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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS1982

Low-speed aerodynamic characteristics of a generic forward-swept-wing aircraft

Low-speed wind-tunnel tests were performed on a generic forward-swept-wing aircraft model in the 7- by 10-Foot Wind Tunnel (No. 2) at Ames Research Center. The effects of various configurational changes and control-surface deflections on the performance of the model were measured. Six-component force measurements were augmented by flow-visualization photographs, using both surface oil-flow and tufts. It was found that the tendency toward premature root separation on the forward-swept wing could be reduced by use of either canards or leading-edge wing strakes and that differential canard deflections can be used to produce a direct side-force control.

Ross, J. C.↗
DOE OSTI2025

Adsorption of REEs to Kaolinite via Ion Exchange and Surface Complexation as a Function of Water Chemistry

Rare earth elements (REEs) are critical components of modern technology behind renewable energy, transportation, and electronics but have a limited current supply. A substantial portion of global REE production relies on ion adsorption deposits. A high abundance of kaolinite in REE enrichment zones within these deposits suggests that kaolinite controls the subsurface migration of REEs. This study aimed to improve the current understanding of REE binding to kaolinite under varying water chemistry conditions. We conducted batch experiments with kaolinite (KGa-2) and three REEs (Nd, Dy, and Yb) at varying pH, electrolyte concentration, dissolved inorganic carbon (DIC), low molecular weight organic acids (citric and oxalic acids), and total REE concentration conditions. Increasing electrolyte concentration inhibits REE adsorption at pH < 7, suggesting that ion exchange contributes to adsorption at these pH values. DIC affects adsorption above pH 7–8 by forming strong aqueous complexes with heavy REEs. Citric acid decreases REE adsorption via aqueous complexation of REEs at pH > 5 but does not affect adsorption at pH < 5. The surface complexation model captures the main adsorption trends with two mechanisms: ion exchange on basal planes at pH < ∼6 and inner-sphere surface complexation to edge sites at pH > ∼6. Equilibrium constants for surface complexation increase in the order of Yb > Dy > Nd, indicating a higher strength of adsorption for heavy REEs. This study demonstrates how water chemistry conditions control the adsorption mechanisms that may determine the mobility of REEs in subsurface environments rich in kaolinite.

58 GEOSCIENCES↗
DOE OSTI2025

Adsorption of Rare Earth Elements to Kaolinite [dataset]

Rare earth elements (REEs) are critical components of modern technology behind renewable energy, transportation, and electronics but have a limited current supply. A substantial portion of global REE production relies on ion adsorption deposits. A high abundance of kaolinite in REE enrichment zones within these deposits suggests that kaolinite controls the subsurface migration of REEs. This study aimed to improve the current understanding of REE binding to kaolinite under varying water chemistry conditions. We conducted batch experiments with kaolinite (KGa-2) and three REEs (Nd, Dy, and Yb) at varying pH, electrolyte concentration, dissolved inorganic carbon (DIC), low molecular weight organic acids (citric and oxalic acids), and total REE concentration conditions. Increasing electrolyte concentration inhibits REE adsorption at pH 7, suggesting that ion exchange contributes to adsorption at these pH values. DIC affects adsorption above pH 7−8 by forming strong aqueous complexes with heavy REEs. Citric acid decreases REE adsorption via aqueous complexation of REEs at pH 5 but does not affect adsorption at pH 5. The surface complexation model captures the main adsorption trends with two mechanisms: ion exchange on basal planes at pH ∼6 and inner-sphere surface complexation to edge sites at pH ∼6. Equilibrium constants for surface complexation increase in the order of Yb Dy Nd, indicating a higher strength of adsorption for heavy REEs. This study demonstrates how water chemistry conditions control the adsorption mechanisms that may determine the mobility of REEs in subsurface environments rich in kaolinite.

58 GEOSCIENCES↗
NASA NTRS2011

Mount Protects Thin-Walled Glass or Ceramic Tubes from Large Thermal and Vibration Loads

