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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2012

Characterization of Depleted-Uranium Strength and Damage Behavior

The intent of this report is to document the status of our knowledge of the mechanical and damage behavior of Depleted Uranium(DU hereafter). This report briefly summaries the motivation of the experimental and modeling research conducted at Los Alamos National Laboratory(LANL) on DU since the early 1980’s and thereafter the current experimental data quantifying the strength and damage behavior of DU as a function of a number of experimental variables including processing, strain rate, temperature, stress state, and shock prestraining. The effect of shock prestraining on the structure-property response of DU is described and the effect on post-shock mechanical behavior of DU is discussed. The constitutive experimental data utilized to support the derivation of two constitutive strength (plasticity) models, the Preston-Tonks-Wallace (PTW) and Mechanical Threshold Stress (MTS) models, for both annealed and shock prestrained DU are detailed and the Taylor cylinder validation tests and finite-element modeling (FEM) utilized to validate these strength models is discussed. The similarities and differences in the PTW and MTS model descriptions for DU are discussed for both the annealed and shock prestrained conditions. Quasi-static tensile data as a function of triaxial constraint and spallation test data are described. An appendix additionally briefly describes low-pressure equation-of-state data for DU utilized to support the spallation experiments. The constitutive behavior of DU screw/bolt material is presented. The response of DU subjected to dynamic tensile extrusion testing as a function of temperature is also described. This integrated experimental technique is planned to provide an additional validation test in the future. The damage data as a function of triaxiality, tensile and spallation data, is thereafter utilized to support derivation of the Tensile Plasticity (TEPLA) damage model and simulations for comparison to the DU spallation data are presented. Finally, a discussion of future needs in the area of needed DU strength and damage research at LANL is presented to support the development of physically-based predictive strength and damage modeling capability.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Mica filled polyetherketoneketones for material extrusion 3D printing

Polyetherketoneketone (PEKK) has superior physical properties to most available thermoplastics compatible with material extrusion-based 3D printing, including analogs in the polyaryletherketone (PAEK) family. To date, the performance of fused filament fabrication (FFF) compatible PEKK has been detailed primarily as a function of varying the isomer ratios composing the co-polymer structure. The strategy to form blends or composites with PEKK for FFF is attractive for further tailoring of performance in application, yet has received limited attention. Here, we report the integration of three grades of mica platelets into PEKK at 10% and 30% mass loadings to generate an array of filament feedstocks that were then used to print objects with a simple FFF machine. The effects of mica coating chemistry and surface treatment on the compatibility with PEKK and resulting properties are described. Mica fillers at both loadings have only subtle influence on the FFF relevant melt rheological properties inherent to PEKK. Pigment micas at high loadings can lower the melting temperature of PEKK (up to 19 ºC) without shifting its glass transition temperature and inhibit much of the undesirable crystallization occurring during processing with unfilled PEKK. The printed composites were effectively cold crystallized post-printing, affording crystalline fractions up to 90% relative to unfilled PEKK with increased dimensional stabilities. All micas, when used as fillers in low and high relative PEKK crystallinities, significantly increased the tensile modulus (as high as 126% or to 7.31 GPa) of parts in correlation to the loading. Furthermore, the underlying microstructural features of a printed composite were compared to unfilled PEKK by use of a high-resolution helical micro-computed tomography instrument. Practically, pigment micas can confer a wide range of rich colors to 3D-printed PEKK.

