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At least 127 records · Page 7

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DOE OSTI2022

Multi-process tooling for discontinuous carbon and hybrid glass fiber thermoplastics

Expensive tooling often constraints the use of composites in the design and development of automotive parts. While there is significant confidence and knowledge in sheet and bulk metals, composite processes are less understood in mass production environment. The processes used to produce composites and resulting properties are influenced by fiber length attrition, resin to fiber ratio, process waste etc. Tool designs are determined very early in the engineering process. It is cost prohibitive to build additional tools, in the event it becomes obvious a better processing method and material would be beneficial, the original decision is not easily changed. In the present work we recognize the bottleneck of tooling costs and provide an approach of multi-process tooling. The innovation of this work is the design and demonstration of a single tool for different processes namely injection, injection-compression and extrusion-compression. The materials used in this study were long and short fiber thermoplastics (LFTs and SFTs). The resulting structure-property relationships have been reported for the materials and processing methods with a battery tray (BT) tool.

Vaidya, Uday↗

DOE OSTI2020

Low cost carbon fiber as potential lightning strike protection for wind turbine blades

Until recently, glass fiber composites (GFRP) were the preferred choice to prepare wind turbine blades due to their low cost compared to their counterpart carbon fiber composites (CFRP). However, to harvest the maximum wind energy, ever larger wind turbine blades are being manufactured. To support such a large structure carbon fiber composites CFRP have become the integral part of load bearing structures in the blade. In this work, we are proposing to utilize the low cost carbon fiber (LCCF), manufactured at Carbon Fiber Technology Facility (CFTF) of Oak Ridge National Laboratory (ORNL) as not only the cost effective alternative to the currently used carbon fiber (CF) but also as the lightning strike protection of the wind turbine blades. Wind turbines often get hit by lightning strikes due to their operating locations. LCCF can provide structural integrity to these gigantic structures and mitigate the effect of lightning strike on them by effectively dissipating the current. Two composite panels made of LCCF were tested against artificial lightning strikes of 100 kA and 200 kA (component A of lightning waveform SAE ARP 5412-B). The results showed very high resilience of LCCF composite due to their high electrical conductivity both in-plane and in through-thickness directions. There was no significant damage (fiber breakage, resin evaporation or delamination) in both the cases.

Kumar, Vipin↗

DOE OSTI2023

Enhanced lightning strike protection using vertically oriented carbon fiber melded with conventional carbon fiber-reinforced composite and its validation through damage analysis

Lightning strike protection (LSP) is one of the prime factors in aerospace and wind industries concerning safety, enhanced service life, and reduced downtime. To ensure better LSP, high electrical conductivity is required to dissipate the current, which is always a challenge for polymer composites due to the inherent insulating nature of the polymer matrix. Conventional carbon fiber-reinforced composites (CFRP) offer electrical conductivity in the planar direction while the vertical i.e. through-thickness conductivity still remains a challenge. Having been motivated by this fact, we have fabricated CFRP interleaved with vertically oriented CF (Z-fiber) for the lightning strike test (100 kA). A paint was applied to mimic the actual service condition of the composite laminates. We have prepared two Z-fiber composites: (a) Z-1 containing one Z-fiber layer on the top along with conventional CF layers and (b) Z-5 containing five interleaved Z-fiber layers and compared the properties with conventional CFRP (Z-0). Interestingly, even a single Z-fiber layer (Z-1) showed lower damage (visual damage diameter 22 mm) than Z-0 (visual damage diameter 26 mm). Z-5 displayed the lowest damage (visual damage diameter 16.7 mm), which was further confirmed by cross-sectional optical microscopy. Improved LSP was attributed to the higher through-thickness electrical conductivity in the case of Z-5 (9 times with respect to Z-0) reflecting a lower electrical anisotropy for Z-fiber composites. The residual mechanical property after the lightning test was analyzed through the flexural test, and the retention of flexural strength and modulus was 66% and 86%, respectively for Z-5 showing a significant improvement in comparison to Z-0 (>40% for both).

Saha, Subhabrata↗

DOE OSTI2021

Recent developments in filtration media and respirator technology in response to COVID-19

Abstract The COVID-19 pandemic triggered a surge in demand for N95 or equivalent respirators that the global supply chain was unable to satisfy. This shortage in critical equipment has inspired research that addresses the immediate problems and has accelerated the development of the next-generation filtration media and respirators. This article provides a brief review of the most recent work with regard to face respirators and filtration media. We discuss filtration efficiency of the widely utilized cloth masks. Next, the sterilization of and reuse of existing N95 respirators to extend the existing stockpile is discussed. To expand near-term supplies, optimization of current manufacturing methods, such as melt-blown processes and electrospinning, has been explored. Future manufacturing methods have been investigated to address long-term supply shortages. Novel materials with antiviral and sterilizable properties with the ability for multiple reuses have been developed and will contribute to the development of the next generation of longer lasting multi-use N95 respirators. Finally, additively manufactured respirators are reviewed, which enable a rapidly deployable source of reusable respirators that can use any filtration fabric. Graphic abstract

