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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

The Viscosity and Atomic Structure of Volatile-Bearing Melilititic Melts at High Pressure and Temperature and the Transport of Deep Carbon

Understanding the viscosity of mantle-derived magmas is needed to model their migration mechanisms and ascent rate from the source rock to the surface. High pressure–temperature experimental data are now available on the viscosity of synthetic melts, pure carbonatitic to carbonate–silicate compositions, anhydrous basalts, dacites and rhyolites. However, the viscosity of volatile-bearing melilititic melts, among the most plausible carriers of deep carbon, has not been investigated. In this study, we experimentally determined the viscosity of synthetic liquids with ~31 and ~39 wt% SiO 2 , 1.60 and 1.42 wt% CO 2 and 5.7 and 1 wt% H 2 O, respectively, at pressures from 1 to 4.7 GPa and temperatures between 1265 and 1755 °C, using the falling-sphere technique combined with in situ X-ray radiography. Our results show viscosities between 0.1044 and 2.1221 Pa·s, with a clear dependence on temperature and SiO 2 content. The atomic structure of both melt compositions was also determined at high pressure and temperature, using in situ multi-angle energy-dispersive X-ray diffraction supported by ex situ microFTIR and microRaman spectroscopic measurements. Our results yield evidence that the T–T and T–O (T = Si,Al) interatomic distances of ultrabasic melts are higher than those for basaltic melts known from similar recent studies. Based on our experimental data, melilititic melts are expected to migrate at a rate ~from 2 to 57 km·yr -1 in the present-day or the Archaean mantle, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Experimental Analysis of Advanced Turbine for Supercritical CO2 Power Cycle

An advanced first stage high pressure turbine blade for a supercritical CO2 power cycle is tested in the Big Rig for Aerothermal Stationary Turbine Analysis (BRASTA) annular cascade at the Purdue Experimental Turbine Aerothermal Laboratory (PETAL) high pressure blow down facility alongside a baseline blade for comparison of aerodynamic performance. Both geometries are tested simultaneously using a novel off-axis rig design to allow for the blade geometries to be scaled up to achieve higher Reynolds numbers. The off-axis design necessitates the use of discrete sectors of airfoils, which are designed and additively manufactured in house using an mSLA printer. Printing the blades allows for unique routing of passage for blade surface static pressure taps that contour to the blade shape instead of requiring a straight line view from surface tap to egress, allowing all instrumentation for 15%, 50%, and 85% span to exist in the same passage. A flow conditioning gauze [1] is placed upstream of the blade passages to impart pressure, Mach, and swirl profiles to mimic the rotor relative frame inlet conditions to the blade. Downstream, a sonic valve is used to alter the backpressure to achieve different pressure ratios for different blowdown setpoints. The design of the rig, sonic wheel, and instrumentation are discussed along with the manufacturing and GD&T of the blades with respect to the build-up of this novel experimental apparatus. Initial commissioning data is obtained from inlet total pressure and temperature rakes, blade static pressure taps, and exit total pressure rakes. Oil visualization is performed using a silicone oil mixture containing titanium dioxide and pigmented for contrast of the blade suction side surface with the hub and shroud endwalls. The viscosity of the oil is tuned so that the oil does not fully thin and blow away during the time of the test, and endoscopic cameras are placed in the rig for live monitoring and recording. The preliminary oil visualization and rake profiles are presented, showcasing the operability of this additively manufactured off-axis flow path design.

Tuite, Logan [Purdue University]↗
DOE OSTI2025

Basin-Size Mapping: Prediction of Metastable Polymorph Synthesizability Across TaC–TaN Alloys

