Process Specification for Flame Retardant Treatment of Fabrics and Webbings
This process specification establishes requirements for the application of flame retardant coatings to fabrics and webbings.
flame retardant↗
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Hair treatment process providing dispersed colors by light diffraction
A hair treatment process for providing dispersed colors by light diffraction including (a) coating the hair with a material comprising a polymer, (b) pressing the hair with a pressing device including one or more surfaces, and (c) forming a secondary nanostructured surface pattern on the hair that is complementary to the primary nanostructured surface pattern on the one or more surfaces of the pressing device. The secondary nanostructured surface pattern diffracts light into dispersed colors that are visible on the hair. The section of the hair is pressed with the pressing device for from about 1 to 55 seconds. The polymer has a glass transition temperature from about 55.degree. C. to about 90.degree. C. The one or more surfaces include a primary nanostructured surface pattern.
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
Carbon fiber and parylene structural capacitor
A structural capacitor and method for manufacturing the structural capacitor. A first layer of nonconductive fiber glass may be formed into a desired shape of the structural capacitor, and then a conductive layer made of carbon fiber pre-impregnated material may be placed on the fiber glass layer. A dielectric layer of parylene may then be coated onto the conductive layer using a conformal vapor deposition process. More conductive and dielectric layers may be added in alternating succession until desired structural and/or electrical properties are achieved. A final layer of fiber glass may then be applied and the resulting structural capacitor may be cured.
36 MATERIALS SCIENCE↗
Laser ablation sampling system and method
A method and system for sampling a solid sample material can include the step of mounting the sample material on a support. A sample surface is coated with a surface treatment composition in a dry deposition process. A solvent supply conduit for supplying solvent to the sample surface and a solvent exhaust conduit for withdrawing solvent from the sample surface can be provided. Solvent is flowed from the solvent supply conduit to the surface treatment composition and the sample surface such that the solvent contacts the surface treatment composition. A laser beam is directed from a laser source to the sample and the surface treatment composition. The laser beam will ablate the sample and the surface treatment composition in portions intersected by the laser beam. Ablated sample material enters the solvent liquid and will be transported with the solvent away from the sample surface through the solvent exhaust conduit.
Kertesz, Vilmos↗
The U.S. Accident Tolerant Fuels Program — Update on a National Initiative
In 2012 the U.S. Congress directed the Department of Energy’s (DOE) Office of Nuclear Energy to give priority to developing enhanced fuels and cladding for light water reactors to improve safety in the event of accidents in the reactor or spent fuel pools. DOE developed a plan with a goal to insert a Lead Test Assembly (LTA) into a commercial light water reactor by the end of FY 2022. Three of the leading commercial nuclear fuel vendors, in concert with several participating commercial nuclear utilities, are now seriously engaged in this initiative and have exceeded initial expectations by having met DOE’s goal this year, three years ahead of schedule. The early successes of the ATF program are due in part to a strong collaboration by the DOE national laboratories with both commercial nuclear fuel vendors and the U.S. Nuclear Regulatory Commission. This undertaking has recently been expanded to incorporate an effort to extend burnup from the current U.S. regulatory limit of 62 GWD/MTU and increase enrichment as necessary to support routine utilization of fuel at >75 GWD/MTU. This effort provides a critical economic incentive to accelerate the deployment of ATF technologies. This paper reviews the DOE-sponsored, industry-led ATF concepts currently under development and highlights the contributions made by the DOE laboratories in support of these ATF concepts, including: 1) steady-state irradiation testing in the Advanced Test Reactor (ATR) and High Flux Isotope Reactor (HFIR); 2) transient irradiation testing in the Transient Reactor Test Facility (TREAT); 3) fabrication process development and characterization of high density fuels, Cr-coated Zry cladding, FeCrAl cladding, and SiC cladding; and 4) post-irradiation examination of lead test rods irradiated in commercial reactors.
