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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
DOE OSTI2019

Tunable Porosity in Fused Filament 3D-Printed Blends of Intrinsically Porous Polymer and Thermoplastic Aliphatic Polyesters Polycaprolactone and Polylactic Acid

Future advances and usage of all-organic polymeric materials with permanent void spaces and high surface areas, in applications such as separations or as supports, depends heavily on the development of processing techniques to produce complex geometry objects. Here, the high free volume glassy microporous polymer PIM-1 was fabricated, as a major component in a polymer blend, into complex and customizable 3D objects by fused filament fabrication (FFF). PIM-1 was found to be compatible with polycaprolactone (PCL) and polylactic acid (PLA) and thus could be processed by extrusion into filaments with high loadings of PIM-1 (50% by mass). Ternary PCL/PLA/PIM-1 composite filaments provided an optimal balance of durability and melt flow characteristics for consistent FFF 3D printing of intricate structures. As printed, the micropores of PIM-1 were blocked and inaccessible to N2 during sorption experiments; however, the ternary composite structures displayed significant meso- and macroporosity and nanostructured phase separation. Postprinting immersion in 3-chloro-1-propanol was identified to selectively remove PCL within the composites, re-expose the characteristic micropores of PIM-1, and retain the macrostructure of the printed object. After postprinting treatments, specific surface areas by the Brunauer–Emmett–Teller method (as high as 460 m2 g–1) were found to directly correlate with the PCL content originally present. In conclusion, the extrusion-based processing methodology provides a new approach for production of intrinsically porous polymer objects in custom and complex shapes by reinforcement with thermoplastics (PCL and PLA).

36 MATERIALS SCIENCE↗
DOE OSTI2014

Thin-thick hydrogen target for nuclear physics

In spectroscopic studies of unstable nuclei, hydrogen targets are of key importance. The CHyMENE Project aims to provide to the nuclear physics community a thin and pure solid windowless hydrogen or deuterium target. CHyMENE project must respond to this request for the production of solid Hydrogen. The solid hydrogen target is produced in a continuous flow (1 cm/s) by an extrusion technique (developed with the PELIN laboratory) in a vacuum chamber. The shape of the target is determined by the design of the nozzle at the extrusion process. For the purpose, the choice is a rectangular shape with a width of 10 mm and a thickness in the range of 30-50 microns necessary for the physics objectives. The cryostat is equipped with a GM Cryocooler with sufficient power for the solidification of the hydrogen in the lower portion of the extruder. In the higher part of the cryostat, the hydrogen gas is first liquefied and partially solidified. It is then compressed at 100 bars in the cooled extruder before expulsion of the film through the nozzle at the center of the reaction vacuum chamber. After the previous step, the solid hydrogen ribbon falls by gravity into a dedicated chamber where it sublimes and the gas is pumped and evacuated in a exhaust line. This paper deals with the design of the cryostat with its equipment, with the sizing of the thermal bridge (Aluminum and copper), with the results regarding the contact resistance as well as with the vacuum computations of the reaction and recovery hydrogen gas chambers.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2015

Development and Quality Assessments of Commercial Heat Production of ATF FeCrAl Tubes

Development and quality assessment of the 2 nd generation ATF FeCrAl tube production with commercial manufacturers were conducted. The manufacturing partners include Sophisticated Alloys, Inc. (SAI), Butler, PA for FeCrAl alloy casting via vacuum induction melting, Oak Ridge National Laboratory (ORNL) for extrusion process to prepare the master bars/tubes to be tube-drawn, and Rhenium Alloys, Inc. (RAI), North Ridgeville, OH, for tube-drawing process. The masters bars have also been provided to Los Alamos National Laboratory (LANL) who works with Century Tubes, Inc., (CTI), San Diego, CA, as parallel tube production effort under the current program.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Technology Transfer from Fermi Research Alliance to Itasca Plastics for the purpose of Commercializing Scintillator Material