The sizes of the basins of attraction on the potential energy surface are helpful indicators in determining the experimental synthesizability of metastable phases. In principle, these basins can be controlled with changes in thermodynamic conditions such as composition, pressure, and surface energy. Herein, we use random structure sampling to computationally study how alloying smoothly perturbs basin of attraction sizes. The TaC 1-x N x pseudobinary is an ideal test system given the structural and polymorphic contrast of its parent compounds and their technological relevance as epitaxial substrates for Al 1-x Ga x N. While we find limited thermodynamic stability across all computationally observed phases, random structure sampling shows a significant composition region where the rocksalt basin dominates. As such, we predict the potential for the nonequilibrium synthesis of metastable rocksalt TaC 1-x N x alloys as substrates for Al 1-x Ga x N. At higher nitrogen concentrations, other low-energy metastable polymorphs emerge that continue to retain the hexagonal close packing suitable for III-N growth. Confidence in these trends was established through uncertainty quantification of the basin sizes and energy distributions; such analysis utilized the Beta and Dirichlet distributions. In conclusion, we also find (a) polymorph basin sizes can be rationalized in terms of energetic preferences for different coordination environments; and (b) basin sizes universally shrink with increasing nitrogen content, making the system more prone to amorphous growth.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Evaluating the Feasibility of Measuring and Analyzing Strain Caused by Changes in Barometric Pressure in the Vadose Zone

Changes in barometric pressure propagate into the subsurface where they can affect water level measurements in wells and cause vertical strain. Previous strain sensors were developed to measure vertical strain, but they were limited to measurements at a single depth, making it difficult to evaluate strains from a migrating pressure wave. Technology known as Coherence-length-gated Microwave Photonics Interferometry (CMPI) uses optical fiber sensors to measure strain at multiple locations. It has the potential to detect strain caused by variations in barometric pressure at multiple depths in the subsurface. The goal of this study is to evaluate the feasibility of using this technology to record the changes in vertical strain in the vadose zone from small fluctuations in air pressure. Propagation of these air pressure fluctuations is affected by hydrogeological properties such as water content and permeability. A second goal of this study is to evaluate how these properties affect the air pressure distribution, strain, and gas-phase diffusivity with a long-term goal of using strain to monitor the vadose zone. The focus of this study is on a suite of laboratory experiments that used a sand-filled column with an open head space. The CMPI fiber was packaged and embedded along the axis of the column to measure the strain at multiple locations while air pressure transducers were installed through the wall of the column. Small periodic fluctuations in air pressure, similar to barometric pressure fluctuations, were created in the head space of the column using an audio driven speaker driven at 4 Hz using a sinusoidal signal created by a function generator. Then, the fluctuations propagated along the column where they were measured by the transducers and recorded as functions of time. Initial tests were conducted using dry sand, but then additional tests were conducted after injecting water into the column, which changed the hydrologic and mechanical properties. Another experiment was conducted after creating a thin barrier to air flow, which was designed to simulate a thin layer of saturated ground during rainfall. A final experiment was conducted by changing the grain size of the material to create a heterogeneity in the upper half of the column. The suite of six experiments was conducted to highlight effects of variations in water content and heterogeneities on air pressure and vertical strain. Numerical simulations were also created to evaluate the laboratory data and to provide a baseline analysis for the results. The numerical simulations used the governing equations to linear poroelasticity and two-phase flow with boundary conditions representing the experiments. The conceptual model for strain caused by barometric pressure recognizes that a fluctuating barometric pressure causes fluctuations in the air pore pressure that decrease in amplitude and lag in time with increase depth. The pressure distribution results in two different loads that cause strain: 1.) a mechanical load as the barometric pressure acts on the ground surface; and 2.) pressure loading in the pore space. The results show that the total vertical strain is a contribution of both of these loads, and this is the strain that was observed in the laboratory. The lab experiments show that both air pressure and strain vary as sinusoids that propagate with depth. The amplitude of the air pressure and strain decrease as a function of depth in all the conditions that were evaluate. For example, in the dry sand, the amplitude of the air pressure decreases from 25 Pa at the head space to 5 Pa at a depth of 70 cm, whereas the amplitude of the strain decreases from 0.15 to 0.06 µε over the same depth interval. In many cases the amplitudes decrease is approximately negative exponential functions of depth. When water was injected into the sand and the saturation increased, the amplitude of the air pressure increased in the partially saturated sand but decreased sharply to zero where the soil was saturated. The strain decreased with depth, but the transition from partially to fully saturated conditions had little effect on the strain profile, even though it had a major effect on the air pressure. This apparently is because strain is caused by variations in both water and air pressure. The fluctuating air pressure caused the water pressure to fluctuate, which caused strain throughout the column. Phase delay of the air pressure and the strain both increase as linear to bi-linear functions of depth. The phase delays indicate that pressure propagates at a velocity of 7 to 8 m/s in dry or partially saturated sand, but it drops by more than an order of magnitude in the vicinity of the capillary fringe. The phase delays indicate the strain propagates faster than the pressure. The data indicate that the strain propagates from 1.2 to more than 4x faster than the pressure. Switching from sand to silt in the column caused the velocity of the pressure to drop by roughly half for both pressures, but curiously, it had little effect on the velocity of the strain.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Experimental investigation into coal wettability changes caused by reactions with scCO 2 -H 2 O

