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All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Fabrication, microstructure and mechanical properties of W-NiTi composites

Here, new two-phase tungsten-based composites containing 88 wt% tungsten powders and 12 wt% nearly equiatomic NiTi alloy deforming by martensite variant detwinning were fabricated by infiltration and hot pressing in this study. The change of Ti/Ni ratio in NiTi mater alloy and the effect of addition of Nb element on the microstructure, martensitic transformation and mechanical properties of W-NiTi composites were investigated by comparison of W-Ni 50 Ti 50 , W-Ni 44 Ti 56 , W-Ni 42 Ti 58 and W-Ni 42 Ti 53 Nb 5 composites. The results showed that brittle Ni 3 Ti formed in the W-Ni 50 Ti 50 and W-Ni 44 Ti 56 composites and brittle Ti 2 Ni formed in the W-Ni 42 Ti 58 composites while no brittle intermetallics formed in the W-Ni 42 Ti 53 Nb 5 composite. The W-Ni 42 Ti 53 Nb 5 composite exhibited the sharpest martensitic transformation with the largest transformation enthalpy among the four different composites. The W-Ni 42 Ti 53 Nb 5 composite exhibited a double-yielding phenomenon under compression with an ultimate compressive strength of 3820 MPa and a deformation of 50.4%. In-situ synchrotron high-energy Xray diffraction measurements revealed the first yielding was caused by the martensite reorientation of the NiTi matrix and the second was due to the commencement of massive plastic deformation of the reoriented martensite and is also attributed to the microscopic internal fracturing of the W particles.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Mechanical properties of SiC composites neutron irradiated under light water reactor relevant temperature and dose conditions

Silicon carbide (SiC) fiber–reinforced SiC matrix (SiC/SiC) composites are being actively investigated for use in accident-tolerant core structures of light water reactors (LWRs). Owing to the limited number of irradiation studies previously conducted at LWR-coolant temperature, this paper examined SiC/SiC composites following neutron irradiation at 230–340 °C to 2.0 and 11.8 dpa in the High Flux Isotope Reactor. The investigated materials were chemical vapor infiltrated (CVI) SiC/SiC composites with three different reinforcement fibers. The fiber materials were monolayer pyrolytic carbon (PyC) -coated Hi-Nicalon™ Type-S (HNS), Tyranno™ SA3 (SA3), and SCS-Ultra™ (SCS) SiC fibers. The irradiation resistance of these composites was investigated based on flexural behavior, dynamic Young's modulus, swelling, and microstructures. There was no notable mechanical properties degradation of the irradiated HNS and SA3 SiC/SiC composites except for reduction of the Young's moduli by up to 18%. The microstructural stability of these composites supported the absence of degradation. In addition, no progressive swelling from 2.0 to 11.8 dpa was confirmed for these composites. On the other hand, the SCS composite showed significant mechanical degradation associated with cracking within the fiber. Finally, this study determined that SiC/SiC composites with HNS or SA3 SiC/SiC fibers, a PyC interphase, and a CVI SiC matrix retain their properties beyond the lifetime dose for LWR fuel cladding at the relevant temperature.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2014

Characterization of the correlation between the interfaces and failure behaviors for particle reinforced Mg–Li composites