The design allows for the low-stress mounting of fragile objects, like thin walled glass, by using particular ways of compensating, isolating, or releasing the coefficient of thermal expansion (CTE) differences between the mounted object and the mount itself. This mount profile is lower than true full kinematic mounting. Also, this approach enables accurate positioning of the component for electrical and optical interfaces. It avoids the higher and unpredictable stress issues that often result from potting the object. The mount has been built and tested to space-flight specifications, and has been used for fiber-optic, optical, and electrical interfaces for a spaceflight mission. This mount design is often metal and is slightly larger than the object to be mounted. The objects are optical or optical/electrical, and optical and/or electrical interfaces are required from the top and bottom. This requires the mount to be open at both ends, and for the object s position to be controlled. Thin inside inserts at the top and bottom contact the housing at defined lips, or edges, and hold the fragile object in the mount. The inserts can be customized to mimic the outer surface of the object, which further reduces stress. The inserts have the opposite CTE of the housing material, partially compensating for the CTE difference that causes thermal stress. A spring washer is inserted at one end to compensate for more CTE difference and to hold the object against the location edge of the mount for any optical position requirements. The spring also ensures that any fiber-optic or optic interface, which often requires some pressure to ensure a good interface, does not overstress the fragile object. The insert thickness, material, and spring washer size can be traded against each other to optimize the mount and stresses for various thermal and vibration load ranges and other mounting requirements. The alternate design uses two separate, unique features to reduce stress and hold the object. A release agent is applied to the inside surface of the mount just before the binding potting material is injected in the mount. This prevents the potting material from bonding to the mount, and thus prevents stress from being applied, at very low temperatures, to the fragile object being mounted. The potting material mixing and curing is temperature- and humidity-controlled. The mount has radial grooves cut in it that the potting material fills, thus controlling the vertical position of the mounted object. The design can easily be used for long and thin objects, short and wide objects, and any shape in between. The design s advantages are amplified for long and thin fragile objects. The general testing range was 45 to +45 C, but multiple mounts were successfully tested down to 60 and up to 50 C and the design can be adjusted for larger ranges.

Amato, Michael↗
DOE OSTI2021

Accelerating Hydrogen Absorption and Desorption Rates in Palladium Nanocubes with an Ultrathin Surface Modification

Exploiting the high surface-area-to-volume ratio of nanomaterials to store energy in the form of electrochemical alloys is an exceptionally promising route for achieving high-rate energy storage and delivery. Nanoscale palladium hydride is an excellent model system for understanding how nanoscale-specific properties affect the absorption and desorption of energy carrying equivalents. Hydrogen absorption and desorption in shape-controlled Pd nanostructures does not occur uniformly across the entire nanoparticle surface. Instead, hydrogen absorption and desorption proceed selectively through high-activity sites at the corners and edges. Such a mechanism hinders the hydrogen absorption rates and greatly reduces the benefit of nanoscaling the dimensions of the palladium. To solve this, we modify the surface of palladium with an ultrathin platinum shell. This modification nearly removes the barrier for hydrogen absorption (89 kJ/mol without a Pt shell and 1.8 kJ/mol with a Pt shell) and enables diffusion through the entire Pd/Pt surface.

25 ENERGY STORAGE↗
NASA NTRS1990

Curvature continuity in arbitrary bicubic Bezier patches

Two methods are outlined for imposing interpatch curvature continuity in existing Bezier bicubic patch surfaces. Each method assumes that coordinates of the corners of the patches can not be altered but the interior Bezier control point can. Each method also preserves outer edge slope and outer corner twist derivatives. Neither method requires intersection or C0 continuity nor slope or C1 continuity at the start. A computer program for each method is given in the appendices.

Roach, Robert L.↗
NASA NTRS2007

Manufacturing Large Membrane Mirrors at Low Cost

Relatively inexpensive processes have been developed for manufacturing lightweight, wide-aperture mirrors that consist mainly of reflectively coated, edge-supported polyimide membranes. The polyimide and other materials in these mirrors can withstand the environment of outer space, and the mirrors have other characteristics that make them attractive for use on Earth as well as in outer space: With respect to the smoothness of their surfaces and the accuracy with which they retain their shapes, these mirrors approach the optical quality of heavier, more expensive conventional mirrors. Unlike conventional mirrors, these mirrors can be stowed compactly and later deployed to their full sizes. In typical cases, deployment would be effected by inflation. Potential terrestrial and outer-space applications for these mirrors include large astronomical telescopes, solar concentrators for generating electric power and thermal power, and microwave reflectors for communication, radar, and short-distance transmission of electric power. The relatively low cost of manufacturing these mirrors stems, in part, from the use of inexpensive tooling. Unlike in the manufacture of conventional mirrors, there is no need for mandrels or molds that have highly precise surface figures and highly polished surfaces. The surface smoothness is an inherent property of a polyimide film. The shaped area of the film is never placed in contact with a mold or mandrel surface: Instead the shape of a mirror is determined by a combination of (1) the shape of a fixture that holds the film around its edge and (2) control of manufacturing- process parameters. In a demonstration of this manufacturing concept, spherical mirrors having aperture diameters of 0.5 and 1.0 m were fabricated from polyimide films having thicknesses ranging from <20 m to 150 m. These mirrors have been found to maintain their preformed shapes following deployment.