Geological CO 2 sequestration (GCS) can help mitigate global warming and enhance methane recovery from coal beds. However, few studies have linked the effects of CO 2 to surface chemistry changes controlling wetting behavior in deep coal beds. Contact angles (CAs) of CO 2 /N 2 -high volatile bituminous coal-water systems were measured under different temperatures and pressures. The surface chemistry and physical structure of coals were characterized to investigate changes in physicochemical properties and their relations with wettability after reactions. For N 2 treatment, the time-dependence of static and dynamic CAs were insignificant, ranging within 4°. For gaseous CO 2 treatment, the static CAs and the average advancing angles increased slightly. With supercritical (sc) CO 2 , both the static and dynamic CAs increased significantly, and θ adv changed to intermediate-wet (92°). Reactions with minerals exposed to scCO 2 resulted in greater surface roughness and heterogeneity, greater contact angle hysteresis and more surface sites occupied by scCO 2 rather than H 2 O. Increases in hydrophobic functional groups and decreases in hydrophilicity were shown by FTIR spectra, reflecting the shedding of polar oxygen-containing functional groups, reduction of hydrogen bonds, and increasing percentage of hydrocarbons. XRD patterns obtained following scCO 2 -treatment showed that crystallite growth and molecular polymerization were higher toward graphite-like. The calculated structural parameters of functional groups and crystallites both showed elevated coal rank. Changes in crystallite structure, notably higher carbon content and decreased negative surface charge, are unfavorable for water-wetting. Finally, this study contributes to understanding surface chemistry changes responsible for decreased wettability during CO 2 -enhanced coal bed methane recovery and GCS in coal reservoirs.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Understanding Flow Characteristics in Metal Additive Manufacturing

In fluid flow, the frictional effects from interior surfaces of flow components create pressure loss across the surface. Understanding this inherent pressure loss due to friction and other phenomena is important when designing a flow system. For conventional manufacturing, friction loss has been empirically studied and is well known in the engineering community. However, newer manufacturing techniques, such as laser powder bed fusion (LPBF), an additive manufacturing technique, need to be understood. The inherent flow conditions resulting from the additive processes were studied. Test samples were printed with the flow path oriented in the vertical direction with different channel diameters to characterize the inherent fundamental flow properties of the process. Moody diagrams were replicated for a greater understanding of possibilities and shortfalls when implementing LPBF into design applications. Experimental flow testing revealed that greater effective sand grain roughness resulted from this process when compared to conventional machining methods. This roughness did not correlate well to the average roughness measured with a laser scanning microscope but was consistent with the average particle size of the powder metal feedstock.

42 ENGINEERING↗
DOE OSTI2022

Dynamically Downscaled (WRF) 1km, Hourly Meteorological Conditions 1987-2020. East/Taylor Watersheds

This dataset contains meteorological output from the Weather Research and Forecasting (WRF) version 3.8.1. This dataset has been created to 1) investigate hydrometeorological processes impacting the East River and water-delivery to the Critical Zone, and 2) provide meteorological forcing data for distributed Earth-science modeling applications in the East River watershed. Variables have a 1 kilometer spatial resolution and hourly temporal resolution and encompass a rectangular region encompassing the East and Taylor River watersheds, Colorado, near the town of Crested Butte. WRF was forced using Climate Forecast System Reanalysis (CFSR) lateral boundary conditions. Each .zip file contains one "water year" of data (October 1 -- September 30; i.e. water year 2017 starts October 1, 2016 and ends September 30, 2017). Each zip folder contains 12 netcdf (.nc) files containing one month of hourly data each and are approximately 250mb. Model timestamps are in UTC time.The files contain the following data variables:EAST_MASK: binary mask of the watershed regionTAYLOR_MASK: binary mask of the watershed regionGLW downwelling longwave radiation (w/m2)HR_PRCP: Hourly Precipitation Rate (mm/hr). Includes all hydrometeors (solid+liquid). HFX NoahMP LSM total grid-cell modelled sensible heat flux (w/m2) [positive towards atmosphere]LH NoahMP LSM total grid-cell modelled latent heat flux (w/m2) [positive towards atmosphere; can be converted to ET]PSFC Surface Barometric Pressure (hPa)Q2 Two-meter specific humidity (kg/kg)SWDOWN Downwelling shortwave solar radiation (w/m2)SWNORM Terrain-normal downwelling shortwave radiation (w/m2)T2 Two-meter air temperature (deg K)U10 10-m U-component of wind velocity (m/s)V10 10m V-component of wind velocity (m/s)XLAT Latitude of grid-center point XLONG Longitude of grid-center point XTIME Model timestamp, **in UTC**

