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At least 91 records · Page 5

System characterization of a magnetically suspended flywheel

The purpose of flywheel energy storage is to provide a means to save energy during times when the satellite is in sunlight, and then return the energy during the time when the satellite is in darkness. Typically, an energy storage device operates cyclically, where for satellites in Low Earth Orbit (LEO) the typical period is 60 minutes of sunlight followed by 30 minutes of darkness. If a lifetime of 17 years is required the energy storage system must be capable of sustaining approximately 100,000 cycles. The recent developments at the University of Maryland and how these progressions apply to a 500 Watt-hour magnetically suspended flywheel stack energy storage system are covered. The work includes hardware testing results from a stack flywheel energy storage system, improvements in the area of non-contacting displacement transducers, and performance enhancements of magnetic bearings. The experimental results show that a stack flywheel energy storage system is a feasible technology.

Kirk, James A.↗

The energy spectrum of cosmic rays beyond the turn-down around 10 17 eV as measured with the surface detector of the Pierre Auger Observatory

We present a measurement of the cosmic-ray spectrum above 100 PeV using the part of the surface detector of the Pierre Auger Observatory that has a spacing of 750 m. An inflection of the spectrum is observed, confirming the presence of the so-called second-knee feature. The spectrum is then combined with that of the 1500 m array to produce a single measurement of the flux, linking this spectral feature with the three additional breaks at the highest energies. The combined spectrum, with an energy scale set calorimetrically via fluorescence telescopes and using a single detector type, results in the most statistically and systematically precise measurement of spectral breaks yet obtained. These measurements are critical for furthering our understanding of the highest energy cosmic rays.

79 ASTRONOMY AND ASTROPHYSICS↗

AlScO 3 perovskite—An ~8 eV bandgap oxide predicted to exhibit low small hole polaron ionization energies and p -type conductivity at elevated temperatures

Here, we investigate electronic structure and dopability of an ultrawide bandgap (UWBG) AlScO 3 perovskite, a known high-pressure and long-lived metastable oxide. From first-principles electronic structure calculations, HSE06(+G 0 W 0 ), we find this material to exhibit an indirect bandgap of around 8.0 eV. Defect calculations point to cation and oxygen vacancies as the dominant intrinsic point defects limiting extrinsic doping. While acceptor behaving Al and Sc vacancies prevent n-type doping, oxygen vacancies permit the Fermi energy to reach ~0.3 eV above the valence band maximum, rendering AlScO 3 p-type dopable. Furthermore, we find that both Mg and Zn could serve as extrinsic p-type dopants. Specifically, Mg is predicted to have achievable net acceptor concentrations of ~10 17 cm -3 with ionization energy of bound small hole polarons of ~0.49 eV and free ones below 0.1 eV. These values place AlScO 3 among the UWBG oxides with lowest bound small hole polaron ionization energies, which, as we find, is likely due to large ionic dielectric constant that correlates well with low hole polaron ionization energies across various UWBG oxides.

14 SOLAR ENERGY↗

Electrification of Boilers in U.S. Manufacturing

Decarbonization of the industrial heat demand through electrification where low/no-carbon electricity is used can contribute significantly to global greenhouse gas (GHG) reduction. In U.S. manufacturing, thermal processes account for approximately 75% of the total final energy demand, of which nearly 17% was consumed by conventional industrial boilers for steam generation in 2018 (this does not include boilers for combined heat and power – CHP). Steam is generally used in industry to regulate temperatures and pressures in industrial processes, dry products, strip impurities from process fluids, etc. Although all kinds of energy sources such as fossil fuels, renewables, nuclear, and electricity can generate steam, fossil fuels’-fired boilers are dominant in U.S. manufacturing. Electric boilers, which are a mature technology, have a small market share for steam generation in the global and U.S. industry (approximately 2% in U.S. manufacturing) due to several techno-economic reasons.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Observations of galactic cosmic ray energy spectra between 1 and 9 AU

The variation of the 5 to 500 MeV/nuc cosmic ray helium component was studied between 1 and 9 A.U. using essentially identical detector systems on Pioneer 10 and 11 and Helios I. Between 100 and 200 MeV/nuc a radial gradient of 3.3?1.3%/A.U. is found. At 15 MeV/nuc this value increases to 20?4%/A.U. Between 4 and 9 A.U. a well defined intensity maximum is observed at approximately 17 MeV/nuc. The average adiabatic energy loss between 1 and 9 A.U. is approximately 4 MeV/nuc/A.U. The observed radial variation between 1 and 9 A.U. is well described by the Gleeson-Axford force field solution of the modulation equations over an energy range extending from 15 to 500 MeV/nuc and is in good agreement with the results reported by other Pioneer experiments. These values are much smaller than had been theoretically predicted.

