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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Applying Improved Optical Recognition with Machine Learning on Sorting Cu Impurities in Steel Scrap

Annually, 20–55 million tons of electronic waste (e-waste) is produced worldwide (5% of all municipal solid waste). Although e-waste embodies only 2% of America’s municipal waste, it accounts for a significantly larger proportion of the heavy metals and flame retardants present in the waste stream. Currently, less than 20% of all e-waste is recycled in the United States because the heterogeneity of the feedstock limits the opportunity for reuse in high value products and processing of the waste itself is often too costly to justify handling. To address this concern, the aims of this study are: 1) to identify the major plastic and metal compositions within electronic shredder residue (ESR), 2) to formulate solvents and processing conditions to separate 90% of the plastics targeted from consumer shred ESR, and 3) to develop a process design model to estimate the cost and energy efficiency of the proposed solvent-based processing. In this study, a pre-sorted heterogeneous ESR feedstock (one where aluminum, magnetic components, and hazardous battery materials removed by an e-waste recycling facility) was used, with the major compositions of the ESR characterized. It was found that 25 wt.% of the feedstock was composed of plastics, 6 wt.% rubber, 27 wt.% printed circuit boards, 23% wire, and the remainder metals and capacitors. Within the plastic portion, polystyrene (PS, 40 wt.%), acrylonitrile butadiene styrene (ABS, 25 wt.%), and styrene-acrylonitrile (SAN, 9wt.%) were identified to compose the majority of the screened plastics using Fourier transform infrared spectroscopy (FTIR). Next, selective solvents were screened using Hansen Solubility Parameter Theory (HSP) for dissolving PS and ABS. The pre-screening results show that methylene chloride (dichloromethane, DCM) and tetrahydrofuran (THF) are capable of dissolving the most PS and ABS, while methanol (MeOH) and ethylene glycol (EG) are capable of precipitating the most PS and ABS. These solvents were subsequently used to recover polymers and remove. flame retardants within the ESR feedstock. By optimizing the dissolution time and the solvents used, the highest polymer dissolution yield (99 wt.%%) was achieved using DCM for 48 hr. Both pre-screened anti-solvents (MeOH and EG) showed the highest polymer precipitation yield (71 wt.%). In terms of flame retardant removal rate, EG was found to have a high phosphorus-containing flame retardant removal rate (up to 98%). Characterization shows that the proposed solvent-based processing can preserve a high molecular weight fraction of the polymers and effectively remove flame retardants. Cost analysis indicates that the amount of the solvent/anti-solvent recovered after the reaction would play a critical role in reducing the operating costs. The energy analysis shows that the proposed solvent-based processes can save up to 60% of the embodied energy used to manufacture plastics used in electronics (PS and ABS were used for calculations). The results from this project prove the potential of solvent-based processing to produce secondary materials (plastics and metals) from e-waste for cross-industry reuse.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Mechanical Characterization of Low Modulus Polymer-Modified Calcium-Silicate-Hydrate (C-S-H) Binder

Calcium-silicate-hydrate (C-S-H) represents a key microstructural phase that governs the mechanical properties of concrete at a large scale. Defects in the C-S-H phase are also responsible for the poor ductility and low tensile strength of concrete. Manipulating the microstructure of C-S-H can lead to new cementitious materials with improved structural performance. This paper presents an experimental investigation aiming to characterize a new synthetic polymer-modified synthetic calcium-silicate-hydrate (C-S-H)/styrene-butadiene rubber (SBR) binder. The new C-S-H/SBR binder is produced by calcining calcium carbonate and mixing this with fumed silica (SiO 2 ), deionized water and SBR. Mechanical, physical, chemical and microstructural characterization was conducted to measure the properties of new hardened C-S-H binder. Results from the experimental investigation demonstrate the ability to engineer a new C-S-H binder with low elastic modulus and improved toughness and bond strength by controlling the SBR content and method of C-S-H synthesis. The new binder suggests the possible development of a new family of low-modulus silica-polymer binders that might fit many engineering applications such as cementing oil and gas wells.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

