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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 OSTI2021

Aspenplus Model For Msw Sorting Process

Unit operations for the MSW sorting process include shredding, magnets for ferrous separation, screening, air classification, eddy current for non-ferrous separation, and near-infrared detection for plastic recovery. The MIXCINC module within Aspen Plus was selected to handle mixed solid streams containing inert (metals and glass) and non-conventional materials (paper, plastics, biomass, organic waste). The Peng-Robinson equation of state with Boston-Mathias modifications was applied to predict properties for a nonconventional solids mix. Enthalpy and density of the non-conventional materials were defined using non-conventional material properties.

Hu, Hongqiang↗
DOE OSTI2021

Liquid-induced topological transformations of cellular microstructures

The fundamental topology of cellular structures—the location, number and connectivity of nodes and compartments—can profoundly affect their acoustic, electrical5, chemical, mechanical and optical properties, as well as heat, fluid and particle transport. Approaches that harness swelling, electromagnetic actuation and mechanical instabilities in cellular materials have enabled a variety of interesting wall deformations and compartment shape alterations, but the resulting structures generally preserve the defining connectivity features of the initial topology. Achieving topological transformation presents a distinct challenge for existing strategies: it requires complex reorganization, repacking, and coordinated bending, stretching and folding, particularly around each node, where elastic resistance is highest owing to connectivity. Here we introduce a two-tiered dynamic strategy that achieves systematic reversible transformations of the fundamental topology of cellular microstructures, which can be applied to a wide range of materials and geometries. Our approach requires only exposing the structure to a selected liquid that is able to first infiltrate and plasticize the material at the molecular scale, and then, upon evaporation, form a network of localized capillary forces at the architectural scale that ‘zip’ the edges of the softened lattice into a new topological structure, which subsequently restiffens and remains kinetically trapped. Reversibility is induced by applying a mixture of liquids that act separately at the molecular and architectural scales (thus offering modular temporal control over the softening–evaporation–stiffening sequence) to restore the original topology or provide access to intermediate modes. Guided by a generalized theoretical model that connects cellular geometries, material stiffness and capillary forces, we demonstrate programmed reversible topological transformations of various lattice geometries and responsive materials that undergo fast global or localized deformations. In conclusion, we then harness dynamic topologies to develop active surfaces with information encryption, selective particle trapping and bubble release, as well as tunable mechanical, chemical and acoustic properties.

42 ENGINEERING↗
DOE OSTI2024

Role of interfaces on the mechanical response of accumulative roll bonded nanometallic laminates investigated via dislocation dynamics simulations

Unraveling the effects of continuous dislocation interactions with interfaces, particularly at the nanometer length scales, is key to a broader understanding of plasticity, to material design and to material certification. To this end, this work proposes a novel discrete dislocation dynamics-based model for dislocation interface interactions tracking the fate of residual dislocation on interfaces. This new approach is used to predict the impact of dislocation/interface reactions on the overall mechanical behavior of accumulative roll bonded nanometallic laminates. The framework considers the dynamic evolution of the interface concurrent with a large network of dislocations, thus, accounting for the local short and long range effects of the dislocations under the external boundary conditions. Specifically, this study focuses on two-phase Fe/Cu nanometallic laminates, and investigates the role of the underlying elastic and plastic contrast of the Fe and the Cu layers on the composite response of the material. Moreover, the role of initial microstructures, resulting from processing is also investigated. Subsequently, the model is used to examine the effect of layer thickness and interface orientation relationship on the residual stresses of the relaxed microstructure. The associated mechanical response of these laminates are compared when loaded under normal direction compression, as well as shear compression. Finally, this work predicts a dominant effect of the layer thickness, as compared to the interface orientation relationship, on the macroscopic response and on the residual stresses of these nanolaminates, while the local dislocation transmission propensity through the interface is significantly influenced by the corresponding orientation relationship.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Material Extrusion Printing of Poly(Acrylonitrile‐Styrene‐Acrylate) and Poly(Acrylonitrile‐Butadiene‐Styrene) Structures Reinforced with Poly(Phenylene Oxide) Additives for Improved Thermomechanical Properties and their Surface Analysis by Time‐of‐Flight Secondary Ion Mass Spectrometry