FROM↗
NASA NTRS2019

Sea Surface Salinity Distribution in the Southern Ocean as Observed from Space

Large-scale spatial and temporal variabilities of sea surface salinity (SSS) in the Southern Ocean from 2011 to 2017 were studied using products derived from microwave sensors on board Aquarius, Soil Moisture and Ocean Salinity (SMOS), and Soil Moisture Active and Passive (SMAP) satellites. Four products, three from Aquarius and one from SMOS, were evaluated and shown to be generally consistent within 0.3 to 0.6 psu and agree favorably with in situ measurements. However, although the Aquarius products show consistent seasonality of SSS with high values of 34.45 psu in October and low values of 33.40 psu in May, theSMOS and SMAP products lack such seasonal variations. This may be caused by larger uncertainties in the SMOS and SMAP data due in part to the lack of concurrent scatterometer measurements that is used to correct for roughness effects. The four products provide similar spatial distributions of SSS with root mean square difference from 0.25 to 0.58 psu. Differences among Aquarius products are mainly due to varying salinity retrieval algorithms, smoothing, and masking of sea ice, while the SMOS product showed the highest SSS deviation that is likely due to the bias adjustment done on the data set. Our analyses show that SSS in the Southern Ocean region has significant meridional variations with the lowest SSS near the ice edge and highest at lower latitudes. The SSS is also lowest in summer indicating the predominant influence of sea ice and glacial melt, but it stays low near ice edges even during the growth season. Salinity together with temperature is the key parameters that control the state and circulation of the World's oceans. The large‐scale distribution of the sea surface salinity of the Southern Ocean is quantified for the first time using Aquarius, Soil Moisture and Ocean Salinity, and Soil Moisture Active and Passive satellite microwave data. Seasonal and interannual changes in the distribution as affected by the sea ice cover, surface temperature, and precipitation are evaluated. Comparative studies were done, using four different products that are publicly available, in conjunction with in situ observations to gain insights into the true nature of the distribution and how consistently the sea surface salinity is depicted by the different products. There are general consistencies in the products, and discrepancies are attributed to different algorithms, smoothing techniques, and sea ice masking. Aquarius data are shown to have higher accuracy than Soil Moisture and Ocean Salinity and Soil Moisture Active and Passive products in part because of having concurrent scatterometer that provides accurate correction to roughness effects.

Garcia-Eidell, Cynthia↗
DOE OSTI2022

Observation of formation and local structures of metal-organic layers via complementary electron microscopy techniques

Abstract Metal-organic layers (MOLs) are highly attractive for application in catalysis, separation, sensing and biomedicine, owing to their tunable framework structure. However, it is challenging to obtain comprehensive information about the formation and local structures of MOLs using standard electron microscopy methods due to serious damage under electron beam irradiation. Here, we investigate the growth processes and local structures of MOLs utilizing a combination of liquid-phase transmission electron microscopy, cryogenic electron microscopy and electron ptychography. Our results show a multistep formation process, where precursor clusters first form in solution, then they are complexed with ligands to form non-crystalline solids, followed by the arrangement of the cluster-ligand complex into crystalline sheets, with additional possible growth by the addition of clusters to surface edges. Moreover, high-resolution imaging allows us to identify missing clusters, dislocations, loop and flat surface terminations and ligand connectors in the MOLs. Our observations provide insights into controllable MOL crystal morphology, defect engineering, and surface modification, thus assisting novel MOL design and synthesis.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Design of low Reynolds number airfoils. I

The low Reynolds number airfoils designated ASM-LRN-003 and -007 have been designed for high section L/D ratios using Drela's (1985) design-and-analysis code; close to 70-percent laminar flow is maintained on the upper surfaces, and 100-percent on the lower, at coefficients of lift of 1.0-1.3, assuming optimum laminar separation and transition control on the upper surface by means of suitable turbulators. If peak performance is critical, airfoils of this type with an undercut front lower surface and a correspondingly sharper leading edge may be resorted to.