2,3-Butanediol recovery from fermentation broth using membrane pertraction

2,3-Butanediol (BDO) has gained immense interest for use as a platform chemical in the production of many important chemicals such as synthetic rubber, plasticizer, and octane boosters. Using BDO as a precursor for sustainable aviation fuel production may significantly reduce the carbon footprint of the airline industry. However, recovery of BDO is challenging due to its relatively low concentration (∼10 wt %) in fermentation broth and its high affinity for water. In this work, we developed a membrane pertraction process for BDO recovery from biomass derived fermentation broth. Different organic solvents such as hexanol and oleyl alcohol were investigated. With traditional solvent extraction, hexanol required a solvent to feed ratio of 10 to recover >90 % BDO, and oleyl alcohol could recover 35 % of BDO at the same ratio. BDO recovery of >90 % was demonstrated with pertraction; a BDO extraction rate of 15 g 1 m −2 h −1 was achieved using hexanol, and an extraction rate of 10 g 1 m −2 h −1 was achieved using oleyl alcohol. Impurities commonly found in fermentation broth did not affect the separation performance of the pertraction process. In conclusion, this work demonstrates pertraction as a low-footprint, scalable method for recovery of high-purity BDO from fermentation broth.

2,3 butanediol↗
DOE OSTI2021

Modeling swelling behavior of hydrogels in aqueous organic solvents

Hydrogel, a three-dimensional elastic structure of cross-linked polymer chains, swells or deswells when immersed in aqueous organic solutions. The swelling of hydrogels depends on temperature, solvent composition, and hydrogel structure as the thermodynamic driving forces for hydrogel swelling are due to solvent – hydrogel interactions and expansion of elastic network. Here in this work, polymer Nonrandom Two-Liquid activity coefficient model is used to account for the solvent – hydrogel interactions and a semi-empirical expression for rubber elasticity is used to describe the expansion of elastic network. The model successfully correlates data for both swelling and equilibrium phase compositions for n-isopropyl acrylamide hydrogels in water – ethanol, water – acetone, water – n-butanol, and water – methyl isobutyl ketone mixed solvents.

42 ENGINEERING↗
DOE OSTI2022

Effect of solution concentration on ethylene propylene diene monomer (EPDM) nonmetallic components used in caustic liquid waste transfer lines

The hose-in-hose transfer lines (HIHTL) used to transfer waste at the United States Department of Energy’s Hanford Site Tank Farm are fabricated from an ethylene propylene diene monomer (EPDM) synthetic rubber. During waste transport, these hoses are exposed to several stressors including caustic solutions at high temperatures and high pressures, as well as β and γ radiation. The aging behavior of HIHTL and dog-bone shaped EPDM specimens were evaluated by exposure to solutions at 77 °C containing 0.00, 6.25, 12.50, and 25.00 % (v/v) sodium hydroxide (NaOH) for 12-months. After the exposure, the material properties of the specimens were measured and compared to the unaged samples. The material properties evaluated included the tensile strength of the EPDM dog-bone samples and the burst pressure of the HIHTL. Both the tensile strength of the EPDM dog-bone samples and the burst pressure of the HIHTL specimens exposed to the 6.25 % NaOH solution exhibited the most significant deterioration and those exposed to 25.00 % NaOH solution had the least deterioration. Finally, examination of the HIHTL and the EPDM dog-bone specimens with scanning electron microscopy showed that the deterioration for the specimens exposed to 6.25 % NaOH solution were the most severe and the samples exposed to 25.00 % NaOH solution had the least deterioration.

42 ENGINEERING↗
DOE OSTI2025

Innovative use of CaO in combination with amino acid salt to convert CO 2 as CaCO 3 nanoparticles under mild pH and low temperature

The increasing demand for sustainable CO 2 management has driven the development of innovative methods that can convert point source CO 2 into value-added products. In this study, CaO in combination with amino acid salt was used to convert CO 2 into CaCO 3 nanoparticles. Different from the conventional method where CO 2 diffusion presents a major challenge in reacting with CaO to form CaCO 3 , amino acid salt solvent was applied to absorb CO 2 first and then rapidly reacted with CaO to form CaCO 3 nanoparticles (∼50 nm) at a low temperature (e.g., 60 °C). Our experiments showed that at a glycine (Gly)/NaOH ratio of 2:1 or 3:1, the solution pH values during the CO 2 absorption and conversion were about 8–9 at 60 °C, while at a ratio of 1:1, the solution pH values were about 9–11; without Gly, the solution pH values were about 12. Gly-optimized solvent substantially reduced corrosion risk to reactors. In addition, the use of amino acid (i.e., Gly) led to much smaller CaCO 3 particles, distinctly different chemical phases, and fundamentally different chemical reactions. Moreover, in the presence of Gly, the solution pH was completely reversed and the solution was regenerated for cyclic use when CaO was added. The solvent was recyclable and reusable, highlighting the cost-effectiveness and sustainability of this approach. The Gly-modulated CaCO 3 nanoparticles may have significant potential for industrial applications in the biomedicine, construction, plastics, and rubber industries.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A renewable lignin-based thermoplastic adhesive for steel joining