Fused filament fabrication offers the ability to 3D print complex geometries made from plastic filament materials; however, these parts are mechanically outperformed by parts created by traditional fabrication methods. To overcome this challenge, a high-performance polymer poly(2,6-dimethyl-1,4-phenylene oxide) (PPO) is incorporated as an additive into two common engineering thermoplastics, poly(acrylonitrile-styrene-acrylate) (ASA) and poly(acrylonitrile-butadiene-styrene) (ABS). Structures printed from these polymer blends are more mechanically robust compared to those prepared from the parent polymers, with low loading levels (1–5 wt%) of PPO improving the elastic strength by up to ≈30% relative to the parent terpolymers. Even at higher loading levels (10 and 20 wt% PPO), there is no evidence of additive aggregation in the model thin films, which is supported by compositional analysis of the copolymers and chemical analysis via time-of-flight secondary ion mass spectrometry. The enhancements in mechanical properties of ASA and ABS blends appear to be a consequence of homogeneous incorporation of the PPO additive. In conclusion, this work explores expanding materials-property space using miscible blends of engineering thermoplastics to improve mechanical performance as a general approach to overcoming challenges with parts created by melt-based material extrusion printing.

additive manufacturing↗
DOE OSTI2020

Crystallographic orientation and spatially resolved damage in a dispersion-hardened Al alloy

The in-situ neutron diffraction technique, in combination with both the full-field crystal elasto-viscoplastic finite element model and microstructural characterization, was used to study the deformation-induced damage anisotropy in a commercial Al alloy, subjected to uniaxial tensile and cyclic loading. The simulations capture well the crystallographic-orientation-dependent lattice strain behavior. The hard grains, e.g. those orientated with the <111> and <422> orientations parallel with the uniaxial loading direction (LD), feature large Taylor factors and seem more prone to form damage-related band structures. Their effective elastic moduli decrease with the accumulation of damage, which are different from the soft grains orientated with the <200> orientation along the LD. Correlation between the distribution of voids and that of the residual lattice strain developed after failure may exist. The maximum tensile type residual lattice strain observed after failure may be resulted from the band structure formed in the hardest <111> grains. It was revealed that the band structure triggered by the hard particles could be one of sources of damage. In addition, while the specimen was obviously damaged, a fast stress relief was evidenced after unloading from the tension, especially at the beginning of unloading. Our present investigations provide a novel method for exploring the damage mechanisms of polycrystalline materials during plastic deformation.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Background Information on ARPA-E's REUSE Program (White Paper)

Under the REUSE Topic, ARPA-E seeks to fund the development of technologies to convert high-energy materials currently going to landfills to a high-energy content liquid product capable of displacing energy imports used for fuel or chemical production. The high-energy materials include plastics (#1-7 polymers, rubber, and composites) and paper. As discussed below, we estimate 30-34 MM ton plastic, 2-6 MM ton rubber, 18 MM ton of paper, and up to 0.1 MM ton composites are potentially available annually for this purpose. These numbers may be conservative based on changes in the plastic and paper export markets. ARPA-E anticipates deployment of multiple low-cost, simple, flexible, small-scale (100-500 ton per day) regional facilities using modular plants. This scale is consistent with the sources for high-energy materials, which include ~300 Material Recovery Facilities and industrial waste sources. The assumption is that such facilities can be more economical than the paradigm of large-scale facilities making purity products, due to cost for transporting and aggregating waste and the high operating costs (OPEX) and capital cost (CAPEX) for product purification. This document gives a brief technical review for multiple potential process technologies. The review is not intended to be comprehensive or limiting, only to provide an introduction to potential Applicants.

