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At least 145 records · Page 8

Solidification interface shape for continuous casting in an offset mold - Two analytical methods

A solution method for finding the unknown solidification interface in manufacturing slab ingots as a continuous casting is presented, which involves a product solution in the potential plane and the use of conjugate harmonic functions. It is argued that the method may be more direct for some geometries than the Cauchy boundary value method. Moreover, the usefulness of the Cauchy boundary value method is demonstrated through the example of a nonsymmetric horizontal mold where the walls are offset to support the lower ingot boundary.

Siegel, R.↗

Reduced hazard chemicals for solid rocket motor production

During the last three years. the NASA/Thiokol/industry team has developed and started implementation of an environmentally sound manufacturing plan for the continued production of solid rocket motors. NASA Marshall Space Flight Center (MSFC) and Thiokol Corporation have worked with other industry representatives and the U.S. Environmental Protection Agency (EPA) to prepare a comprehensive plan to eliminate all ozone depleting chemicals from manufacturing processes and reduce the use of other hazardous materials used to produce the space shuttle reusable solid rocket motors. The team used a classical approach for problem-solving combined with a creative synthesis of new approaches to attack this challenge.

Larry A. Caddy↗

Roll-to-Roll Advanced Materials Manufacturing DOE Laboratory Collaboration (FY2020 Final Report)

R2R processing is used to manufacture a wide range of products for various applications which span many industrial business sectors. The overall R2R methodology has been in use for decades and this continuous technique traditionally involves deposition of material(s) onto moving webs, carriers or other continuous belt-fed or conveyor-based processes that enable successive steps to build a final version which serves to support the deposited materials. Established methods that typify R2R processing include tape casting, silk-screen printing, reel-to-reel vacuum deposition/coating, and R2R lithography. Products supported by R2R manufacturing include micro-electronics, electro-chromic window films, PVs, fuel cells for energy conversion, battery electrodes for energy storage, and barrier and membrane materials. Due to innovation in materials and process equipment, high-quality yet very low-cost multilayer technologies have the potential to be manufactured on a very cost-competitive basis. To move energy-related products from high-cost niche applications to the commercial sector, the means must be available to enable manufacture of these products in a cost-competitive manner that is affordable. Fortunately, products such as fuel cells, thin- and mid-film PVs, batteries, electrochromic and piezoelectric films, water separation membranes, and other energy saving technologies readily lend themselves to manufacture using R2R approaches. However, more early-stage research is needed to solve the challenge of linking the materials (particles, polymers, solvents, additives) used in ink and slurry formulations and the coating and drying processes to the ultimate performance of the final R2R product, especially for a process that uses multiple layers of deposition to achieve the end product. To solve the problems associated with these challenges, the R2R Collaboration is executing a research program with outcomes that will ultimately link modeling, processing, metrology and defect detection tools, thereby directly relating the properties of constituent particles and processing conditions to the performance of final devices. This collaborative approach was designed to foster identification and development of materials and processes related to R2R for clean-energy materials development. Using computational and experimental capabilities by acknowledged subject matter experts within the supported National Laboratory system, this project leverages the capabilities and expertise at each of five National Laboratories to further the development of multilayer technologies that will enable high-volume, cost-competitive platforms. A typical R2R process has three steps: (1) mixing of particles and various constituents in a slurry, (2) coating of the ink/slurry mixture on a substrate, and (3) drying/curing and processing of the coating. Final performance of devices made via R2R processes is dependent on the active materials (e.g., electrochemical particles in battery or fuel cell electrodes) and the device structure that stems from the governing component interactions within the various steps. However, a fundamental understanding of the underlying mechanisms and phenomena is still lacking, which is why industrial-scale R2R process development and manufacturing is still largely empirical in nature. The FY 2019 through FY 2021 program addresses aspects of the following two targets from the AMO Multi-Year Program Plan: (1) Target 8.1 Develop technologies to reduce the cost per manufactured throughput of continuous R2R manufacturing processes. (A) Increasing throughput of R2R processes by 5 times for batteries (to 50 square feet per minute (50 ft 2 /min)) and capacitors and 10 times for printed electronics and the manufacture of other substrates and MEs used in support of these products. (B) Developing resolution capabilities to enable registration and alignment that will detect, align, and co-deposit multiple layers of coatings and print < 1-micron (1 µm) features using continuous process scalable for commercial production. (C) Developing scalable and reliable R2R processes for solution deposition of ultra-thin (<10 nm) films for active and passive materials. (D) Develop in-line multilayer coating technology on thin films with yields greater than 95%. (2) Target 8.2 Develop in-line instrumentation tools that will evaluate the quality of single and multilayer materials in-process. (A) Developing in-line QC technologies and methodologies for real-time identification of defects and expected product properties “in-use/application” during continuous processing at all size-scales with a focus on the “micro” and “nano” scale traces, lines, and devices, i.e., <1 μm at 300 ft./min for R2R processing in air and <10 nm at 20 ft./min for vacuum (B) Developing technologies to increase the measurement frequency of surface rheology without significant cost increases with a goal of a 10-nanometer in-line profilometry at a production rate of 100,000 square millimeters per minute (100,000 mm 2 /min).

