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

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Advanced HVAC Humidity Control for Hot-Humid Climates

During this project we develop and validate a cost-effective, integrated control solution to improve humidity control and comfort for energy-efficient homes in hot-humid climates. This study focuses on developing a strategy that is effective, field tested, and practical for builders to install with minimal disruption to standard practices. A successful solution would simplify the transition to high-performance humidity control and be the basis for design and installation guidance. By relying on the central system as a starting point, the strategy employed minimizes system complexity and cost for builders, while improving comfort and operating cost for homeowners. The solution strategy was to coordinate the cooling, dehumidification, and ventilation functions of central, ducted HVAC systems to better control indoor humidity, improve occupant thermal comfort, and capture energy savings. The primary strategic goals were to: (1) optimize dehumidification by the central air-conditioning system, particularly during part-load conditions, using conventional equipment with modified control settings and lower system airflows; (2) maximize ventilation during heating/cooling on-cycles, to “bank” and condition outdoor ventilation air, and minimize ventilation during off-cycles; (3) quantify the effectiveness and energy impact of the dehumidification and ventilation strategies, while identifying a metric that would be useful to evaluate latent effectiveness. For the test houses in our study, located in Richmond Hill, Georgia; Houston, Texas; and Monroe, Louisiana we observed: (1) the indoor humidity did not exceed 60% RH during the monitored cooling season for 99% of the time in Richmond Hill, 96% of the time in Houston, and 90% of the time in Monroe; (2) the dehumidification strategy improved the steady-state latent capacity of the HVAC system at design conditions by 16% to 49% at the Houston test house and by 28% to 71% at the Monroe test house, depending on which mode the system was operating in; and (3) the good results at the test houses were primarily due to the amount of time the air-conditioning system operated in ramping or dehumidification modes, or both, particularly during the early cooling season. This study demonstrates that air conditioners or heat pumps with a single-stage compressor can provide good humidity control without the need for a two-stage or variable-stage compressor system. The airflow and control settings for ramping and dehumidification modes are critical to control indoor humidity in hot-humid climates, particularly during part-load and shoulder season conditions. The dehumidification strategy used in this study did not jeopardize the mechanical reliability of the cooling equipment. The strategies used in this study are applicable across various equipment brands, models, and efficiency levels, and also applicable to a broad range of homes in hot-humid climates. Results will vary by specific equipment, location, and house configuration and construction.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2017

Challenges and Recent Developments of Neutron Non-Destructive Assay with UO{sub 2}F{sub 2}-Bearing Materials - 17336

In the enrichment process of an operating Gaseous Diffusion Plant (GDP), such as the Portsmouth and Paducah facilities, UF6 gas will immediately hydrolyze forming the chemical compound UO{sub 2}F{sub 2} (Uranyl Fluoride). This mostly happens in Alumina (Al{sub 2}O{sub 3}) traps where the UF6 adsorbs to moistened Alumina pellets forming a UO{sub 2}F{sub 2} layer around the pellet. Similarly, NaF.UF{sub 6} absorption traps produce the complex Na{sub 2}UF{sub 8} which also hydrolyzes when exposed to moist air. UO{sub 2}F{sub 2} can also be formed in many other processes where UF6 gas comes into contact with moisture within structures and objects such as pipes, converters compressors and coolers. When the structures are refurbished, or designated for D and D, UO{sub 2}F{sub 2}-bearing objects are generated both in situ and ex situ requiring fissile (U-235) characterization. In addition, ex situ waste streams are generated when UO{sub 2}F{sub 2}-bearing materials are placed in drummed or boxed waste containers. Gamma spectroscopy Non-Destructive Assay (NDA) is commonly utilized to characterize UO{sub 2}F{sub 2}-bearing waste but generally has high associated Total Measurement Uncertainties (TMU's) and, in some cases, Data Quality Objectives (DQO's) cannot be met. In addition, high UO{sub 2}F{sub 2} mass loadings, such as hold-up materials, require gamma modeling when infinitely thick to the Uranium energy lines. A common neutron NDA technique, or method, is to exploit the neutrons generated from the F-19(a, n)Na-22 reaction which has an appreciable reaction cross-section. The isotopes of Uranium are a-emitters, and, in particular, U-234 has a significantly higher a-decay reaction cross-section leading to a significant relative neutron Specific Activity (nSA). Neutron NDA is appealing since, in some cases, it has potentially lower TMU's than gamma NDA and neutron detector slabs facilitate surrounding large, complex-shaped, objects. Characterizing UO{sub 2}F{sub 2}-bearing waste for fissile content using neutrons generated from U-234, requires the U-235/U-234 ratio as well as the enrichment as well as the corresponding nSA's. It is also noted that U-238 has a considerable, relative, spontaneous fission nSA and this is a higher concern for low-enrichments where the mass of U-238 dominates. Additional neutron interfering elements include cosmic-ray induced spallation within the objects and background from other, in situ, UO{sub 2}F{sub 2}-bearing objects. In this paper we present the challenges and recently developed hardware and algorithmic strategies for quantifying fissile mass both in situ and ex situ using neutron NDA that works in conjunction to gamma spectroscopy NDA, or process knowledge, for objects and drummed/boxed waste containing UO{sub 2}F{sub 2}-bearing materials leading to minimal TMU's and achievable DQO's. (authors)

