Design of fiber geometry to improve carbon fiber performance for wind blades
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Ennis, Brandon Lee [Sandia National Laboratories (↗
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Initial assessment of alternative carbon fiber geometries for design of cost-effective compressive performance: Size effect studies
Carbon fiber provides opportunity to reduce weight in structural composites, including wind turbine blades, due to the material's superior specific stiffness and specific strength compared to alternatives. Despite these advantages, cost and compressive performance are considered weaknesses for carbon fiber products available today. Studies to produce low-cost carbon fiber alternatives, including the use of textile-derived precursor systems, have shown progress and merit through the DOE/ORNL low-cost carbon fiber initiatives. Here, this work focuses on enabling increases in compressive strength through design of the carbon fiber geometry, applicable to both textile and conventional precursor systems, while also providing opportunities to reduce carbon fiber processing costs. Fiber-resin interface and fiber alignment are among the most frequently cited factors controlling composite compressive performance. However, it is believed that there is opportunity in traditionally unexplored routes to increasing compressive strength through alteration of the carbon fiber geometry by increasing the fiber area moment of inertia and/or the fiber perimeter and interfacial area. This paper presents initial results from manufacturing carbon fiber materials to assess the impacts of carbon fiber size on tested composite compressive performance with projected neutral or even beneficial impact on fiber and composite manufacturing economics. Carbon fiber systems with increasing size illustrate a favorable correlation for compressive performance greater than predicted from a micromechanical failure model. The manufacturing and mechanical test results support the hypothesis of this work that alterations to fiber geometry can be used to produce improvements of the compressive strength of carbon fiber reinforced polymers and provide incentive for related work in designing alternative shapes to further enhance compressive performance.
42 ENGINEERING↗
Identification of the optimal carbon fiber shape for cost-specific compressive performance
We report carbon fiber composites offer superior mechanical performance compared to nearly all other useful materials for the design of structures. However, for cost-driven industries, such as with the wind energy and vehicle industries, the cost of commercial carbon fiber materials is often prohibitive for their usage compared to alternatives. This paper develops an approach to optimize fiber geometries for use in carbon fiber reinforced polymers to increase the compressive strength per unit cost. Compressive strength is a composite property that depends on the fiber, matrix, and interface, and an exact analytic expression does not exist that can accurately represent these complicated relationships. The approach taken instead is to use a weighted summation between the fiber cross-sectional area moment of inertia and perimeter as a proxy for compressive strength, with different weightings explored within the paper. Analyses are performed to identify optimal fiber geometries that increase the cost-specific compressive strength based on various assumptions and desired fiber volume fraction. Robust optimal shapes are identified which outperform circular fibers due to increases in area moment of inertia and perimeter, as well as decreases in carbon fiber processing costs.
36 MATERIALS SCIENCE↗
Carbon fiber design improvements based on economic models
Circular fiber geometries are predominant in commercial carbon fiber material systems, but the use of this fiber shape has numerous limitations. Circular geometries have continuous symmetry, which is helpful for various processing considerations, but also have the largest possible maximum diffusion thickness for a given fiber area. This characteristic means that circular carbon fibers always have the highest material processing cost and lowest production throughput compared to any other fiber shape with the same area and tow count. To quantify material cost and other benefits for non-circular carbon fiber geometries, process models for polyacrylonitrile based carbon fiber production are developed in relationship to the carbon fiber shape, size, and tow count. For a given fiber shape, precursor production costs are shown to favor maximizing fiber size while conversion costs are minimized by the smallest fiber size. These competing cost trends result in a numerically optimal fiber size for a given shape and tow count, while both cost components are decreased by increasing tow count. Cost–performance tradeoffs for three lobe fiber geometries are studied by supplementing the cost trends with a numerical failure model to predict compressive strength for discrete shape variants. The shape selection is shown to be more sensitive to variations in cost than compressive strength while suboptimal shape designs can improve manufacturing robustness and achievable fiber volume fractions. Finally, an optimal three lobe carbon fiber is identified that balances the set of considerations while reducing costs and embodied energy and increasing production throughput compared to a commercial carbon fiber.
Carbon fiber↗
Comparative study of spectral broadening and few-cycle compression of Yb:KGW laser pulses in gas-filled hollow-core fibers
While industrial-grade Yb-based amplifiers have become very prevalent, their limited gain bandwidth has created a large demand for robust spectral broadening techniques that allow for few-cycle pulse compression. In this work, we perform a comparative study between several atomic and molecular gases as media for spectral broadening in a hollow-core fiber geometry. Exploiting nonlinearities such as self-phase modulation, self-steepening, and stimulated Raman scattering, we explore the extent of spectral broadening and its dependence on gas pressure, the critical power for self-focusing, and the optimal regime for few-cycle pulse compression. Using a 3-mJ, 200-fs input laser pulses, we achieve 17 fs, few-cycle pulses with 80% fiber energy transmission efficiency. The optimal parameters can be scaled for higher or lower input pulse energies with appropriate gas parameters and fiber geometry.