42 ENGINEERING↗

Opportunities for Industry to Provide Flexibility While Increasing Profitability

Supply and demand flexibility will both be needed to ensure the electricity system functions properly as the share from variable renewable generation continues to grow. Industrial manufacturing currently consumes about a third of primary energy worldwide, and electricity is projected to supply an increasing share of this demand as the global economy decarbonizes. Therefore, the ability for industry to flex demand poses an enticing opportunity to enable grid flexibility. However, large capital outlays prevent industry from voluntarily altering demand. Here we show that as battery costs continue to fall, industry will soon be able to profitably alter demand in accordance with electricity price variations. Focusing on two established industries– chlor-alkali and electric arc furnaces – and two industries with large future potential – methane pyrolysis and atmospheric CO 2 capture, we use a linear program (LP) optimization to assess the technoeconomic feasibility of flexible industrial demand across both historical and future-looking wholesale day-ahead marginal prices for the Electricity Reliability Council of Texas (ERCOT). We find positive net present values (NPV) from $\$$400K to $\$$50M using projected 2050 battery prices for industrial purchase of behind-the-meter batteries, using only arbitrage as a source of value. These results indicate that, with projected battery prices, profit-seeking industrial players could voluntarily play a future role in stabilizing a high-renewables grid where electricity prices act as accurate signals of grid needs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Putting EVM to the Test

IN MANY INSTANCES THERE IS NO FOREWARNING; SCHEDULES slip, costs soar, and the project manager is faced with the near impossible task of explaining why each impact occurred. With contractors performing the majority of the work, the management job can become even more obscure. The simple lack of proximity to the contractor can limit effective communication. Add to that a mixture of cultural differences and a desire for the contractor to portray the most optimistic view of their performance, and you create an even more difficult task for the project manager. This was the scenario when the Habitat Holding Rack (HHR) manager at Marshall Space Flight Center (MSFC), Stacy Counts, was introduced to the overall concept of Earned Value Management (EVM). Faced with increased costs (which eventually resulted in decreased scope of the project), continued schedule slides, and several technical anomalies, she was looking for a way to gain a better handle on the project performance. As a component of the Space Station Biological Research Program (SSBRP), the HHR project is an integral piece of the Program content. The HHR is the first rack hardware to be delivered for the Program and has therefore been the first rack to move through the trials of test and verification-documenting anomalies and technical difficulties that will benefit the other SSBRP rack projects. For these reasons, the HHR maintained high visibility throughout the manufacturing and assembly process, continuing through test and verification activities. Needless to say, the higher visibility emphasized the need for improved performance on this project. And to improve project performance, Stacy first had to figure out how to measure the cost, schedule and technical objectives effectively.

