the multi-model difference-based sensitivity (MMDS) analysis method, which can be implemented using the Latin Hypercube Sampling. The second one is the implementation of MMDS method using a binning method. The numerical example for the Sobol-G* function indicates the two methods are capable of identifying non-influential models, and the numerical examples for the groundwater flow and reactive transport show that the two methods are effective for groundwater problems. However, it should be noted that the two methods are numerical approximations, and they can only be used for screening non-influential processes, not for ranking importance of system processes. All the sensitivity analysis methods are implemented by developing python codes, and the codes are in a software called SAMMPY: a python package for process sensitivity analysis under multiple models. The SAMMPY design and structure are discussed in Chapter 5, and the package is released to the public for free download.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2019

Process Modeling of U-10wt% Mo Alloys Using Integrated Computational Materials Engineering

Low-enriched uranium alloyed with 10 wt% molybdenum (U-10Mo) has been identified as a promising alternative to highly enriched uranium as fuel for the nation’s high-performance research reactors. Manufacturing the U-10Mo alloy consists of multiple complex thermomechanical processes, which is highly challenging for computational modeling. The integrated computational materials engineering (ICME) concept supports building a microstructure-based framework to investigate the effect of manufacturing processes on the material microstructure. In this report, an ICME model that combines homogenization, hot rolling, annealing, and cold rolling is presented as an example of implementing the ICME concept for modeling the manufacturing processes of the U-10Mo alloy. The integrated model enables information to be passed between the different model components, leading to an improved prediction and a better understanding of microstructure across multiple processes. The integrated model was also implemented to investigate the variation of chemical composition, thickness of the zirconium interlayer, grain growth, and carbide redistribution and fracture of U-10Mo during the thermomechanical processes. With the homogenization model, a molybdenum concentration map can be reconstructed from any given microstructure, and the homogenization time needed to reach a desired homogenization level can also be approximated. The microstructure-based finite-element rolling model, shows that the homogenization process reduces the nonuniformity in the thickness of the zirconium interlayers on the U-10Mo. With the output from the rolling model, a statistical analysis of second-phase hard particles was conducted to quantify the particle redistribution and interparticle spacing between carbides during the deformation. Also, new stringer identification criteria were proposed to predict the correlation between stringer volume fractions and hot-rolling reduction. A macro-finite-element method hot-rolling model showed that higher reduction passes can be achieved within the mill separation force range, and a new “aggressive” rolling schedule was proposed. The model also showed the importance of can material on the quality of rolled foils, with stronger can materials resulting in hot-rolled U-10Mo free of defects (waviness, dog-boning). The deformation-induced recrystallization model demonstrated capability to use inputs from deformation simulations of strain accumulation in U-10Mo samples to predict grain growth behavior of the fuel during thermal treatment stages. Finally, a plane-strain compression mode simulated particle fracture and calculates the void volume fraction generated during cold rolling. The macro-finite-element method cold-rolling model showed that smaller diameter rolls are necessary to achieve the desired foil thickness.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Processing behavior evolution of recycled polypropylene: An integrated experimental and Computer-Aided engineering simulation study

Polypropylene (PP) comprises 21% of global plastics production and 18% of plastics waste, yet less than 1% of solid-waste PP is recycled in the United States (U.S.), representing significant environmental and economic challenges. Mechanical recycling, the most prevalent recycling method, subject's materials to thermomechanical stresses, which typically degrade polymer properties, affecting the quality of polymer products. This study replicates the impact of mechanical recycling through multiple extrusion cycles to examine the effects on PP's processing behavior. Dynamic scanning calorimetry (DSC) measurements showed stable melting behavior across all processing conditions, while crystallization analysis exhibited consistent shifts in kinetic parameters. Rheological characterization demonstrated progressive viscosity reductions through successive cycles, particularly pronounced at elevated reprocessing temperatures. Here, the integration of this experimental data into injection molding simulations showed that recycled PP maintains viable processing characteristics. Our findings establish quantitative correlations between processing history and material behavior, enabling optimization of processing parameters directly rather than relying on trial-and-error approaches. While these results reflect idealized recycling conditions with minimal contamination, they provide a framework for understanding fundamental property evolution during mechanical recycling.