Mcdonald, F. B.↗

Leveraging Existing Assets for Long Duration Energy Storage

Increased renewables penetration to electrical grid is necessary to reduce overall emissions from the electrical power generation sector. Nonetheless, its integration creates challenges to grid operators who must match the power being generated by intermittent renewables and other traditional energy sources with the demand from consumers, while ensuring the reliability and power quality for the entire system. Energy storage has been proposed as an alternative to natural gas peaking plants and a form to deliver excess renewable energy generation at times of peak demand. For energy storage to provide benefits to end customers (energy consumers), it must be reliable, efficient, and cost effective. The Illinois Sustainable Technology Center (ISTC), one of the surveys that integrate the Prairie Research Institute (PRI), aims to develop a Center for Energy Storage at Existing Assets (CESEA) at UIUC with the participation of Waste Pressure Corp and Ecotek Engineering USA LLC. CESEA will focus on LDES systems that can integrate to existing infrastructure in a manner that reduces the initial capital expenditure and demonstrates the ability to repurpose fossil assets that would otherwise become stranded, to serve the energy transition. CESEA aims to leverage UIUC’s unique facilities to validate LDES systems performance at a relevant operating environment. UIUC’s facilities include a 85-MW combined heat and power (CHP) power plant, two (2) solar PV plants totaling over 18 MWdc of installed capacity, an electrical grid along with a substation at transmission and distribution voltages, a 22-mile gas pipeline network operating at two pressure levels, along with steam and chilled water distribution networks. The new LDES systems will connect to the existing UIUC grid through a new test electrical station, which will have the capacity to accommodate additional connections to test new devices and technologies as part of future CESEA R&D activities. The test electrical station will contain meters, instrumentation, and controls to accurately capture data and allow optimization of control algorithms. CESEA will initially focus on technologies that: i) utilize existing equipment or facilities to perform at least one of the process steps in LDES (charging, storage, or discharging), ii) leverage mature or commercially available components or controls, iii) show potential for cost-leadership in 10+ hour storage at a commercial scale. Initial technologies that were identified to meet these criteria include Compressed Gas Energy Storage (CGES), and TES. CGES stores electricity by raising the pressure of a compressible gas inside a control volume and converting the stored energy to electricity via expansion-generation. CGES is a generalization of CAES that covers any working gas (not just air). A successful CGES demo will help to circumvent many challenges faced by CAES (long development times due to site prospecting, high cost of compression and storage, heat recovery management, etc.) by: 1) utilizing existing infrastructure (compressors, pipelines, underground storage or pressure vessels) used in the transportation and storage of industrial gases for LDES charging and storage; 2) deploying over sites already-developed for industrial applications with minor additional work; 3) leveraging the price structure of commercial industrial gas to cover the costs of electricity used during charging. A previous DOE-sponsored conceptual study (DE-FE-0032018) estimated the levelized cost of energy of a 1.1 MW / 17 MWh CGES system at $0.08/kWh, with a commercial 10x scale system cost estimated at <$0.04/kWh (Giardinella, 2022). The pilot-sized system was estimated to avoid up to 2693 tons of CO2/year.

25 ENERGY STORAGE↗

Structural damage response of lanthanum and yttrium aluminate crystals to nuclear collisions and electronic excitation: Threshold assessment of irradiation damage

A comparative analysis is performed on the structural damage response and associated mechanisms in lanthanum aluminate and yttrium aluminate crystals under various irradiation conditions by a combination of experimental and theoretical approaches. Under low-energy Au+ irradiation, the damage accumulation curve shows a higher damage rate for LaAlO 3 crystals than YAlO 3 crystals. The relatively low irradiation tolerance of LaAlO 3 to the action of nuclear collisions is ascribed to the large amorphization cross-section and effective cross-section for defect-stimulated amorphization. Under swift Ar 12+ , Ni 19+ and Kr 17+ irradiation with different ion energies and velocities, the formed highly-disordered/amorphous latent tracks with different morphologies in pristine and predamaged crystals are discussed, and the corresponding electronic energy loss and lattice temperature thresholds are quantitatively determined. Compared to YAlO 3 , LaAlO 3 exhibits lower sensitivity and higher damage tolerance to the electronic energy loss process, attributing to its relatively high recrystallization efficiency during the rapid quenching process. Furthermore, the introduction of lattice defects into LaAlO 3 and YAlO 3 crystals considerably enhances the sensitivity and intensity of thermal spike response to the electronic energy loss, and the induced effective modification of track morphologies demonstrates the synergistic effect between the electronic energy loss and pre-existing defects created by nuclear collisions. In this case, even under the action of electronic energy loss below the threshold, the lattice temperature in the nuclear-collision damaged crystalline system could still meet the criterion for track production. The irradiation energy deposited to atoms and induced lattice temperature evolution discussed in this work provide a deeper insight into the complex processes involved in irradiation-induced latent track behaviors.

