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

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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Effect of tube processing methods on the texture and grain boundary characteristics of 14YWT nanostructured ferritic alloys

In this paper, texture and microstructure of tubes and plates fabricated from a nanostructured ferritic alloy (14YWT), produced either by spray forming followed by hydrostatic extrusion (Process I) or hot extrusion and cross-rolling a plate followed by hydrostatic tube extrusion (Process II) have been characterized in terms of their effects on texture and grain boundary character. Hydrostatic extrusion results in a combination of plane strain and shear deformations which generate low intensity α- and γ-fiber components of {001}<110> and {111}<110> together with a weak ζ-fiber component of {011}<211> and {011}<011>. In contrast, multi-step plane strain deformation by hot extrusion and cross-rolling of the plate leads to a strong texture component of {001}<110> together with a weaker {111}<112> component. Although the total strains are similar, shear dominated deformation leads to much lower texture indexes compared to plane strain deformations. Further, the texture intensity decreases after hydrostatic extrusion of the alloy plate formed by plane strain deformation, due to a lower number of activated slip systems during shear dominated deformation. Finally and notably, hot extruded and cross-rolled plate subjected to plane strain deformation to ~50% engineering strain creates only a modest population of low angle grain boundaries, compared to the much larger population observed following the combination of plane strain and shear deformation of ~44% engineering strain resulting from subsequent hydrostatic extrusion.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure, Texture, and Mechanical Properties of AM60 Magnesium Alloy Processed by Extrusion and Multidirectional Forging

In the present paper, multidirectional forging (MDF), as a severe plastic deformation process, was carried out on an extruded AM60 magnesium alloy. The microstructure, texture, and mechanical properties of the MDFed samples were examined. Microstructural findings indicated that the grain size of the alloy decreased from 10.2 to 3.7 µm after six MDF passes, carried out at a constant temperature of 220 °C. Textural studies revealed that after six MDF passes, the fiber texture of the extruded material was transformed to another texture, in which the basal planes tend to rotate toward 45{sup o} to the transverse direction. Shear punch testing (SPT) was employed to assess the shear yield stress (SYS) and ultimate shear strength (USS) at room temperature. Both SYS and USS were enhanced after two MDF passes, but decreased in the next pressing stages, despite developing finer grains at higher levels of imposed strain. The observed drop in strength is ascribed to texture softening that counterbalances the grain refinement strengthening effects. The variation in average microhardness values after different passes of MDF showed the trend that was in concurrence with the rise and fall of the SPT results. Finally, the changes in mechanical properties were discussed, based on the microstructural and textural findings.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Frictional conditions between alloy AA6060 aluminium and tool steel

The frictional conditions in the new process of screw extrusion of aluminium have been investigated. The contact behaviour between the aluminum alloy and the tool steel in the extruder is vital for understanding the extrusion process. Using a compressive-rotational method for frictional measurements the conditions for unlubricated sticking friction between aluminum alloy AA6060 and tool steel at different combinations of temperatures and pressures have been investigated. In this method the samples in the form of disks are put under hydrostatic pressure while simultaneously being rotated at one end. Pins made from contrast material have been inserted into the samples to measure the deformation introduced. This approach along with 3D simulations form a method for determining the frictional conditions. The paper describes the test method and the results. It was found that the necessary pressure for sticking to occur between the aluminum AA6060 and the different parts of the extruder is heavily influenced by the temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Microstructure evolution and mechanical properties of nano-SiCp/AZ91 composite processed by extrusion and equal channel angular pressing (ECAP)

Nano-SiCp/AZ91 magnesium matrix composite was fabricated by stir casting. The as-cast ingots were extruded at 350 °C, then processed by equal channel angular pressing (ECAP) at various temperatures (250 °C, 300 °C and 350 °C). Grains are significantly refined after the extrusion and the ECAP. A basal fibre texture was detected by neutron diffraction after the extrusion, which inclines about 45° to the extrusion direction (ED) after the ECAP. Nano-scaled SiC particles agglomerate in the as-cast composite. After the extrusion, the agglomeration tends to form continuous or discontinuous strips along the extrusion direction. By application of the ECAP, the agglomerated SiC particles are partly dispersed and the strips formed during the extrusion tend to be thinner and broken with the increasing pass number. The yield tensile strength (YTS) and the ultimate tensile strength (UTS) of the composite are dramatically increased after the extrusion. ECAP for one pass at various temperatures further increases the strength, however, the YTS decreases with the increasing ECAP temperature and the pass number. The Orowan equations predict the maximum YTS of the composite may be up to 400 MPa providing SiC particles are homogenously distributed in the matrix. - Highlights: •Nano-scaled SiC particles were successfully added into AZ91 by stirring casting. •Agglomeration of nano-particles were improved by extrusion and ECAP. •Yield strength of the composite is 328 MPa after one pass of ECAP. •Further ECAP process with optimized parameters may fully disperse nano-particles. •Yield strength is predicted to up to 400 MPa when particles are fully dispersed.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Zr Extrusion – Direct Input for Models & Validation