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

A Scale‐Dependent Analysis of the Barotropic Vorticity Budget in a Global Ocean Simulation

Abstract The climatological mean barotropic vorticity budget is analyzed to investigate the relative importance of surface wind stress, topography, planetary vorticity advection, and nonlinear advection in dynamical balances in a global ocean simulation. In addition to a pronounced regional variability in vorticity balances, the relative magnitudes of vorticity budget terms strongly depend on the length‐scale of interest. To carry out a length‐scale dependent vorticity analysis in different ocean basins, vorticity budget terms are spatially coarse‐grained. At length‐scales greater than 1,000 km, the dynamics closely follow the Topographic‐Sverdrup balance in which bottom pressure torque, surface wind stress curl and planetary vorticity advection terms are in balance. In contrast, when including all length‐scales resolved by the model, bottom pressure torque and nonlinear advection terms dominate the vorticity budget (Topographic‐Nonlinear balance), which suggests a prominent role of oceanic eddies, which are of km in size, and the associated bottom pressure anomalies in local vorticity balances at length‐scales smaller than 1,000 km. Overall, there is a transition from the Topographic‐Nonlinear regime at scales smaller than 1,000 km to the Topographic‐Sverdrup regime at length‐scales greater than 1,000 km. These dynamical balances hold across all ocean basins; however, interpretations of the dominant vorticity balances depend on the level of spatial filtering or the effective model resolution. On the other hand, the contribution of bottom and lateral friction terms in the barotropic vorticity budget remains small and is significant only near sea‐land boundaries, where bottom stress and horizontal viscous friction generally peak.

Khatri, Hemant↗
DOE OSTI2021

Deforestation strengthens atmospheric transport of mineral dust and phosphorus from North Africa to the Amazon

Phosphorus contained in atmospheric mineral dust aerosol originating from Africa fertilizes tropical forests in Amazonia. However, the mechanisms influencing this nutrient transport pathway remain poorly understood. Here we use the Community Earth System Model to investigate how large-scale deforestation affects mineral dust aerosol transport and deposition in the tropics. We find that the surface biophysical changes that accompany deforestation produce a warmer, drier and windier surface environment that perturbs atmospheric circulation and enhances long-range dust transport from North Africa to the Amazon. Tropics-wide deforestation weakens the Hadley circulation, which in turn, leads to a northward expansion of the Hadley cell and increases surface air pressure over the Sahara Desert. Additionally, the high pressure anomaly over the Sahara, in turn, increases northeasterly winds across North Africa and the tropical North Atlantic Ocean, which subsequently increases dust transport to the South America continent. We estimate that the annual atmospheric phosphorus deposition from dust significantly increases by 27% (P < 0.01) in the Amazon under a scenario of complete deforestation. These interactions exemplify how land surface changes can modify tropical nutrient cycling, which in turn, may have consequences for long-term changes in tropical ecosystem productivity and biodiversity.