Kerby, Jerald↗

Injection Overmolding of Continuous Carbon Fiber Preforms

This project explored and developed a process to injection overmold continuous carbon fiber preforms fabricated with tailored fiber placement. Much early work was focused on the ability to infuse dry carbon fiber tow, fully wetting out the fibers, in an injection molding process. Various approaches were explored, including using commingled fiber and pre-consolidated flexible preforms. The commingled fiber was a blend of carbon fiber and polymer fiber matching the injecting polymer. This approach showed some merit but required an extremely high quality homogeneous mixing of the polymer fibers with the carbon fibers to wet out the carbon fiber tow. Therefore, the project focused on pre-consolidated preforms. The pre-consolidated preform manufacturing method was first developed using compression molded flat plates that were cut into tensile specimen for testing. Work then progressed to an injection molded simplified corner fitting bracket. It was shown that a viable manufacturing method for overmolding continuous carbon fiber preforms could be developed.

36 MATERIALS SCIENCE↗

Prototype development and test results of a continuous ambient air monitoring system for hydrazine at the 10 ppb level

A Hydrazine Vapor Area Monitor (HVAM) system is currently being field tested as a detector for the presence of hydrazine in ambient air. The MDA/Polymetron Hydrazine Analyzer has been incorporated within the HVAM system as the core detector. This analyzer is a three-electrode liquid analyzer typically used in boiler feed water applications. The HVAM system incorporates a dual-phase sample collection/transport method which simultaneously pulls ambient air samples containing hydrazine and a very dilute sulfuric acid solution (0.0001 M) down a length of 1/4 inch outside diameter (OD) tubing from a remote site to the analyzer. The hydrazine-laden dilute acid stream is separated from the air and the pH is adjusted by addition of a dilute caustic solution to a pH greater than 10.2 prior to analysis. Both the dilute acid and caustic used by the HVAM are continuously generated during system operation on an "as needed" basis by mixing a metered amount of concentrated acid/base with dilution water. All of the waste water generated by the analyzer is purified for reuse by Barnstead ion-exchange cartridges so that the entire system minimizes the generation of waste materials. The pumping of all liquid streams and mixing of the caustic solution and dilution water with the incoming sample are done by a single pump motor fitted with the appropriate mix of peristaltic pump heads. The signal to noise (S/N) ratio of the analyzer has been enhanced by adding a stirrer in the MDA liquid cell to provide mixing normally generated by the high liquid flow rate designed by the manufacturer. An onboard microprocessor continuously monitors liquid levels, sample vacuum, and liquid leak sensors, as well as handles communications and other system functions (such as shut down should system malfunctions or errors occur). The overall system response of the HVAM can be automatically checked at regular intervals by measuring the analyzer response to a metered amount of calibration standard injected into the dilute acid stream. The HVAM system provides two measurement ranges (threshold limit value (TLV): 10 to 1000 parts per billion (ppb)/LEAK: 100 ppb to 10 parts per million (ppm)). The LEAK range is created by dilution of the sulfuric acid/hydrazine liquid sample with pure water. This dual range capability permits the analyzer to quantify ambient air samples whose hydrazine concentrations range from 10 ppb to as high as 10 ppm. The laboratory and field prototypes have demonstrated total system response times on the order of 10 to 12 minutes for samples ranging from 10 to 900 ppb in the lLV mode and is greater than 2 minutes for samples ranging from 100 to 1300 ppb in the LEAK mode. Service intervals of over 3 months have been demonstrated for continuous 24 hour/day, 7 day/week usage. The HVAM is made up of a purged cabinet that contains power supplies, RS422 signal transmission capabilities, a UPS, an on-site warning system, and a Line Replaceable Unit (LRU). The LRU includes all of the liquid flow system, the analyzer, the control/data system microprocessor and assorted flow and liquid-level sensors. The LRU is mounted on a track slide system so it can be serviced inplace or totally removed and quickly exchanged with another calibrated unit, thus minimizing analyzer downtime. Once an LRU is removed from an analyzer enclosure, it can be brought to a laboratory facility for complete calibration and periodic maintenance.

Meneghelli, Barry↗

Evaluation of additive manufacturing side channels for nuclear nonproliferation applications

The nuclear industry is continuing to grow and adopt new technologies to manufacture components. One of the technologies under consideration is additive manufacturing (AM). AM could make production of components at lower cost and could lessen lead times significantly. However, AM could be prone to proliferation risks. AM machines give off signatures during the manufacturing process, and these signatures offer an alternative means of observing the component. Correlations between these signatures and the geometry being manufactured could be developed; enabling proliferators as they could take advantage of these correlations to steal AM manufacturing instructions relating to nuclear technology. This work pertains to preliminary work exploring the feasibility of tapping into AM side channels to predict geometries being manufactured on AM machines. The feasibility of utilizing vibration to draw geometric correlations will be assessed on an Ultimaker 2 + thermoplastic 3D printer.