42 ENGINEERING↗
DOE OSTI2019

Simple non-galvanic flip-chip integration method for hybrid quantum systems

A challenge faced by experimenters exploring hybrid quantum systems is how to integrate and interconnect different materials and different substrates in a quantum-coherent fashion. Here, we present a simple and inexpensive flip-chip bonding process, suitable for integrating hybrid quantum devices on chips from different substrates. The process only requires equipment and materials used routinely for contact photolithography, and it is possible to undo the bonding and reuse the chips. The technique requires minimal compressive force, so it is compatible with a wide range of different substrates. Unlike indium-based bonding, this process does not establish a galvanic connection between the two chips, but as we show, in some situations this is not necessary. We demonstrate the technique using lithographically patterned quarter-wave coplanar waveguide resonators, fabricated on one chip, and couple these inductively to a transmission line patterned lithographically on a separate chip. The two chips have a vertical interchip gap of about 7 μm, and we can repeatedly achieve lateral alignments of better than 2μm. We measure electromagnetic resonances with low-power (similar to ~1 photon) internal quality factors Q i around 5 x 10 5 , comparable to single-chip performances, with as-designed coupling quality factors Q c ranging from 2 x 10 2 to 5 x 10 5 .

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Accelerating Instanton Theory with the Line Integral Nudged Elastic Band Method and Gaussian Process Regression

Quantum tunneling plays a fundamental role in many chemical reactions, particularly proton transfer processes. Ring polymer instanton theory offers a practical framework for computing tunneling rates in complex molecular systems. However, applying the ring polymer instanton method with a potential energy surface generated on-the-fly using electronic structure calculations can be computationally demanding. Here, in this work, we present a new efficient implementation of the ring polymer instanton method by combining the Line Integral Nudged Elastic Band (LI-NEB) approach with Gaussian Process Regression (GPR). We benchmarked this method on prototypical ground-state proton transfer systems, including the benchmark gas-phase hydrogen abstraction reaction H + CH 4 → H 2 + CH 3 , malonaldehyde, and Z-3-amino-propenal (aminopropenal). Our results show that this approach is an order of magnitude faster than traditional instanton algorithms while maintaining excellent agreement with their tunneling rates. This development opens the door to studying proton transfer in larger systems with improved efficiency.

chemical physics↗
DOE OSTI2022

Dispersal and fire limit Arctic shrub expansion

Abstract Arctic shrub expansion alters carbon budgets, albedo, and warming rates in high latitudes but remains challenging to predict due to unclear underlying controls. Observational studies and models typically use relationships between observed shrub presence and current environmental suitability (bioclimate and topography) to predict shrub expansion, while omitting shrub demographic processes and non-stationary response to changing climate. Here, we use high-resolution satellite imagery across Alaska and western Canada to show that observed shrub expansion has not been controlled by environmental suitability during 1984–2014, but can only be explained by considering seed dispersal and fire. These findings provide the impetus for better observations of recruitment and for incorporating currently underrepresented processes of seed dispersal and fire in land models to project shrub expansion and climate feedbacks. Integrating these dynamic processes with projected fire extent and climate, we estimate shrubs will expand into 25% of the non-shrub tundra by 2100, in contrast to 39% predicted based on increasing environmental suitability alone. Thus, using environmental suitability alone likely overestimates and misrepresents shrub expansion pattern and its associated carbon sink.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Development of quantum dot materials for infrared cameras (Final CRADA Report)

The aim of this project was to develop scalable methods to produce infrared (IR) mercury telluride (HgTe) colloidal quantum dot (CQD) thin films and demonstrate their utility in a proof-of-concept monolithic SWIR focal plane array (FPA). These objectives were accomplished by scaling up the HgTe CQD synthesis, characterizing physical and electrical properties of HgTe CQDs, evaluating solution-processed coating methods for quality and efficiency, and developing a process flow to integrate HgTe CQDs with commercial-off-the-shelf silicon CMOS readout circuits by solution-processed coating to produce monolithic FPAs. The FPA is the image sensor in an infrared imaging system responsible for detecting and processing reflected or emitted light into an infrared image of the scene under observation. The quality of the image is determined by the sensitivity and resolution of the image sensor in the system. Higher resolution IR FPAs enable higher throughput in manufacturing quality assurance, wider field of view for autonomous navigation, and longer range surveillance for defense.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2024

Sustainable Valorization of CO2 through Nuclear Power-to-X Pathways

Some of the issues concerning energy security and climate change can be addressed by employing nuclear power (NP) to supply the energy required for the conversion of carbon dioxide (CO2) into chemicals, products, and materials. Nuclear energy represents a neutral carbon source that can be generated sustainably, reliably, and consistently. Nuclear power plants (NPPs) could supply energy in the form of heat, electricity, and ionizing radiation to drive CO2 chemical reactions underpinning NP-to-X type of pathways. CO2 conversion processes are either commercially available or emerging technologies at different developmental maturity stages. This work reviews the published literature (articles and patents) that reports R&D results and the understanding and development of chemical reactions and processes, as well as the efforts in integrating NPPs and chemical processes (CPs). As will be made evident, a new industrial era for the manufacturing of decarbonized chemicals, products, and materials will be possible by developing and implementing new (more energy- and carbon-efficient) processes responding to the NP-to-X pathways. This new decarbonizing platform not only contributes to achieving net zero goals but also broadens the NPP product beyond electricity.