10 SYNTHETIC FUELS↗
DOE OSTI2020

White Paper: Background Information on ARPA-E's Reuse Program

This document provides supplemental information for ARPA-E’s exploratory research program, “Recycle Underutilized Solids to Energy” (REUSE). The goal is to provide additional technical information to prospective Applicants. Further information is available in a blog interview and webinar at https://arpa-e.energy.gov/?q=news-item/trash-treasure-reuse-creates-feedstock-plastic-waste. Award information, submission requirements, evaluation criteria, and other applicable information is provided in Funding Opportunity Announcements DE-FOA-0001953 and DE-FOA-0001954 (SBIR/STTR). REUSE-specific requirements are provided in Topic K of those FOAs, and is available at https://arpa-e-foa.energy.gov/Default.aspx?Search=0001953&SearchType=#FoaIde8647d89-1cac-4b58-8622-1b04de8958c4. Under the REUSE Topic, ARPA-E seeks to fund the development of technologies to convert high-energy materials currently going to landfills to a high-energy content liquid product capable of displacing energy imports used for fuel or chemical production. The high-energy materials include plastics (#1-7 polymers, rubber, and composites) and paper. As discussed below, we estimate 30-34 MM ton plastic, 2-6 MM ton rubber, 18 MM ton of paper, and up to 0.1 MM ton composites are potentially available annually for this purpose. These numbers may be conservative based on changes in the plastic and paper export markets. ARPA-E anticipates deployment of multiple low-cost, simple, flexible, small-scale (100-500 ton per day) regional facilities using modular plants. This scale is consistent with the sources for high-energy materials, which include ~300 Material Recovery Facilities and industrial waste sources. The assumption is that such facilities can be more economical than the paradigm of large-scale facilities making purity products, due to cost for transporting and aggregating waste and the high operating costs (OPEX) and capital cost (CAPEX) for product purification. This document gives a brief technical review for multiple potential process technologies. The review is not intended to be comprehensive or limiting, only to provide an introduction to potential Applicants.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Technology Transfer from Fermi Research Alliance to Itasca Plastics for the purpose of Commercializing Scintillator Material

Researchers at the Fermi National Accelerator Laboratory (Fermilab) developed extruded plastic scintillator in the late 1990s, which was first used in the D-Zero experiment. Extruded plastic scintillator is currently produced at Fermilab and is used in particle detectors worldwide. The purpose of this CRADA is to transfer the knowledge related to the Fermilab extrusion process to Itasca Plastics, Inc. (Itasca Plastics). Much of this knowledge is contained in documentation that is in the public domain, although it is distributed over several communications (papers, conference records, etc.) and over several years. Under this CRADA Fermilab will assemble the information, provide it to Itasca Plastics and provide limited consulting to complete the knowledge transfer. If the transfer is successful, Itasca Plastics will be able to establish a U.S. commercial manufacturing capability for extruded scintillator material that can be used for high energy physics and commercial applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Towards a multiscale approach for understanding irradiation induced swelling and creep in 316 stainless steels - A coupled cluster dynamics and crystal plasticity approach

Structural materials undergo mechanical degradation, in part due to irradiation-induced swelling and creep, under nuclear reactor conditions. While swelling results from the migration and clustering of irradiation-induced atomic-scale mobile defects, the interaction of mesoscale dislocations with these defects causes creep deformation. A coupled crystal plasticity (CP) and mean-field cluster dynamics (CD) approach is presented to investigate the effect of irradiation on the long-term mechanical behavior of 316 stainless steel, which are under consideration for use in nuclear reactors. The temporal evolution of Frenkel pairs and extended defect population, under a chosen irradiation flux and temperature, is predicted using the CD model. The impact of the irradiation defects on the stress state, and the resulting dislocation-mediated inelastic deformation, is modeled concurrently with the CP model. The inelastic deformation is irradiation flux dependent, and early-stage defect evolution determines the later-stage mechanical behavior in 316 stainless steel.