As we examine differences in the high strain rate, high strain tensile response of high purity, highly textured Zr as a function of loading direction, temperature and extrusion velocity with primarily post mortem characterization techniques, we have also developed a technique for characterizing the in-situ extrusion process. This particular measurement is useful for partitioning energy of the system during the extrusion process: friction, kinetic energy, and temperature

36 MATERIALS SCIENCE↗
DOE OSTI2017

Digestibility of the defatted microalgae Nannochloropsis sp. and Desmodesmus sp. when fed to Atlantic salmon, Salmo salar

The aim of the study was to investigate the apparent digestibility coefficient (ADC) of defatted biomass derived from microalgae Nannochloropsis sp. and Desmodesmus sp. when fed to Atlantic salmon postsmolts in seawater. Two experiments, one employing cold-pelleted and the other employing extruded pellets, were carried out to determine the ADC of dry matter (DM), protein, ash and energy. The test feeds consisted of a fishmeal-based reference feed and the algal biomass, at a ratio of 70:30, and yttrium oxide as the inert marker. The ADC of DM and protein in fish fed microalgae-incorporated cold-pelleted feeds were significantly higher for Nannochloropsis sp. compared with Desmodesmus sp. Here, the Nannochloropsis sp. inclusion in extruded feeds also led to higher ADCs of DM and energy compared with Desmodesmus sp. The extrusion processing significantly increased the ADC of ash in both defatted microalgae biomass, as well as ADCs of DM in Nannochloropsis and protein in Desmodesmus sp. In conclusion, the microalga Nannochloropsis sp. was more digestible than Desmodesmus sp., and extrusion processing can be used as a means to improve digestibility of certain nutrients.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2018

A rational asymmetric hollow fiber membrane for oxygen permeation

Abstract A typical oxygen permeation hollow fiber membrane fabricated by phase inversion‐based extrusion process demonstrates heterogeneous porous microstructures, in which the surface layer with relatively low porosity is used as a separation layer after sintering. It is usually not convenient to control the thickness of separation layer. And a high sintering temperature is needed to densify the separation layer, which in turn could destroy the desired porous microstructures in other portion. This paper studies a novel process to fabricate multilayer asymmetric hollow fiber membrane with a rational design using 67 vol. % Gd 0.2 Ce 0.8 O 2−δ −33 vol. % La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3−δ ( GDC ‐ LSCF ) as a model material system. The phase inversion‐based extrusion process in open literature is employed to fabricate a hollow fiber substrate featuring radially well‐aligned microchannels open at the inner surface. Built upon the hollow fiber substrate, a thin dense separation layer and porous surface catalyst layer at shell side are then fabricated through dip‐coating and sintering process alternatively. The oxygen permeation flux of the fabricated hollow fiber membrane reaches 2.68 mL/cm 2 /min at 900°C under Ar/air gradient, the highest performance of the membranes with GDC ‐ LSCF material system in open literature. The innovative fabrication process is able to readily control the thickness of functional layers while decreasing sintering temperatures.

Ren, Chunlei↗
DOE OSTI2017

Rheological Characteristics of Fiber Reinforced Poly(Ether Ketone Ketone) (PEKK) for Melt Extrusion Additive Manufacturing

Several grades of unreinforced and short fiber reinforced poly(ether ketone ketone) (PEKK) copolymers are analyzed for their potential use as feedstock materials in melt extrusion-based additive manufacturing (AM) systems. Rheological characterization has been performed to study the effect of extrusion processing parameters such as time, temperature, environment, and shear rate for the selected materials. The effect of reinforcing filler content on the melt processing conditions of PEKK composites are also reported, and processing conditions for successful extrusion of these materials on AM systems are determined.