Pfenninger, W.↗
NASA NTRSDate not supplied

Effects of Porous Gap Fillers on 30P30N Leading-Edge SlatNoise. Part I: Surface Pressure and Acoustics

The leading edge slat of a high-lift system is one of the main contributors to airframe noise during approach. In a previous experimental study, we assessed the performance of an impermeable slat gap filler as a passive flow control device to reduce the slat noise associated with a two-dimensional, three-element high-lift airfoil. The present paper, the first of two parts,represents a follow-on investigation to assess the relative efficacy of permeable gap fillers thatallow successively higher amounts of flow to pass through the gap. To evaluate the influence of this passive flow control device on the acoustics generated by the unsteady flow near the slat, experiments are conducted in an anechoic wind tunnel by mounting a gap filler to the slat element of the two-dimensional 30P30N high-lift configuration. Measurements are performed at a single geometric angle of attack (𝛼𝑘=8◦) and three different flow speeds that correspond to Reynolds numbers of𝑅𝑒𝑐=1.2𝑒6,1.5𝑒6, and1.71𝑒6, respectively. Steady surface pressure measurements are used to gauge the influence of the permeable gap filler treatments on the overall lift. The effect of each treatment on the radiated noise is analyzed via acoustic array measurements, followed by delay-and-sum beamforming to locate the slat noise sources and to provide the integrated acoustic spectra. The porous gap fillers are found to eliminate the narrowband peaks in the acoustic spectra and, also, to yield a 10 dB reduction in the broadband noise in comparison with the baseline case with no gap filler. The porous gap filler with thelowest permeability acts similar to the impermeable gap filler examined previously. However, the aerodynamics and noise reduction both degrade with increasing permeability. An accompanying abstract describes the particle image velocimetry measurements of the flowfield within the slat cove and on either side of the permeable gap f

slat noise↗
DOE OSTI2020

Calcium-Uranyl-Carbonato Species Kinetically Limit U(VI) Reduction by Fe(II) and Lead to U(V)-Bearing Ferrihydrite

Reaction conditions and mechanisms promoting or inhibiting U reduction exert a central control on U solubility and, therefore, U transport and its associated risks. Here, we vary and track common aqueous uranium species to show that a kinetic restriction inhibits homogeneous reduction of the calcium-uranyl-carbonato species (CaUO$_2$(CO$_3$)$_3$$^{2–}$ and Ca$_2$UO$_2$(CO$_3$)$_3$) by Fe(II)$_{(aq)}$, while ferrihydrite surface-catalyzed reduction of all aqueous uranyl by Fe(II) proceeds. Using U L$_3$ high energy resolution fluorescence detection (HERFD) X-ray absorption near edge structure (XANES) spectroscopy, U L$_3$ extended X-ray absorption fine structure (EXAFS) spectroscopy, and transmission electron microscopy (TEM), we also show that U(V) is generated and incorporated into ferrihydrite formed from homogeneous U(VI) reduction by Fe(II)(aq). Through elucidation of the mechanisms that inhibit reduction of the calcium-uranyl-carbonato species and promote stabilization of U(V), we advance our understanding of the controls on U solubility and thus improve prediction of U transport in surface and subsurface systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Ligand Controls Excited Charge Carrier Dynamics in Metal-Rich CdSe Quantum Dots: Computational Insights

Small metal-rich semiconducting quantum dots (QDs) are promising for solid-state lighting and single-photon emission due to their highly tunable yet narrow emission line widths. Nonetheless, the anionic ligands commonly employed to passivate these QDs exert a substantial influence on the optoelectronic characteristics, primarily owing to strong electron–phonon interactions. In this work, we combine time-domain density functional theory and nonadiabatic molecular dynamics to investigate the excited charge carrier dynamics of Cd 28 Se 17 X 22 QDs (X = HCOO – , OH – , Cl – , and SH – ) at ambient conditions. These chemically distinct but regularly used molecular groups influence the dynamic surface-ligand interfacial interactions in Cd-rich QDs, drastically modifying their vibrational characteristics. The strong electron–phonon coupling leads to substantial transient variations at the band edge states. The strength of these interactions closely depends on the physicochemical characteristics of passivating ligands. Consequently, the ligands largely control the nonradiative recombination rates and emission characteristics in these QDs. Our simulations indicate that Cd 28 Se 17 (OH) 22 has the fastest nonradiative recombination rate due to the strongest electron–phonon interactions. Conversely, QDs passivated with thiolate or chloride exhibit considerably longer carrier lifetimes and suppressed nonradiative processes. The ligand-controlled electron–phonon interactions further give rise to the broadest and narrowest intrinsic optical line widths for OH and Cl-passivated single QDs, respectively. Finally, obtained computational insights lay the groundwork for designing appropriate passivating ligands on metal-rich QDs, making them suitable for a wide range of applications, from blue LEDs to quantum emitters.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Drift-kinetic effects of tungsten on plasma response to RMP in ITER

