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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 1,099 records · Page 61
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Reactive transport of uranium in fractured crystalline rock: Upscaling in time and distance

In this study, batch adsorption and breakthrough column experiments were conducted to evaluate uranium transport through altered material that fills fractures in a granite rock system at the Grimsel Test Site in Switzerland at pH 6.9 and 7.9. The role of adsorption and desorption kinetics was evaluated with reactive transport modeling by comparing one-, two-, and three-site models. Emphasis was placed on describing long desorption tails that are important for upscaling in time and distance. The effect of increasing pH in injection solutions was also evaluated. For pH 6.9, a three-site model with forward rate constants between 0.07 and 0.8 ml g –1 h –1 , reverse rate constants between 0.001 and 0.06 h –1 , and site densities of 1.3, 0.104, and 0.026 μmol g –1 for ‘weak/fast’, ‘strong/slow’, and ‘very strong/very slow’ sites provided the best fits. For pH 7.9, a three-site model with forward rate constants between 0.05 and 0.8 mL g –1 h –1 , reverse rate constants between 0.001 and 0.6 h –1 , and site densities of 1.3, 0.039, and 0.013 μmol g –1 for a ‘weak/fast’, ‘strong/slow’, and ‘very strong/very slow’ sites provided the best fits. Column retardation coefficients (R d ) were 80 for pH 6.9 and 10.3 for pH 7.9. Model parameters determined from the batch and column experiments were used in 50 year large-scale simulations for continuous and pulse injections and indicated that a three-site model is necessary at pH 6.9, although a K d -type equilibrium partition model with one-site was adequate for large scale predictions at pH 7.9. Batch experiments were useful for predicting early breakthrough times in the columns while column experiments helped differentiate the relative importance of sorption sites and desorption rate constants on transport.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Global Feedback Simulator

GFS is a simulation engine that is used for the characterization of Accelerator performance parameters based on the machine layout, configuration and noise sources. It combines extensively tested Feedback models with a longitudinal phase space tracking simulator along with the interaction between the two via beam-based feedback using a computationally efficient simulation engine. The models include beam instrumentation, considerations on loop delays for in both the R and beam-based feedback loops, as well as the ability to inject noise (both correlated and uncorrelated) at different points of the machine including a full characterization of the electron gun performance parameters.

Doolittle, Lawrence↗
DOE OSTI2018

Recommendations for Filler Material Composition and Delivery Method for Bench-Scale Testing

This report supplements Joint Workplan on Filler Investigations for DPCs (SNL 2017) providing new and some corrected information for use in planning Phase 1 laboratory testing of slurry cements as possible DPC fillers. The scope description is to "Describe a complete laboratory testing program for filler composition, delivery, emplacement in surrogate canisters, and post-test examination. To the extent possible specify filler material and equipment sources." This report includes results from an independent expert review (Dr. Arun Wagh, retired from Argonne National Laboratory and contracted by Sandia) that helped to narrow the range of cement types for consideration, and to provide further guidance on mix variations to optimize injectability, durability, and other aspects of filler performance.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Neural network model of neutral beam injection in the EAST tokamak to enable fast transport simulations

The neutral beam injection (NBI) system in EAST produces energetic neutral particles, which collide with electrons and ions in tokamak plasmas and heat the plasmas through Coulomb collisions. Moreover, it drives a non-inductive source of current, due to the charge-exchange collision between neutral particles and ions, and injects toroidal torque, which generates a toroidal rotation of the plasma. The effect caused by the NBI system, such as plasma heating, current drive, total neutron rate, momentum transfer, and shine-through, are modeled by a comprehensive module called NUBEAM. However, NUBEAM is computationally intensive since it relies on Monte Carlo methods. In this work, a neural network model has been developed as a surrogate model for NUBEAM in EAST. The database for neural-network model training, validation and testing is generated by running TRANSP for experimental discharges from recent EAST campaigns (after the latest NBI upgrade) while using the NUBEAM module. Simulation results illustrate that the trained neural network has the capability of replicating the predictions made by NUBEAM while demanding a significantly shorter execution time. Finally, these results indicate that surrogate models like the one proposed in this work could enable fast transport simulations for EAST after integrating them into a control-oriented predictive code such as COTSIM.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Density wavenumber spectrum measurements, synthetic diagnostic development, and tests of quasilinear turbulence modeling in the core of electron-heated DIII-D H-mode plasmas