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2016

A constitutive mechanical model for gas hydrate bearing sediments incorporating inelastic mechanisms

Gas hydrate bearing sediments (HBS) are natural soils formed in permafrost and sub-marine settings where the temperature and pressure conditions are such that gas hydrates are stable. If these conditions shift from the hydrate stability zone, hydrates dissociate and move from the solid to the gas phase. Hydrate dissociation is accompanied by significant changes in sediment structure and strongly affects its mechanical behavior (e.g., sediment stiffenss, strength and dilatancy). The mechanical behavior of HBS is very complex and its modeling poses great challenges. Here this paper presents a new geomechanical model for hydrate bearing sediments. The model incorporates the concept of partition stress, plus a number of inelastic mechanisms proposed to capture the complex behavior of this type of soil. This constitutive model is especially well suited to simulate the behavior of HBS upon dissociation. The model was applied and validated against experimental data from triaxial and oedometric tests conducted on manufactured and natural specimens involving different hydrate saturation, hydrate morphology, and confinement conditions. Particular attention was paid to model the HBS behavior during hydrate dissociation under loading. The model performance was highly satisfactory in all the cases studied. It managed to properly capture the main features of HBS mechanical behavior and it also assisted to interpret the behavior of this type of sediment under different loading and hydrate conditions.

42 ENGINEERING↗
DOE OSTI2020

Amorphous Pd-Loaded Ti 4 O 7 Electrode for Direct Anodic Destruction of Perfluorooctanoic Acid

In this work we present a novel Ti 4 O 7 -based electrode loaded with amorphous Pd clusters that achieve efficient anodic destruction of perfluorooctanoic acid (PFOA), a persistent water pollutant with significant environmental and human health concerns. These amorphous Pd clusters were characterized by the disordered, noncrystalline arrangement of Pd single atoms in close proximity, in contrast to crystalline Pd nanoparticles that have been often employed to tailor the electronic properties of an electrode. We found that the Ti 4 O 7 electrode loaded with amorphous Pd clusters significantly outperformed the Ti 4 O 7 electrode loaded with crystalline Pd particles due to enhanced electron transfer through dominant Pd–O bonds. Combined with the efficient binding of PFOA and its degradation intermediates to the fluorinated electrode surface, this electrode was capable of mineralizing PFOA and releasing fluoride as F – . The reaction pathway was found to proceed without involving reactive oxygen species and therefore was not quenched by common anions in complex natural water systems such as chloride ions.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Tailoring the Toughening Effects in Two-Dimensional Nanomaterial-Reinforced Ceramic Matrix Composites

Abstract Ceramic matrix composites (CMCs) reinforced by two-dimensional (2D) nanomaterials have shown extraordinary load-carrying capacities, even in the harsh environments required by emerging applications. Their exceptional mechanical performance, especially fracture toughness, primarily arises from their heterogeneous microstructures. The deliberate dispersion of 2D reinforcements enables toughening mechanisms that are extrinsic to the matrix and thus endows the composites with substantial resistance to catastrophic failure. However, the incomplete understanding of the fracture behavior of such nanocomposites, especially the complex energy dissipation process of the matrix/reinforcement interface, limits the development of stronger and tougher CMCs. To overcome these limitations, we investigate crack deflection and energy dissipation in nanocomposites using an extended cohesive shear-lag model. This new model accounts for interfacial debonding and friction, which critically control the toughening of nanocomposites. Our analysis provides mechanistic insights for optimizing the toughening effects of CMCs.