36 MATERIALS SCIENCE↗

DOE OSTI2020

Hot Press Market Study

A study has been conducted to identify vendors for a hot press suitable for meeting program deliverables chiefly to achieve a higher TRL for the material and process. This study identities the high level specifications for the hot press which must be able to produce samples to support both the fabrication method development and fabricate full size components for testing to demonstrate success. Three vendors capable of meeting hot press specifications were contacted and estimates were obtained. A comparison of the equipment was performed and a recommendation is made for equipment acquisition.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Electrically Driven Ion Separations in Permeable Membranes

Ion separations are critical for producing materials such as Li and rare-earth element salts that are essential for applications including energy storage and production. This research aimed to develop and understand separations of singly and multiply charged ions as well as separations among different singly charged ions such as Li + and Na + . Thin layers of polyelectrolytes on membranes allow passage of singly charged ions at rates 1000 times faster than those for multiply charged ions. This allows purification of mixtures with equal concentrations of Li + and Mg 2+ to create a permeate solution with >99% Li + . Such membranes may also effectively isolate rare earth elements. To separate Li + and K + , this work developed opposing flow and current in membranes. The current overcomes the flow of K + to allow Li + to selectively pass through the membrane, leading to Li + /K + selectivities around 70. All of the research employs modelling to better understand the mechanism of these separations, which includes transport driven by gradients in electrical potential, concentration, and pressure. The interplay of these driving forces can create highly selective separations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

MOFX-DB: An online database of computational adsorption data for nanoporous materials.

Abstract not provided.

Bobbitt, Nathaniel↗

DOE OSTI2020

Finite Element Modeling of the Fiber-Matrix Interface in Polymer Composites

Polymer composites are used in numerous industries due to their high specific strength and high specific stiffness. Composites have markedly different properties than both the reinforcement and the matrix. Of the several factors that govern the final properties of the composite, the interface is an important factor that influences the stress transfer between the fiber and matrix. The present study is an effort to characterize and model the fiber-matrix interface in polymer matrix composites. Finite element models were developed to study the interfacial behavior during pull-out of a single fiber in continuous fiber-reinforced polymer composites. A three-dimensional (3D) unit-cell cohesive damage model (CDM) for the fiber/matrix interface debonding was employed to investigate the effect of interface/sizing coverage on the fiber. Furthermore, a two-dimensional (2D) axisymmetric model was used to (a) analyze the sensitivity of interface stiffness, interface strength, friction coefficient, and fiber length via a parametric study; and (b) study the shear stress distribution across the fiber-interface-matrix zone. It was determined that the force required to debond a single fiber from the matrix is three times higher if there is adequate distribution of the sizing on the fiber. The parametric study indicated that cohesive strength was the most influential factor in debonding. Moreover, the stress distribution model showed the debonding mechanism of the interface. It was observed that the interface debonded first from the matrix and remained in contact with the fiber even when the fiber was completely pulled out.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Mechanical Response and Processability of Wet-Laid Recycled Carbon Fiber PE, PA66 and PET Thermoplastic Composites

The interest in recycled carbon fiber (rCF) is growing rapidly and the supply chain for these materials is gradually being established. However, the processing routes, material intermediates and properties of rCF composites are less understood for designers to adopt them into practice. This paper provides a practical pathway for rCFs in conjunction with low cost and, for the most part, commodity thermoplastic resins, namely polyethylene (PE), polyamide 66 (PA66) and polyethylene terephthalate (PET). Industrially relevant wet-laid (WL) process routes have been adopted to produce mats using two variants of WL mats, namely (a) high speed wet-laid inclined wire to produce broad good ‘roll’ forms and (b) 3DEPTM process patented by Materials Innovation Technologies (MIT)-recycled carbon fiber (RCF), now Carbon Conversions, which involves mixing fibers and water and depositing the fibers on a water-immersed mold. These are referred to as ‘sheet’ forms. The produced mats were evaluated for their processing into composites as ‘fully consolidated mats’ and ‘non-consolidated’ as-produced mats. Comprehensive mechanical data in terms of tensile strength, tensile modulus and impact toughness for rCF C/PE, C/PA66 and C/PET are presented. The work is of high value to sustainable composite designers and modelers.

compression molding↗

DOE OSTI2022

Ion Separations Based on Spontaneously Arising Streaming Potentials in Rotating Isoporous Membranes