Abstract Measurements of the turbulent density wavenumber spectrum, δ n ˆ e ( k ⊥ ) , using the Doppler Back-Scattering (DBS) diagnostic are reported from DIII-D H-mode plasmas with electron cyclotron heating as the only auxiliary heating method. These electron-heated plasmas have low collisionality, ν e ∗ < 1 , T e / T i > 1 , and zero injected torque—a regime expected to be relevant for future fusion devices. We probe density fluctuations in the core ( ρ ≈ 0.7) over a broad wavenumber range, 0.5 ⩽ k ⊥ ⩽ 16 cm −1 ( 0.1 ⩽ k ⊥ ρ s ⩽ 5 ), to characterize plasma instabilities and compare with theoretical predictions. We present a novel synthetic DBS diagnostic to relate the back-scattered power spectrum, P s ( k ⊥ ) —which is directly measured by DBS—to the underlying electron density fluctuation spectrum, δ n ˆ e ( k ⊥ ) . The synthetic DBS P s ( k ⊥ ) spectrum is calculated by combining the SCOTTY beam-tracing code with a model δ n ˆ e ( k ⊥ ) predicted either analytically or numerically. In this work we use the quasi-linear code Trapped Gyro-Landau Fluid (TGLF) to approximate the δ n ˆ e ( k ⊥ ) spectrum. We find that TGLF, using the experimental profiles, is capable of closely reproducing the DBS measurements. Both the DBS measurements and the TGLF-DBS synthetic diagnostic show a wavenumber spectrum with variable decay. The measurements show weak decay ( k −0.6 ) for k < 3.5 cm −1 , with k −2.6 at intermediate- k ( 3.5 ⩽ k ⩽ 8.5 cm −1 ), and rapid decay ( k −9.4 ) for k > 8.5 cm −1 . Scans of physics parameters using TGLF suggest that the normalized ∇ T e scale-length, R / L T e , is an important factor for distinguishing microturbulence regimes in these plasmas. A combination of DBS observations and TGLF simulations indicate that fluctuations remain peaked at ITG-scales (low k ) while R / L T e -driven TEM/ETG-type modes (intermediate/high k ) are marginally sub-dominant.

synthetic diagnostics↗
DOE OSTI2017

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

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

36 MATERIALS SCIENCE↗
DOE OSTI2021

A learning-augmented approach for AC optimal power flow

Because of the high nonlinearity of AC optimal power flow (OPF), numerous efforts have been made in recent decades to find efficient methods. Machine learning (ML) has proven to significantly reduce the computational costs in many real-world problems. Thus, this paper develops a learning-augmented method for solving AC OPF, which integrates both power network equations and ML to yield near-optimal solutions. More specifically, ML models are developed to first predict bus voltage magnitudes and angles. Then, physics-based network equations are employed to calculate the power injection at different buses. Three ML algorithms, i.e., random forest, multi-target decision tree, and extreme learning machine, are explored and compared. To evaluate the efficiency of the proposed learning-augmented AC OPF solver, the MATPOWER Interior Point Solver is adopted as a baseline. Case studies on both 500-bus and 4918-bus test networks show that the proposed learning-augmented method has reduced the computational time by 15–100 times depending on the network size with a minimal loss in optimality.