Researchers at the Fermi National Accelerator Laboratory (Fermilab) developed extruded plastic scintillator in the late 1990s, which was first used in the D-Zero experiment. Extruded plastic scintillator is currently produced at Fermilab and is used in particle detectors worldwide. The purpose of this CRADA is to transfer the knowledge related to the Fermilab extrusion process to Itasca Plastics, Inc. (Itasca Plastics). Much of this knowledge is contained in documentation that is in the public domain, although it is distributed over several communications (papers, conference records, etc.) and over several years. Under this CRADA Fermilab will assemble the information, provide it to Itasca Plastics and provide limited consulting to complete the knowledge transfer. If the transfer is successful, Itasca Plastics will be able to establish a U.S. commercial manufacturing capability for extruded scintillator material that can be used for high energy physics and commercial applications.

36 MATERIALS SCIENCE↗
DOE OSTI2017

NASICON-polymer electrolyte structure

A method is provided for forming a sodium-containing particle electrolyte structure. The method provides sodium-containing particles (e.g., NASICON), dispersed in a liquid phase polymer, to form a polymer film with sodium-containing particles distributed in the polymer film. The liquid phase polymer is a result of dissolving the polymer in a solvent or melting the polymer in an extrusion process. In one aspect, the method forms a plurality of polymer film layers, where each polymer film layer includes sodium-containing particles. For example, the plurality of polymer film layers may form a stack having a top layer and a bottom layer, where with percentage of sodium-containing particles in the polymer film layers increasing from the bottom layer to the top layer. In another aspect, the sodium-containing particles are coated with a dopant. A sodium-containing particle electrolyte structure and a battery made using the sodium-containing particle electrolyte structure are also presented.

Wang, Long↗
DOE OSTI2019

Large-Scale Thermoset Pick and Place Testing and Implementation

Oak Ridge National Laboratory is developing the first commercially available medium to large-scale thermoset additive manufacturing (AM) system with Magnum Venus Products (MVP). This 3D printer is capable of fabricating large-scale thermoset components at room temperature with a build volume of 16’ x 8’ x 42’’. The thermoset extrusion process uses irreversible exothermic chemical reactions to form a cross-linked polymer. Printing thermosets at such large scales with highly customizable materials at room temperature provides huge opportunities for complex and smart tooling applications. Integrating a pick and place actuator into this system will allow for the placement of heating/cooling channels as well as sensors to monitor tooling health and heat distribution. The pneumatically-driven pick and place actuator is integrated into the existing electrical and mechanical design and is controlled using custom M-code commands. The system is comprised mostly of commercially available components, providing easy adoptability by future thermoset systems.

Boulger, Alex↗
DOE OSTI2025

Wire Arc Additive Manufacturing of Multi-material Parts Using H-13 Tool Steel

H-13 tools steel’s relative hardness, resistance to thermal fatigue, and high tolerance of thermal shock, make it very desirable for use in forging, pressing, casting, and extrusion processes[1]. H-13 is however typically quite expensive when compared to many other steel compositions. It is therefore desirable to encase a lower cost steel composition with H-13. This configuration allows for the benefits of H-13 tooling to be realized, at a considerably reduced cost. To demonstrate the viability of this concept, a casting tool was fabricated using a Wire Arc Additive Manufacturing (WAAM) process. Initial materials testing was conducted on a multi-material wall which consisted of one section of H-13 tool steel, and one section of 410NiNmo. These tests included scanning electron microscopy, energy dispersive X-ray spectroscopy, and hardness testing. This testing generated favorable results and subsequently a casting tool was fabricated for evaluation. Utilization of a Multi-Material WAAM process to fabricate large tooling in this manner could yield significant improvements in material cost, manufacturing agility, and supply chain complexity.