36 MATERIALS SCIENCE↗

Observation of inverse Compton emission from a long γ-ray burst

Long-duration γ-ray bursts (GRBs) originate from ultra-relativistic jets launched from the collapsing cores of dying massive stars. They are characterized by an initial phase of bright and highly variable radiation in the kiloelectronvolt-to-megaelectronvolt band, which is probably produced within the jet and lasts from milliseconds to minutes, known as the prompt emission. Subsequently, the interaction of the jet with the surrounding medium generates shock waves that are responsible for the afterglow emission, which lasts from days to months and occurs over a broad energy range from the radio to the gigaelectronvolt bands. The afterglow emission is generally well explained as synchrotron radiation emitted by electrons accelerated by the external shock. Recently, intense long-lasting emission between 0.2 and 1 teraelectronvolts was observed from GRB 190114C. Here we report multifrequency observations of GRB 190114C, and study the evolution in time of the GRB emission across 17 orders of magnitude in energy, from 5 × 10^(−6) to 10^(12) electronvolts. We find that the broadband spectral energy distribution is double-peaked, with the teraelectronvolt emission constituting a distinct spectral component with power comparable to the synchrotron component. This component is associated with the afterglow and is satisfactorily explained by inverse Compton up-scattering of synchrotron photons by high-energy electrons. We find that the conditions required to account for the observed teraelectronvolt component are typical for GRBs, supporting the possibility that inverse Compton emission is commonly produced in GRBs.

P. Veres↗

X-Ray Synchrotron Emission From 10-100 TeV Cosmic-Ray Electrons In The Supernova Remnant SN 1006

We present the results of a joint spectral analysis of RXTE PCA, ASCA SIS, and ROSAT PSPC data of the supernova remnant SN 1006. This work represents the first attempt to model both the thermal and nonthermal X-ray emission over the entire X-ray energy band from 0.12 to 17 key. The thermal flux is described by a nonequilibrium ionization model with an electron temperature kTe = 0.6 key, an ionization timescale n(sub 0)t = 9 x 10(exp 9)/cc s, and a relative elemental abundance of silicon that is 10 - 18 times larger than the solar abundance. The nonthermal X-ray spectrum is described by a broken power law model with low- and high-energy photon indices Gamma(sub 1) = 2.1 and Gamma(sub 2) = 3.0, respectively. Since the nonthermal X-ray spectrum steepens with increasing energy, the results of the present analysis corroborate previous claims that the nonthermal X-ray emission is produced by synchrotron radiation. We argue that the magnetic field strength is significantly larger than previous estimates of about 10 micro G and arbitrarily use a value of 40 micro G to estimate the parameters of the cosmic-ray electron, proton, and helium spectra of the remnant. The results for the ratio of the number densities of protons and electrons (R = 160 at 1 GeV), the total energy in cosmic rays (E(sub cr) = 1 x 10(exp 50) ergs), and the spectral index of the electrons at 1 GeV (Gamma(sub e) = 2.14 +/- 0.12) are consistent with the hypothesis that Galactic cosmic rays are accelerated predominantly in the shocks of supernova remnants. Yet, the remnant may or may not accelerate nuclei to energies as high as the energy of the "knee," depending on the reason why the maximum energy of the electrons is only 10 TeV.