Additive manufacturing↗

Toward a Fully Capable In-Space Manufacturing Ecosystem

As technology for in-space refueling and servicing continues to mature, in-space assembly and manufacturing efforts can expand to leverage these new capabilities. This paper expands upon previous work and describes four use cases for a fully capable in-space manufacturing ecosystem. Based on those use cases, enabling technology areas are identified and shortfalls in those technologies are noted for seven key categories. Finally, a survey of options for in-space experiments and demonstrations are presented, showing pathways for technology development in relevant environments.

in-space manufacturing ecosystem↗

Performance Evaluation of LPBF Manufactured 316H Components

This work represents the continuation of a benchmark study that includes modeling, fabrication and characterization as demonstration to support industry’s adoption of advanced manufacturing processes in a variety of structures. This comprehensive study investigated the feasibility of using additive manufacturing (AM) technologies, specifically Laser Powder Direct Energy Deposition (LP-DED) and Laser Powder Bed Fusion (LPBF), to produce complex nuclear microreactor components using 316H stainless steel. The research focused on manufacturing an expanded elbow pipe component with transitioning sections, which are traditionally difficult and costly to produce through conventional manufacturing methods. The overall study’s primary objectives are therefore demonstrating AM viability for nuclear applications, optimizing process parameters, developing comprehensive material characterization protocols, validating computational modeling approaches, and establishing manufacturing guidelines for complex geometries. Although the initial work included the phased approach of cubical, upscaled cylindrical components, it is to enable to obtain more knowledge for the printing of the expanded elbow structure. The project achieved significant progress in process development by successfully optimizing LP-DED parameters to achieve 99.16-99.97% relative density in 316H stainless steel components. Through systematic evaluation of sixteen cube samples with varied laser powers (400-700W) and scan speeds (600-900 mm/min), optimal processing windows were identified at 500-550W with 600-700 mm/min or 650-700W with 650-900 mm/min scan speeds. The DED manufactured 316H demonstrated mechanical properties comparable or superior to wrought materials, with Young's modulus ranging from 153-208 GPa and controlled microstructural characteristics including greater than 95% face-centered cubic (FCC) phases and engineered cellular structures with sizes between 3.23-6.17 µm.

36 MATERIALS SCIENCE↗

Prominent radiative contributions from multiply-excited states in laser-produced tin plasma for nanolithography

Extreme ultraviolet (EUV) lithography is currently entering high-volume manufacturing to enable the continued miniaturization of semiconductor devices. The required EUV light, at 13.5 nm wavelength, is produced in a hot and dense laser-driven tin plasma. The atomic origins of this light are demonstrably poorly understood. Here we calculate detailed tin opacity spectra using the Los Alamos atomic physics suite ATOMIC and validate these calculations with experimental comparisons. Our key finding is that EUV light largely originates from transitions between multiply-excited states, and not from the singly-excited states decaying to the ground state as is the current paradigm. Moreover, we find that transitions between these multiply-excited states also contribute in the same narrow window around 13.5 nm as those originating from singly-excited states, and this striking property holds over a wide range of charge states. We thus reveal the doubly magic behavior of tin and the origins of the EUV light.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

AMMT FY23 HFIR Irradiation Test Matrix – Supported by the Design of a Miniature Bend Bar Irradiation Vehicle

With the continued advancement of additive manufacturing (AM) techniques, interest has grown in the development and qualification of steels produced via these methods for use in the structural components of advanced nuclear reactors. Therefore, it is crucial that the properties of these materials such as the tensile strength and fracture toughness be investigated following neutron irradiation to support their use in industry. To that end, a test plan to irradiate several tensile and bend bar specimens in the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory was proposed, along with the development of a new “MINBEN” capsule design that features MBS-1 bend bar specimens that have a larger cross-sectional area than those of previous designs, which allows for higher temperature out-of-pile testing. The specimens include AM 316H stainless steel with wrought 316H and A709 stainless steels for reference, and they will be irradiated at 2 dpa and 10 dpa—corresponding to roughly 1 and 5 cycles at the HFIR midplane—at temperatures of 400°C and 600°C. The MINBEN design was found to be capable of providing specimen test plane average temperatures in the range of 220–660°C for six specimens, with a min-max spread in this temperature of ~40°C and a 95% confidence interval of ~24°C. This analysis shows that the capsule provides an effective vehicle for gathering needed high-temperature fracture toughness data.