The interfacial microstructure of SiC{sub p} or YAl{sub 2p} reinforced Mg–14Li–3Al matrix composites was comparatively characterized by scanning electron microscopy and electron probe microanalysis. A nanoindentation combined with scanning electron microscopy technique was used to characterize the interfacial mechanical properties between the reinforcements and matrix. The interfacial strength and failure behaviors for the composites were analyzed from the load–penetration curves and corresponding images. In situ tensile tests were used to observe the fracture and deformation processes with the aid of scanning electron microscopy. The results show that both the chemical and mechanical compatibilities between the YAl{sub 2} particles and LA143 matrix are better than those between the SiC particles and LA143 matrix. The interfacial breakage load for the SiC/LA143 composite is lower than that for the YAl{sub 2}/LA143 composite because of the worse chemical and mechanical compatibilities between the ceramic particles and metal matrix. Interfacial breakage is the main failure mechanism for the SiC/LA143 composite, while the particle breakage and matrix crack are the main failure mechanism for the YAl{sub 2}/LA143 composite. These may be related to the stronger interfacial bonding between the intermetallic particles and metal matrix. - Highlights: • The compatibility for YAl{sub 2} particle with LA143 matrix is better than SiC particle. • The strength of the YAl{sub 2}/LA143 interface is higher than the SiC/LA143 interface. • The main failure behavior for the SiC/LA143 composite is interfacial breakage. • The main failure behavior for YAl{sub 2}/LA143 composite is particle and matrix breakage. • The interfacial strength plays an important role on the composite failure behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Development of an in-situ multi-component reinforced Al-based metal matrix composite by direct metal laser sintering technique — Optimization of process parameters

In the present investigation, an in-situ multi-component reinforced aluminum based metal matrix composite was fabricated by the combination of self-propagating high-temperature synthesis and direct metal laser sintering process. The different mixtures of Al, TiO{sub 2} and B{sub 4}C powders were used to initiate and maintain the self-propagating high-temperature synthesis by laser during the sintering process. It was found from the X-ray diffraction analysis and scanning electron microscopy that the reinforcements like Al{sub 2}O{sub 3}, TiC, and TiB{sub 2} were formed in the composite. The scanning electron microscopy revealed the distribution of the reinforcement phases in the composite and phase identities. The variable parameters such as powder layer thickness, laser power, scanning speed, hatching distance and composition of the powder mixture were optimized for higher density, lower porosity and higher microhardness using Taguchi method. Experimental investigation shows that the density of the specimen mainly depends upon the hatching distance, composition and layer thickness. On the other hand, hatching distance, layer thickness and laser power are the significant parameters which influence the porosity. The composition, laser power and layer thickness are the key influencing parameters for microhardness. - Highlights: • The reinforcements such as Al{sub 2}O{sub 3}, TiC, and TiB{sub 2} were produced in Al-MMC through SHS. • The density is mainly influenced by the material composition and hatching distance. • Hatching distance is the major influencing parameter on porosity. • The material composition is the significant parameter to enhance the microhardness. • The SEM micrographs reveal the distribution of TiC, TiB{sub 2} and Al{sub 2}O{sub 3} in the composite.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Hydrothermal synthesis of manganese oxides/carbon nanotubes composites as anode materials for lithium ion batteries

Graphical abstract: Carbon nanotubes in the composites not only accommodate the volume change during charge/discharge processes, but also provide a good electron conducting network at high power rates, resulting in high reversible capacity of the electrodes. - Highlights: • MnO/CNTs composites are obtained by heating Mn{sub 3}O{sub 4}/CNTs at 500 °C for 3 h in flowing Ar/H{sub 2}. • MnO/CNTs electrode exhibits higher specific capacity at the current density of 100 mAh g{sup −1} and a better cycle performance. • Enhancement of cyclability of MnO/CNTs electrode can be attributed to the presence of CNTs in the composites. - Abstract: Mn{sub 3}O{sub 4} nanoparticles and Mn{sub 3}O{sub 4}/carbon nanotubes (CNTs) composites are prepared via a hydrothermal synthesis method. MnO and MnO/CNTs composites are obtained by heating Mn{sub 3}O{sub 4} and Mn{sub 3}O{sub 4}/CNTs at 500 for 3 h in flowing Ar/H{sub 2}. The phase structure, composition and morphology of the composites are characterized by X-ray diffraction (XRD), field emission scanning electron microscopy (FESEM). The electrochemical properties of the composite electrodes are studied by performing cyclic voltammetry (CV), galvanostatic charge and discharge tests. The results reveal that the Mn{sub 3}O{sub 4}/CNTs and MnO/CNTs electrodes exhibit higher specific capacity at the current density of 100 mAh g{sup −1} and a better cycle performance than pure Mn{sub 3}O{sub 4} and MnO electrodes. The excellent electrochemical properties of Mn{sub 3}O{sub 4}/CNTs and MnO/CNTs electrodes can be attributed to the presence of CNTs in the composites offering an electron conducting network and suppressing the volume expansion of Mn{sub 3}O{sub 4} and MnO particles efficiently during the charge and discharge processes.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Efficient photocatalytic degradation of gaseous formaldehyde by the TiO{sub 2}/tourmaline composites