Kishore, Vidya↗
DOE OSTI2013

Analysis of the flow imbalance on the profile shape during the extrusion of thin magnesium sheets

The extrusion process facilitates the production of magnesium sheets featuring a very thin thickness as well as excellent surface properties by using a single process step only. However, the extrusion of the magnesium sheets applying not optimized process parameters, e.g. low billet temperature or/ and poorly deformable magnesium alloy, produce pronounced buckling and waving of the extruded sheets as well as a variation of accuracy in profile shape along the cross section. The present investigation focuses on the FEM-simulation of the extrusion of magnesium sheets in order to clarify the origin of the mentioned effects. The simulations identify the flow imbalance during extrusion as the main critical factor. Due to the flow imbalance after passing the die a large compression stress zone is formed causing the buckling and waving of the thin sheets. Furthermore, the simulations of the magnesium sheet extrusion reveal that the interaction of the material flow gradients along the width and along the thickness direction near the die orifice lead to the variation of the accuracy in profile shape.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Effect of tube processing methods on microstructure, mechanical properties and irradiation response of 14YWT nanostructured ferritic alloys

In this research, innovative thermal spray deposition (Process I) and conventional hot extrusion processing (Process II) methods have been used to produce thin walled tubing (~0.5 mm wall thickness) out of 14YWT, a nanostructured ferritic alloy. The effects of processing methods on the microstructure, mechanical properties and irradiation response have been investigated by using scanning electron microscopy (SEM), transmission electron microscopy (TEM) and, micro- and nano-hardness techniques. It has been found that these two processes have a significant effect on the microstructure and mechanical properties of the as-fabricated 14YWT tubes. Even though both processing methods yield the formation of various size Y-Ti-O particles, the conventional hot extrusion method results in a microstructure with smaller, homogenously distributed nano-oxides (NOs, Y-Ti-O particles < 5 nm) with higher density. Therefore, Process II tubes exhibit twice the hardness of Process I tubes. It has also been found that these two tremendously different initial microstructures strongly affect irradiation response in these tubes under extremely high dose ion irradiations up to 1100 peak dpa at 450 °C. The finer, denser and homogenously distributed NOs in the Process II tube result in a reduction in swelling by two orders of magnitude. On the other hand, inhomogeneity of the initial microstructure in the Process I tube leads to large variations in both swelling and irradiation induced hardening. Moreover, hardening mechanisms before and after irradiation were measured and compared with detailed calculations. In conclusion, this study clearly indicates the crucial effect of initial microstructure on radiation response of 14YWT alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Melt Flow Behavior and Processability of Polylactic Acid/Polystyrene (PLA/PS) Polymer Blends

The present investigation dealt with the flow behavior and processability of polylactic acid/polystyrene (PLA/PS) polymer blends using a capillary rheometer. For this purpose, PLA/PS blends with different ratios of the concentrations were prepared using a single screw extruder. The shear viscosity, shear stress, shear rate, power-law index, viscous activation energy at a constant shear stress, and elongational stress were determined. PLA/PS blends exhibited a typical shear-thinning behavior over the entire range of shear rates tested, and the viscosity values of the blends would tend to decrease with increasing amount of PLA. In addition, the polymer blend of 70 % PLA and 30 % PS was found to be relatively less sensitive to the processing temperature, implying that the extrusion process was more desirable for fabrication of PLA/PS polymer blend than the injection process.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Planar slicing for nonextrusion AM processes

Extrusion-based AM processes, including material extrusion and directed energy deposition, construct objects by continuously depositing a relatively small amount of molten feedstock to a specific location. Nonextrusion AM processes, on the other hand, tend to form each layer by linearly or areally projecting either energy onto a vat of photocurable liquid or a binding agent into a bed of loose powder. Such systems vary significantly from extrusion-based AM processes but do share similarities. The general approach to path planning is the same, but nonextrusion processes typically favor the use of bitmap representations, instead of polygons, for pathing computation and do not use a g-code file to command the printer. In this chapter, a high-level discussion of these differences will be covered.

Macdonald, Eric↗
DOE OSTI2014

Study on the recycling of waste PVC compounds from electrical wires

The good mechanical, thermal and electrical properties of poly (vinyl chloride) (PVC) make it a polymer used in many applications, among which is the coating of wires and cables. The processing of PVC for this application is made using the extrusion process. The PVC waste resulting from extrusion can be recycled or placed on landfills. The objective of this work is to develop recycling methods to decrease the amount of PVC stored in landfills. This work evaluated the influence of successive processing of PVC on the final properties of the obtained compound, which will be used in the process of coating wire and cable by extrusion. The mechanical properties of the electrical wires were assessed according to the Brazilian Association of Technical Standards (ABNT NBR 6251). Tests of tensile strength, elongation at break, before and after thermal aging in an oven with air circulation for a period of 168 hours at 100 °C were performed. The degradation of the PVC compound was carried out through Fourier transform infrared spectroscopy (FTIR) and mechanical properties evaluation. The results showed that the compound can be reprocessed five times keeping the minimum requirements of the ABNT NBR 6251 Standard. Reprocessing was stopped upon color changing (yellowing) of the compound. Yellowing is a characteristic degradation behavior by dehydrochlorination of PVC. FTIR analysis showed changes at 1600 cm{sup −1}, 1430 cm{sup −1}, 685 cm{sup −1} and 614 cm{sup −1} bands. The performance of the PVC compound for coating electrical wire and cable was fair, meeting the requirements of the ABNT NBR 6251 Standard even after five reprocessing cycles.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Outcomes and Conclusions from the 2022 AM Bench Measurements, Challenge Problems, Modeling Submissions, and Conference

