A green ultra-lightweight chemically foamed concrete for building exterior: A feasibility study
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Shi, Jinyan (ORCID:0000000266412097)↗
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Molded Concrete Center Mine Wall
Proposed semiautomatic system forms concrete-foam wall along middle of coal-mine passage. Wall helps support roof and divides passage into two conduits needed for ventilation of coal face. Mobile mold and concrete-foam generator form sections of wall in place.
Lewis, E. V.↗
Continuous Processing of Carbon Foam Products Made from Coal at Atmospheric Pressure
The main goal of the project was to create a continuous manufacturing process for carbon foam that operates at atmospheric pressure and can generate well-formed carbon foam panels and lightweight aggregates. This objective was accomplished and has enabled a platform where carbon foam products can be manufactured at significantly reduced cost and cycle time relative to the conventional high-pressure batch process, which in turn can enable the manufacture of much larger volumes of carbon foam. All these features should enable carbon foam to enter much larger markets and create meaningful demand for U.S. coal. Carbon foam panels and aggregate both consisted of at least 70 weight percent carbon per program requirements (typical was over 90-wt%), and at least 51 weight percent of the carbon was to be coal derived (typical was over 90-wt% carbon was from coal). Analyses regarding life cycle, technoeconomics, and final technological gaps have been documented in separate reports. This final report documents the methods used to attain the main goal and describes the technical results.
01 COAL, LIGNITE, AND PEAT↗
The feasibility of solar reflector production from lunar materials for solar power in space
Science Applications International Corporation (SAIC) investigated the feasibility of producing solar reflectors from indigenous lunar materials for solar power production on the moon. First, lunar construction materials and production processes were reviewed, and candidate materials for reflector production were identified. At the same time, lunar environmental conditions were reviewed for their effect on production of concentrators. Next, conceptual designs and fabrication methods were proposed and studied for production of dish concentrators and heliostats. Finally, fabrication testing was performed on small-scale models using earth analogs of lunar materials. Findings from this initial investigation indicate that production of concentrators from lunar materials may be an attractive approach for solar energy production on the moon. Further design and testing are required to determine the best techniques and approaches to optimize this concept. Four materials were identified as having high potential for solar reflector manufacture. These baseline materials were foamed glass, concrete with glass-fiber reinforcement, a glass-fiber/glass-melt composite, and an iron-glass sintered material.
Source record↗
Pathways to formulate lightweight and ultra-lightweight 3D printable cementitious composites
Here, this paper studies the pathways to formulate lightweight and ultra-lightweight 3D printable cementitious composites. A hybrid approach was proposed by combining the advantages of traditional chemical-induced foaming (foaming approach) and lightweight particulate inclusions (synthetic foam approach). A comprehensive experimental program was conducted to evaluate the effects of foaming agents and fly ash cenosphere (FAC) on the printability, microstructure, mechanical and thermal properties of 3D printed samples. The results showed that the hybrid approach could produce a mixture with a density as low as 470 kg/m 3 while ensuring good flowability and buildability owing to the lubricating effect of foaming and supporting skeleton formed by FAC. In addition, a three-step homogenization procedure was also developed to predict the effective elastic modulus and thermal conductivity of 3D printable cementitious composites and cementitious foam. The findings of the study highlighted the effectiveness of the hybrid approach in formulating 3D printable ultra-lightweight cementitious composites in thermal insulation and acoustic applications.
36 MATERIALS SCIENCE↗
Experimental validation study of an analytical model of discrete frequency sound propagation in closed-test-section wind tunnels
The principal objective is to assess the adequacy of linear acoustic theory with an impedence wall boundary condition to model the detailed sound field of an acoustic source in a duct. Measurements and calculations are compared of a simple acoustic source in a rectangular concrete duct lined with foam on the walls and anechoic end terminations. Measurement of acoustic pressure for twelve wave numbers provides variation in frequency and absorption characteristics of the duct walls. Close to the source, where the interference of wall reflections is minimal, correlation is very good. Away from the source, correlation degrades, especially for the lower frequencies. Sensitivity studies show little effect on the predicted results for changes in impedance boundary condition values, source location, measurement location, temperature, and source model for variations spanning the expected measurement error.
Mosher, Marianne↗
Evaluation of discrete frequency sound in closed-test-section wind tunnels
The principal objective of this study is to assess the adequacy of linear acoustic theory with an impedance wall boundary condition for modeling the detailed sound field of an acoustic source in a duct. This study compares measurements and calculations of a simple acoustic source in a rectangular concrete duct lined with foam on the walls and anechoic end terminations. Measuring acoustic pressure for 12 wave numbers provides variation in frequency and absorption characteristics of the duct walls. The cases in this study contain low frequencies and low wall absorptions corresponding to measurements of low-frequency helicopter noise in a lined wind tunnel. This regime is particularly difficult to measure in wind tunnels due to high levels of the reverberant field relatively close to the source. Close to the source, where the interference of wall reflections is minimal, correlation is very good. Away from the source, correlation degrades, especially for the lower frequencies. Sensitivity studies show little effect on the predicted results for changes in impedance boundary condition values, source location, measurement location, temperature, and source model for variations spanning the expected measurement error.