Allen, G. E.↗

A System Approach to Deep Heating Savings Through Measurement, Management, and Motivation

Across multi-tenant commercial office and multifamily buildings, centrally metered fuel use represents a substantial fraction of whole-building energy use. Energy audit practitioners understand that improving heating distribution efficiency is typically more of an opportunity than combustion efficiency and that differing thermal comfort preferences between tenants are the bane of operators across these building typologies. There is an unmet market need for retrofit technologies that allow for the delivery of the right amount of heat to the right spaces, at the right time. The Energy Management and Information System (EMIS) package fills this gap through enhanced controls and metering, incorporating low-cost sensors and wireless communication infrastructure to provide a platform for ongoing commissioning and tenant feedback, including heat cost allocation. With support from the US DOE Building Technologies Office, Steven Winter Associates, Inc. (SWA) partnered with Sentient Buildings, E Source, building owners, and utility and policy stakeholders, to demonstrate a market viable EMIS that achieves a reduction in space heating energy use by reducing heating load, improving control, and positively impacting behavior while providing an acceptable financial return. In this study, EMIS packages were implemented in two New York City multifamily rental buildings. Both buildings conducted basic mechanical work (e.g., repairing steam traps) to ensure the heating system was operating well before any tenant feedback was layered in. Heating Energy Use Reports (HEUR) were created to provide tenants with social comparisons and energy savings tips to influence their behavior; these were provided monthly to all tenants in both buildings. Additionally, one building allocated heating costs to a portion of the tenants. Heat cost allocation (HCA) has a long history in the European Union (EU), although it is not common in the US or in steam-heated buildings. SWA leveraged existing EU best practices and stakeholder feedback to develop a Heat Cost Allocation algorithm that was considered equitable and intuitive. Energy use and tenant behavior impacts were tracked throughout the study. The basic mechanical repair work saved between 11-20% of heating energy. Those savings rose to 17-24% with the addition of tenant feedback. While it may not be possible to precisely determine the impact of COVID-19 on research studies like this, there may have been additional savings realized had the study taken place in a period of normal occupancy patterns. These types of central heating systems have been a blind spot for utilities, who have traditionally had little visibility into detailed behind-the-meter gas usage. Heating energy savings stayed consistent during the coldest months, indicating the potential for utilities to utilize EMIS packages for peak gas demand reductions or demand response programs. Tenant comfort was also improved. Post installation, room temperatures more closely matched thermostat set points. Perhaps due to this greater level of control, the vast majority of tenants being billed for heating were accepting of the allocation costs. And tenants receiving heat cost allocations were more likely to reduce their thermostat setpoints than tenants receiving behavioral feedback without financial impacts were. Variation in building specifics makes it difficult to provide precise energy and financial savings estimates. But within the range of expected conditions, the study identified a few key variables that can have the greatest impact on financial returns: the cost of fuel, the ability and willingness to allocate heating costs to tenants, and a well-functioning heating system as a starting point. This study focused on two multifamily buildings, but additional use cases, such as commercial buildings and affordable housing, should be explored to better understand the full market potential. While this type of upgrade has the potential for deep energy reductions and cost savings, future projects should take into account the balance of costs and benefits between owners and tenants, especially in the affordable, regulated, or other low-to-moderate income (LMI) segments of the market. Rent credits, utility allowances, or a shared savings program are possible options to accelerate adoption of this strategy in these market segments.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

H/+/ and He/2+/ in the dawnside magnetosheath

Mass and energy analyses of energetic ions in the dawnside magnetosheath have been made by the energetic ion composition experiment on the ISEE-1 spacecraft over the energy range 10 eV/e to 17 keV/e. The significant observations are: the bulk flows of the H(+) and He(2+) components determined from first moments of the distributions averaged over several minutes are equal within the uncertainties of the measurement. The H(+) and He(2+) distributions are similar in that they both show temperature anisotropies with perpendicular temperature not less than parallel temperature; however, the distributions are not well characterized by temperatures derived from second moments. In at least one case high energy tails of both distributions can be characterized by an additional higher temperature component. The major difference between the H(+) and He(2+) distributions is the depletion of the low velocity (in the center of mass frame) part of the He(2+) distributions, relative to the H(+) distributions.

Peterson, W. K.↗

Density functional modeling of the binding energies between aluminosilicate oligomers and different metal cations