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

Improved representation of laminar and turbulent sheet flow in subglacial drainage models

Subglacial hydrology models struggle to reproduce seasonal drainage patterns that are consistent with observed subglacial water pressures and surface velocities. We modify the standard sheet-flow parameterization within a coupled sheet–channel subglacial drainage model to smoothly transition between laminar and turbulent flow based on the locally computed Reynolds number in a physically consistent way (the ‘transition’ model). We compare the transition model to standard laminar and turbulent models to assess the role of the sheet-flow parameterization in reconciling observed and modelled water pressures under idealized and realistic forcing. Relative to the turbulent model, the laminar and transition models improve seasonal simulations by increasing winter water pressure and producing a more prominent late-summer water pressure minimum. In contrast to the laminar model, the transition model remains consistent with its own internal assumptions across all flow regimes. Based on the internal consistency of the transition model and its improved performance relative to the standard turbulent model, we recommend its use for transient simulations of subglacial drainage.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Tomographic optical emission spectroscopy of atmospheric pressure plasma interacting with complex surfaces

Plasma distribution in 3D space is heavily influenced by complex surfaces and the coupling interactions between plasma properties and interfacing material properties. For example, guided streamers that transition to surface ionization waves (SIWs) and propagate over structured dielectrics experience field enhancements that can lead to localized increases in ionization rates and complex 3D configurations that are difficult to analyze. Investigating these configurations requires techniques than can provide a more complete 3D picture. To help address this capability gap, a tomographic optical emission spectroscopy (tomo-OES) diagnostic system has been developed at Sandia National Laboratories that can resolve SIWs. The system includes four intensified cameras that measure the angular projections of the plasma light emission through bandpass filters. A dot calibration target co-registers each angular projection to the same voxel grid and an algebraic reconstruction technique (ART) recovers the light intensity at each voxel. An atmospheric pressure plasma jet (APPJ), provided by Peter Bruggeman, has been investigated and representative results are shown in Figure 1. Here, a bandpass filter was used to isolate emission from the N 2 second positive system (SPS) at 337.1 nm to capture the transition of the streamer to SIW on a planar dielectric surface (relative permittivity 3.3) located 3 mm below the APPJ [3]. The surface wave velocity was 3.5x10 4 (m/s), consistent with measurements made by Steven Shannon. Characterization of this APPJ will support the group effort of standing up a reproducible APPJ across institutions for applications such as liquid treatment, catalysis, and plasma aided combustion. Future work will investigate non-planar surfaces and eventually develop tomographic laser-induced fluorescence (tomo-LIF) approaches.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Study of a linear surface wave plasma source for tin removal in an extreme ultraviolet source

Tin deposition mitigation employs hydrogen radicals and ions, formed in a hydrogen plasma, to interact with tin to form tin hydride (SnH 4 ) in the gaseous state, which is then pumped away. Surface wave plasma (SWP) technology developed at Illinois generates hydrogen radicals and ions, resulting in tin etch rates that are high enough to keep extreme ultraviolet (EUV) lithographic tools clean. An advantage of an SWP antenna is the ability to generate a high density of hydrogen radicals and hydrogen ions directly at the desired etching location. In situ etching of tin enables high availability EUV tools by maintaining high reflectivity of the multilayer mirror of the collector. Additionally, the SWP is characterized with low ion energies and low electron temperature, such that the multilayer mirror does not suffer any damage from sputtering or implantation of hydrogen ions during operation. Here, experiments elucidating the fundamental processes of tin removal are conducted by varying pressure, power, surface temperature, and gas flow rate in order to observe the etch rate behavior. Our results have shown that the presence of hydrogen ions increases etch rates because ion bombardment weakens Sn–Sn bonds, which, in turn, allows for a higher rate of chemical etching by the radicals. The ion bombardment reduces the number of radicals needed to etch a single tin atom to the range of 10 2 –10 3 . The linear SWP antenna yields plasma densities on the order of 10 17 to 10 18 m -3 and radical densities on the order of 10 18 to 10 19 m -3 , allowing for greater utilization of ion etch enhancement. Etch rates of up to 200 nm/min have been achieved. The surface temperature of the samples is an important factor in the etching process such that the decrease in the surface temperature increases the etch rates and decreases the hydrogen desorption rates. In addition, a kinetic etch model is developed to explain the behavior of etch rates as a function of surface temperature. Furthermore, results from experiments performed in an Illinois NXE:3100 chamber will be discussed.