Graphical abstract: - Highlights: • The TiO{sub 2}/tourmaline composites were prepared by a sol–gel method. • The composites exhibited excellent photocatalytic activity and good stability. • The physicochemical property of tourmaline may be favor for the degradation of HCHO. • The mixed-phase of anatase and rutile TiO{sub 2} may be favor for the degradation of HCHO. - Abstract: The TiO{sub 2} supported tourmaline composites were prepared by a sol–gel method and used as a photocatalyst for the degradation of formaldehyde (HCHO). The composites were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), high-resolution transmission electron microscopy (HRTEM), N{sub 2} adsorption–desorption, Fourier transform infrared (FT-IR) spectroscopy and UV–vis diffuse reflectance spectroscopy (UV–vis DRS). The results indicate that the mixed-phase of anatase and rutile exists in the TiO{sub 2}/tourmaline composites. The specific surface area of the TiO{sub 2}/tourmaline composites is much higher than that of the pure TiO{sub 2}. The TiO{sub 2}/tourmaline composites exhibited excellent photocatalytic activity for the degradation of HCHO, which was 6 times higher than that of the pure TiO{sub 2}. Moreover, the excellent photocatalytic activity of the composites was fully maintained after five photocatalytic cycles, which may be attributed to the physicochemical property of tourmaline and the mixed-phase of anatase and rutile in the TiO{sub 2}/tourmaline composites.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Wet chemical synthesis of ZnO-CdS composites and their photocatalytic activity

Highlights: • ZnO-CdS composites were synthesized by wet chemical method. • TEM, correlated SAED pattern, XRD, and SEM confirmed the structure of composites. • CdS amount added during composites synthesis influences their morphologies. • RhB degradation efficiency is higher for composites than that of pristine ZnO, depending on the catalyst morphology. - Abstract: The present study is focused on the wet chemical synthesis and the characterization of ZnO-CdS composites. The X-ray diffraction shows that the composites contain ZnO in hexagonal wurtzite structure and CdS in cubic phase. The scanning/transmission electron microscopy images reveal flower-like structures with different sizes depending on the CdS content. The optical investigations on composites reveal that the reflectance spectra disclose two thresholds of ∼370 nm and ∼460 nm associated with the ZnO and CdS, respectively. The photocatalytic activity measurements evidenced that the degradation efficiency of RhB in the presence of composites is higher comparatively with pristine ZnO, depending on the catalyst morphology, which varies with CdS content and the pH value of RhB solution. The electron paramagnetic resonance revealed the presence of the paramagnetic point defects in the samples. Thus, the wet chemical approaches are suitable for a large scale production of such ZnO-CdS composites having enhanced photocatalytic activity.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Lepidocrocite Titanate–Graphene Composites for Sodium-Ion Batteries