The Additive Manufacturing Benchmark Test Series (AM Bench) provides rigorous measurement data for validating additive manufacturing (AM) simulations for a broad range of AM technologies and material systems. AM Bench includes extensive in situ and ex situ measurements, simulation challenges for the AM modeling community, and a corresponding conference series. In 2022, the second round of AM Bench measurements, challenge problems, and conference were completed, focusing primarily upon laser powder bed fusion (LPBF) processing of metals, and both material extrusion processing and vat photopolymerization of polymers. In all, more than 100 people from 10 National Institute of Standards and Technology (NIST) divisions and 21 additional organizations were directly involved in the AM Bench 2022 measurements, data management, and conference organization. The international AM community submitted 138 sets of blind modeling simulations for comparison with the in situ and ex situ measurements, up from 46 submissions for the first round of AM Bench in 2018. Analysis of these submissions provides valuable insight into current AM modeling capabilities. The AM Bench data are permanently archived and freely accessible online. The AM Bench conference also hosted an embedded workshop on qualification and certification of AM materials and components.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Quality Optimization of Commercial FeCrAl Tube Production

The objectives of this report are to summarize the various process parameters and conditions that trigger premature failures during the production steps for Generation II ATF FeCrAl seamless tubes in commercially available manufacturing processes, and to suggest optimized processing routes and parameters to improve the quality and the material yield of commercial tube production. The production process steps include (1) the heat production process, (2) the master bar production process, and (3) the tube reduction process. For heat production, not only chemical composition control but also elimination of solidification defects in the vacuum induction–melted ingot are key. A hot-isostatic press helped in reducing and eliminating the internal, preexisting cracks in the ingot, which could be a source of premature failure (e.g., crack initiation from oxide particles) in the latter part of the tube production process. The master bars were produced by a hot-extrusion process. The area reduction ratio and the extrusion temperature are key to controlling the quality of the master bars and the grain structure. Because of the limited deformation ability of FeCrAl alloys, especially at ambient temperatures, a controlled, uniform grain structure with relatively small grains (<100 µm) is required at the beginning of the tube reduction process. Furthermore, a relatively small amount of area reduction per pass, combined with controlled inter-pass annealing, is important to achieve a reduction in failure events, a highly uniform wall thickness, concentricity, and a high-quality surface finish. Based on the knowledge obtained regarding process conditions, FeCrAl tube production with optimized process parameters is currently in progress. A portion of the final tube inventory was delivered in late June 2017. Cross-sectional microstructural characterization was completed for screening the quality of as-received tubes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2010

A Technical Review on Biomass Processing: Densification, Preprocessing, Modeling and Optimization

It is now a well-acclaimed fact that burning fossil fuels and deforestation are major contributors to climate change. Biomass from plants can serve as an alternative renewable and carbon-neutral raw material for the production of bioenergy. Low densities of 40–60 kg/m3 for lignocellulosic and 200–400 kg/m3 for woody biomass limits their application for energy purposes. Prior to use in energy applications these materials need to be densified. The densified biomass can have bulk densities over 10 times the raw material helping to significantly reduce technical limitations associated with storage, loading and transportation. Pelleting, briquetting, or extrusion processing are commonly used methods for densification. The aim of the present research is to develop a comprehensive review of biomass processing that includes densification, preprocessing, modeling and optimization. The specific objective include carrying out a technical review on (a) mechanisms of particle bonding during densification; (b) methods of densification including extrusion, briquetting, pelleting, and agglomeration; (c) effects of process and feedstock variables and biomass biochemical composition on the densification (d) effects of preprocessing such as grinding, preheating, steam explosion, and torrefaction on biomass quality and binding characteristics; (e) models for understanding the compression characteristics; and (f) procedures for response surface modeling and optimization.

09 BIOMASS FUELS↗
DOE OSTI2020

Functionally graded coatings and claddings

A shear assisted extrusion process for producing cladded materials wherein a cladding material and a material to be cladded are placed in sequence with the cladded material positioned to contact a rotating scroll face first and the material to be cladded second. The two materials are fed through a shear assisted extrusion device at a preselected feed rate and impacted by a rotating scroll face to generate a cladded extrusion product. This process allows for increased through wall strength and decreases the brittleness in formed structures as compared to the prior art.

36 MATERIALS SCIENCE↗