Adhesive bonding of metals has become increasingly relevant in recent years due to the demand for reducing weight and improving performance in structural applications such as automobiles and aerospace. We developed renewable thermoplastic adhesives from technical organosolv lignin isolated from hardwood biomass and acrylonitrile butadiene co-polymer rubber (NBR) for joining steel substrates. NBR33, NBR41 and NBR51 with acrylonitrile molar ratios of 33, 41 and 51%, respectively, were blended with lignin to form two-phase thermoplastic adhesives, and their adhesion, viscoelastic and surface properties were measured. Lignin content in the compositions were varied, ranging from 40% to 80% (w/w), to alter toughness, stiffness, and surface energy characteristics of the material. Better interaction or reactivity between the lignin and NBR phases was observed with greater nitrile content in NBR, leading to greater modulus and stiffness of the adhesive. Simultaneously, increasing the proportion of lignin reduced toughness and improved stiffness, with the highest adhesive strength of 13.1 MPa measured in a 60% lignin loading ratio with NBR51. Surface energy measurements revealed that total surface energy (sum of polar and dispersive surface energy) raised with lignin loading, suggesting that both surface energy and matrix strength play a critical role in the adhesive properties of the synthesized materials. A finite element-based cohesive zone model (CZM) was developed and implemented to study the failure strength of the adhesively bonded joint. Here, this study demonstrates the viability of lignin as a valuable building block for adhesives, not only due to its inherent chemical structure and rigidity, but also for its surface energy characteristics.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Improved adhesion of polyurethane-based nanocomposite coatings to tin surface through silane coupling agents

Conformal coatings with higher adhesion strength is critical for mitigating the growth of whiskers from the pure tin (Sn) or Sn-rich surfaces of the Pb-free electronics. Silane coupling agents have the ability to form a durable bond between polymeric coatings and metallic materials. The main goal of this paper is to investigate the effect of silane agents on the adhesion behavior of polyurethane (PU), polyurethane acrylate (PUA) and both coatings filled with silicone rubber (SR) nanoparticles on the tin solder pads. It was found that an isocyanate-based silane provided excellent adhesion for PU and PU + SR coatings and an acrylic-based silane for PUA and PUA + SR coatings on the tin surface. This was due to the reaction bond formation between the silane coupling agent and the coating. Hence, the selection of silane coupling agents with the organofunctional group similar to the coating material is crucial to improve the adhesion properties of the coating.

36 MATERIALS SCIENCE↗
DOE OSTI2020

H-Mat Hydrogen Compatibility of Polymers and Elastomers

The H2@Scale program of the U.S. Department of Energy (DOE) Fuel Cell Technologies Office is supporting work on the hydrogen compatibility of polymers to improve the durability and reliability of materials for hydrogen infrastructure. The hydrogen compatibility program (H-Mat) seeks “to address the challenges of hydrogen degradation by elucidating the mechanisms of hydrogen-materials interactions with the goal of providing science-based strategies to design materials, (micro)structures, and morphology with improved resistance to hydrogen degradation.” This research has observed interactions of hydrogen and pressure with model rubber-material compounds resulting in volume change and compression-set differences in the materials. The materials were investigated using helium-ion microscopy (HeIM), which revealed significant morphological changes in the plasticizer-incorporating compounds after exposure, as evidenced by time-of-flight secondary ion mass spectrometry. Additional studies using transmission electron microscopy and nuclear magnetic resonance were performed to correlate morphological change to potential chemical change in the materials.

08 HYDROGEN↗
DOE OSTI2022

High-pressure hydrogen decompression in sulfur crosslinked elastomers

High-pressure storage and cyclic (de)pressurization of hydrogen gas is known to result in degradation and failure of gas canisters, hoses, linings, and O-rings as the relatively small hydrogen molecule can readily permeate most materials. Hence, identifying material compositions that are less susceptible to hydrogen-induced damage is of significant importance to the hydrogen energy infrastructure. Here, we use classical atomistic molecular dynamics simulations to study hydrogen exposed ethylene-propylene-diene monomer (EPDM) rubber, an elastomer typically used in O-rings. We make chemical modifications to the model by adjusting the crosslink density and report on gas solubility, diffusivity, and molecular restructuring in response to rapid decompression. Our simulations indicate that increases in crosslink density can reduce volumetric expansion during decompression and result in smaller free volume pore sizes. However, these favorable properties for sealing materials come with a tradeoff. At pressure, crosslinks introduce extra free volume, providing potential sites for gas localization, the precursor to cavitation-induced failure.