Goldner, Frank J.↗
Fabrication of Flexible Perovskite Solar Cells via Rapid Thermal Annealing
Adaptability, lightweight, and low cost of materials make flexible perovskite solar cells essential for the perovskite technology to breach commercial photovoltaic market. Roll-to-roll manufacturing has great potential for high-throughput perovskite manufacturing; however, conventional annealing methods are not capable of producing flexible perovskite solar cells at scale. Rapid thermal annealing (RTA), a radiative method, is utilized on roll-to-roll lines within many different industries and has shown promising potential for perovskite annealing. Here, we introduce a blade-coated perovskite thin film on flexible ITO-coated PET annealed via RTA that reduces post-deposition processing time from ~150 seconds to ~14 seconds. Performance was not sacrificed for scalability as a perovskite solar cell was produced with a power conversion efficiency (PCE) of 14.58%.
Martin, Blake↗
Laser ablation sampling system and method
A method and system for sampling a solid sample material can include the step of mounting the sample material on a support. A sample surface is coated with a surface treatment composition in a dry deposition process. A solvent supply conduit for supplying solvent to the sample surface and a solvent exhaust conduit for withdrawing solvent from the sample surface can be provided. Solvent is flowed from the solvent supply conduit to the surface treatment composition and the sample surface such that the solvent contacts the surface treatment composition. A laser beam is directed from a laser source to the sample and the surface treatment composition. The laser beam will ablate the sample and the surface treatment composition in portions intersected by the laser beam. Ablated sample material enters the solvent liquid and will be transported with the solvent away from the sample surface through the solvent exhaust conduit.
Kertesz, Vilmos↗
Iridium thin-film coatings for the BabyIAXO hybrid X-ray optic
Reflective coatings are an essential feature of X-ray telescopes. Their overall performance relies heavily on substrate compatibility and how well they conform to the optics assembly processes. We use X-ray reflectometry (XRR) to demonstrate the compatibility of shaping flat substrates coated with iridium, and show that specular and nonspecular reflectance before and after shaping is on par with traditional hot-slumped coated substrates. From 1.487 and 8.048 k e V measurements, we find that the substrates have rms roughness of 0.38 n m and magnetron sputtered iridium deposits with rms surface roughness of 0.27 − <#comment/> 0.35 n m . A hydrocarbon overlayer from atmospheric contamination is present with a thickness of 1.4 – 1.6 n m and a density of 1.2 − <#comment/> 1.6 g / c m 3 . Both the traditional hot slumped and the flat substrates undergoing post-coating shaping have a similar characteristic surface morphology and are equally well-suited for use with X-ray optics. Finally, we demonstrate by simulation the improved effective area achieved by using a low-Z overlayer, and illustrate the performance of a hybrid optic coated with optimized bilayers for a Primakoff axion spectrum emitted by the sun.
Henriksen, Peter L. (ORCID:0000000259031878)↗
Fiber-Optic Temperature Sensor Using a Thin-Film Fabry-Perot Interferometer
A fiber-optic temperature sensor was developed that is rugged, compact, stable, and can be inexpensively fabricated. This thin-film interferometric temperature sensor was shown to be capable of providing a +/- 2 C accuracy over the range of -55 to 275 C, throughout a 5000 hr operating life. A temperature-sensitive thin-film Fabry-Perot interferometer can be deposited directly onto the end of a multimode optical fiber. This batch-fabricatable sensor can be manufactured at a much lower cost than can a presently available sensor, which requires the mechanical attachment of a Fabry-Perot interferometer to a fiber. The principal disadvantage of the thin-film sensor is its inherent instability, due to the low processing temperatures that must be used to prevent degradation of the optical fiber's buffer coating. The design of the stable thin-film temperature sensor considered the potential sources of both short and long term drifts. The temperature- sensitive Fabry-Perot interferometer was a silicon film with a thickness of approx. 2 microns. A laser-annealing process was developed which crystallized the silicon film without damaging the optical fiber. The silicon film was encapsulated with a thin layer of Si3N4 over coated with aluminum. Crystallization of the silicon and its encapsulation with a highly stable, impermeable thin-film structure were essential steps in producing a sensor with the required long-term stability.