Here, effects of high- Z ( Z is the particle charge number) tungsten impurity ions on the plasma response to the resonant magnetic perturbation (RMP) field are numerically investigated for the ITER 15 MA baseline scenario, where the tungsten contribution to the plasma response is computed with a drift-kinetic model while the bulk thermal particle contributions follow the fluid approximation. The study yields three highlights: (i) the drift-kinetic contribution of the tungsten impurity exerts minor influence on the plasma response compared to that computed by the pure fluid model without tungsten; (ii) a new figure of merit, based on the resonant spectrum perturbation at the plasma boundary surface, results in different optimal coil phasing compared to that previously obtained by maximizing the edge-peeling plasma response; (iii) the optimal $n = 3$ RMP (for edge localized mode (ELM) control, $n$ is the toroidal mode number) is found to induce a large tungsten particle influx near the plasma edge associated with the neoclassical toroidal viscosity. The study thus provides useful data on the compatibility of the full tungsten wall with RMP ELM control in ITER.

ITER↗
NASA NTRS1972

Study of the detail content of Apollo orbital photography

The results achieved during a study of the Detail Content of Apollo Orbital Photography are reported. The effect of residual motion smear or image reproduction processes upon the detail content of lunar surface imagery obtained from the orbiting command module are assessed. Data and conclusions obtained from the Apollo 8, 12, 14 and 15 missions are included. For the Apollo 8, 12 and 14 missions, the bracket-mounted Hasselblad camera had no mechanism internal to the camera for motion compensation. If the motion of the command module were left totally uncompensated, these photographs would exhibit a ground smear varying from 12 to 27 meters depending upon the focal length of the lens and the exposure time. During the photographic sequences motion compensation was attempted by firing the attitude control system of the spacecraft at a rate to compensate for the motion relative to the lunar surface. The residual smear occurring in selected frames of imagery was assessed using edge analyses methods to obtain and achieved modulation transfer function (MTF) which was compared to a baseline MTF.

Kinzly, R. E.↗
NASA NTRS2008

The Characterization of the Selected Materials for Space Shuttle

The harsh conditions to which the Space Shuttles are exposed during flight required the development and use of many unique materials. These materials were specially designed to withstand extreme temperatures, in some cases over 1600 C, while other material must withstand the cryogenic conditions of -253 C, and others must operate while under extreme loads. All of these materials must not only operate in the harsh condition but they must be light weight as well. The Space Shuttle is composed of three major components when configured for launch, Figure 1; the Shuttle, solid rocket boosters, and external tank (ET). The different heat shields of the Shuttle make up the thermal protection system (TPS); this system consists of many different types of components designed to operate on various parts of the vehicle. The body of the Shuttle and ET are composed mainly of aluminum alloy and graphite epoxy. The TPS consists of reinforced carbon-carbon (RCC) used on the wing leading edges and nose cap areas while the upper forward fuselage areas, the entire underside of the Shuttle, the Orbiter maneuvering system, and reaction control system utilize blacc high temperature reusable surface insulation (HRSI) tiles, Figure 2. Other areas of the Orbiter are protected by fibrous refractory composite insulation (FRCI) tiles. Areas where the temperature stays below 649 C, such as the forward fuselage, mid-fuselage, aft fuselage, vertical tail, and upper wing, are protected by other material such as, white low temperature reusable surface insulation (LRSI) tiles, advanced flexible reusable surface insulation (AFRSI) blankets, and felt reusable surface insulation (FRSI) white blankets. The RCC is a pyrolized laminated carbon with the outer surface converted to silicon carbide to prevent oxidation. The FiRST tiles are made of a low-density, high purity silica 99.8-percent amorphous fiber insulation that is made rigid by ceramic bonding resulting in 90-percent void and 10-percent materials. The RCC and HRSI are used in areas where the temperature rises above 1260 T. The FRCI tiles are high strength tiles derived by adding alumina-bososilicate fiber to the pure silica tile slurry that welds the micron-sizes fibers of pure silica into a rigid structure during sintering. The FRCI is composed of 20-percent alumina-borosilicate fibers and 80-percent silica fibers, and provided improved strength, durability and resistance to coating cracking and weight reduction than HRSI.