08 HYDROGEN↗
DOE OSTI2024

An in-situ view cell system for investigating swelling behavior of elastomers upon high-pressure hydrogen exposure

The transition to hydrogen as a clean and efficient energy carrier is impeded by challenges in the compatibility of hydrogen with materials used within hydrogen infrastructure. Elastomers, crucial in sealing components, often exhibit premature failures in high-pressure hydrogen environments due to excessive swelling. This study employs an innovative in-situ view cell system to assess the swelling behavior of hydrogenated nitrile butadiene rubber (HNBR) under various hydrogen conditions. The system, designed to withstand pressures up to 96.5 MPa, incorporates Digital Image Correlation (DIC) for strain measurements and volume estimation. Results reveal non-linear volume increases during depressurization, challenging conventional assumptions. Furthermore, investigations into peak hydrogen pressures and pressure-holding scenarios during decompression highlight complex swelling trends. The introduction of a novel computer vision (CV) method enhances precision in volume estimation, overcoming DIC limitations. The study provides insights into mitigating elastomer swelling, crucial for developing robust materials to support future hydrogen-driven energy systems.

Elastomer↗
DOE OSTI2020

A multi-physics constitutive model to predict hydrolytic aging in quasi-static behaviour of thin cross-linked polymers

The effect of hydrolytic aging on mechanical quasi-static responses of rubber-like materials, in particular, the idealized Mullins effect and permanent set have been modeled. The effect of hydrolytic damage on the mechanical integrity of the polymer matrix is modeled as the direct competition of two micro-structural phenomena (i) chain scission and (ii) reduction of cross-links. Both phenomena and their correlation were modeled and thus, the strain energy of the polymer matrix is written with respect to three independent mechanisms; i) the shrinking original matrix that has not been attacked by water, ii) conversion of the first network to a new network due to the reduction of the cross-links, and iii) energy loss from network degradation due to water attacks to polymer active agents. The proposed model satisfies the Clausius-Duhem inequality and is thus physically feasible. The model is validated with respect to sets of our experimental data and other sets available in the literature. The proposed model is based on the assumption of homogeneous diffusion and mainly relevant for thin samples. In view of its accuracy, interpret-ability, and deep insight it provides into the nature of damage accumulation, the model is a good choice for further implementation in FE applications.

42 ENGINEERING↗
DOE OSTI2025

Experimental investigation of the dependence of void nucleation and growth on initial microstructure in high-purity titanium under tension

An experimental investigation of failure mechanisms in relation to the initial microstructure in high-purity titanium samples is presented. The initial microstructure of the specimens was measured in 3D using diffraction-contrast tomography (DCT). Ex-situ X-ray computed tomography (XCT) was used to visualize voids in specimens at various levels of deformation attained by interrupted tensile testing. Electron backscatter diffraction (EBSD) mapping was used to characterize the deformed microstructures per specimen. The investigation showed that the location of failures was unrelated to the formation of the first voids, but rather the nucleation and growth of cracks were from heavily deformed surface regions. The areas surrounding the failure-causing cracks had the highest propensity for void development of any area in the specimen. This facilitated crack propagation through the specimen via “linking up”. The failure of the specimens by microvoid coalescence was bolstered by “dimpled” fracture surfaces. Paint composed of gallium embedded in rubber was used to track the displacement of points along the loading direction of the specimens, to relate the location of failure to the material's initial microstructure. However, the correlation proved difficult, due to complex microstructural evolution involving voids, grain fragmentations, and profuse twinning. Nevertheless, it was shown that necking occurred near the largest grain in the gauge section of the specimens. This is likely caused by the decrease in strength of larger grains, causing strain to concentrate in their vicinity. Here, a comprehensive picture of the failure processes in high-purity titanium under axial loading is presented and discussed in the paper.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Upcycling and urban mining for nanomaterial synthesis

Responsible processing of complex waste streams, especially through resource recovery and upgrading, is essential to lessen the environmental and societal impacts of materials production and disposal. Upcycling waste into materials that have higher value than their original form, and urban mining, the recovery of metals from electronic waste, are two recent strategies in waste management. Sustainable cradle-to-grave manufacturing means recovering resources that would otherwise contaminate the planet. Here, we discuss upcycling of plastic, rubber, and related carbon waste streams into graphene, as well as the recovery of precious metals and rare earth elements, while removing toxic heavy metals, all using flash Joule heating. Furthermore, this article provides a brief overview of the current state of upcycling and urban mining as it applies to materials conversion, recovery, or nanomaterial synthesis, with a concluding perspective highlighting the considerations, opportunities, and challenges that accompany upcycling and urban mining research.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