Lambert, Nathan [ORNL] (ORCID:0009000324134206)↗
DOE OSTI2018

Equal channel angular extrusion for bulk processing of Fe–Co–2V soft magnetic alloys, part II: Texture analysis and magnetic properties

In Part I, equal channel angular extrusion (ECAE) was demonstrated as a novel, simple-shear deformation process for producing bulk forms of the low ductility Fe–Co–2V (Hiperco 50A®) soft ferromagnetic alloy with refined grain sizes. Microstructures and mechanical properties were discussed. In this Part II contribution, the crystallographic textures and quasi-static magnetic properties of ECAE-processed Hiperco were characterized. The textures were of a simple-shear character defined by partial {110} and <111> fibers inclined relative to the extrusion direction, in agreement with the expectations for simple-shear deformation textures of BCC metals. These textures were observed throughout all processing conditions and only slightly reduced in intensity by subsequent recrystallization heat treatments. Characterization of the magnetic properties revealed a lower coercivity and higher permeability for ECAE-processed Hiperco specimens relative to the conventionally processed and annealed Hiperco bar. In conclusion, the effects of the resultant microstructure and texture on the coercivity and permeability magnetic properties are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Enhanced strength and electrical conductivity of ultrafine-grained Al-Mg-Si alloy processed by hydrostatic extrusion

Highlights: • Al-Mg-Si alloy was subjected to hydrostatic extrusion combined with aging treatment. • UFG Al-Mg-Si alloy with UTS of 332 MPa and conductivity of 58% IACS was obtained. • Precipitation process depended on applied strains and crystallographic texture. • Strengthening effect was achieved by UFG structure and needle-like β″ precipitates. • Precipitation of β″ and spherical β′/β particles at GB provided high conductivity. - Abstract: The effect of hydrostatic extrusion combined with an artificial aging on microstructure, mechanical and electrical properties of 6101 Al-Mg-Si alloy was investigated. It has been shown that such thermo-mechanical treatment is an effective method for producing of long wires with an ultrafine-grained microstructure (grain size of 300–400 nm) and enhanced ultimate tensile strength (> 330 MPa) and electrical conductivity (up to 58% IACS). The mechanical behavior of 6101 Al-Mg-Si alloy depended strongly on applied strains by hydrostatic extrusion and crystallographic texture. Higher accumulative strain accelerated the precipitation kinetics but decreased the age hardening response. The double fiber <100> and <111> texture was observed for hydrostatically extruded samples. The <001> grains with homogenously distributed needle-like β″ precipitates provided precipitation strengthening of material while <111> grains resulted in more efficient grain boundary strengthening. Quantitative microstructure characterization allowed adjusting physical model to estimate the electrical conductivity and compare it with experimental data. The high conductivity was provided mainly by decomposition of solid solution due to precipitation of needle-like β″ precipitates in the grain interior and spherical β′ or β particles located at grain boundaries.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Characterization of ultrafine-grained aluminum tubes processed by Tube Cyclic Extrusion–Compression (TCEC)

Tube Cyclic Extrusion–Compression as a novel severe plastic deformation technique for tubes was utilized for processing ultrafine grained 1050 aluminum alloy for the first time. In this method, aluminum tube is fully constrained and deformed between mandrel and chamber with a small neck zone. The material deformation during Tube Cyclic Extrusion–Compression processing analyzed and the grain refinement mechanism were described. The capability of Tube Cyclic Extrusion–Compression in grain refinement of the aluminum alloy was demonstrated by transmission electron microscopy observations and X-ray diffraction line profile analysis. The micrographs of the evolved microstructure show grain size of 850 nm and 550 nm after the first and second processing cycles of Tube Cyclic Extrusion–Compression, respectively. Mechanical properties of the initial and processed specimens were extracted from ring-hoop tensile tests. The documented results confirm grain refinement by showing remarkable increase in the yield and ultimate strengths. The main increase in strength and decrease in elongation take place after the first cycle. The microhardness assessments illustrate increase from the initial value of 29 Hv to 44 and 49 Hv respectively after the first and second cycles of Tube Cyclic Extrusion–Compression. There is a good homogeneity in peripheral microhardness and microhardness across the tube thickness. - Highlights: • Tubes of AA1050 for the first time were successfully SPD processed by TCEC. • The grain size was refined to 550 nm after two cycles of TCEC. • Notable increase in the strength and decrease in the elongation were documented. • The microhardness increased to 49 Hv from the initial value of 29 Hv. • Good homogeneity in the microhardness distribution was recorded.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Ultrafine-grained Al-Mg-Zr Alloy Processed by Shear-Assisted Extrusion with High Thermal Stability