Mechanics↗
DOE OSTI2024

Description of FY25 Theory and Simulation Performance Target: Development of an integrated modeling framework for fusion reactor design and assessment

The urgency to deliver fusion power is growing now more than ever, with increasing pressure for both public programs and private companies to meet milestones timelines and overcome significant remaining technical challenges to ensure growth of a nascent fusion industry in time to meet rapidly growing clean energy demands. With incredible advancements in computation and years of investment in fusion model development and validation, integrated modeling is poised to fill a key role in accelerating the timeline to a fusion pilot plant (FPP). Future fusion pilot plants will operate in regimes far beyond current experience, and device design will rely on physics-based prediction and extrapolation. Many concepts will also rely on simulation to assess safety (shielding, tritium management, materials activation and lifetimes), economics and scalability before the decision to build. Importantly, integrated simulation can be used to reveal and solve the complexities of system integration that may otherwise not be apparent in physical components or models developed in isolation. New experimental test facilities that produce relevant conditions to validate and resolve key technical challenges for various subsystems (materials, blankets, fuel cycle, etc.) have been repeatedly called for by the fusion community but are not yet realized. Integrated modeling has an important role in identifying realistic load conditions (thermal, electromagnetic, plasma, neutron and photon loads, etc.) and defining the components and experiments for these test facilities in order to ensure meaningful validation that sufficiently reduces modeling uncertainties and technical risk for the full integrated reactor. The Fusion REactor Design and Assessment (FREDA) SciDAC project is building a component-based integrated modeling framework & data structure to enable self-consistent, multi-fidelity, iterative optimization workflows for the fusion reactor design process. FREDA aims to shorten the time to viable designs by providing a set of flexible workflows to support the various stages of the design process using an integrated model hierarchy, ranging from the simple analytic descriptions to the highest fidelity, theory-based plasma and engineering modeling developed by the fusion and fission communities. These tools are expected to be needed for timely support of FPP design in the milestone program and in the FIRE collaboratives. The plasma simulation backbone of FREDA is IPS-FASTRAN with newly developed coupled Core-Edge Pedestal-SOL (CESOL) workflows, which is being extended to the far-SOL region up to the plasma facing components. FREDA incorporates the FERMI engineering modeling suite and will enable self-consistent evaluation of the thermal shields, limiters, blanket, magnets, and other surrounding structures with predictions of temperatures, erosion, dpa, activation, tritium generation and transport, creep, corrosion, material degradation, etc. Parametric generation of 3D CAD enables rapid iteration of component geometry in response to plasma and loading specifications.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2018

Virologic outcome among patients receiving antiretroviral therapy at five hospitals in Haiti

Introduction Viral load (VL) assessment is the preferred method for diagnosing and confirming virologic failure for patients on antiretroviral therapy (ART). We conducted a retrospective cross-sectional study to evaluate the virologic suppression rate among patients on ART for 6 months in five hospitals around Port-au-Prince, Haiti. Methods Plasma VL was measured and patients with VL <1,000 copies/mL were defined as virologically suppressed. A second VL test was performed within at least six months of the first test. Factors associated with virologic suppression were analyzed using logistic regression models accounting for site-level clustering using complex survey procedures. Results Data were analyzed for 2,313 patients on ART for six months or longer between July 2013 and February 2015. Among them, 1,563 (67.6%) achieved virologic suppression at the first VL test. A second VL test was performed within at least six months for 718 (31.0%) of the patients. Of the 459 patients with an initial HIV-1 RNA <1,000 copies/mL who had a second VL performed, 394 (85.8%) maintained virologic suppression. Virologic suppression was negatively associated with male gender (adjusted odds ratio [aOR]: 0.80, 95% CI: 0.74– 0.0.86), 23 to 35 months on ART (aOR:0.72[0.54–0.96]), baseline CD4 counts of 201–500 cells/mm 3 and 200 cells/mm 3 or lower (aORs: 0.77 [0.62–0.95] and 0.80 [0.66–0.98], respectively), poor adherence (aOR: 0.69 [0.59–0.81]), and TB co-infection (aOR: 0.73 [0.55–0.97]). Conclusions This study showed that over two-thirds of the patients in this evaluation achieved virologic suppression after six months on ART and the majority of them remained suppressed. These results reinforce the importance of expanding access to HIV-1 viral load testing in Haiti for monitoring ART outcomes.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2018

Fabrication and Properties of Composite Artificial Muscles Based on Nylon and a Shape Memory Alloy