36 MATERIALS SCIENCE↗

Nested Pebble Bed Blanket (NesPeB)

Recent advances in magnetic confinement fusion technology have attracted billions of dollars of investments in startups from venture capitals and corporations, resulting in the development of devices aiming to demonstrate net energy gain in a self-heated burning plasma, such as SPARC (under construction) and others. However, future fusion power plants must operate in regimes that will require technologies far beyond current experience. According to a National Academies of Science, Engineering, and Medicine report, to have nuclear fusion power plants contributing in a timely manner to the planned reduction of atmospheric carbon dioxide, a pilot plant should be built by 2035, and it should demonstrate fusion power production and the performance of the tritium fuel system (requiring a high enough tritium breeding) by 2040. A recognized key technology gap by [26] is the fusion first wall and blanket since no current blanket concept is considered satisfactory or has been built and proven. The first wall and blanket in magnetic fusion reactors form a vital and complex system, as it must satisfy different functions such as power extraction, tritium breeding, plasma containment, radiation shielding, and safety. The list of design requirements is even longer: high enough tritium production for fusion self-sufficiency, low material activation, decay heat and shutdown dose rates, high thermal efficiency, high-capacity factor, high magnets-divertor-vacuum vessel-first wall life, low corrosion, low cost, and intrinsically safe (requiring minimal licensing). Despite fifty-plus years of research, the first wall and blanket concepts proposed suffer from fundamental technical problems and immaturity (TRL=2-3) that jeopardize the timely delivery of a commercial fusion power plant. A fusion first-wall blanket has never been built nor tested, and a "winning", practical functioning design requires enough engineering margins (high enough tritium breeding considering the uncertainty, etc.), manufacturing simplicity, ease of continuous operation, maintenance, and low cost. A new, groundbreaking blanket concept called "Nested Pebble Bed Blanket" (NesPeB) was developed at ORNL under the successful ARPA-E GAMOW FERMI project (patent application allowed by the USPTO). The NesPeB blanket concept addresses current blanket concepts' shortcomings and technical immaturity, paving the way for accelerated delivery of fusion power plants. NesPeB is based on nested pebbles, which are binary-sized lithium-ceramic pebbles enclosed in "Beryllide" perforated and coated spherical shells, which are also binary-sized, stacked on top of each other, forming a "bed" and cooled by Nitrogen gas also "sweeping" the Helium and Tritium generated by the neutron irradiation of Lithium; the vacuum vessel plasma facing material is Molybdenum-96 and -97 with the first wall cooled by Helium while the divertor armor is made of Tungsten. The simulations of the NesPeB blanket using Fusion Reactors Models Integrator (FERMI) are encouraging as they estimate a tritium breeding ratio (TBR) greater than 1.2 using natural Lithium, acceptable pressure drop, and excellent heat transfer properties. Furthermore, the NesPeB blanket is not limited by magneto-hydro-dynamics (MHD) effects, is designed for online refueling, relies on existing tritium extraction technologies, has a simple construction, and limits the corrosion and chemical reactivity problems. NesPeB has the potential to be transformational and disruptive since it can solve all the main, challenging technical problems of fusion device blankets and accelerate a pilot plant delivery for 10 or more years.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Multi-Functional Smart Structures for Smart Vehicles

This report summarizes the development of a new class of recyclable multi-functional composite materials for production of lightweight smart structures and surfaces. Functional high stiffness conductive composites were processed using molding methods that integrated continuous fiber and additively manufactured features. Methods for integration of sensing functionality and controls were also developed to reduce system cost while providing a new capability for structural health monitoring. This new class of composites is applicable to a broad range of vehicle interior, exterior and battery enclosure systems. By way of demonstration, a vehicle instrument panel cross car beam was developed that provided a 38% mass savings compared to steel while maintaining a cost penalty competitive to alternate lightweight material solutions. These technologies were validated for implementation by a uniquely qualified project team comprising a US automotive OEM, Tier 1 and Tier 2 supplier, with key contributions from Oak Ridge National Lab, Purdue University and Michigan State University.