To overcome electronic transport issues of layered titanates in sodium-ion batteries, we have designed and synthesized composites of lepidocrocite titanates with reduced graphene oxide through a solution-based self-assembly approach. The parent lepidocrocite titanate (K 0.8 [Ti 1.73 Li 0.27 ]O 4 ) was exfoliated by a soft-chemical approach and mechanical shaking. Exfoliated layered titania sheets (LTO) were then combined with reduced graphene oxide (rGO) layers to assemble into composites through flocculation. Countercations (i.e., Mg 2+ ) were used for the self-assembly of negatively charged titania and rGO nanosheets via flocculation. The carbon content in the composites was tuned from 1 to 17% by changing the ratio of titania and rGO sheets in the mixed colloidal suspensions. Electrodes were processed with as-prepared LTO-rGO composites without any carbon additives and tested in sodium half-cell configurations. Mg + -coagulated LTO-rGO composite electrodes deliver higher capacities than electrodes prepared with coagulated titania sheets and 10% acetylene black in sodium half-cells and display good capacity retention after 50 cycles. Electrochemical impedance spectroscopy results indicate lower charge transfer resistance for LTO-14.5%rGO composites than that of coagulated titania sheets with 10% acetylene black. A power law analysis of cells containing the composites indicate a hybrid mechanism consisting of both surface and diffusional processes. A comparison with a similar system, that of dopamine-derived LTO-C heterostructures, reveal significant differences. While capacities showed a strong dependence on carbon content for the dopamine-derived materials, this was not true for the LTO-rGO composites. Instead, the highest capacity was obtained for the 14.5% rGO sample, with a lower value obtained for the 17% rGO sample. A greater proportion of the redox processes were surface rather than diffusional in nature for the LTO-rGO composites as well.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Unusual electronic transport in (1 - x )Cu 2 Se-( x )CuInSe 2 hierarchical composites

The ability to control the relative density of electronic point defects as well as their energy distribution in semiconductors could afford a systematic modulation of their electronic, optical, and optoelectronic properties. Using a model binary hybrid system Cu 2 Se–CuInSe 2 , we have investigated the correlation between phase composition, microstructure, and electronic transport behavior in the synthesized composites. We found that both Cu 2 Se and CuInSe 2 phases coexist at multiple length scales, ranging from sub-ten nanometer to several micrometers, leading to the formation of a hybrid hierarchical microstructure. Astonishingly, the electronic phase diagram of the (1 - x)Cu 2 Se–(x)CuInSe 2 (15% ≤ x ≤ 100%) hierarchical composites remarkably deviates from the trend normally expected for composites between a heavily doped semiconductor (Cu 2 Se) and a poorly conducting phase (CuInSe 2 ). A sudden 3-fold increase in the electrical conductivity and carrier concentration along with a marginal increase in the carrier mobility is observed for composites at the vicinity of equimolar composition (48% ≤ x ≤ 52%). The carrier concentration increases from ~1.5 × 10 20 cm -3 for the composites with x ≤ 45% to 5.0 × 10 20 cm -3 for x = 50%, and remains constant at 4.5 × 10 20 cm -3 with x value in the range of 52% < x ≤ 90%, then quickly drops to 8 × 10 18 cm -3 for pristine CuInSe 2 phase (x = 100%). The atypical electronic behavior was rationalized in the light of the formation of an inter-band (IB) within the band gap, which arises from the hybridization of native electronic point defects from both Cu 2 Se and CuInSe 2 phases in the resulting hierarchical composites. The result points to a new strategy to modulate the electronic structure of semiconductor composites to maximize interaction and coupling between two fundamentally contrasting properties enabling access to electronic hybrid systems with potential applications as interactive and stimuli-responsive multifunctional materials.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Design of step composition gradient thin film transistor channel layers grown by atomic layer deposition

In this study, we proposed the artificially designed channel structure in oxide thin-film transistors (TFTs) called a “step-composition gradient channel.” We demonstrated Al step-composition gradient Al-Zn-O (AZO) channel structures consisting of three AZO layers with different Al contents. The effects of stacking sequence in the step-composition gradient channel on performance and electrical stability of bottom-gate TFT devices were investigated with two channels of inverse stacking order (ascending/descending step-composition). The TFT with ascending step-composition channel structure (5 → 10 → 14 at. % Al composition) showed relatively negative threshold voltage (−3.7 V) and good instability characteristics with a reduced threshold voltage shift (Δ 1.4 V), which was related to the alignment of the conduction band off-set within the channel layer depending on the Al contents. Finally, the reduced Al composition in the initial layer of ascending step-composition channel resulted in the best field effect mobility of 4.5 cm{sup 2}/V s. We presented a unique active layer of the “step-composition gradient channel” in the oxide TFTs and explained the mechanism of adequate channel design.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2016