Kim, Hae-Soo↗
NASA NTRSDate not supplied

Roman-WFI: characterization of widefield chromatic response

Characterization of filter transmission is essential to control systematic chromatic errors in photometric surveys. Widefield surveys employ large filter optics viewed from high angles of incidence. Large optics may have variations in edge wavelength definition across their surface, and their spectral response shifts at high incidence angles. I will describe the characterization of the band definitions for the Wide Field Instrument of the Roman Space Telescope as part of its thermal vacuum test campaigns and through preparatory work. The measurement approach and analysis enable joint retrieval of chromatic response variations across the filter and focal plane. Additional tests probe out-of-band response and thermal straylight paths.

Eric Switzer↗
DOE OSTI2022

High-Silicon Steel Strip by Single-Step Shear Deformation Processing

It is well known that Fe-Si alloys with Si content higher than in conventional electrical sheet steels (>3.2% Si) can make a significant impact in improving the efficiency of electrical motors if they are available in sheet/foil (strip) forms at suitable cost. While the magnetic and electrical attributes (e.g., resistivity, core loss) of these high-Si Fe alloys, of relevance to electrical motor core laminations, are known to be exceptional, the alloys have limited workability, making them difficult to produce consistently in sheet/foil (strip) forms. Current processing techniques such as rolling, while adequate for producing conventional electrical steel sheet, do have important disadvantages - large energy consumption and emissions, limitations in processing of low-workability alloys (e.g., high-Si content steels), large-scale plant infrastructure, and less than adequate capability to engineer sheet metals with specific microstructures (e.g., fine-grained) and crystallographic textures (e.g., shear textures). It is therefore of interest to have an alternative commercial process that can produce sheet/foil (strip) from high-Si Fe alloys and which can also overcome some of the deficiencies of current multistage strip processes. The goal of the present project was design and demonstration of a new energy-efficient pilot process for producing high-Si electrical steel strip of commercial widths and thickness, and with superior electrical and magnetic properties than current electrical steels (Fe-3.2% Si as benchmark). The applications domain for these steels is electrical motor core laminations. We have addressed this goal by accomplishment of the following specific objectives and tasks: a) Development of an Fe-4Si-4Cr alloy with electrical resistivity >80 μΩ-cm, induction flux density >1.48 T at 5000 A/m and core loss 35% lower than the benchmark 3.2% Si alloy. The alloy which meets DOE target specifications for motor core attributes was designed with the Si content controlled for the electrical properties and the Cr content tailored to meet material/process workability requirements. b) A unique machining-based deformation processing system was designed and scaled-up to produce strip of commercial width (25 mm to 150 mm) and thickness (up to 0.5 mm) from the Fe-4Si-4Cr alloy and other alloys of varied workability including copper, Al6061-T6 and naval brass. The key attributes of the machining-based strip production are deformation processing by concentrated simple-shear; single-step production of strip from ingot using compact machine infrastructure; strip surface finish of Ra 0.35 to 1 micrometer that is comparable/superior to that of rolled strip; discrete production of strip that can potentially be done at point of use; and controllability of strip mechanical/formability properties by deformation control. c) The electrical, magnetic, surface quality, mechanical, formability, and metallurgical properties/attributes of the machining-based strip were established by direct ASTM standard or equivalent measurement techniques. d) Punching characteristics of the strip in terms of load, edge quality and macro defects were similar to those of conventional 3.2% Si electrical steels. These punching characteristics are critical from a manufacturability perspective for motor/transformer core applications. e) A modeling framework for energy analysis of multistage rolling and the machining-based deformation processing has been established. Application of this modeling to the two strip-processes showed that the machining-based process requires significantly lower specific energy for processing, ~ 25% of that for rolling. The modeling framework can be adapted for a range of sheet-metal forming, bulk metal forming, and machining processes. It can be used to identify key parameters controlling process specific energy. f) A comparative analysis of advantages and disadvantages of machining-based processing against rolling for strip production. The single stage machining-based processing, with compact infrastructure, represents a new manufacturing paradigm for sheet and foil manufacturing that can potentially also be applied to advanced titanium, aluminum, copper and magnesium alloys. The goals and objectives were accomplished by a cross-disciplinary project team comprising of personnel from Purdue University; M4 Sciences LLC, a small-business focused on advanced manufacturing technology development; the Pacific Northwest National Labs; and tool manufacturers. The team is currently in advanced discussions with multiple entities for future process development for commercialization.

36 MATERIALS SCIENCE↗