Beheim, Glenn↗
Twenty-First Century Research Needs in Electrostatic Processes Applied to Industry and Medicine
From the early century Nobel Prize winning (1923) experiments with charged oil droplets, resulting in the discovery of the elementary electronic charge by Robert Millikan, to the early 21st century Nobel Prize (2002) awarded to John Fenn for his invention of electrospray ionization mass spectroscopy and its applications to proteomics, electrostatic processes have been successfully applied to many areas of industry and medicine. Generation, transport, deposition, separation, analysis, and control of charged particles involved in the four states of matter: solid, liquid, gas, and plasma are of interest in many industrial and biomedical processes. In this paper, we briefly discuss some of the applications and research needs involving charged particles in industrial and medical applications including: (1) Generation and deposition of unipolarly charged dry powder without the presence of ions or excessive ozone, (2) Control of tribocharging process for consistent and reliable charging, (3) Thin film (less than 25 micrometers) powder coating and Powder coating on insulative surfaces, (4) Fluidization and dispersion of fine powders, (5) Mitigation of Mars dust, (6) Effect of particle charge on the lung deposition of inhaled medical aerosols, (7) Nanoparticle deposition, and (8) Plasma/Corona discharge processes. A brief discussion on the measurements of charged particles and suggestions for research needs are also included.
Mazumder, M. K.↗
Additive Manufacturing for Large Displacement Unmanned Underwater Vehicles (LDUUVs)
Oak Ridge National Laboratory partnered with Anduril Industries to develop the process for adapting large format additive manufacturing for the production of underwater vehicles. This research started by defining and selecting a polymer for the vehicle panels. Coatings were tested at 9000PSI to ensure proper bonding to the 3D printed panels, then tensile tested to understand the mechanical properties. A vehicle panel fairing set was design optimized for the 3D printing process and then 3D printed. Additional work optimized coatings and tested additional reinforcements methods such as fiber weave and z-casting with fiber rods and resin. Finally, a full vehicle was constructed and successfully tested in open water by Anduril.
36 MATERIALS SCIENCE↗
Investigation into the Wear and Dent Resistance of Ni/Ti Nanolaminates and Superelastic NiTi Coating
Metallic wear-resistant coatings, such as chromium based, are desired to prevent premature failure of working parts and are widely used in the oil and gas and aerospace industries. These coatings are extremely hard; however, researchers have found that an optimal coating will also be resilient. Bulk NiTi possesses a superelasticity effect that can provide wear resistance to parts that will experience impact, wear, and erosion daily. Yet, NiTi as a surface coating has not been fully exploited in industrial applications. Bulk NiTi production presents significant challenges, such as poor formability and machinability. This study attempts to fabricate NiTi through a heat treatment process of sputter-deposited alternating nanosized Ni and Ti layers. After annealing, the nanolaminate coatings contained the austenitic NiTi phase. The elastic modulus to hardness ratio and wear resistance showed that the nanolaminate annealed at 650 °C is comparable to the sputtered superelastic NiTi coating. The annealed nanolaminate coating is found to exhibit higher hardness than the monolayered NiTi, as well as, comparable elastic modulus to hardness values and dent resistance. The findings in this study reveal the superiority of 650 °C annealed nanolaminate NiTi coating over the monolayer NiTi.