08 HYDROGEN↗
DOE OSTI2015

A cradle to grave decontamination process - 15266

As the rate of decommissioning of nuclear facilities is accelerating there is an ever increasing need for technologies which will decrease dose to operators, reduce overall cost and allow minimization of waste volumes. A new fully integrated decontamination and waste management process is described herein. This method approaches surface decontamination in an integrated fashion in that it deals with the full cycle of the process including the final disposition of the secondary wastes generated during the cleaning cycle. This approach also simplifies decontamination in that it addresses issues observed in previous chemical decontamination applications such as generation of orphan wastes and the requirements for multi-step reagent additions over repeated cycles. The waste management aspect of this system is key to providing a fully integrated process and deals with the issues related to grout formulations in the presence of high waste loadings. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Decision-support for Digester-Algae IntegRation for Improved Environmental and Economic Sustainability (DAIRIEES)

Manure management is a major concern for dairy farms, as manure emits significant quantities of greenhouse gases and contains concentrated nutrients, especially nitrogen and phosphorus. Current manure management practices consist of spreading minimally processed manure on agricultural fields, which releases greenhouse gases directly to the atmosphere and often leads to nutrient overloading on fields and runoff to surface and groundwater. A novel manure treatment system has been proposed that mitigates many of the current environmental concerns and creates value added products from the manure including bioplastics, electricity, fertilizer, and animal bedding. DAIRIEES, an Excel based model, allows users to enter characteristics about a dairy farm’s manure, manure management plan, and regional market. Based on these inputs, the five main processes of the integrated system—fermenter, anaerobic digester, bioplastics reactor, algae cultivation, and hydrothermal liquefaction or fast pyrolysis system—are analyzed in detail using data from laboratory scale experiments supplemented by information on full-scale processes from the literature. The model can be used to estimate performance of the integrated manure treatment system, including: 1) carbon and nutrient sequestration, 2) quantities and market value of end products, and 3) the system’s overall economic viability. The DAIRIEES model outlines the major economic considerations for construction and operation of a full scale integrated treatment system. This information can be used to inform a more detailed pro forma analysis of the deployed system.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Understanding the performance of membrane for direct air capture of CO 2

Abstract Direct air capture (DAC) of CO 2 is becoming increasingly important for reducing greenhouse gas concentrations in the atmosphere. However, the cost and energy requirements associated with DAC make it less economically feasible than carbon capture from flue gases. While various methods like solid sorbents and gas–liquid absorption have been explored for DAC, membrane processes have only recently been investigated. The objective of this study is to examine the separation performance of a membrane unit for capturing CO 2 from ambient air. The performance of a membrane depends on several factors, including the composition of the feed gas, pressure ratio, material selectivity, and membrane area. The single‐stage separation process with the co‐current flow and constant permeability flux model is evaluated using a commercial module integrated with a process simulator to separate a binary mixture of carbon dioxide and nitrogen to assess the sensitivity of selectivity on purity and recovery of CO 2 in permeate, and power requirement. Additionally, three levels of CO 2 reduction from the feed stream to the retentate stream (25%, 50%, and 75%) are studied. A trade‐off between purity and recovery factor is observed, and achieving high purity in permeate requires high concentration in the retentate.

Panja, Palash↗
DOE OSTI2015

Identification and prioritization of high risk deteriorating support infrastructure - 15475

Identification and prioritization for the re-capitalization of deteriorating waste processing and storage support infrastructure and information technology (IT) is essential for a safe, cost effective, and sustainable waste management program. Funding restraints have limited programs to performing only maintenance on aging infrastructure support systems whose operational costs, technological obsolescence, and reliability risks continue to grow without a disciplined and balanced re-capitalization program. Savannah River Site (SRS) comprises both Department of Energy Environmental Management and NNSA missions, and includes a lab, Savannah River National Laboratory. SRS has developed a crosscutting identification and prioritization tool and process that provides integration of all Site mission support infrastructure re-capitalization requirements and prioritizes into a single database that can be readily accessed for infrastructure investment decisions. This database, referred to as the SRS Critical Integrated Infrastructure Priority List (CIIPL) captures risk data that includes impacts toward safety, regulatory compliance, mission, and cost for inclusion in its prioritization process. Further, the CIIPL provides a status of each entered project's readiness for execution that includes funding source, reliability of current cost estimate, and an out year budget profile. The SRS CIIPL, created in 2009, was initially comprised of re-capitalization projects for the Site's common infrastructure (i.e. shared roads and utilities) that supported all Site missions and activities. As mission program funding became constrained, the value for a Site wide integrated prioritization tool became more apparent and the CIIPL grew to include all Site mission and tenant activities which included safeguards and security requirements. The SRS CIIPL has become a highly effective tool for achieving senior management situational awareness of the Site's most pressing support infrastructure and IT needs. The mission programs have used the CIIPL to prioritize and fund high risk projects within their own program budgets. This past year, the CIIPL was used as a budgeting and decision making tool to allocate funding for two common infrastructures high risk projects for the FY16 Site budget submission and has received laudatory comments from DOE headquarters review teams. The SRS CIIPL and its process can be a benefit to other waste management organizations by demonstrating a proven approach toward the integration of support infrastructure and IT re-capitalization requirements across diverse mission and tenant boundaries. The SRS CIIPL can provide senior management with an objective decision making tool that delivers a balanced evaluation of project requirements in terms of multiple risk criteria; safety, regulatory, mission, and cost impacts. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