On component isolation of conceptual advanced reactors

Implementation of component isolation in nuclear industry is challenging due to gaps in research and the lack of specific guidelines. In this study, parameters affecting component-level isolation of advanced reactor vessels are identified based on a representative numerical model with explicit consideration of nonlinear soil-structure interaction (SSI). The objective of this study is to evaluate the effectiveness of, and to identify potential limitations of using conventional friction pendulum and lead-rubber bearings to seismically isolate vessels. It is found that slender vessels or components are particularly vulnerable to rotational accelerations at the isolation interface, which are caused by rotation of the sub-structure and by excitation of higher modes in the horizontal direction of the seismically isolated system. Component isolation is found to be more effective for relatively stiffer vessels and at sites with stiff soil properties. Considering that conventional isolators are deficient in resisting axial tension, it is observed that the optimum location for supporting a component to achieve seismic isolation, is at a cross-sectional plane passing through the center of mass of the vessel. These findings are corroborated by numerous simulations of the response of seismically isolated reactor vessels at different nuclear sites subject to a variety of ground motions.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

Aging of UV curable PDMS developed for large-scale, high viscosity stereolithography

Polydimethylsiloxane (PDMS) elastomers are silicone rubbers that find widespread application in both academic and industrial settings. This study investigates the use of photosensitive platinum catalysts for UV-activated hydrosilylation of PDMS, which enables the additive manufacturing of PDMS objects through techniques such as stereolithography. Specifically, this study focuses on understanding the aging behavior of Pt-catalyzed, UV-curable PDMS samples, including their mechanical behavior under thermal and UV-accelerated aging conditions. The results show that the Pt-catalyzed, UV-curable PDMS introduced in this research is ‘under-cured’ after being printed and will slowly evolve over time resulting in increased stiffness and decreased elongation, likely due to the formation of additional crosslinks. FTIR spectroscopy indicates that no new chemical bonds or functional groups are generated through the aging process, suggesting that no thermal degradation or polymer chain scissions occur in the polymer matrix. Overall, this PDMS formulation exhibits greater mechanical strength and significantly less reduction in strength with aging, compared with the commonly used, UV-curable thiol-ene PDMS.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Connecting radiation-driven changes in structural, thermal, and mechanical properties in several medical device polymers

Stemming from security threats and shortages in supply, a recent push has emerged to develop alternatives to radioisotope Cobalt-60 gamma radiation for sterilization of polymeric medical products, including electron beam (e-beam) and X-ray machine-based sources. However, before large-scale implementation, the effects of these non-isotope-based methods must be thoroughly investigated from several perspectives, involving their potential detrimental effects on the structural, thermal, and mechanical properties of polymers in medical devices. This paper investigates such effects in commonly used medical device polymers, including polypropylene homopolymer (PPH), polyolefin elastomer (POE), low-density polyethylene (LDPE), acrylonitrile butadiene styrene (ABS), and chlorobutyl rubber (CIIR). To connect radiation-driven changes in polymer structural and thermal properties and corresponding changes in mechanical properties, several characterization techniques were utilized, including gel permeation chromatography (GPC), Fourier transform infrared spectroscopy (FTIR), dynamic mechanical analysis (DMA) and differential scanning calorimetry (DSC). We found that the tensile strength of X-ray irradiated PPH, as well as X-ray, e-beam, and gamma irradiated CIIR decreases due to chain scission, which is corroborated by GPC and DMA. The GPC results of LDPE suggest chain scission, but interestingly without a corresponding decline in tensile strength. By comparison, POE and ABS appear to undergo further crosslinking with increasing irradiation dose, which generally strengthens them. Importantly, in the vast majority of the cases, there were small to no changes in properties upon changing radiation technologies (at a given dose), i.e., no radiation source dependence. However, in a few specific cases, radiation method dependencies did arise, for instance, in terms of the molecular weight of PPH being significantly increased upon X-ray irradiation, while the melting temperature, glass transition temperature, and elongation at break reduced compared to gamma. Overall, this study provides valuable insight into radiation-driven chemical and structural changes in polymers that produce changes in physical and functional properties.

36 MATERIALS SCIENCE↗