36 MATERIALS SCIENCE↗
Dry Sliding Wear Resistance of Cobalt Boride Coatings Formed on ASTM F1537 Alloy
New results about the wear resistance of CoB-Co{sub 2}B coatings under dry sliding conditions were estimated in this work. The cobalt boride coatings were developed at the surface of the ASTM F1537 alloy by means of the powder-pack boriding process using two experimental conditions: 1223 K with 6 h of exposure and 1273 K with 10 h of exposure. Before the sliding wear tests, Vickers depth-sensing microindentation tests were conducted on the cross section of the cobalt boride coatings to estimate the distribution of hardness, Young’s modulus, and residual stresses. Otherwise, the sliding wear tests were performed on both boriding conditions and on the untreated material, using a ball-on-flat configuration comprised of an alumina ball as a counterpart with applied loads between 5 and 20 N. The wear rates of the borided ASTM F1537 alloy were ranged between 4.02 and 8.91 × 10{sup −6} mm{sup 3} N{sup −1} m{sup −1} compared with the values of the untreated material (13.90 and 15.78 × 10{sup −6} mm{sup 3} N{sup −1} m{sup −1}) for the overall set of experimental conditions; nevertheless, the influence of boriding conditions (1273 K with 10 h of exposure) tended to increase the CoB coating thickness, developing a more brittle layer that decreased the sliding wear resistance at the surface of the borided ASTM F1537 alloy. Finally, the presence of failure mechanisms on the surface of the wear tracks was analyzed for both borided ASTM F1537 alloy and untreated material.
36 MATERIALS SCIENCE↗
Antifouling Properties and Release of Dissolved Copper of Cold Spray Cu/Cu{sub 2}O Coatings for Ships and Steel Structures in Marine Environment
At the submarine screen doors of ships, the flow of water was fast and organic coatings were easy to peel off. To solve the problems of biofouling, the Cu/Cu{sub 2}O coatings were prepared by cold spray technology. In this paper, the release mechanism of effective antifouling components of the coatings was studied by micro-domain electrochemical potential scanning technique. Cuprous oxide in the coatings and the surrounding copper constituted micro-cells which accelerated the local electrochemical dissolution of copper. Cuprous oxide acted as the cathode, and the surrounding copper acted as the anode. Meanwhile, under the action of current, chloride ions were transferred from cathode to the anode and promoted local electrochemical dissolution of copper. Experiments show that the higher the Cu{sub 2}O content in the coatings, the greater the release rate of dissolved copper and inhibitory effect on diatoms. In the environments varied in dissolved oxygen, salinity, temperature and flow rate, the coatings maintained sufficient release rate of dissolved copper, unless the salinity was very low. Most of the dissolved copper was provided by the electrochemical dissolution process of copper. Whether in the indoor test or marine environment experiments, 30% Cu{sub 2}O coatings show the best performance. After insulating layer was sprayed, the effect of antifouling was improved evidently and the coatings were applied to the submarine screen doors of ships.
36 MATERIALS SCIENCE↗
Effects of Laser Fluence on Microstructure and Bonding Characteristics of Wideband Laser-Deposited Nickel Composite Coatings
The wideband laser has shown great potential in metal–ceramic coatings deposition due to the high efficiency and low dilution rate. However, the effects of wideband laser process on microstructure evolution and bonding mechanism at the coatings/substrate interface are still a critical problem and need further investigation. In this work, nickel composite coatings are fabricated on the surface high-strength low-alloy steel. The effects of laser fluence on microstructure evolution, shear strength and fracture mechanism are studied. Results indicated the added WC particles were partly dissolved due to the high-power laser irradiation. Many block precipitates and dense eutectic were synthesized in composite coatings. Reinforced phases mainly consist of Cr{sub 5}B{sub 3}, Cr{sub 23}C{sub 6}, W{sub 2}C and Cr{sub 3}Ni{sub 2}. The dilution of Q550 steel contributed to the formation of nickel dendrites and facilitated a dense metallurgical bonding at coating/substrate interface when laser fluence was high. Shear strength tests indicated the laser fluence and shear strength had a positive correlation. For Ni60/WC composite coatings designed in these experiments, the recommend laser fluence should be higher than 55 J/mm{sup 2}, above which the shear strength could be greater than 200 MPa. Fracture surfaces indicated the failure mechanism of composite coatings was quasi-cleavage fracture.