42 ENGINEERING↗
DOE OSTI2023

The Dynamics of Megafire Smoke Plumes in Climate Models: Why a Converged Solution Matters for Physical Interpretations

As the climate system warms, megafires have become more frequent with devastating effects. A byproduct of these events is the creation of smoke plumes that can rise into the stratosphere and spread across the globe where they reside for many months. To gain a deeper understanding of the plume dynamics, global climate simulations of a megafire were performed at a wide range of grid spacings from 2.0° down to 7 km, including a 7 km nonhydrostatic experiment. The analysis focuses on how the resolved dynamics affects the specification of the plume characteristics such as injection height and black carbon (BC) mass. Prior studies initialize the smoke plume at one or a few grid points and this is shown here to produce severely dissipative dynamics. In order to validate such simulations with observations, enhancements of the plume characteristics to offset the dissipation is necessary. Using a numerically converged simulation, sensitivity tests show that to approximate the observed stratospheric lifetime, a reduction in BC fraction by 50% is necessary for external mixtures. The vorticity dynamics of the plume is also analyzed with a Lagrangian budget to understand the mechanisms responsible for the evolution of a collocated anticyclonic vortex. The results can be distilled down into a simple conceptual model. As the plume rises, the air diverges at the top of the updraft where the largest concentrations of smoke are found. This divergence induces a dilution of the background cyclonic absolute vorticity producing an anticyclonic vortex. Vortex decay occurs from opposite arguments.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2018

Integrated plasma facing component calorimetry for measurement of shot integrated deposited energy in the NSTX-U

Here, the upgrade to the National Spherical Torus eXperiment (NSTX-U) increases the injected neutral beam power up to 12 MW and the plasma current up to I p = 2 MA for plasma durations up to 5 s. The graphite plasma facing components have been re-designed to handle greater heat and energy fluxes than were seen in NSTX using a castellated design. We present the experimental testing and validation of a castellated graphite target, similar to the prototype tile design, instrumented with thermocouples at various depths in the castellation. During testing, incident heat flux is provided by a programmed electron beam system and surface temperatures are measured via infrared thermography directly viewing the target surface. It was found that the thermocouple response scaled linearly with the measured surface temperature rise regardless of thermocouple depth in the castellation. A sensitivity of 14.3 °C/kJ of deposited energy was found when treating individual castellations as a semi-infinite solid.

47 OTHER INSTRUMENTATION↗
DOE OSTI2015

Southeast Regional Carbon Sequestration Partnership (SECARB): Analyze Data Collected, Revise Surface Monitoring Plan to Maximize Benefit and Continue Data Collection

Objectives of the shallow groundwater study at the Cranfield site since 2008, as a part of the SECARB Phase III early test, were to 1) assess potential impacts of CO 2 leakage on groundwater quality; and 2) test and develop monitoring technologies for CO 2 leakage detection. The study did not intend to seek CO2 leakage signals via monitoring groundwater chemistry in the Cranfield shallow aquifer. Instead, quarterly or semi-annually groundwater sampling from the shallow aquifer was used to characterize spatial and temporal variations in geochemical parameters because CO 2 injection into the deep reservoir started in 2008.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Using Controlled-Source Electromagnetic (CSEM) for CO 2 Storage Monitoring in the North Dakota CarbonSAFE Project

Conference presentation for International Meeting for Applied Geophysics & Energy (IMAGE), September 26 – October 1, 2021, Denver, CO. Geophysical methods are key for characterizing the geologic formations to store CO 2 and monitor the injected CO 2 over time to ensure containment. In the integrated multimeasurement geophysical approach considered for this project, it is expected that the controlled-source electromagnetic (CSEM) method is a strong contributor to mapping the CO 2 movement. A feasibility study of the CSEM method, including 1D and 3D modeling and a field noise test, was conducted to determine its effectiveness in monitoring CO 2 in the Broom Creek and Deadwood Formations. The study results demonstrate that the CSEM method can be used for CO 2 storage monitoring in the study area.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2017

Method and apparatus to produce high specific impulse and moderate thrust from a fusion-powered rocket engine

A system and method for producing and controlling high thrust and desirable specific impulse from a continuous fusion reaction is disclosed. The resultant relatively small rocket engine will have lower cost to develop, test, and operate that the prior art, allowing spacecraft missions throughout the planetary system and beyond. The rocket engine method and system includes a reactor chamber and a heating system for heating a stable plasma to produce fusion reactions in the stable plasma. Magnets produce a magnetic field that confines the stable plasma. A fuel injection system and a propellant injection system are included. The propellant injection system injects cold propellant into a gas box at one end of the reactor chamber, where the propellant is ionized into a plasma. The propellant and fusion products are directed out of the reactor chamber through a magnetic nozzle and are detached from the magnetic field lines producing thrust.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2018