Structural, thermal and electrical characterizations of multiwalled carbon nanotubes and polyaniline composite

The undoped and doped composite of MWNTs (Multiwalled Carbon Nanotubes) with PANI (/Polyaniline) was prepared by chemical oxidative polymerization. The MWNTs/PANI composites have been characterized by using various techniques like Thermogravometric Analysis (TGA), Fourier transform infrared (FT-IR) spectrometer and Field emission scanning electron microscope (FE-SEM) and conductivity measurement by using two probe method. TGA results has shown that thermal stability followed the pattern undoped MWNTs/PANI composite < doped MWNTs/PANI composite. FE-SEM micrographs demonstrated the morphological changes on the surface of MWNTs as a result of composite formation. Fourier transformed infrared (FT-IR) spectra ascertained the formation of the composite. Study of electrical characteristics demonstrated that the doped MWNTs/PANI composite (1.2 × 10{sup 1} Scm{sup −1}) have better conductivity than the undoped MWNTs/PANI composite (10{sup −4} Scm{sup −1}). These CNTs based polymeric composites are of great importance in developing new nano-scale devices for future chemical, mechanical and electronic applications.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2018

The effect of nanoparticle enhanced sizing on the structural health monitoring sensitivity and mechanical properties of carbon fiber composites

With current carbon composites being introduced into new commercial market sectors, there is an opportunity to develop multifunctional composites, which are poised to be the next generation of composites that will see future commercial applications. This multifunctional attribute can be achieved via integrated nanomaterials, which are currently under-utilized in real-world applications despite significant research efforts focused on their synthesis. This research utilizes a simple, scalable approach to integrate various nanomaterials into carbon fiber composites by embedding the nanomaterials in the epoxy fiber sizing. Illustrated in this work is the effect of silicon carbide nanoparticle concentrations and dimensions on the structural health monitoring sensitivity of unidirectional carbon fiber composites. Additionally, the nanoparticles contribute to the overall damping property of the composites thus enabling tunable damping through simple variations in nanoparticle concentration and size. Not only does this nanoparticle sizing offer enhanced sensitivity and tunable damping, but it also maintains the mechanical integrity and performance of the composites, which demonstrates a truly multifunctional composite. Therefore, this research establishes an efficient route for combining nanomaterials research with real-world multifunctional composite applications using a technique that is easily scalable to the commercial level and is compatible with a wide range of fibers and nanomaterials.

Bowland, Christopher↗
DOE OSTI2014

SU-E-T-40: Analysis of Composite MVCT Planning Dosimetry with SBRT of Upper Peripheral Lung Cancer