36 MATERIALS SCIENCE↗
Fabrication of oxide dispersion strengthened bond coats with low Al 2 O 3 content [Fabrication of ODS bond coats with low Al 2 O 3 content]
Here, nanoscale oxide dispersions have long been used to increase the oxidation and wear resistance of alloys used as bond coatings in thermal barrier coatings. Their manufacturing via mechanical alloying is often accompanied by difficulties regarding their particle size, homogeneous distribution of the oxide dispersions inside the powder, involving considerable costs, due to cold welding of the powder during milling. A significant improvement in this process can be achieved by the use of process control agent (PCA) to achieve the critical balance between cold welding and fracturing, thereby enhancing the process efficiency. In this investigation, the influence of the organic additive stearic acid on the manufacturing process of Al 2 O 3 -doped CoNiCrAlY powder was investigated. Powders were fabricated via mechanical alloying at different milling times and PCA concentrations. The results showed a decrease in particle size, without hindering the homogeneous incorporation of the oxide dispersions. Two powders manufactured with 0.5 and 1.0 wt.% PCA were deposited by high velocity oxygen fuel (HVOF) spraying. Results showed that a higher content of elongated particles in the powder with the higher PCA content led to increased surface roughness, porosity and decreased coating thickness, with areas without embedded oxide particles.
36 MATERIALS SCIENCE↗
Numerical Modeling of High-Temperature Corrosion Processes
Numerical modeling of the diffusional transport associated with high-temperature corrosion processes is reviewed. These corrosion processes include external scale formation and internal subscale formation during oxidation, coating degradation by oxidation and substrate interdiffusion, carburization, sulfidation and nitridation. The studies that are reviewed cover such complexities as concentration-dependent diffusivities, cross-term effects in ternary alloys, and internal precipitation where several compounds of the same element form (e.g., carbides of Cr) or several compounds exist simultaneously (e.g., carbides containing varying amounts of Ni, Cr, Fe or Mo). In addition, the studies involve a variety of boundary conditions that vary with time and temperature. Finite-difference (F-D) techniques have been applied almost exclusively to model either the solute or corrodant transport in each of these studies. Hence, the paper first reviews the use of F-D techniques to develop solutions to the diffusion equations with various boundary conditions appropriate to high-temperature corrosion processes. The bulk of the paper then reviews various F-D modeling studies of diffusional transport associated with high-temperature corrosion.
Nesbitt, James A.↗
Development of a Prototype Nickel Optic for the Constellation-X Hard-X-Ray Telescope
The Constellation-X mission, planned for launch in 2011, will feature an array of hard-x ray telescopes with a total collecting area goal of 1500 square centimeters at 40 keV. Various technologies are currently being investigated for the optics of these telescopes including multilayer-coated Eletroformed-Nickel-Replicated (ENR) shells. The attraction of the ENR process is that the resulting full-shell optics are inherently stable and offer the promise of good angular resolution and enhanced instrument sensitivity. The challenge for this process is to meet a relatively tight weight budget with a relatively dense material (rho nickel = 9 grams per cubic centimeters.) To demonstrate the viability of the ENR process we are fabricating a prototype HXT mirror module to be tested against a competing segmented-glass-shell optic. The ENR prototype will consist of 5 shells of diameters from 150 mm to 280 mm and of 426 mm total length. To meet the stringent weight budget for Con-X, the shells will be only 150 micron thick. The innermost of these will be coated with Iridium, while the remainder will be coated with graded-density multilayers. Mandrels for these shells are currently under fabrication (Jan 03), with the first shells scheduled for production in February 03. A tentative date of late Summer has been set for prototype testing. Issues currently being addressed are the control of stresses in the multiplayer coating and ways of mitigating their effects on the figure of the necessarily thin shells. Also, the fabrication, handling and mounting of these shells without inducing permanent figure distortions. A full status report on the prototype optic will be presented along with test results as available.
Basso, S.↗