Shalaby, Islam (ORCID:0000000332846636)↗
Automated Manufacturing of Grid Stiffened Panels with Radically Reduced Tooling
Grid stiffened continuous fiber reinforced composite panels are an attractive option for creating lightweight structures due to the tailorability for various applications and the resulting high specific properties. However, the panel stiffeners and stiffener intersections result in high tooling complexity and correspondingly high cost of implementation. These factors have limited the impact of such structures in the composites industry. Previous research has demonstrated the ability to produce high quality, high aspect ratio beams, representative of individual grid stiffeners, using E-glass/PET comingled tow via direct digital manufacturing. Further, prior preliminary efforts have demonstrated the potential to use the same approach to manufacture grid intersections that have continuous fiber in both directions. To expand on the previous efforts in grid stiffeners produced by direct digital manufacture with radically reduced tooling requirements, this effort compares two methods of providing positioning and consolidation, nozzle vs. roller. Both processes are based on a commingled yarn feedstock. The extrusion through a nozzle has been shown to enable grid intersection control through local variations in applied consolidation and serves as the baseline process. However, this approach requires a continuous placement path to create the complete grid stiffened panel as no mechanism for cutting and restarting has been implemented. Alternatively, a newly developed placement head incorporating cut and refeed, mounted to a 6-axis robot, offers the potential of improved path placement efficiency. The two techniques are used to produce similar grid composite stiffeners to evaluate the effectiveness of producing the grid intersections. Rate of deposition of the two end effectors are compared and the quality of the associated grid stiffeners, and intersections, are determined through measurement of geometry, fiber volume fraction and void fraction.
Engineering↗
Point-Defect-Localized Bound States in the Continuum in Photonic Crystals and Structured Fibers
In this work, we show that point defects in two-dimensional photonic crystals can support bound states in the continuum (BICs). The mechanism of confinement is a symmetry mismatch between the defect mode and the Bloch modes of the photonic crystal. These BICs occur in the absence of band gaps and therefore provide an alternative mechanism to confine light. Furthermore, we show that such BICs can propagate in a fiber geometry and exhibit arbitrarily small group velocity which could serve as a platform for enhancing nonlinear effects and light-matter interactions in structured fibers.
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
Design and Production for Maximum Structural Efficiency With Respect to Fiber Orientation With Increased Understanding of Hybrid Fiber Flow Behavior
Discontinuous fiber-reinforced thermoplastic composites have gained considerable attention in automotive, aerospace, and other industries, due to their high-rate of production combined with their ability to attain complex and intricate shapes. Among other high-rate thermoplastic manufacturing processes, injection-molding is one of the most common manufacturing methods due to fast production and high surface finishing of complex geometries. Fiber orientation in discontinuous fiber composites plays a pivotal role in determining the mechanical, electrical, and thermomechanical properties, underscoring the necessity to comprehend fiber orientation in injection molded parts. Among different fiber types, glass and carbon fibers are most common in the composite industries. The recent trend of hybrid composites comprising both glass fiber (GF) and carbon fiber (CF) is also gaining importance in the automotive industry. Hybrid fiber options allow designers to optimize the balance between glass and carbon fibers by leveraging the high durability and low cost of GF while the strength and lightweight properties of CF. Consequently, comparing the fiber oriented distribution (FOD) of injection molded composites containing GF, CF, and a hybrid of GF/CF is critical to investigating the local mechanical properties of intricate structures for high-end applications. In Phase I of this project, FOD in injection-molded panels with respect to distance from the gate was analyzed using X-ray computed tomography (X-CT) for GF, CF, and hybrid CF/GF (CGF) reinforced nylon 66. To understand the reason behind the FOD with different fiber types, computational fluid dynamics (CFD) and rheology were performed. Samples were extracted at three locations: near the gate, center, and opposite end. Thickness of the layers of typical skin-shell-core type FOD varies with fiber type and location. GF achieved flow direction alignment (in shell) earlier than viscous CF and CGF near the gate, whereas CF showed the highest flow-direction alignment at the center due to shear induced orientation. At the opposite end, GF experienced more backflow than others indicating faster mold filling owing to its lower viscosity. Hybrid CGF exhibited GF-dominated center and CF-dominated end region. The numerical model used to obtain FOD and rheological predictions for the CF and GF composites served to corroborate the trends observed in the experimental trials. The FOD responses across fiber types and location were reflected in their longitudinal and transverse properties. Only GF showed higher longitudinal modulus over transverse modulus near the gate attributed to rapid alignment, whereas CF and CGF exhibited opposite trend. However, fountain flow enhanced the longitudinal modulus over transverse modulus with the distance for all, particularly for CF. This study offers insights into mold filling behavior of different fibers which are critical in optimizing injection molding conditions for tailored final properties.