This paper focuses on the design, fabrication and investigation of the mechanical properties of new artificial muscles formed by twisting and annealing. The artificial muscles designed by twisting nylon have become a popular topic in the field of smart materials due to their high mechanical performance with a large deformation and power density. However, the complexity of the heating and cooling system required to control the nylon muscle is a disadvantage, so we have proposed a composite artificial muscle for providing a direct electricity-driven actuation by integrating nylon and a shape memory alloy (SMA). In this paper, the design and fabrication process of these composite artificial muscles are introduced before their mechanical properties, which include the deformation, stiffness, load and response, are investigated. The results show that these composite artificial muscles that integrate nylon and a SMA provide better mechanical properties and yield up to a 44.1% deformation and 3.43 N driving forces. The good performance and direct electro-thermal actuation make these composite muscles ideal for driving robots in a method similar to human muscles.

36 MATERIALS SCIENCE↗
DOE OSTI2019

X-ray characterization of the micromechanical response ahead of a propagating small fatigue crack in a Ni-based superalloy

The small fatigue crack (SFC) growth regime in polycrystalline alloys is complex due to the heterogeneity in the local micromechanical fields, which result in high variability in crack propagation directions and growth rates. Here in this study, we employ a suite of techniques, based on high-energy synchrotron-based X-ray experiments that allow us to track a nucleated crack, propagating through the bulk of a Ni-based superalloy specimen during cyclic loading. Absorption contrast tomography is used to resolve the intricate 3D crack morphology and spatial position of the crack front. Initial near-field high-energy X-ray diffraction microscopy (HEDM) is used for high-resolution characterization of the grain structure, elucidating grain orientations, shapes, and boundaries. Cyclic loading is periodically interrupted to conduct far-field HEDM to determine the centroid position, average orientation, and average lattice strain tensor for each grain within the volume of interest. Reciprocal space analysis is used to further examine the deformation state of grains that plasticize in the vicinity of the crack. Analysis of the local micromechanical state in the grains ahead of the crack front is used to rationalize the advancing small crack path and growth rate. Specifically, the most active slip system in a grain, determined by the maximum resolved shear stress, aligns with the crack growth direction; and the degree of microplasticity ahead of the crack tip helps to identify directions for potential occurrences of crack arrest or propagation. The findings suggest that both the slip system level stresses and microplasticity events within grains are necessary to get a complete description of the SFC progression. Further, this detailed dataset, produced by a suite of X-ray characterization techniques, can provide the necessary validation, at the appropriate length-scale, for SFC models.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Plant Reload Optimization (prlo)

The PRLO framework is built on a modular and extensible architecture that tightly couples advanced evolutionary optimization algorithms with nuclear fuel depletion solvers (i.e., nuclear physics neutronics code). It supports exploring complex, high-dimensional design spaces constrained by user-specified operational, safety, and economic constraints. Objectives such as minimizing fresh fuel enrichment, flattening radial and axial power distributions, and maximizing discharge burnup are evaluated. PRLO’s equilibrium cycle optimization capability enables the identification of core configurations that maintain fuel cycle sustainability over extended planning horizons. Its integration with the RAVEN platform facilitates optimization of loading patterns or fuel shuffling schemes across multiple cycles. The interface with SIMULATE, a licensed industry-standard nodal code developed by Studsvik, ensures accurate neutronic and thermal-hydraulic feedback for reactor core design. PRLO’s automated workflow engine supports iterative design refinement, enabling utilities to streamline core design processes and meet evolving performance and regulatory targets.