Highly selective ion separations are vital for producing pure salts, and membrane-based separations are promising alternatives to conventional ion-separation techniques. Our previous work demonstrated that simple pressure-driven flow through negatively charged isoporous membranes can separate Li+ and K+ with selectivities as high as 70 in dilute solutions. The separation mechanism relies on spontaneously arising streaming potentials that induce electromigration, which opposes advection and separates cations based on differences in their electrophoretic mobilities. Although the separation technique is simple, this work shows that high selectivities are possible only with careful consideration of experimental conditions including transmembrane pressure, solution ionic strength, the K+/Li+ ratio in the feed, and the extent of concentration polarization. Separations conducted with a rotating membrane show Li+/K+ selectivities as high as 150 with a 1000 rpm membrane rotation rate, but the selectivity decreases to 1.3 at 95 rpm. These results demonstrate the benefits and necessity of quantitative control of concentration polarization in highly selective separations. Increases in solution ionic strength or the K+/Li+ feed ratio can also decrease selectivities more than an order of magnitude.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Energy-Efficient Neuromorphic Architectures for Nuclear Radiation Detection Applications

A comprehensive analysis and simulation of two memristor-based neuromorphic architectures for nuclear radiation detection is presented. Both scalable architectures retrofit a locally competitive algorithm to solve overcomplete sparse approximation problems by harnessing memristor crossbar execution of vector–matrix multiplications. The proposed systems demonstrate excellent accuracy and throughput while consuming minimal energy for radionuclide detection. To ensure that the simulation results of our proposed hardware are realistic, the memristor parameters are chosen from our own fabricated memristor devices. Based on these results, we conclude that memristor-based computing is the preeminent technology for a radiation detection platform.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2026

The Vera C. Rubin Observatory Data Preview 1

We present Rubin Data Preview 1 (DP1), the first data from the National Science Foundation–Department of Energy Vera C. Rubin Observatory, comprising raw and calibrated single-epoch images, coadds, difference images, detection catalogs, and ancillary data products. DP1 is based on 1792 optical–near-infrared exposures acquired over 48 distinct nights by the Rubin Commissioning Camera (LSSTComCam) on the Simonyi Survey Telescope at the Summit Facility on Cerro Pachón, Chile in late 2024. DP1 covers ∼15 deg 2 distributed across seven roughly equal-sized noncontiguous fields, each independently observed in six broad photometric bands, ugrizy. The median FWHM of the point-spread function across all bands is approximately 1"14, with the sharpest images reaching about 0." 58. The 5σ point-source depths for coadded images in the deepest field, the Extended Chandra Deep Field South, are u = 24.55, g = 26.18, r = 25.96, i = 25.71, z = 25.07, and y = 23.1. Other fields are no more than 2.2 mag shallower in any band, where they have nonzero coverage. DP1 contains approximately 2.3 million distinct astrophysical objects, of which 1.6 million are extended in at least one band in coadds, and 431 solar system objects, of which 93 are new discoveries. DP1 is approximately 3.5 TB in size and is available to Vera C. Rubin Observatory data rights holders via the Rubin Science Platform, a cloud-based environment for the analysis of petascale astronomical data. While small compared to future LSST releases, its high quality and diversity of data support a broad range of early science investigations ahead of full operations in 2026.

Ground-based astronomy↗

DOE OSTI2022

Early Results from GLASS-JWST. V: The First Rest-frame Optical Size–Luminosity Relation of Galaxies at z > 7

We present the first rest-frame optical size–luminosity relation of galaxies at z > 7, using the NIRCam imaging data obtained by the GLASS James Webb Space Telescope Early Release Science (GLASS-JWST-ERS) program, providing the deepest extragalactic data of the ERS campaign. Our sample consists of 19 photometrically selected bright galaxies with m F444W ≤ 27.8 at 7 < z < 9 and m F444W < 28.2 at z ~ 9–15. We measure the size of the galaxies in five bands, from rest-frame optical (~4800 Å) to the UV (~1600 Å) based on the Sérsic model, and analyse the size–luminosity relation as a function of wavelength. Remarkably, the data quality of the NIRCam imaging is sufficient to probe the half-light radius r e down to ~100 pc at z > 7. Given the limited sample size and magnitude range, we first fix the slope to that observed for larger samples in rest-frame UV using Hubble Space Telescope samples. The median size r 0 at the reference luminosity M = –21 decreases slightly from rest-frame optical (600 ± 80 pc) to UV (450 ± 130 pc). We then refit the size–luminosity relation allowing the slope to vary. The slope is consistent with β ~ 0.2 for all bands except F150W, where we find a marginally steeper slope of β = 0.53 ± 0.15. The steep UV slope is mainly driven by the smallest and faintest galaxies. If confirmed by larger samples, it implies that the UV size–luminosity relation breaks toward the faint end, as suggested by lensing studies.