36 - MATERIALS SCIENCE↗
DOE OSTI2020

Mix and match—a versatile equilibrium approach for hybrid colloidal synthesis

Colloidal synthesis is a powerful bottom-up approach for programmed self-assembly which holds promise for both research and industry. While diverse, each synthetic process is typically restricted to a specific chemistry. Many applications however require composite materials, whereas a chemical equilibrium can typically only match one material but not the other. Here, a scalable general approach is presented, alleviating the dependency on a specific chemical reaction, by resorting to a mechanical equilibrium; an isopycnic density-gradient-step is tailored to form clusters with prescribed composition. Valence control is demonstrated, making dimers, trimers, and tetramers with purity as high as 96%. The measured kinetics shows a scaleable throughput. The density gradient step plays a dual role of both filtering out undesired products and concentrating the target structures. The “Mix-and-Match” approach is general, and applies to a broad range of colloidal matter: diverse material compositions (plastics, glasses, and emulsions); a range of colloidal interactions (van der Waals, Coulomb, and DNA hybridization); and a spectrum of sizes (nanoscale to multiple micrometers). Lastly, the strength of the method is displayed by producing a monodisperse suspension from a highly polydisperse emulsion. The ability to combine colloids into architectures of hybrid materials has applications in pharmaceuticals, cosmetics, and photonics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Implementation and experimental validation of nonlocal damage in a large-strain elasto-viscoplastic FFT-based framework for predicting ductile fracture in 3D polycrystalline materials

Ductile materials, such as metal alloys, can undergo substantial deformation before failure. Additionally, these materials are usually of polycrystalline composition and exhibit strongly anisotropic behavior at small length scales. Previously developed fast Fourier transform (FFT)-based models can model ductile fracture of isotropic materials or the elastic–plastic behavior of anisotropic polycrystalline materials; however, there remains a need to couple both capabilities. This work extends a large-strain FFT-based crystal plasticity model to simulate ductile fracture of polycrystalline materials. In this work, a triaxiality-based continuum damage mechanics (CDM) formulation is incorporated into a large-strain elasto-viscoplastic FFT (LS-EVPFFT) framework. The CDM formulation is augmented with an integral-based nonlocal regularization approach that correctly handles gas-phase material necessary to model unconstrained surfaces. To validate the damage-enabled LS-EVPFFT framework, mesoscale copper tensile coupons were machined using microwire electrical discharge machining and experimentally characterized using electron backscatter diffraction. In-situ optical digital image correlation was performed during uniaxial testing to provide a side-by-side comparison of the experimental and computational strain fields and stress–strain responses. The damage-enabled LS-EVPFFT framework can simulate the complete macroscopic stress–strain response of ductile polycrystals to failure. The model reproduces necking behavior that qualitatively agrees with experimental observations. By leveraging the relatively low computational cost of the damage-enabled LS-EVPFFT framework, the framework presented here allows the ductile fracture response of 3D polycrystalline materials to be tractably predicted.

36 MATERIALS SCIENCE↗
DOE OSTI2023

NETL Plastic Pipes Project (Final Report)