Purpose: Quantitatively evaluate and compare the final adaptive planning doses of upper peripherally located lung SBRT treated with Tomotherapy using 3rd party software tool. Methods: With tumor located in the upper quadrant of lung, a 3rd party software tool was implemented to evaluate the Tomotherapy composite dosimetry created by adaptive fan beam MVCT images described by RTOG 0915 dose criteria (48 Gy / 4 fractions). The composite doses was then summarized with deformable registration in this package with corresponding target and critical structures. The final dosimetry variation, both for target and critical structures, were evaluated in a tabular format and isodose distribution comparisons. Results: Composite SBRT treatment doses were evaluated with adaptive planning. The PTV and several critical structures were mapped/deformed into the package via DICOM from Tomotherapy after the final composite doses were created. Initial plan versus the final composite plan calculated from verification images were compared. The ITV defined by 4D CT and contoured on MVCT images were correlated in patient repositioning. Final composite dose calculated for PTV coverage has shown 0.1–0.17 cGy coverage (0.2–0.4% of prescription dose) variation. Total lung and cord were both less than 0.17 Gy which represented <0.4% difference. All other critical structure were within statistical significance. The adaptive plans justified/included the breathing and motion during the treatment process. Final 95% isotope line coverage from prescription has been met without issues. Conclusions: With lung tumor location in the upper peripheral area, breathing control was not necessary required during SBRT treatment using Tomotherapy technique. Slow fan beam CT provides definitive ITV information and the adaptive composite plan for all fractions were suitable for final dose delivery. The final composite dose calculated with Tomotherapy adaptive tool indicated that the composite dosimetry justified the target location with SBRT delivery, safe with minimum margin of errors.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2014

Development of an Innovative High-Thermal Conductivity UO2 Ceramic Composites Fuel Pellets with Carbon Nano-Tubes Using Spark Plasma Sintering

Uranium dioxide (UO2) is the most common fuel material in commercial nuclear power reactors. Despite its numerous advantages such as high melting point, good high-temperature stability, good chemical compatibility with cladding and coolant, and resistance to radiation, it suffers from low thermal conductivity that can result in large temperature gradients within the UO2 fuel pellet, causing it to crack and release fission gases. Thermal swelling of the pellets also limits the lifetime of UO2 fuel in the reactor. To mitigate these problems, we propose to develop novel UO2 fuel with uniformly distributed carbon nanotubes (CNTs) that can provide high-conductivity thermal pathways and can eliminate fuel cracking and fission gas release due to high temperatures. CNTs have been investigated extensively for the past decade to explore their unique physical properties and many potential applications. CNTs have high thermal conductivity (6600 W/mK for an individual single- walled CNT and >3000 W/mK for an individual multi-walled CNT) and high temperature stability up to 2800°C in vacuum and about 750°C in air. These properties make them attractive candidates in preparing nano-composites with new functional properties. The objective of the proposed research is to develop high thermal conductivity of UO2–CNT composites without affecting the neutronic property of UO2 significantly. The concept of this goal is to utilize a rapid sintering method (5–15 min) called spark plasma sintering (SPS) in which a mixture of CNTs and UO2 powder are used to make composites with different volume fractions of CNTs. Incorporation of these nanoscale materials plays a fundamentally critical role in controlling the performance and stability of UO2 fuel. We will use a novel in situ growth process to grow CNTs on UO2 particles for rapid sintering and develop UO2-CNT composites. This method is expected to provide a uniform distribution of CNTs at various volume fractions so that a high thermally conductive UO2-CNT composite is obtained with a minimal volume fraction of CNTs. The mixtures are sintered in the SPS facility at a range of temperatures, pressures, and time durations so as to identify the optimal processing conditions to obtain the desired microstructure of sintered UO2-CNT pellets. The second objective of the proposed work is to identify the optimal volume fraction of CNTs in the microstructure of the composites that provides the desired high thermal conductivity yet retaining the mechanical strength required for efficient function as a reactor fuel. We will systematically study the resulting microstructure (grain size, porosity, distribution of CNTs, etc.) obtained at various SPS processing conditions using optical microscopy, scanning electron microscopy (SEM), and transmission electron microscope (TEM). We will conduct indentation hardness measurements and uniaxial strength measurements as a function of volume fraction of CNTs to determine the mechanical strength and compare them to the properties of UO2. The fracture surfaces will be studied to determine the fracture characteristics that may relate to the observed cracking during service. Finally, we will perform thermal conductivity measurements on all the composites up to 1000° C. This study will relate the microstructure, mechanical properties, and thermal properties at various volume fractions of CNTs. The overall intent is to identify optimal processing conditions that will provide a well-consolidated compact with optimal microstructure and thermo-mechanical properties. The deliverables include: (1) fully characterized UO2-CNT composite with optimal CNT volume fraction and high thermal conductivity and (2) processing conditions for production of UO2-CNT composite pellets using SPS method.