Kim, Junyung [Idaho National Laboratory] (00090005↗
DOE OSTI2022

GLUE Code: A framework handling communication and interfaces between scales

Many scientific applications are inherently multiscale in nature. Such complex physical phenomena often require simultaneous execution and coordination of simulations spanning multiple time and length scales. This is possible by combining expensive small-scale simulations (such as molecular dynamics simulations) with larger scale simulations (such continuum limit/hydro solvers) to allow for considerably larger systems using task and data parallelism. However, the granularity of the tasks can be very large and often leads to load imbalance. Traditionally, we use approximations to streamline the computation of the more costly interactions and this introduces trade-offs between simulation cost and accuracy. In recent years, the available computational power and the advances in machine learning have made computing these scale-bridging interactions and multiscale simulations more feasible. One driving application has been plasma modeling in inertial confinement fusion (ICF), which is fundamentally multiscale in nature. This requires deep understanding of how to extrapolate microscopic information into macroscopically relevant scales. For example, in ICF one needs an accurate understanding of the connection between experimental observables and the underlying microphysics. The properties of the larger scales are often affected by the microscale behavior incorporated usually into the equations of state and ionic and electronic transport coefficients (Liboff, 1959; Rinderknecht et al., 2014; Rosenberg et al., 2015; Ross et al., 2017). Instead of incorporating this information using reliable molecular dynamics (MD) simulations, one often needs to use theoretical models, due to the inability of MD to reach engineering scales (Glosli et al., 2007; Marinak et al., 1998). One approach to resolve this issue is by coupling two MD simulations of different scales via force interpolation, e.g., the AdResS method (Krekeler et al., 2018; Nagarajan et al., 2013). Another approach, which we will pursue in the scope of this work, is by enabling scale bridging between MD simulations and meso/macro-scale models through the development and support of application programming interfaces that these different applications can interact through.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2019

Asynchronous Navier-Stokes Solver on 3D Unstructured Grids for the Exascale Era

This project has developed multiple fluid dynamics solvers for complex 3D flows using fully asynchronous distributed-memory task-parallel algorithms on top of the Charm++ runtime system. The algorithms solve the Euler or Navier-Stokes equations of compressible flows using unstructured tetrahedron meshes with optional solution-adaptive mesh-, and polynomial-order refinement. We have demonstrated excellent strong scaling up 50K compute cores and the benefits of Charm++’s automatic load balancing.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Allosterically coupled conformational dynamics in solution prepare the sterol transfer protein StarD4 to release its cargo upon interaction with target membranes

Complex mechanisms regulate the cellular distribution of cholesterol, a critical component of eukaryote membranes involved in regulation of membrane protein functions directly and through the physiochemical properties of membranes. StarD4, a member of the steroidogenic acute regulator-related lipid-transfer (StART) domain (StARD)-containing protein family, is a highly efficient sterol-specific transfer protein involved in cholesterol homeostasis. Its mechanism of cargo loading and release remains unknown despite recent insights into the key role of phosphatidylinositol phosphates in modulating its interactions with target membranes. We have used large-scale atomistic Molecular dynamics (MD) simulations to study how the dynamics of cholesterol bound to the StarD4 protein can affect interaction with target membranes, and cargo delivery. We identify the two major cholesterol (CHL) binding modes in the hydrophobic pocket of StarD4, one near S136&S147 (the Ser-mode), and another closer to the putative release gate located near W171, R92&Y117 (the Trp-mode). We show that conformational changes of StarD4 associated directly with the transition between these binding modes facilitate the opening of the gate. To understand the dynamics of this connection we apply a machine-learning algorithm for the detection of rare events in MD trajectories (RED), which reveals the structural motifs involved in the opening of a front gate and a back corridor in the StarD4 structure occurring together with the spontaneous transition of CHL from the Ser-mode of binding to the Trp-mode. Further analysis of MD trajectory data with the information-theory based NbIT method reveals the allosteric network connecting the CHL binding site to the functionally important structural components of the gate and corridor. Mutations of residues in the allosteric network are shown to affect the performance of the allosteric connection. These findings outline an allosteric mechanism which prepares the CHL-bound StarD4 to release and deliver the cargo when it is bound to the target membrane.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Sludge Removal: Success and Partnership with T Plant - 20510

U.S. DOE contractor CH2M Hill Plateau Remediation Company (CHPRC) has safely and efficiently managed the removal of highly radioactive sludge from the 105-K West Reactor fuel storage basin (105- KW Basin) near the Columbia River. In mid-September 2019, sludge retrieval was completed after 21 storage containers were safely loaded with highly radioactive sludge and transported approximately 13 miles from the 105-KW Basin to T Plant, located in the 200 West Area on the Central Plateau of the Hanford Site. Sludge removal represents the last major source term reduction necessary before the K West Reactor and fuel storage basin can transition to closure activities in preparation for final deactivation and demolition. The technical complexity of the sludge retrieval process, coupled with the challenging physical and radiological characteristics of the waste, necessitated a methodical and deliberate approach using unique design and operational solutions to safely conduct the work. This challenge was further complicated by the need to plan and conduct the work in two separate facilities, each subject to the controls and requirements of its own nuclear facility safety basis. The project overcame these challenges through creating an integrated team that actively engaged, communicated and coordinated each phase of the project to ensure successful completion. This paper will cover how these key elements of the Sludge Removal Project led to its success: - Integrating project planning and management; - Lessons learned from design and construction; - Preparing for a successful campaign (lessons learned from testing and start-up); - Lessons learned from operating in two separate facilities, transporting sludge containers on the Hanford Site and ensuring compliance with a range of regulatory and safety basis requirements. The establishment of an integrated group spanning two facilities and multiple organizations created a team capable of overcoming the challenges necessary to successfully plan and execute the sludge retrieval mission. Sharing lessons learned from this successful project can enhance the ability of teams across the DOE complex to successfully plan and execute complex projects. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