The FNAL Booster 2nd Harmonic RF Cavity

A second harmonic RF cavity which uses perpendicularly biased garnet for frequency tuning is currently being constructed for use in the Fermilab Booster. The cavity will operate at twice the fundamental RF frequency, from ~76 - 106 MHz, and will be turned on only during injection, and transition or extraction. Its main purpose is to reduce beam loss as required by Fermilab’s Proton Improvement Plan (PIP). After three years of optimization and study, the cavity design has been finalized and all constituent parts have been received. We discuss the design aspects of the cavity and its associated systems, component testing, and status of the cavity construction.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Improving Subsurface Stress Characterization for Carbon Dioxide Storage Projects by Incorporating Machine Learning Techniques

The overall objective of this project is to develop a framework for reliable characterization and prediction of the state of stress in the overburden and underburden (including the basement) in CO 2 storage reservoirs using machine learning and integrated geomechanics and geophysical methods. Specifically, we propose to develop workflow encompassing of technologies and/or methods to predict stress and pressure changes due to CO 2 injection in an active tertiary recovery site and their impacts on subtle fault activation, fractures and occurrence of microseismic events and compare responses to field observations. In this project, we anticipate using dataset from the Farnsworth field Unit (FWU) which is operated by Purdure Petroleum. A novel elastic-waveform VSP inversion technique will be used to estimate high-resolution spatial and temporal changes of elastic moduli in CO 2 storage reservoirs, which will be combined with velocity-stress relationship derived from laboratory tests to obtain subsurface pressure and stress. Clustered microseismic data will be jointly inverted for improved focal mechanisms. Least-squares reverse-time migration of microseismic waveform data will be performed to directly image fracture/fault zones. Additionally, a deep neural network machine learning technique with convolutional and recurrent layers will be used for learning the spectro-temporal structures in microseismic waveforms. The results of this geotechnical data analysis will be integrated to develop a high-resolution 3D mechanical earth model extending from the overburden sealing formations to the underburden including the basement. Mechanical properties will be derived through integration of mechanical logs, tests, available results from chemo-mechanical laboratory tests, and elastic inversion of seismic data using a combination of Bayesian and stochastic methods as well as machine learning technique. Failure features (faults/fractures) will be represented and/or modeled based on seismic and core data analysis. A transient hydrodynamic-geomechanical model will be developed through coupling with the calibrated FWU reservoir simulation model. The full physics coupled model will be used to train a reduced order proxy model using machine learning algorithm for estimating stress which will then be used with appropriate constitutive relationships and forward seismological models to simulate pressure changes and induced microseismicity. An advanced optimization framework will be developed to perform a history match to minimize error between field observations and simulated. The history matched proxy model will be verified against the full-physics equivalent. The field observations that will be used in the coupled model calibration process include pressure/stress inverted from VSP, moment magnitude from microseismic analysis, real time downhole pressure measurements, production and injection data. Parameter sensitivity and uncertainty analysis will be performed to characterize the impact of model parameter uncertainty on stress estimates. The proposed project will have significant impact on future field implementation of the proposed technology. Because the project field site is an ongoing CO 2 EOR development, the value of the new technology will be demonstrated in an operational context and evaluated as a viable risk mitigation strategy. Cost/benefit will be evaluated together with the various commercial incentives for CO 2 sequestration available to oil and gas operators. The extensive available dataset and ongoing data acquisition under the SWP Phase III work plan provides flexibility for investigation of multiple approaches and reduces technical risk.