Subhash, Ghatu↗
DOE OSTI2021

Bamboo Bio-composite Truck/Trailer Decking

Bamboo is one of the fastest growing plants in the world. Massively productive, bamboo will maintain that productivity with limited inputs and minimal management resulting in predictable volume and operating margins and with low overhead. The goal of this project was to develop a bamboo bio-composite trailer decking product that replaces apitong, is lighter weight, stronger and luminescent. The collaboration partners, Fontaine, Resource Fiber and IACMI, worked closely to develop the bamboo bio-composite decking to Fontaine Trailer’s (end-user) specifications. The various technological objectives were (a) To conduct a comprehensive Design of Experiments study for bamboo composites to understand the structure-property relationships for different resin composites and bamboo forms (strips, woven, bulk etc); (b) To establish the nail pull out characteristics of trailer deck geometry bamboo composite form. The nail pull out is a critical test in trailer decks; (c) To design, process and prototype select number of trailer decking planks for Fontaine evaluation; and (d) To conduct life cycle analysis to conduct energy calculations from the various conversion steps of the bamboo from crop to product. The project meets DOE/IACMI metrics of reduced embodied energy, lightweighting and lowering the cost of the end product. It also offers a green solution to a value-added application, i.e. trailer decking. The development goals and benefits of bamboo composite decking included: A. Decreased weight when compared to Apitong and Gen 1, thereby reducing operating costs and petroleum usage due to increased miles per gallon. B. Flexibility to allow camber design into trailers. C. Luminescence to increase safety during low light and dark conditions. D. Composite material to maximize use of bamboo bio-composites as substitute for petroleum-based composites. E. Embedded layer(s) of conditioned bamboo for added strength and stability. F. Improved safety over Apitong by temporary cargo indentation in planks for better stability. G. Cradle-to-cradle design so end-of-life becomes beginning-of-life for other products. Resource Fiber’s bamboo biocomposite trailer decking passed nail pullout tests as compared to apitong (incumbent), was lighter weight than apitong, and used less embodied energy particularly when bamboo is sourced domestically. The planks were optimized in the lab setting to the extent possible and successfully installed on the trailer at Fontaine for field testing. Despite the process not being fully optimized due to through-heat and tooling limitations within the budget constraints, the prototype decking withstood 400 cycles of reverse fatigue loading of a 107,000 lb Caterpillar 349F which was extreme conditions of field testing by Fontaine Trailer. Resource Fiber plans to outsource production of a next round of planks with a commercial pultrusion processor, then to do a re-test with Fontaine Trailers. Tooling specific to the part is required. Long-term commercial plans are to continue outsourcing production while supplying bamboo fiber and mats. Commercial markets include heavy haul trailers, military trailers, and decking for marine, industrial and residential use.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Thermogravimetric Analysis (TGA) for Carbon Fiber and Glass Fiber Epoxy Composites and their Constituents

In this work, thermogravimetric analysis (TGA) was performed on samples of a carbon fiber epoxy composite, a glass fiber epoxy composite, and a mixed carbon fiber/glass fiber epoxy composite, as well on each constituent material (polymer epoxy, carbon fibers and glass fibers). TGA was conducted for heating rates from 1-20 C/min with purified purge gases of nitrogen and dry air. For the fiberglass composite, we find that ~70% of the material remains after heating in air to 1200 C. For the carbon fiber epoxy composite, we observe greater mass loss as the carbon fibers can oxidize, leaving little material by the end of the test. The mixed composite, which has a 2:1 ratio of glass fibers to carbon fibers, experienced a total mass loss between the two other composites. By determining the relationship between the thermal decomposition of a composite material and its constituent materials, we can predict the fire behavior of novel composites during the material design phase.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Technical Considerations on MURR Control Blade Design Change and Testing using a New Metal Matrix Composite