Interactions between negatively charged aluminosilicate species and positively charged metal cations are critical to many important engineering processes and applications, including sustainable cements and aluminosilicate glasses. In an effort to probe these interactions, here we have calculated the pair-wise interaction energies (i.e., binding energies) between aluminosilicate dimer/trimer and 17 different metal cations M n+ (M n+ = Li + , Na + , K + , Cu + , Cu 2+ , Co 2+ , Zn 2+ , Ni 2+ , Mg 2+ , Ca 2+ , Ti 2+ , Fe 2+ , Fe 3+ , Co 3+ , Cr 3+ , Ti 4+ and Cr 6+ ) using a density functional theory (DFT) approach. Analysis of the DFT-optimized structural representations for the clusters (dimer/trimer + M n+ ) shows that their structural attributes (e.g., interatomic distances) are generally consistent with literature observations on aluminosilicate glasses. The DFT-derived binding energies are seen to vary considerably depending on the type of cations (i.e., charge and ionic radii) and aluminosilicate species (i.e., dimer or trimer). A survey of the literature reveals that the difference in the calculated binding energies between different M n+ can be used to explain many literature observations associated with the impact of metal cations on materials properties (e.g., glass corrosion, mineral dissolution, and ionic transport). Analysis of all the DFT-derived binding energies reveals that the correlation between these energy values and the ionic potential and field strength of the metal cations are well captured by 2nd order polynomial functions ( R 2 values of 0.99–1.00 are achieved for regressions). Given that the ionic potential and field strength of a given metal cation can be readily estimated using well-tabulated ionic radii available in the literature, these simple polynomial functions would enable rapid estimation of the binding energies of a much wider range of cations with the aluminosilicate dimer/trimer, providing guidance on the design and optimization of sustainable cements and aluminosilicate glasses and their associated applications. Finally, the limitations associated with using these simple model systems to model complex interactions are also discussed.

Gong, Kai↗

Nexus of electrification and energy efficiency retrofit of commercial buildings at the district scale

Rapid electrification of buildings at the district scale is needed for cities to achieve climate change mitigation goals. However, most electrification studies focus on either the single building level or the city/region building stock level, and depend on the slow and uncertain process of requesting personally identifiable customer energy usage data from utilities. To answer a key question facing local policymakers: “Where can electrification proceed at scale without first upgrading the grid?” this study aims to quantify and inform building electrification impacts at the district scale using detailed building energy modeling and based on public records datasets. We explore how energy efficiency retrofits can help mitigate increased peak electric demand, and quantify impacts to energy use and carbon emissions. Building energy models of a baseline, and scenarios of simple electrification, energy retrofits, and electrification in combination with retrofits were created and simulated for 54 commercial buildings in two contiguous districts of San Francisco. A simple electrification scenario increased annual electricity consumption but reduced annual site energy usage by 15% to 17%, mainly due to replacing inefficient gas furnaces and boilers with more efficient heat pumps. Peak demand increased 7.4% for Fisherman's Wharf (e.g. within the capacity of the existing power grid), while the Design District showed a marginal decrease. Annual carbon emissions were reduced by 46% and 37%. Combining electrification with efficiency upgrades reduced peak demand by 26% and 40%, and annual carbon emissions by 63% and 64% for the two districts. Furthermore, these results indicate that impacts of electrification depend on the mix of building uses within a district, and coupling electrification with energy efficiency upgrades is an effective strategy to decarbonize buildings while maintaining or reducing the peak electric demand.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

National energy savings potential of cellular shades: A measurement and simulation study

Windows are major contributors to energy demand in residential homes because of their inferior thermal resistance compared with the opaque envelope, and sometimes from unwanted solar heat gain. Window attachments can help mitigate the energy demand by controlling the solar heat gains and enhancing window thermal resistance. Cellular shades have the potential of superior thermal performance compared with generic shades because of its honeycomb structure. Here, in this study, the team analyzed the energy savings potential of cellular shades in residential homes via experimental testing for two heating seasons and energy simulations. Five shading devices—three single-cell and two double cellular/cell-in-cell shades—were used to compare the performance with generic horizontal venetian blinds using two nearly identical side-by-side rooms in a residential home. The experimental testing showed daily heating energy savings in the range of 17%–36% compared with the case without shades. The experimental testing data also exhibited improvements in thermal comfort when using cellular shades. Additionally, energy simulations were performed to evaluate the energy savings potential of the cellular shades using a residential prototype home, which demonstrated energy savings up to 9 kWh/m2/year in cold climates. The total site energy savings for heating and cooling from cellular shades was up to ~9% for the home with a heat pump and up to ~15% for a home with a gas furnace compared with cases without any shading devices. The energy savings at a national scale were up to 14.6 TWh assuming a 20% penetration rate in residential homes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Chapter 17: Residential Behavior Evaluation Protocol. The Uniform Methods Project: Methods for Determining Energy Efficiency Savings for Specific Measures, September 2011 - August 2020