58 GEOSCIENCES↗
DOE OSTI2021

A novel framework for hosting capacity analysis with spatio-temporal probabilistic voltage sensitivity analysis

Smart grids are envisioned to accommodate high penetration of distributed photovoltaic (PV) generation, which may cause adverse grid impacts in terms of voltage violations. Therefore, PV Hosting capacity is being used as a planning tool to determine the maximum PV installation capacity that causes the first voltage violation and above which would require infrastructure upgrades. Additionally, traditional methods of Hosting capacity analysis are scenario based and computationally complex as they rely on iterative load flow algorithms that require investigating a large number of scenarios for accurate assessment of PV impacts. Therefore, this paper presents a computationally efficient analytical approach to compute the probability distribution of voltage change due to random behavior of randomly located multiple distributed PVs. The proposed approach is based on Spatio-temporal probabilistic voltage sensitivity analysis that exploits both spatial and temporal uncertainties associated with PV injections. Thereafter, the derived distribution is used to quantify voltage violations for various PV penetration levels and subsequently determine the hosting capacity of the system without the need to examine large number of scenarios. Results of the proposed framework are validated via conventional load flow based simulation approach on the IEEE 37 and IEEE 123 node test systems.

42 ENGINEERING↗
DOE OSTI2017

Characterization of the Triassic Newark Basin of New York and New Jersey for geologic storage of carbon dioxide

The Newark Basin is a Triassic-aged rift basin underlying densely populated, industrialized sections of New York, New Jersey and Pennsylvania. The Basin is an elongate half-graben encompassing an area of more than 7,510 square-kilometers (2,900 square-miles), and could represent a key storage component for commercial scale management of carbon dioxide emissions via geologic sequestration. The project team first acquired published reports, surface and subsurface maps, and seismic data, which formed the basis for a three-dimensional model framework for the northern end of the Basin incorporating stratigraphic, hydrologic, and water quality data. Field investigations included drilling, coring, and logging of two stratigraphic test borings in Clarkstown, NY (Exit 14 Tandem Lot Well No. 1), drilled to a depth of 2,099 meters (6,885 feet); and Palisades, NY (Lamont-Doherty Earth Observatory Test Well No. 4) drilled to a depth of 549 meters (1,802 feet). Two two-dimensional seismic reflection data lines arrayed perpendicularly were acquired by Schlumberger/WesternGeco to help characterize the structure and stratigraphy and as part of pre-drilling field screening activities for the deep stratigraphic borehole. A total of 47 meters (155 feet) of continuous whole core was recovered from the Tandem Lot boring from depths of 1,393 meters (4,570 feet) to 1,486 meters (4,877 feet). Twenty-five horizontal rotary cores were collected in mudstones and sandstones in the surface casing hole and fifty-two cores were taken in various lithologies in the deep borehole. Rotary core plugs were analyzed by Weatherford Laboratories for routine and advanced testing. Rotary core plug trim end thin sections were evaluated by the New York State Museum for mineralogical analysis and porosity estimation. Using core samples, Lawrence Berkley National Laboratory designed and completed laboratory experiments and numerical modeling analyses to characterize the dissolution and reaction of carbon dioxide with formation brine and minerals, and resulting effects on injection rate, pressure, effective storage volume, and carbon dioxide migration within a prospective sandstone reservoir. $$Three potential porous and permeable sandstone units were identified in the Passaic Formation at the New York State Thruway Exit 14 location. Potential Flow Unit 1, at a depth of 643 meters (2,110 feet) to 751 meters (2,465 feet); Potential Flow Unit 2 at a depth of 853 meters (2,798 feet) to 1,000 meters (3,280 feet); and Potential Flow Unit 3, at a depth of 1,114 meters (3,655 feet) to 1,294 meters (4,250 feet). Reactive transport simulations of interactions between carbon dioxide, brine and formation minerals were carried out to evaluate changes in formation water chemistry, mineral precipitation and dissolution reactions, and any potential resulting effects on formation permeability. The experimental and modeling analyses suggest that mineral precipitation and dissolution reactions (within the target formation) are not expected to lead to significant changes to the underground hydrologic system over time frames (~30 years) typically relevant for carbon dioxide injection operations. Key findings of this basin characterization study include an estimate of carbon dioxide storage capacity in the Newark Basin. Assuming an average porosity of twelve percent and an aquifer volume of 6.1E+12 meters3, calculated ranges of likely storage capacity range from 1.9 – 20.2 gigatonnes under high temperature (low carbon dioxide density) conditions; and 2.9 – 30.2 gigatonnes under low temperature (low carbon dioxide density) conditions. Intra-basin faulting, geometry of the Palisades Sill, and the presence of altered meta-sediments above and below the Sill, increase potential compartmentalization within the basin. A structural/stratigraphic trap type may occur where porous/permeable sediments are cross-cut by the Palisades Sill. Potential injection intervals are present within the Stockton Formation of the Newark Basin. Additional porous/permeable intervals may be present within sandstones of the Passaic Formation, increasing projected storage capacity. Deeper wedges of strata are likely present in the deeper portions of the basin in southern New York and into northern New Jersey. Abundant mudstones are present in the Passaic, Lockatong, and Stockton Formations. These intervals have the requisite petrophysical properties to form effective primary and secondary containment intervals to industrial-scale sequestration of carbon dioxide in the Newark Basin. Hydro-thermally altered meta-sediments in the region immediately surrounding the top and base of the Palisades Sill is devoid of porosity/permeability and forms an additional effective lateral/vertical sealing cap rock.