33 ADVANCED PROPULSION SYSTEMS↗

Space Station design integration

This paper discusses the top Program level design integration process which involves the integration of a US Space Station manned base that consists of both US and international Elements. It explains the form and function of the Program Requirements Review (PRR), which certifies that the program is ready for preliminary design, the Program Design Review (PDR), which certifies the program is ready to start the detail design, and the Critical Design Review (CDR), which certifies that the program is completing a design that meets the Program objectives. The paper also discusses experience, status to date, and plans for continued system integration through manufacturing, testing and final verification of the Space Station system performance.

Carlisle, Richard F.↗

Phase 9 Fiber Optic Cable Microbending and Temperature Cycling Tests

Optical fibers represent the back bone of the current communications networks. Their performance in the field lacks long term testing data because of the continuous evolution of the manufacturing of fibers and cables. An optical fiber cable that is installed in NASA's KSC has experienced a dramatic increase in attenuation after three years of use from 0.7 dB/km to 7 dB/km in some fibers. A thorough study is presented to assess the causes of such an attenuation increase. Material and chemical decomposition testing showed that there are no changes in the composition of the fiber which might have caused the increase in attenuation. Microbending and heat cycling tests were performed on the cable and individual fibers. It was found that the increase in attenuation is due to microbending caused by excessive stress exerted on the fibers. This was the result of manufacturing and installation irregularities.

Abushagur, Mustafa A.G.↗

Thermoplastic polymides and composites therefrom

A new class polyimide and polyimide precursors based on diaryl oxyalkylene diamines, such as 1,3-bis[4-aminophenoxy]-2,2-dimethyl propane, a process for their preparation and their use as the continuous phase for the manufacture of composites and composite laminates reinforced by reinforcing agents such as carbon fibers, Kevlar.TM., and other similar high strength reinforcing agents. The polyimides and molecular composites obtained from the diamines according to the invention show thermoplastic properties, excellent flex fatigue and fracture resistance, and excellent thermal and oxidative stability.

Harris, Frank W.↗

Hypervelocity Impact Performance of 3D Printed Aluminum Panels

With the continued development of additive manufacturing methods, control over the shape of ligaments, cell regularity, and macroscopic shape can all be easily tuned. This capability allows for tailoring of component architecture and promotes potential mass savings in a space vehicle structure. Additionally, it allows one the flexibility of combining structural elements such as MMOD protection and vehicle stiffness for launch loads for an overall mass reduction. At NASA JSC this technology is being explored in many different ways with the goal being a multifunctional structural component. For this study, four different types of aluminum panels have been 3D printed for testing, three being of a body centric cubic (BCC) lattice structure core and one being kelvin cell structure core. All samples have a 5.33 cm (0.05”) nominally thick aluminum face sheet printed on the front and back side of each panel, with all core materials having a 5.08 cm (2.0”) nominal thickness (see Table 1 for test sample summary and Figures 1 – 2 for sample illustrations). These tests will evaluate the performance of 3D printed aluminum panels under hypervelocity impact (HVI) conditions. The hypervelocity impact tests are being conducted at the JSC White Sands Test Facility (WSTF) Remote Hypervelocity Test Laboratory (RHTL), located in Las Cruces, New Mexico. All tests will be conducted with a 3.4mm Al 2017-T4 sphere at 6.8 km/s impacting at 0° to surface normal (i.e., impacting with no obliquity). Each sample will be trapped between two metal frames, with gasket material residing between the sample and frame, which will be the shipping and testing configuration for all tests. There will be an Al 2017-T4 witness plate staged 5.08 cm (2.0”) from each sample to capture signature of debris, if the rear face sheet of the sample were to perforate from the HVI test event.

Davis, B. A.↗