Shear-assisted processing and extrusion (ShAPE) is used to consolidate Al-4.2Mg-1.6Zr-0.25Si-0.1Fe (wt.%) powders. The extruded alloy exhibits: (i) near-zero porosity; (ii) an attractive combination of tensile yield strength (~220 MPa), ultimate strength (330 MPa) and elongation (>20%); and (iii) excellent thermal stability at 400 ºC. The ultra-fine grain size in the gas-atomized powders – created and stabilized by primary L12-Al3Zr submicron precipitates - is maintained after consolidation and subsequent exposure at 400 ºC, contributing twice as much to strength as Mg in solid-solution. Electron microscopy reveals the microstructure of the L12-Al3Zr precipitates, and other precipitates (Mg2Si and Al3Fe) and dispersoids (oxides).

ShAPE, Friction Extrusion, aluminum powder, Shear ↗
DOE OSTI2020

Process Intensification for Nanocomposite Aluminum Extrusions: CRADA 411 (Final Report)

The project evaluated the feasibility of using Shear Assisted Processing and Extrusion (ShAPE) for the fabrication of extrusions with a diameter of 0.5” and higher from an Al-alloy powder feedstock that contains nanoscale second phases for achieving enhanced elevated temperature strength. PNNL has previously extruded 0.2” diameter rods with high strength aluminum alloy powder Al-12.4TM. This project aimed to scale the process up to a diameter of 1.0” at a length of >24” while retaining the excellent mechanical properties achieved for the 0.2” diameter rods. As part of the project, extrusion dies were fabricated with various design features. As an example, scroll features on the tool die face was introduced to enhance powder mixing, and reduce extrusion load. Varying extrusion ratios were used to obtain better microstructural homogeneity. Use of tool design features together with the optimization of process parameters helped in the fabrication of extrusions that were up to 48” long with a diameter of 0.5” using Al-12.4 TM powder feedstock in a two-step process involving cold compaction followed by extrusion. Extrusions with a diameter of 1.0” could also be fabricated, but limitations on the extent of consolidation were experienced as a result of the torque and ram force capacity of the current ShAPE machine.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Selective Deposition and Fusion of AISI 316L: An Additive Manufacturing Process for Space Environments via Direct Ink Writing and Laser Processing

Unlocking the potential of additive manufacturing (AM) for space exploration hinges on overcoming key challenges, notably the ability to manufacture or repair parts on-site during exploration missions with consideration of quality, feedstock utilization, and challenges involved in microgravity environments. While there are multiple efforts to investigate the use of existing metal AM processes such as powder bed fusion (PBF), directed energy deposition (DED), and filament-based material extrusion, each process comes with a different set of challenges in space environments. Here, in this work, we introduce a new AM method that integrates the benefits of direct ink writing (DIW) to selectively deposit metallic pastes with laser-based processing to locally debind and subsequently melt and fuse metal powder, layer by layer, enabling the manufacturing of AISI 316L samples with densities exceeding 99.0%. The impact of process parameters on single-track dimensions, surface morphology, and porosity was characterized. The efficacy of laser debinding was assessed via secondary-ion mass spectrometry, permitting the carbon content to be estimated at 0.0152%, which is safely below the acceptable limit (0.03 wt%) for AISI 316L.

36 MATERIALS SCIENCE↗