This document has been updated in August 2020. This document was developed for the U.S. Department of Energy Uniform Methods Project (UMP). The UMP provides model protocols for determining energy and demand savings that result from specific energy-efficiency measures implemented through state and utility programs. In most cases, the measure protocols are based on a particular option identified by the International Performance Verification and Measurement Protocol; however, this work provides a more detailed approach to implementing that option. Each chapter is written by technical experts in collaboration with their peers, reviewed by industry experts, and subject to public review and comment. The protocols are updated on an as-needed basis. The UMP protocols can be used by utilities, program administrators, public utility commissions,evaluators, and other stakeholders for both program planning and evaluation. To learn more about the UMP, visit the website, https://energy.gov/eere/about-us/ump-home, or download the UMP introduction document at http://www.nrel.gov/docs/fy17osti/68557.pdf.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Voyager measurements of the energy spectrum, charge composition, and long term temporal variations of the anomalous components in 1977-1982

The large collecting area and wide energy range of the cosmic ray experiment on Voyager 1 and 2 was used to examine the energy spectra, charge composition, and long term temporal variations of the anomalous components in 1977-1982. Individual energy spectra are obtained for 17 separate quiet time periods during the time interval. The composite spectra of anomalous He, N, O, and Ne are obtained to a new level of precision. This includes the spectral shape and the relative abundance. Essentially, the spectral shape of N, O, and Ne appear to be similar. The ratios of anomalous N and Ne to O are found to be different from both the solar cosmic ray and galactic cosmic ray source composition. Some evidence is found for the enhancement of Ar as well. In the case of elements such as C, Mg, S, and Fe it is difficult to separate a possible lower intensity anomalous component from a quasi-steady interplanetary component that appears to be present at the lowest energies. The long term temporal variations of the anomalous He and O components were studied from 1977-82, a period from minimum to maximum in the modulation cycle. The tracking between these anomalous component intensities and the integral intensity of 75 MeV protons is striking; however, the intensity decrease of the anomalous components is much greater.

Webber, W. R.↗

Impact Analysis of Transitioning to Heat Pump Rooftop Units for the U.S. Commercial Building Stock: Preprint

20% of the U.S. commercial building sector's energy usage is from on-site combustion of fossil fuels for heating. Decarbonization will require electrification of these systems to meet climate goals, often by transitioning to heat pumps. Rooftop units (RTU) are the most prominent commercial building HVAC system type and should therefore be prioritized for decarbonization solutions. However, there is limited understanding of the impact on emissions that considers regional electricity generation methods, as well as the impact of other heat pump intricacies such as the effects of temperature on capacity/efficiency, defrost operation, realistic sizing methodologies, and supplementary heating. This study explores the effects of transitioning all conventional RTUs to high-performance heat pump RTUs for the U.S. commercial building stock. The analysis is performed using ComStock, DOE's calibrated model of the U.S. commercial building stock developed by NREL. Results show 9% and 17% reductions in stock aggregate energy consumption and GHG emissions, respectively. Furthermore, average heat pump operational details are presented by state. This analysis will help inform the transition to heat pump RTUs for the U.S. commercial building stock.

commercial building electrification↗

Improved Mechanical Performance in FDM Cellular Frame Structures through Partial Incorporation of Faces

The utilization of lattice-type cellular architectures has seen a significant increase, owing to their predictable shape and the ability to fabricate templated porous materials through low-cost 3D-printing methods. Frames based on atomic lattice structures such as face-centered cubic (FCC), body-centered cubic (BCC), or simple cubic (SC) have been utilized. In FDM, the mechanical performance has been impeded by stress concentration at the nodes and melt-solidification interfaces arising from layer-by-layer deposition. Adding plates to the frames has resulted in improvements with a concurrent increase in weight and hot-pocket-induced dimensional impact in the closed cells formed. In this paper, we explore compressive performance from the partial addition of plates to the frames of a SC-BCC lattice. Compression testing of both single unit cells and 4 × 4 × 4 lattices in all three axial directions is conducted to examine stress transfer to the nearest neighbor and assess scale-up stress transfer. Our findings reveal that hybrid lattice structure unit cells exhibit significantly improved modulus in the range of 125% to 393%, specific modulus in the range of 13% to 120%, and energy absorption in the range of 17% to 395% over the open lattice. The scaled-up lattice modulus increased by 8% to 400%, specific modulus by 2% to 107%, and energy absorption by 37% to 553% over the lattice frame. Parameters that emerged as key to improved lightweighting.

FDM↗