36 MATERIALS SCIENCE↗
DOE OSTI2017

On Delamination Toughening of a 14YWT Nanostructured Ferritic Alloy

The FCRD NFA-1 is a high strength, irradiation tolerant nanostructured ferritic alloy (NFA) produced by ball milling argon atomized Fe-14Cr-3W-0.35Ti-0.25Y (wt.%) and FeO powders, followed by hot extrusion at 850 °C, and subsequent annealing and cross-rolling at 1000 °C. The microstructure of the resulting ≈10 mm thick NFA-1 plate is dominated by ultrafine sub-micron pancake shaped grains, and a large population of microcracks lying on planes parallel to the plate faces. Pre-cracked fracture toughness tests in four different orientations (L-T, T-L, L-S and T-S) show stable crack growth by ductile tearing, with peak load K Jc from ≈ 88 to 154 MPa√m at ambient temperature. Stable crack tearing persists down to ≈ -175 °C and is accompanied by extensive delamination due to the propagation of the microcracks. Depending on the specimen orientation, this unusual toughening mechanism is either due to a reduction of crack tip stresses in thin ligaments formed by the delaminations (L-T and T-L), or 90° deflection of cracks initially running normal to the delaminations (L-S and T-S), thereby suppressing cleavage in both cases. Lastly, understanding the fracture processes in NFA-1 is also important to its irradiation tolerance in nuclear service as well as its fabricability in making defect-free components such as thin-walled tubing.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Melt-spinnable polyacrylonitrile copolymer precursors for carbon fibers

This paper describes the feasibility of achieving melt-processable polyacrylonitrile copolymer precursors for producing high strength carbon fibers. High molecular weight poly(acrylonitrile-ran-methyl acrylate) (PAN-MA) copolymers with high acrylonitrile content were mixed were various binary melting point modifiers with one component being water to produce systems that formed stable melts at temperatures below the temperature corresponding to the onset of PAN-MA crosslinking. The structure of the copolymer was 96.5 ± 0.13 mol% AN and 4.40 ± 0.13 mol % MA by 1H NMR with an Mw = 238 kDa and polydispersity of 1.9 determined by size exclusion chromatography. A reduction in the Tm of the copolymer of 200 °C was established for one of the copolymer/melting point modifier systems, which corresponds to the greatest reduction in a PAN-based copolymer melting temperature yet reported. From isothermal DSC and pressurized capillary rheometry experiments it was found that the stability of the resulting melts shows a strong temperature dependence, but does not show a strong dependence on shear-rate. Copolymer mixtures consisting of H2O and acetonitrile or adiponitrile were found to be suitable for melt-extrusion at 170 °C with viscosities ranging from 1800 to 2000 Pa*s and stabilities of the melts ≥1 h.

36 MATERIALS SCIENCE↗
NASA NTRS1996

Effects of thermomechanical processing on the microstructure and mechanical properties of Nb-1Zr-C alloys

A systematic study to evaluate the effects of thermomechanical processing on the microstructure and mechanical properties of Nb-1Zr alloy sheet containing 0.06 and 0.1 wt.%C (PWC-11) was conducted and compared to the results of Nb-1Zr. Coarse orthorhombic Nb2C precipitates were present in all the cast, extruded and cold rolled Nb-Zr samples containing C. After high temperature (greater than 0.5 T(sub m)) exposure (with or without applied stress), the Nb2C transforms to very fine and extremely stable FCC (Zr, Nb)C dispersoid, resulting in a highly creep resistant material. Only ZrO2 precipitates were found in Nb-1Zr. The creep strength of the 0.06C and the 0.1C carbide strengthened alloys were much superior to Nb-1Zr. At 1350 K the strength of the 0.06C alloy was about three times that of Nb-1Zr, while the 0.1C alloy had about five times the creep stress capability of Nb-1Zr. The tensile strength, long term creep strength, and stability of the microstructure of the PWC-11 sheet appear to be independent of the number of 1900 K extrusions performed prior to cold rolling. The microhardness of these single, double and triple extnided PWC-11 sheets also were comparable. The tensile strength of PWC-11 and Nb-1Zr at room temperature and 1350 K were comparable.

Titran, Robert H.↗
DOE OSTI2023

Monitoring the compaction of single DNA molecules in Xenopus egg extract in real time

DNA compaction is required for the condensation and resolution of chromosomes during mitosis, but the relative contribution of individual chromatin factors to this process is poorly understood. We developed a physiological, cell-free system using high-speed Xenopus egg extracts and optical tweezers to investigate real-time mitotic chromatin fiber formation and force-induced disassembly on single DNA molecules. Compared to interphase extract, which compacted DNA by ~60%, metaphase extract reduced DNA length by over 90%, reflecting differences in whole-chromosome morphology under these two conditions. Depletion of the core histone chaperone ASF1, which inhibits nucleosome assembly, decreased the final degree of metaphase fiber compaction by 29%, while depletion of linker histone H1 had a greater effect, reducing total compaction by 40%. Compared to controls, both depletions reduced the rate of compaction, led to more short periods of decompaction, and increased the speed of force-induced fiber disassembly. In contrast, depletion of condensin from metaphase extract strongly inhibited fiber assembly, resulting in transient compaction events that were rapidly reversed under high force. Altogether, these findings support a speculative model in which condensin plays the predominant role in mitotic DNA compaction, while core and linker histones act to reduce slippage during loop extrusion and modulate the degree of DNA compaction.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2019