42 ENGINEERING↗
DOE OSTI2023

Predictive understanding of the surface tension and velocity of sound in ionic liquids using machine learning

Knowledge of the physical properties of ionic liquids (ILs), such as the surface tension and speed of sound, is important for both industrial and research applications. Unfortunately, technical challenges and costs limit exhaustive experimental screening efforts of ILs for these critical properties. Previous work has demonstrated that the use of quantum-mechanics-based thermochemical property prediction tools, such as the conductor-like screening model for real solvents, when combined with machine learning (ML) approaches, may provide an alternative pathway to guide the rapid screening and design of ILs for desired physiochemical properties. However, the question of which machine-learning approaches are most appropriate remains. In the present study, we examine how different ML architectures, ranging from tree-based approaches to feed-forward artificial neural networks, perform in generating nonlinear multivariate quantitative structure–property relationship models for the prediction of the temperature- and pressure-dependent surface tension of and speed of sound in ILs over a wide range of surface tensions (16.9–76.2 mN/m) and speeds of sound (1009.7–1992 m/s). The ML models are further interrogated using the powerful interpretation method, shapley additive explanations. We find that several different ML models provide high accuracy, according to traditional statistical metrics. The decision tree-based approaches appear to be the most accurate and precise, with extreme gradient-boosting trees and gradient-boosting trees being the best performers. However, our results also indicate that the promise of using machine-learning to gain deep insights into the underlying physics driving structure–property relationships in ILs may still be somewhat premature.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Computational flow modeling of triply periodic minimal surfaces as feed channel spacers in ultra-high pressure reverse osmosis applications

Triply periodic minimal surfaces (TPMS) are a special class of mathematical surfaces characterized by a high surface area-to-volume ratio. They have generated considerable interest in fields such as acoustics, heat transfer, and membrane-based filtration processes. This study evaluates the performance of four different TPMS designs—Schoen Gyroid, Schoen Crossed Layers of Parallels (CLP), Schoen Transverse Crossed Layers of Parallels (tCLP), and Schwarz-Primitive—when used as feed channel spacers under ultra-high pressure reverse osmosis (UHPRO) conditions, at approximately 200 bar. Our experimentally validated computational fluid dynamics model reveal different flow patterns within the feed channels for each of the four TPMS designs, leading to varying hydrodynamic and permeation properties. Under the simulated UHPRO conditions, the Gyroid and tCLP designs yield up to a 23% increase in average permeate velocity and a 14% reduction in average membrane-surface concentration relative to a non-woven spacer of the same porosity. Furthermore, the enhanced performance comes with an increased feed channel pressure drop, although it only constitutes less than 4% of the operating pressure when extrapolated for a meter-long membrane module. Additionally, the study analyzes the effects of varying inlet velocity and spacer porosity on membrane performance. Overall, this research provides valuable insights into the potential use of TPMS spacers in UHPRO applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

High Pressure and Two-Sided Mold Surface Solutions (CRADA Final Report)

This project provided surface solutions for highly loaded precision tooling relevant to the automotive industry. Previous development work in coatings for Big Area Additive Manufacturing (BAAM) has produced commercialized coatings for low temperature Acrylonitrile Butadiene Styrene (ABS) tools (TD Coat RT) as well as a soft coating for high temperature applications (TD Seal HT). The team developed these coatings and commercialized them during a prior Manufacturing Demonstration Facility (MDF) technical collaboration (NFE-15-05793). During the prior collaboration, commercialization testing was successfully performed by the Boeing and NAVAIR and resulted in an Awards for Composites Excellence (ACE), award at CAMX – The Composites and Advanced Materials Expo 2016. While this work was clearly successful, gaps in the technology were identified, that prevent widespread adoption of large-scale additive manufacturing in high pressure tooling applications prevalent in the automotive industry. In this project we focused on development of surface solutions for two-sided, compression molding tooling printed on a large-scale polymer AM system in an arbitrary build orientation. We have printed a single cavity extrusion compression molding mold using Polyphenylene sulfide/carbon fiber (PPS/CF) materials, 50% by weight CF samples. These processes are commonly used by Original Equipment Manufacturers (OEM) and Tier 1 suppliers for high volume automotive applications. Several OEMs have identified the need for such technology, indicating significant time and monetary savings could be possible if commercially available surface solutions for high pressure Additive Manufacturing (AM) tooling existed.

36 MATERIALS SCIENCE↗