36 MATERIALS SCIENCE↗
Topological photonic crystal fiber
Photonic crystal fibers (PCFs) provide a versatile platform for various applications, thanks to the flexibility with which light guiding can be customized by modifying the fiber geometry. We realize a PCF with guided modes produced by photonic band structure topology rather than conventional mode-trapping mechanisms. The design, which is compatible with the stack-and-draw fabrication process, consists of a cross-sectional photonic topological crystalline insulator with a disclination. A bulk-defect correspondence produces degenerate topological modes, lying below the cladding light line. We use various theoretical methods to confirm their topological origins, including a spectral localizer that makes minimal assumptions about the band structure. Our experiments on the fabricated fiber show it transmitting visible to near-infrared light with low losses of 10 to 20 decibels per kilometer, which do not increase substantially when the fiber is bent. A comparable solid-core PCF of conventional design exhibits substantially higher bending losses. Optical fibers based on topological modes hold promise for improved performance and versatile functionalities.
Zhu, Bofeng [Nanyang Technological Univ. (Singapor↗
Stretchable electrochemical energy storage devices
The increasingly intimate contact between electronics and the human body necessitates the development of stretchable energy storage devices that can conform and adapt to the skin. Therefore, the development of stretchable batteries and supercapacitors has received significant attention in recent years. This review provides an overview of the general operating principles of batteries and supercapacitors and the requirements to make these devices stretchable. The following sections provide an in-depth analysis of different strategies to convert the conventionally rigid electrochemical energy storage materials into stretchable form factors. Namely, the strategies of strain engineering, rigid island geometry, fiber-like geometry, and intrinsic stretchability are discussed. A wide range of materials are covered for each strategy, including polymers, metals, and ceramics. By comparing the achieved electrochemical performance and strain capability of these different materials strategies, we allow for a side-by-side comparison of the most promising strategies for enabling stretchable electrochemical energy storage. The final section consists of an outlook for future developments and challenges for stretchable supercapacitors and batteries.
25 ENERGY STORAGE↗
Synchrotron X-ray metrology of dopant distribution and oxidation state in high pressure CVD grown TM 2+ :ZnSe optical fibers
High pressure chemical vapor deposition (HPCVD) has shown to be a promising method for producing Cr 2+ :ZnSe and Fe 2+ :ZnSe mid-IR optical fiber lasers. The oxidation state of the dopants and their spatial homogeneity are critical for the characterization of effective fiber laser performance; however, this is challenging for small fiber cores and small doping concentrations. We demonstrate using synchrotron micro X-ray fluorescence (XRF) mapping to study the distribution of the dopants throughout the fiber cross-sections. Furthermore, we study the local chemical environment of these unique fiber structures using micro X-ray near edge absorption spectroscopy (XANES). Our study reveals that transition metal doped ZnSe deposited using HPCVD has nanoscale dopant aggregation although the material is chemically identical to the commercially produced diffusion doped laser crystals, as indicated by the presence +2 oxidation state of the dopants. This work demonstrates the power of synchrotron-based X-ray techniques for use as metrology tools for improving the performance of laser materials in fiber geometry.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Inference of Induced Fracture Geometries Using Fiber-Optic Distributed Strain Sensing in Hydraulic Fracture Test Site 2
Fiber-optic Distributed Strain Sensor observations in a vertical well allow rapid inference of the time evolution of nearby hydraulic fracture heights and their vertical aperture distributions during stimulation and depressurization. We describe a computationally efficient deconvolutional model based on an elastostatic kernel for fracture opening within an isotropic, homogeneous, linear elastic medium. Furthermore, an application of this model to observations from the Hydraulic Fracture Test Site 2 reveals that ultimate fracture heights are typically greater than those indicated by microseismic monitoring, and some hydraulic fractures continue their upward growth for several hours after high-pressure injections ceased.