Large-Scale Reactive Extrusion Deposition of Sparse Infill Structures with Solid Perimeters

Large-scale additive manufacturing of reactive polymer systems offers significant improvements over thermoplastics through improved mechanical properties, faster deposition rates, and deposition at ambient temperatures. At ambient temperatures, the resin exists as a viscoelastic liquid which require additional additives for improved rigidity and bead stability. These filler-reinforced resins, or yield stress fluids, are soft solid-like materials able to withstand compressive forces from successive layer deposition until curing leads to bead solidification. When bead deposition is unsupported by previous layers, as is the case when bridging a gap, the creep due to gravitational loading can lead to bead instabilities which result in excessive sagging or bead breakage. These bead instabilities are material dependent and susceptible to changes in filler composition and temperature rises due to exothermic reactions. This work implements a design solution for bridging sparse infill patterns in additively manufactured parts which are essential in the reduction of weight. A series of span tests over a range of distances, as multiples of nozzle diameter, were conducted to determine the critical distance where a bead would break. Additional layer depositions determined the number of layers needed to recover from sagging effects. This recovery was essential in the transition of sparse infill to solid infill printing, where solid infill is milled for a smooth surface finish. Without the capability of sparse-solid transition, additively manufactured parts would require further surface treatments such as spray coating, adding to cost and increasing production time. A standard domed-mold geometry is presented to show the success of this printing process.

Hershey, Christopher↗
DOE OSTI2016

Crystal Structure of the Nephila clavipes Major Ampullate Spidroin 1A N-terminal Domain Reveals Plasticity at the Dimer Interface

Spider dragline silk is a natural polymer harboring unique physical and biochemical properties that make it an ideal biomaterial. Artificial silk production requires an understanding of the in vivo mechanisms spiders use to convert soluble proteins, called spidroins, into insoluble fibers. Controlled dimerization of the spidroin N-terminal domain (NTD) is crucial to this process. In this paper, we report the crystal structure of the Nephila clavipes major ampullate spidroin NTD dimer. Comparison of our N. clavipes NTD structure with previously determined Euprosthenops australis NTD structures reveals subtle conformational alterations that lead to differences in how the subunits are arranged at the dimer interface. We observe a subset of contacts that are specific to each ortholog, as well as a substantial increase in asymmetry in the interactions observed at the N. clavipes NTD dimer interface. These asymmetric interactions include novel intermolecular salt bridges that provide new insights into the mechanism of NTD dimerization. We also observe a unique intramolecular “handshake” interaction between two conserved acidic residues that our data suggest adds an additional layer of complexity to the pH-sensitive relay mechanism for NTD dimerization. The results of a panel of tryptophan fluorescence dimerization assays probing the importance of these interactions support our structural observations. Based on our findings, we propose that conformational selectivity and plasticity at the NTD dimer interface play a role in the pH-dependent transition of the NTD from monomer to stably associated dimer as the spidroin progresses through the silk extrusion duct.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Butanol-Based Organosolv Lignin and Reactive Modification of Poly(ethylene-glycidyl methacrylate)

Biomass processing industries and modern society are both interested in environmentally friendly plant-based polymers, such as lignin, to replace petrochemical derivatives. In this study, an n-butanol-based solvent system that can be produced through fermentation of cellulosic biomass, was used to fractionate hybrid poplar and isolate high purity lignin. The resulting unique glassy lignin fraction exhibited good melt-flow characteristics but poor mechanical behavior. Therefore, to produce a reusable and tough thermoplastic material, the lignin was reactively blended with glycidyl methacrylate modified polyethylene plastic using a high shear melt-mixing technique at 170 °C. Mechanical and rheological analyses revealed that the reactively processed blends with 30 wt % lignin have good compatibility between both polymers. Scanning electron microscopy, dynamic mechanical thermal analysis, and infrared spectroscopy data indicated improved interaction between lignin and the functional polyethylene matrix. The blends exhibited a thermal relaxation in the temperature range of 10 to 20 °C, because of the branched glycidyl methacrylate moiety. Finally, the optimal composition, consisting of 30% lignin, exhibited ~10 MPa tensile strength with 50% strain to failure; such a lignin-modified polymer may find use as packaging, as textile coatings, and in various horticultural applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
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↗
NASA NTRS1996