An integrated experimental–modeling approach to identify key processes for carbon mineralization in fractured mafic and ultramafic rocks

Abstract Controlling atmospheric warming requires immediate reduction of carbon dioxide (CO2) emissions, as well as the active removal and sequestration of CO2 from current point sources. One promising proposed strategy to reduce atmospheric CO2 levels is geologic carbon sequestration (GCS), where CO2 is injected into the subsurface and reacts with the formation to precipitate carbonate minerals. Rapid mineralization has recently been reported for field tests in mafic and ultramafic rocks. However, unlike saline aquifers and depleted oil and gas reservoirs historically considered for GCS, these formations can have extremely low porosities and permeabilities, limiting storage volumes and reactive mineral surfaces to the preexisting fracture network. As a result, coupling between geochemical interactions and the fracture network evolution is a critical component of long-term, sustainable carbon storage. In this paper, we summarize recent advances in integrating experimental and modeling approaches to determine the first-order processes for carbon mineralization in a fractured mafic/ultramafic rock system. We observe the critical role of fracture aperture, flow, and surface characteristics in controlling the quantity, identity, and morphology of secondary precipitates and present where the influence of these factors can be reflected in newly developed thermo-hydro-mechanical–chemical models. Our findings provide a roadmap for future work on carbon mineralization, as we present the most important system components and key challenges that we are overcoming to enable GCS in mafic and ultramafic rocks.

58 GEOSCIENCES↗
DOE OSTI2023

Laser Driven Hydrothermal Processing (LDHP) for Rapid Dissolution of Glassy Nuclear Debris

Discovered in 2009 on the SLAB laser system at LLNL, Laser-Driven Hydrothermal Processing (LDHP) both spalls and transiently dissolves a wetted surface (e.g., rock, concrete, paint) when that surface is struck by a laser beam pulse under specific conditions. Previous projects have explored the application of LDHP to expediting sample dissolution for post-detonation nuclear forensics. Early results were very promising, indicating that this method could decrease material dissolution time by a factor of 10 or more. However, the large and complicated lasers previously used are impractical for this application. Under the R^3 venture we aimed to benchmark the LDHP capabilities of turn-key commercial off-the-shelf (COTS) lasers, and to establish how this process could be integrated into an analytical workflow for nuclear forensic analysis. We demonstrated that geological rock standards could be quickly processed into fine powder by LDHP followed by complete acid digestion in 15 minutes, without elemental fractionation that would skew analytical results. We determined that the COTS laser can be used for LDHP that could potentially reduce dissolution time for solid nuclear debris samples in post detonation nuclear forensics. One downside to this approach, however, is that the laser interactions are different with every material, so extensive method validation would be required for all likely material compositions. The LDHP processing rates of several materials were tested and determined to be favorable in the beginning with significant slowdown due to particulate scattering. This could be mitigated either by stopping and centrifuging the sample at specific intervals, or through design of a continuous solvent flow through mechanism.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Dissimilar Materials Joining of Carbon Fiber Polymer to Dual Phase 980 by Friction Bit Joining, Adhesive Bonding, and Weldbonding

In the present study, joining of a carbon fiber-reinforced polymer and dual phase 980 steel was studied using the friction bit joining, adhesive bonding, and weldbonding processes. The friction bit joining process was optimized for the maximum joint strength by varying the process parameters. Then, the adhesive bonding and weld bonding (friction bit joining plus adhesive bonding) processes were further developed. Lap shear tensile and cross-tension testing were used to assess the joint integrity of each process. Fractured specimens were compared for the individual processes. The microstructures in the joining bit ranged from tempered martensite to fully martensite in the cross-section view of friction bit-joined specimens. Additionally, the thermal decomposition temperature of the as-received carbon fiber composite was studied by thermogravimetric analysis. Fourier-transform infrared–attenuated total reflectance spectroscopy and X-ray diffraction measurements showed minimal variations in the absorption peak and diffraction peak patterns, indicating insignificant thermal degradation of the carbon fiber matrix due to friction bit joining.

36 MATERIALS SCIENCE↗