58 GEOSCIENCES↗
DOE OSTI2025

Benchmark Exercise Report for Experimental Study of Bubble Scrubbing in Water Coolant Pool

Mechanistic assessments of radionuclide release during postulated accidents are expected to be included in advanced reactor license applications. The mechanistic source term (MST) provides an opportunity for vendors to realistically evaluate the radiological consequences of an incident, and may aid in justifying reduced emergency planning zones and plant sites. However, the development of MSTs for advanced nuclear reactors is challenging because there are numerous phenomena that can affect the transport and retention of radionuclides. As part of a trial MST assessment for a metal-fueled, pool-type sodium cooled fast reactor (SFR), led by Argonne National Laboratory, a simplified radionuclide transport code (SRT code) was developed, which includes models to estimate the quantity of fission product aerosols scrubbed in the sodium pool during postulated accident scenarios. In a pool-type SFR, when fission products are released into the coolant pool due to failure of fuel pins, most of the radionuclides are scrubbed by the coolant pool, but some have the potential to migrate to the cover gas region through entrainment within gas bubbles. The SRT code contains a model that evaluates this scrubbing behavior and calculates the fraction of fission product aerosols that reach the cover gas. Due to a lack of available validation data for sodium pool scrubbing, the U.S. Department of Energy funded an experiment at the University of Wisconsin-Madison to measure aerosol scrubbing by injecting air bubbles containing aerosol into a coolant pool. Prior to performing an experiment with liquid sodium, a water loop experiment was performed. Their experiment evaluated the effect of changing the aerosol size, aerosol density, aerosol concentration, bubble size, and pool depth on the aerosol scrubbing efficiency of the pool. In this benchmark experiment, the base tests were conducted by repeated tests of isolated bubbles. Afterwards, more prototypic tests with bubble swarms were performed to evaluate the interactions between the bubbles. The bubble swarm test was able to confirm that a larger amount of aerosol scrubbing occurred than the single bubble test. It was also confirmed that as the bubble size, aerosol density, and pool height increase, the extent of pool scrubbing also increases and does not change with the aerosol concentration. In addition, since the degree of scrubbing is the lowest at aerosol sizes between 0.01 and 1 μm, that is, the largest amount of aerosol is emitted, it was confirmed that the analysis of this size in MST is the most important. This benchmark experiment informs the direction of future sodium experiments.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

The Economics of Big Area Addtiive Manufacturing

Case studies on the economics of Additive Manufacturing (AM) suggest that processing time is the dominant cost in manufacturing. Most additive processes have similar performance metrics: small part sizes, low production rates and expensive feedstocks. Big Area Additive Manufacturing is based on transitioning polymer extrusion technology from a wire to a pellet feedstock. Utilizing pellets significantly increases deposition speed and lowers material cost by utilizing low cost injection molding feedstock. The use of carbon fiber reinforced polymers eliminates the need for a heated chamber, significantly reducing machine power requirements and size constraints. We hypothesize that the increase in productivity coupled with decrease in feedstock and energy costs will enable AM to become more competitive with conventional manufacturing processes for many applications. As a test case, we compare the cost of using traditional fused deposition modeling (FDM) with BAAM for additively manufacturing composite tooling.

additive manufacturing↗