NMPWG Discussion on - Tracking Initial SAVY-4000 Population and Lifetime Extensions Across the DOE Complex [Slides]

As part of LANL's SAVY-4000 Lifetime Extension efforts, the question of "when does a SAVY's life start?" was posed. The unfortunate answer that can be agreed upon is to start the life based on the serial number which includes month and date of manufacture. For example - 012405025 was a 5QT container produced in January of 2024. This is not the most efficient way to track age of a container if extended lifetimes and usage are desired. Other possibilities include: Tracking on first-use date (date it was loaded); Tracking when it was sold from the warehouse to an operating group for use; Tracing the amount of time nuclear material is within the container (LANMAS transaction histories).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Pressure loadings in a rectangular cavity with and without a captive store

Simulations of the flow past a rectangular cavity containing a model captive store are performed using a hybrid Reynolds-averaged Navier–Stokes/large-eddy simulation model. Calculated pressure fluctuation spectra are validated using measurements made on the same configuration in a trisonic wind tunnel at Mach numbers of 0.60, 0.80, and 1.47. The simulation results are used to calculate unsteady integrated forces and moments acting on the store. Spectra of the forces and moments, along with correlations calculated for force/moment pairs, reveal that a complex relationship exists between the unsteady integrated forces and the measured resonant cavity modes, as indicated in the cavity wall pressure measurements. As a result, the structure of identified cavity resonant tones is examined by visualization of filtered surface pressure fields.

42 ENGINEERING↗
DOE OSTI2023

Carbon Additive Manufacturing with a Near-Replica “Green-to-Brown” Transformation

Nanocomposites containing nanoscale materials offer exciting opportunities to encode nanoscale features into macroscale dimensions, which produces unprecedented impact in material design and application. However, conventional methods cannot process nanocomposites with a high particle loading, as well as nanocomposites with the ability to be tailored at multiple scales. A composite architected mesoscale process strategy that brings particle loading nanoscale materials combined with multiscale features including nanoscale manipulation, mesoscale architecture, and macroscale formation to create spatially programmed nanocomposites with high particle loading and multiscale tailorability is reported. The process features a low-shrinking (<10%) “green-to-brown” transformation, making a near-geometric replica of the 3D design to produce a “brown” part with full nanomaterials to allow further matrix infill. Here, this demonstration includes additively manufactured carbon nanocomposites containing carbon nanotubes (CNTs) and thermoset epoxy, leading to multiscale CNTs tailorability, performance improvement, and 3D complex geometry feasibility. The process can produce nanomaterial-assembled architectures with 3D geometry and multiscale features and can incorporate a wide range of matrix materials, such as polymers, metals, and ceramics, to fabricate nanocomposites for new device structures and applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Hybrid of multi‐dimensional fillers for thermally enhanced polyamide 12 composites fabricated by selective laser sintering

Abstract Selective laser sintering (SLS) is an additive manufacturing technology that can provide a novel strategy to manufacture complex polymer‐based composites with tailored properties. In this study, polyamide 12 (PA12) composite powders based on Al 2 O 3 , boron nitride (BN), and carbon nanotubes (CNTs) were prepared via a two‐step mixing approach. Morphology characterization techniques indicated that the fillers were uniformly dispersed in the PA12 matrix as expected. Under the optimum 3D‐printing parameters, the fabrication of SLS parts with high filler loading could be obtained. With 40 wt% Al 2 O 3 , 8 wt% BN, and 2 wt% CNT hybrid fillers, the thermal conductivity of PA12 composites could reach 1.09 W/mK. It could be attributed to the synergistic effect of multi‐dimensional fillers to form dense and continuous thermal conduction paths. The factors influencing the performance of PA12 composites such as melting and crystallization behaviors, dielectric properties, and mechanical properties were also discussed. The results show that these composites have favorable dielectric and mechanical properties. Overall, the PA12 composites fabricated by SLS technology in this study exhibit excellent thermal management ability.

Yuan, Yue↗