58 GEOSCIENCES↗
Imaging crossing fibers in mouse, pig, monkey, and human brain using small-angle X-ray scattering
Myelinated axons (nerve fibers) efficiently transmit signals throughout the brain via action potentials. Multiple methods that are sensitive to axon orientations, from microscopy to magnetic resonance imaging, aim to reconstruct the brain's structural connectome. As billions of nerve fibers traverse the brain with various possible geometries at each point, resolving fiber crossings is necessary to generate accurate structural connectivity maps. However, doing so with specificity is a challenging task because signals originating from oriented fibers can be influenced by brain (micro)structures unrelated to myelinated axons. X-ray scattering can specifically probe myelinated axons due to the periodicity of the myelin sheath, which yields distinct peaks in the scattering pattern. Here, in this work, we show that small-angle X-ray scattering (SAXS) can be used to detect myelinated, axon-specific fiber crossings. We first demonstrate the capability using strips of human corpus callosum to create artificial double- and triple-crossing fiber geometries, and we then apply the method in mouse, pig, vervet monkey, and human brains. We compare results to polarized light imaging (3D-PLI), tracer experiments, and to outputs from diffusion MRI that sometimes fails to detect crossings. Given its specificity, capability of 3-dimensional sampling and high resolution, SAXS could serve as a ground truth for validating fiber orientations derived using diffusion MRI as well as microscopy-based methods.
59 BASIC BIOLOGICAL SCIENCES↗
Open associahedra and scattering forms
We continue the study of open associahedra associated with bi-color scattering amplitudes initiated in ref. [1]. We focus on the facet geometries of the open associahedra, uncovering many new phenomena such as fiber-product geometries. We then provide novel recursion procedures for calculating the canonical form of open associahedra, generalizing recursion relations for bounded polytopes to unbounded polytopes.
72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
Pore Resolved Simulations of Joule Heating in Fibrous Media using an Embedded Boundary Method
Joule heating has been regarded as an energy-efficient and sustainable method for heating materials and gases at large scales. The modeling of local temperature effects at pore-resolved scales for such systems, however, has been difficult to achieve due to challenges in coupling thermo-chemical processes in complex porous media and in large representative volume elements (RVEs). To this end, we developed an electro-thermal model at the pore scale to study Joule heating effects in large heterogeneous systems with different microstructures. This was achieved using the level set method to implicitly delineate distinct regions within the domain, and an embedded boundary method to facilitate heat exchange across the fluid-solid interface. Moreover, we applied this method to investigate unsteady non-linear electro-thermal effects in non-woven fibrous graphite conductors for RVEs with characteristic lengths of 2 mm, with different fiber orientations, porosity (80% – 90%) and fiber diameters (10 – 20µm). The coupled equations were solved numerically and they produced peak temperatures greater than 2000 K resulting in heating rates as high as 80,000 K/s. Moreover, the results depended strongly on the microstructure of the fiber skeleton and current density. Geometries with large fibers (∼ 20µm) had the highest average and peak temperatures with the mean temperature increasing by 3.9 % while the peak temperature increased by 9.9 %. Anisotropic domains on the other hand had the lowest mean and peak temperatures with peak and mean temperatures of 2293 K and 1437.7K respectively representing a corresponding 12.1% and 5.1% drop in the temperatures. An increase in porosity from 80% to 90%, however, led to an increase in the peak temperature by 5.1%.
Joule heating↗
Experimental investigation of the crush performance of prepreg platelet molding compound tubes
This work presents an experimental study characterizing the crush performance of hollow cylindrical tubes made with prepreg platelet molding compound (PPMC). PPMC is a composite material system that uses platelets from chopped and slit unidirectional prepreg as the basis for a molding compound. This material system has a higher fiber volume fraction and better mechanical properties than traditional short fiber systems and can be molded into complex geometries unlike continuous fiber systems. As such, this material system shows promise for use with complex structural members in vehicles. The failure morphology and specific energy absorption of the material are evaluated with different thickness-to-diameter geometries and test speeds. In addition, this work investigates how PPMC components compare to traditional continuous fiber components and finds that PPMC performs as well as continuous fiber layups with similar effective laminate stiffnesses.
Materials Science↗
Optical fiber system employing topological guidance of light
An optical fiber system exploits a principle of topological confinement for guided higher-order modes, in contrast to more conventional total-internal-reflection (TIR) confinement. The optical fiber has a geometry and index profile defining a cutoff wavelength for a predetermined L-mode of optical signal propagation in the optical fiber, where L is azimuthal mode index. An optical source subsystem is coupled to the optical fiber to establish an optical signal propagating in the optical fiber, wherein the optical signal has the predetermined L-mode and a wavelength being either (1) at least 15% above the cutoff wavelength such that the optical beam propagates as a topologically confined mode, or (2) sufficiently above the cutoff wavelength that, based on the L-mode of the optical beam, the optical beam propagates as a topologically confined mode having propagation loss less than 3 dB/meter.
Ramachandran, Siddharth↗