Plastic or composite pipelines have been the bane of the utility locating industry because they are neither conductive nor magnetic which are the properties traditionally used to locate buried utilities. Ground penetrating radar (GPR) is an effective geophysical tool for locating plastic/composite pipelines where resistive cover allows for adequate penetration of radar energy. However, GPR has limited applicability in areas where the soil cover is conductive due to significant clay and/or salt content. This study examines complementary near-surface geophysical methods that are potentially useful for locating buried plastic/composite pipelines, either singly or in combination. Specifically, this modeling study used computational numerical methods to forward model the response of GPR, resistivity, seismic, gravity gradiometry, and photoacoustic/thermoacoustic imaging methods to plastic/composite pipelines for various scenarios including: (1) pipe diameters ranging between 2 in. to 12 in.; (2) burial depths ranging between 3 ft. to 4 ft.; (3) various degrees in contrast in physical properties (i.e., electrical permittivity, elasticity, resistivity, density); and (4) various experimental acquisition choices (e.g., GPR radar and seismic source frequencies, electrode spacing). Numerical modeling performed herein reconfirmed that GPR is the preferred method for detecting/locating plastic pipelines. A caveat for GPR detection is that the material covering the plastic pipe (trench fill material and adjacent soil) must be sufficiently resistive to allow the two-way propagation to the required depth of investigation and back to the surface. GPR was the only method modeled in this study that can be used to directly detect plastic pipelines of 2-in.-diameter and larger when buried 3-ft-deep. GPR data processing and imaging also can determine pipe depth, pipe diameter, trench dimensions, and moisture conditions. Seismic modeling results suggest that direct detection of a 12-in.-diameter plastic pipe at 3-ft.-depth may be possible under favorable conditions; however, the associated signature would be weak (e.g., surface- to S-wave, backscattered surface-waves, and/or forward scattered surface-waves to S-wave). Direct pipe detection under field conditions with noise and strong lateral geologic heterogeneity is doubtful. Numerical modeling also suggests that plastic pipelines can be indirectly located by detecting the trench in which they are buried. GPR, direct current (DC) resistivity, and seismic methods have the potential to locate the pipeline trench if there is sufficient contrast between the trench-wall and trench-fill materials for the physical property being measured by each method (i.e., electrical permittivity for GPR; resistivity for DC resistivity; or density, compressional velocity, or shear velocity for seismic). Modeling also indicated that currently available (commercial) gravity gradiometers would be unable to directly detect/locate plastic pipelines ≤ 8-in.-diameter when buried 3-ft.-deep given the typical instrument noise floor for field surveying as well as the expected density variations due to geologic heterogeneity. The numerical modeling performed in this project did not identify a universal geophysical technology that can locate buried plastic pipelines in all parts of the United States (although GPR is suggested for all areas with resistive cover). However, the project results suggest that a towed land streamer simultaneously acquiring multiple geophysical data types including multi-offset GPR, multi-channel DC resistivity, seismic geophone- and/or distributed acoustic sensing (DAS), and potentially photoacoustic/thermoacoustic data would be an appropriate platform for locating buried plastic pipeline. Moreover, the complementary multiphysics data acquired by a towed land streamer would permit the use of joint and/or cooperative inversion frameworks for a more rigorous and consistent data interpretation.

42 ENGINEERING↗
DOE OSTI2023

Gradient nanostructured steel with superior tensile plasticity

Nanostructured metallic materials with abundant high-angle grain boundaries exhibit high strength and good radiation resistance. While the nanoscale grains induce high strength, they also degrade tensile ductility. We show that a gradient nanostructured ferritic steel exhibits simultaneous improvement in yield strength by 36% and uniform elongation by 50% compared to the homogenously structured counterpart. In situ tension studies coupled with electron backscattered diffraction analyses reveal intricate coordinated deformation mechanisms in the gradient structures. The outermost nanolaminate grains sustain a substantial plastic strain via a profound deformation mechanism involving prominent grain reorientation. This synergistic plastic co-deformation process alters the rupture mode in the post-necking regime, thus delaying the onset of fracture. The present discovery highlights the intrinsic plasticity of nanolaminate grains and their significance in simultaneous improvement of strength and tensile ductility of structural metallic materials.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Development of a Printable Prill Formulation Technique and Demonstration of Monomodal Prill Size on Compaction Density and Compressive Strength

Polymer-bonded explosive molding powder, or “prills,” are relied on for the fabrication of pressed high explosives since the 1950's. The wet granulation technique, also known as “slurry coating,” that is used to formulate prills, is a complex process that results in polydisperse and variable yields. This makes it difficult to study the mesoscale effect that prills have on the microstructure of a pressed article. The following study introduces a novel approach to energetic granulation that leverages techniques used in the additive manufacturing of paste-like energetic materials. This extrusion granulation, or prill printing technique, makes it possible to tailor the sizes and shapes of prills, allowing for their morphological influences to be studied in a controlled manner. The following work details the fabrication and characterization of four monomodal size lots of prills using an inert formulation (95 wt.% melamine, 5 wt.% polymer binder). Prills from each size lot were die-pressed using a fixed recipe to investigate how prill size impacts compaction density and therefore compressive strength. It was found that larger prills influence the pressing density by creating larger defects within the microstructure of a pressed article, resulting in a decrease in compressive strength.

direct ink write↗
DOE OSTI2022

Accumulative Roll Bonding of Alloy 2205 Duplex Steel and the Accompanying Impacts on Microstructure, Texture, and Mechanical Properties