An Apollo 15 Mare Basalt Fragment and Lunar Mare Provinces

Lunar sample 15474,4 is a tiny fragment of olivine-augite vitrophyre that is a mare basalt. Although petroraphically distinct from all other Apollo 15 samples, it has been ignored since its first brief description. Our new petrographic and mineral chemical data show that the olivines and pyroxenes are distinct from those in other basalts. The basalt cooled and solidified extremely rapidly; some of the olivine might be cumulate or crystallized prior to extrusion. Bulk-chemical data show that the sample is probably similar to an evolved Apollo 15 olivine-normative basalt in major elements but is distinct in its rare earth element pattern. Its chemical composition and petrography both show that 15474,4 cannot be derived from other Apollo 15 mare basalts by shallow-level crystal fractionation. It represents a distinct extrusion of magma. Nonetheless, the chemical features that 15474,4 has in common with other Apollo 15 mare basalts, including the high FeO/Sc, the general similarity of the rare earth element pattern, and the common (and chondritic) TiO2/Sm ratio, emphasize the concept of a geochemical province at the Apollo 15 site that is distinct from basalts and provinces elsewhere. In making a consistent picture for the derivation of all of the Apollo 15 basalts, both the commonalities and the differences among the basalts must be explained. The Apollo 15 commonalities and differences suggest that the sources must have consisted of major silicate phases with the same composition but with varied amounts of a magma trapped from a contemporary magma ocean. They probably had a high olivine/pyroxene ratio and underwent small and reasonably consistent degrees of partial melting to produce the basalts. These inferences may be inconsistent with models that suggest greatly different depths of melting among basalts, primitive sources for the green glasses, or extensive olivine fractionation during ascent. An integrated approach to lunar mare provinces, of which the Apollo 15 mare basalts constitute only one, offers advances in our understanding of the physical and chemical processes of source formation and mare production but has so far not been utilized.

Ryder, Graham↗
DOE OSTI2019

Z-Pinning approach for 3D printing mechanically isotropic materials

Conventional 3D printing approaches are restricted to building up material in a layer-by-layer format, which is more appropriately considered “2.5-D” printing. The layered structure inherently results in significant mechanical anisotropy in printed parts, causing the tensile strength in the build direction (z-axis) to be only a fraction of the in-plane strength – a decrease of 50–75% is common. In this study, a novel “z-pinning” approach is described that allows continuous material to be deposited across multiple layers within the volume of the part. Here, the z-pinning process is demonstrated using a Fused Filament Fabrication (FFF) printer for polylactic acid (PLA) and carbon fiber reinforced PLA. For both materials, z-pinning increased the tensile strength and toughness in the z-direction by more than a factor of 3.5. Direct comparisons to tensile strength in the x-axis showed a significant decrease in mechanical anisotropy as the volume of the pin was increased relative to the void in the rectilinear grid structure. In fact, the PLA sample with the largest pin volume demonstrated mechanically isotropic properties within the statistical uncertainty of the tests. Tensile test results were also analyzed relative to the functional area resisting deformation for each sample.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Rheological requirements for printable concretes

We study in this paper the rheological requirements for printable concrete in terms of yield stress, viscosity, elastic modulus, critical strain, and structuration rate. We first discuss the extrusion/deposition process at the level of the nozzle from a material perspective. We then focus on the rheological requirements needed to prevent the flow of one layer or the strength-based failure of the rising printed element. We moreover discuss the rheological requirements needed to control the final geometrical dimensions of one layer and of the entire object, including buckling stability and surface cracking. We finally describe the requirement for a proper intermixing of the layers interface and also note that drying of the upper surface of the layer at rest could also play a major role on the interlayer bond. Finally, we evaluate the effect of the use of printing supports (i.e. non-direct printing) on the above rheological requirements.