The University of Missouri Research Reactor (MURR) is one of six research reactors, including a critical facility, that are pursuing conversion as part of a collaboration with the U.S. Department of Energy National Nuclear Security Administration Material Management and Minimization Office of Reactor Conversion and Uranium Supply, under the U.S. High Performance Research Reactors (USHPRR) conversion project. Five of the six USHPRR are planned to convert from highly enriched uranium (HEU) fuel using a low-enriched uranium (LEU) high assay monolithic alloy of uranium-10 wt% molybdenum (U-10Mo). As part of the conversion safety analysis, it is necessary to demonstrate the safety performance of the proposed core fueled with LEU as compared to the current HEU cores. The MURR reactor is planning to switch to a new control blade design that uses a metal matrix composite of boron carbide (B 4 C) and aluminum as the absorber in place of Boral®. Since MURR is expected to adopt the new metal matrix composite control blade design prior to conversion, the impact of the new blade design on the neutronics characteristics of the MURR cores for conversion are analyzed in this work through updates to incorporate the changes to the blade design in conversion models as they directly impact the LEU conversion safety analysis. The quantitative comparison shows that the neutronics and thermal hydraulic behavior of one metal matrix composite blade replacing a Boral blade is comparable for the two example MURR LEU and HEU cores states considered. Geometrical changes in the metal matrix composite blade design, combined with a 4% increase in areal boron density, showed local heating effects up to 20% higher than the Boral design. As expected, the metal matrix composite showed slightly lower heat depositions and absorber region temperatures for the LEU cases compared to HEU. Although this analysis was comparative for a single blade, maximum control blade temperatures for both Boral, metal matrix composite, and HEU/LEU remained below 100 °C, though additional analysis at a core level could differ. A qualitative irradiation behavior assessment concludes that the mechanisms that may drive swelling and blistering in the current Boral design are eased by the adoption of the metal matrix composite design. The work concludes that the two blade designs are essentially equivalent with regards to neutronics, thermal hydraulics, and expected material behavior under irradiation. However, due to the geometrical changes to the blades including redesigned and thinner cladding, new testing and increased surveillance for distortion and swelling are recommended to confirm the performance of the metal matrix composite control blade design. Where testing is completed prior to conversion, the only anticipated impacts on conversion to LEU U-10Mo fuel would be the need for models and safety analysis incorporating the metal matrix composite control blades.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Characterization of Mechanical Performance of Composites Fabricated Using Innovative Carbon Fiber Wet Laid Process

Recent innovation in production of optimized nonwoven wet laid (WL) carbon fiber (CF) mats raised the question of optimal translation of the performance and isotropy into composites formed through these dry preforms. This work explores the mechanical behavior of composites produced from WL-CF mats in conjunction with the microstructure predicted through Object Oriented Finite Element Analysis (OOF). The mats used for the composites were prepared in two dispersion regimes using 25.4 mm long CF. The mixing regimes discussed in the author’s previous work, are identified as Method 1 for the traditional processing regime and Method 2 for the innovative regime that provided optimal nonwoven WL-CF mats. Composite panels from Method 2 mats showed a normalized tensile strength increase of 52% over those from Method 1 panels. Reproducibility analysis of composites made from Method 2 mats demonstrated a standard deviation of 2% in fiber weight content, 2% in tensile modulus and 9% in tensile strength, while composites made from Method 1 mats demonstrated a standard deviation of 5% in fiber weight content, 5% in tensile modulus and 17% in tensile strength. Systematic study of the microstructure and its analysis through OOF confirmed the isotropy translation of mats produced through method 2 to the composites. This study validated the hypothesis that optimal nonwoven mats lead to a well-balanced composite with optimal performance and that non-optimal nonwoven mats do not pack into a well-balanced composite.

36 MATERIALS SCIENCE↗