The mechanical and microstructural evolution of Alloy 2205 during severe plastic deformation is examined in this study. A combination of accumulative roll bonding (ARB) and cold rolling results in the successful formation of a nanograined dual-phase microstructure of austenite and ferrite with some transformed martensite. Severe deformation to cumulative reductions of 80.5, 92.5, 95, and 97 pct were performed. Microscopy indicates that grain dimensions in the sheet normal direction is less than 100 nm for reductions ≥ 92.5 pct. Shear banding is observed at reductions ≥ 95 pct while twinning is only observed at reductions < 92.5 pct. Neutron diffraction measurements indicated the presence of martensite for reductions ≥ 95 pct at ~ 8 pct volume fraction. Taken in conjunction, it appears that during initial ARB processing, both slip and twinning are active plastic mechanisms. As twinning becomes exhausted, martensitic transformation, slip, and intermittent shear banding account for the active plasticity mechanisms. Material hardness saturates at 92.5 pct reduction, with a maximum hardness of 45 HRC. Sub-sized tensile testing confirms this approximate hardness with measurements indicating a UTS of ~ 1440 MPa. Texture analysis of crystal orientation distributions in the plate normal direction suggest an approximate Kurdjumov–Sachs orientation relationship at all reductions above 80 pct indicating stability of the orientation relationship at high strains. The intragranular structure develops a fine scale sub-grain content with increasing deformation, resulting in a continual evolution of texture up to and including 97 pct reduction. The final structure presents strong components of Goss and rotated cube texture in both the austenite and ferrite. In this body of work we aim to compare ARB of an industrially relevant FCC/BCC system (Alloy 2205) to historical model FCC/BCC systems such as Cu/Nb.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Recurrent neural network-based multiaxial plasticity model with regularization for physics-informed constraints

We report a recurrent neural network (RNN) based model is developed as a surrogate to predict nonlinear plastic response under multiaxial loading. The RNN-based model is trained and tested on stress versus strain curves generated using a numerical solution based on the classical radial return method. Besides simply learning the basic constitutive relationship, a novel approach is taken to enforce certain physical conditions. Specifically, regularization is employed to maintain non-negative plastic power density throughout the loading history thereby ensuring monotonically increasing plastic work and thermodynamic consistency. Enforcing physics in this manner permits coupling of the data-driven RNN approach with physics-based knowledge and laws. This has the effect of reducing the necessary amount of data and ensuring known physical laws are not violated. Since, once trained, the model need not perform the expensive task of solving nonlinear equations, its efficiency is orders of magnitude greater than its numerical counterpart. The RNN-based model has been trained on varied sets of data and the accuracy on test datasets validated. The developed model is general and robust and has widespread application such as in the simulation of metal forming, large scale plasticity, and part life prediction.

42 ENGINEERING↗
DOE OSTI2022

Leak-tight crack repair for 304L stainless steel using friction surfacing

Here, friction surfacing (FS) was investigated as a method for sealing 50 μm wide thru-cracks in 3-mm-thick 304L stainless steel (304L) plate. Friction surfacing was performed using two sizes of 304L consumable rod, with diameters of 9.52 mm and 12.7 mm, on two substrate conditions (clean and oxidized). Friction surfacing was able to deposit a 600 μm thick coating and repair cracks to a depth of 100 μm - 200 μm below the original surface, when using the 12.7-mm-diameter consumable rod for both substrate conditions. Helium leak rates of 10 -10 atm-cc/s were achieved on crack repairs, designating them as leak-tight by the ANSI N14.5 standard. Optical and scanning electron microscopy were used to investigate the coating microstructure and bond interfaces. In this study, the 12.7-mm-diameter rod performed better with disruption of the oxide layer on the oxidized substrate and providing a more homogenous coating. Mechanical properties of the coated samples were evaluated by performing micro-indentation, tensile, bending, and adhesion testing. Higher hardness in the coatings was observed due to the fine equiaxed grains resulting from dynamic recrystallization. Complete consolidation of plastically deformed material on the substrate and a strong diffusion bond across the interface was observed. This was reflected in tensile and bending properties of the FS coatings being comparable to those of uncoated specimen. No delamination of the FS coating was observed during adhesion testing. The results demonstrate that friction surfacing is a viable option to seal cracks in stainless steels.

36 MATERIALS SCIENCE↗