36 MATERIALS SCIENCE↗
DOE OSTI2016

The onset and evolution of fatigue-induced abnormal grain growth in nanocrystalline Ni–Fe

Conventional structural metals suffer from fatigue-crack initiation through dislocation activity which forms persistent slip bands leading to notch-like extrusions and intrusions. Ultrafine-grained and nanocrystalline metals can potentially exhibit superior fatigue-crack initiation resistance by suppressing these cumulative dislocation activities. Prior studies on these metals have confirmed improved high-cycle fatigue performance. In the case of nano-grained metals, analyses of subsurface crack initiation sites have indicated that the crack nucleation is associated with abnormally large grains. But, these post-mortem analyses have led to only speculation about when abnormal grain growth occurs (e.g., during fatigue, after crack initiation, or during crack growth). In this study, a recently developed synchrotron X-ray diffraction technique was used to detect the onset and progression of abnormal grain growth during stress-controlled fatigue loading. Our study provides the first direct evidence that the grain coarsening is cyclically induced and occurs well before final fatigue failure—our results indicate that the first half of the fatigue life was spent prior to the detectable onset of abnormal grain growth, while the second half was spent coarsening the nanocrystalline structure and cyclically deforming the abnormally large grains until crack initiation. Post-mortem fractography, coupled with cycle-dependent diffraction data, provides the first details regarding the kinetics of this abnormal grain growth process during high-cycle fatigue testing. Finally, precession electron diffraction images collected in a transmission electron microscope after the in situ fatigue experiment also confirm the X-ray evidence that the abnormally large grains contain substantial misorientation gradients and sub-grain boundaries.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A case study of high-temperature polyetherimide film capacitor fabrication

Capacitors, as the basic building block of power electronics and electrical systems, are the major constraint of the increasingly integrated power systems that require new capable polymer dielectric films operating at higher temperatures >125 °C. Despite tremendous research efforts on the lab scale, there remains a considerable barrier and knowledge basis for converting polymeric films to functioning capacitors desired in actual applications. Here, the authors tackled the polyetherimide (PEI) film scale up issues and developed various engineering processes for film de-wrinkling, optimal metallization, static elimination, and capacitor fabrication improvement. The authors discovered various fabrication challenges such as the electrostatic charge, metallization scheme, winding tension, and end electrode disconnects. To fabricate a high yield of PEI capacitor bobbins, it is necessary to utilize static eliminators (radioactive ionizers), moderately thick aluminum metallization (15–30 Ω/sq), and winding tension (60–100 g). It is also effective to evaluate capacitance, dielectric loss, equivalent series resistance, and thermal cycling stability of capacitors. This work sheds some light on converting PEI films and other polymeric films to capacitors on a scale up fabrication effort. The practical learning from film handling to capacitor fabrication in this work provided the necessary knowledge for manufacturing high-temperature polar film capacitors.

36 MATERIALS SCIENCE↗
NASA NTRS2018

Interplanetary Trajectory Design for NASA's Common Probe Study

The Galileo Probe, Pioneer-Venus probes, and SPRITE concept all share a number of common characteristics. They all follow a similar entry and descent sequence, using an aeroshell to protect against entry environments, and parachutes to aid in extrusion and descent speed control of the descent vehicle containing the science instruments. The descent vehicles all contained similar instruments (e.g. mass spectrometers and atmosphere structure sensors), and data was either relayed back to a carrier spacecraft (Galileo Probe, SPRITE) or transmitted direct to Earth (Pioneer-Venus). Based on these similar characteristics, NASA initiated a study to investigate a “common probe' that might be designed to perform similar science in a variety of planetary environments. This concept would leverage a common aeroshell design, and descent vehicle designs that could be made as similar as possible (the primary exception being that Venus will require a pressure vessel due to the extreme pressures and temperatures seen in the lower portion of the descent). To support the Common Probe study, GSFC and JPL performed a series of interplanetary trajectory analyses to help develop the mission designs for Venus, Jupiter, Saturn, Uranus, and Neptune. Primary considerations in the trajectory modeling included: a maximum of 12-year time of flight (for outer planet destinations), generation of both steep and shallow entry trajectories to each destination (where steep and shallow resulted in approximately 150 g and 50 g peak deceleration during entry at each location), and consideration of the data relay. Gravity assists and trajectories with low delta-V requirements (typically much less than 500 m/s) were also incorporated into the design process to enable launch on existing vehicles such as the Atlas V.

Hughes, Kyle M.↗
NASA NTRS1996

Analysis, design and testing of high pressure waterjet nozzles

The Hydroblast Research Cell at MSFC is both a research and a processing facility. The cell is used to investigate fundamental phenomena associated with waterjets as well as to clean hardware for various NASA and contractor projects. In the area of research, investigations are made regarding the use of high pressure waterjets to strip paint, grease, adhesive and thermal spray coatings from various substrates. Current industrial methods of cleaning often use ozone depleting chemicals (ODC) such as chlorinated solvents, and high pressure waterjet cleaning has proven to be a viable alternative. Standard methods of waterjet cleaning use hand held or robotically controlled nozzles. The nozzles used can be single-stream or multijet nozzles, and the multijet nozzles may be mounted in a rotating head or arranged in a fan-type shape. We consider in this paper the use of a rotating, multijet, high pressure water nozzle which is robotically controlled. This method enables rapid cleaning of a large area, but problems such as incomplete coverage (e.g. the formation of 'islands' of material not cleaned) and damage to the substrate from the waterjet have been observed. In addition, current stripping operations require the nozzle to be placed at a standoff distance of approximately 2 inches in order to achieve adequate performance. This close proximity of the nozzle to the target to be cleaned poses risks to the nozzle and the target in the event of robot error or the striking of unanticipated extrusions on the target surface as the nozzle sweeps past. Two key motivations of this research are to eliminate the formation of 'coating islands' and to increase the allowable standoff distance of the nozzle.

Mazzoleni, Andre P.↗
DOE OSTI2023

Multiscale Porous High-temperature Heat Exchanger Using Ceramic Co-extrusion

In this project, our MIT, Purdue, and GE team aims to design, model, fabricate, and test a novel high temperature, compact, and durable ceramic heat exchanger to be operated under high temperature and pressure conditions for aerospace applications. Our approach is grounded in introducing multiscale porosity, i.e., centimeter-scale channels embedded with micrometer-scale channels, into the ceramic heat exchanger to significantly improve its heat transfer performance and mechanical strength while maintaining minimal pressure losses. We first developed high-fidelity thermal-fluid-mechanical model capable of precisely capturing the heat transfer rate, temperature profile, pressure drop, and mechanical stress throughout the entire heat exchanger design. Guided by our model, we identified the optimal design parameters for the SiC heat exchanger body and manifolds. Then, we established a completed fabrication procedure to create multiscale features in the ceramic heat exchanger, including co-extrusion, lamination, burnout, and sintering. We fabricated multiple heat exchanger bodies consisting of 6 × 6 and 3 × 3 centimeter-scale channels where each individual centimeter-scale channel comprises 625 crack-free microchannels with 90 μm × 90 μm opening. Owing to the multiscale features, our fabricated heat exchanger bodies exhibited desirable mechanical strength with 156 MPa flexural strength under 1300 Celsius degree. Despite the demonstrated highly tailorable microscopic features and superior mechanical strength, we identified delamination due to the complex interaction among ceramic, polymer, and gas species can be a critical challenge to create fully defect-free heat exchanger, which requires further fundamental investigations in future works. To test the heat exchanger performance, we constructed a high-temperature and high-pressure experimental apparatus that can be safely operated under 400 Celsius degree and 4 bar. With insights gained from mechanistic modeling, material development, and detailed characterization, a cost model was finally developed to understand the market potential of the developed technology, where a cost of $43,000 Celsius degree/kW was envisioned. This project developed a transformative approach to high-performance heat exchanger design. The thermal-fluid-mechanical design approach developed in this project can serve as a generic tool to guide the design of various heat-exchangers operated under high-temperature and high-pressure conditions. The material fabrication approach established in this project can be a useful guide for ceramic processing at extreme length scales.

42 ENGINEERING↗