Mosher, Marianne↗
Influence of Tire Tread Pattern and Runway Surface Condition on Braking Friction and Rolling Resistance of a Modern Aircraft Tire
A series of taxiing tests was conducted at the Langley landing loads track with both braked and unbraked (freely rolling) single and tandem wheels equipped with 32x8.8 type VII aircraft tires of different tread designs to obtain data on tire and braking characteristics during operation on dry and on contaminated concrete and asphalt run ways. Contaminants used were water, slush, JP-4 jet fuel, and organic and detergent fire-extinguishing foams. Forward velocities for the tests ranged from approximately 13 to 104 knots. Vertical loads of approximately 9,000 to 22,000 pounds and tire inflation pressures of 85 to 350 pounds per square inch were used. Results indicated that the unbraked tire rolling resistance increased with increasing forward velocity on dry and on contaminated runway surfaces. Peak tire-ground friction coefficients developed during wheel braking decreased rapidly with increasing velocity on contaminated runways but remained relatively unchanged on dry runways as the forward velocity was increased. Dry-runway friction coefficients were found to be relatively insensitive to tire tread pattern. However, the magnitude of the friction coefficients developed by tires on contaminated runways was extremely sensitive to the tire tread pat tern used, with circumferential-groove treads developing the highest values of friction coefficient, and smooth and dimple treads the lowest values for the tread patterns and runway conditions investigated.
Horne, Walter B.↗
Characterization of Carbon Foam Products Made from Coal at Atmospheric Pressure
Carbon foam products are currently manufactured on a commercial scale utilizing a high-pressure autoclave in batch mode. In an effort to increase manufacturing speed and reduce cost, carbon foam products (both panels and aggregates) were produced at atmospheric pressure in a continuous belt kiln. Here, the microstructure, properties, and performance of these materials were characterized and assessed in various applications. Lightweight aggregate was explored for use as a proppant, as well as it use in concrete and asphalt. The thermal conductivity, water permeability, and fire resistance of panels were evaluated, and its performance with respect to screw pullout was compared against conventional building materials. Some interesting performance aspects and potential for future work was revealed. This work was supported by a cooperative agreement with the Department of Energy – National Energy Technology Laboratory (DE-FOA-0002185, Area of Interest 4: Coal-Derived Carbon Foam Produced via a Continuous Process, award number DE-FE-0031992).
01 COAL, LIGNITE, AND PEAT↗
Impact Testing and Simulation of a Sinusoid Foam Sandwich Energy Absorber
A sinusoidal-shaped foam sandwich energy absorber was developed and evaluated at NASA Langley Research Center through multi-level testing and simulation performed under the Transport Rotorcraft Airframe Crash Testbed (TRACT) research project. The energy absorber, designated the "sinusoid," consisted of hybrid carbon- Kevlar® plain weave fabric face sheets, two layers for each face sheet oriented at +/-45deg with respect to the vertical or crush direction, and a closed-cell ELFOAM(TradeMark) P200 polyisocyanurate (2.0-lb/ft3) foam core. The design goal for the energy absorber was to achieve an average floor-level acceleration of between 25- and 40-g during the full-scale crash test of a retrofitted CH-46E helicopter airframe, designated TRACT 2. Variations in the design were assessed through quasi-static and dynamic crush testing of component specimens. Once the design was finalized, a 5-ft-long subfloor beam was fabricated and retrofitted into a barrel section of a CH-46E helicopter. A vertical drop test of the barrel section was conducted onto concrete to evaluate the performance of the energy absorber prior to retrofit into TRACT 2. Finite element models were developed of all test articles and simulations were performed using LSDYNA ®, a commercial nonlinear explicit transient dynamic finite element code. Test analysis results are presented for the sinusoid foam sandwich energy absorber as comparisons of load-displacement and acceleration-time-history responses, as well as predicted and experimental structural deformations and progressive damage for each evaluation level (component testing through barrel section drop testing).
Jackson, Karen E.↗
Innovative large overbraided carbon fiber composite beams in historical Friendship Bell Pavilion
The International Friendship Bell Pavilion located in the City of Oak Ridge, Tennessee symbolizes the spirit of the peace and friendship shared by the city of Oak Ridge and city of Naka, Japan. The Bell Pavilion features an 8000-pound bronze cast bell along with futuristic materials and advanced manufacturing technologies. The team has developed innovative overbraided carbon fiber arched beams in conjunction with the bronze bell. Carbon fiber was utilized in these beams because of its lightweight, strong, stiff, and durable characteristics. A sandwich design used a high-performance foam core, overbraided with triaxial carbon fibers. This is the world’s largest overbraided composite structure for parks and recreation. For the first time in such an application, 17 free floating, 33-foot (10 m) long arched carbon fiber composite beams cantilever from a central concrete-steel superstructure over the bronze bell. The arc radius of the bottom of each beam is uniquely different giving an appearance of an open dome when standing underneath the structure.
Parks and Recreation↗
Multi-Level Experimental and Analytical Evaluation of Two Composite Energy Absorbers
Two composite energy absorbers were developed and evaluated at NASA Langley Research Center through multi-level testing and simulation performed under the Transport Rotorcraft Airframe Crash Testbed (TRACT) research program. A conical-shaped energy absorber, designated the conusoid, was evaluated that consisted of four layers of hybrid carbon-Kevlar plain weave fabric oriented at [+45 deg/-45 deg/-45 deg/+45 deg] with respect to the vertical, or crush, direction. A sinusoidal-shaped energy absorber, designated the sinusoid, was developed that consisted of hybrid carbon-Kevlar plain weave fabric face sheets, two layers for each face sheet oriented at +/-45deg with respect to the vertical direction and a closed-cell ELFOAM P200 polyisocyanurate (2.0-lb/cu ft) foam core. The design goal for the energy absorbers was to achieve average floor-level accelerations of between 25- and 40-g during the full-scale crash test of a retrofitted CH-46E helicopter airframe, designated TRACT 2. Variations in both designs were assessed through dynamic crush testing of component specimens. Once the designs were finalized, subfloor beams of each configuration were fabricated and retrofitted into a barrel section of a CH-46E helicopter. A vertical drop test of the barrel section was conducted onto concrete to evaluate the performance of the energy absorbers prior to retrofit into TRACT 2. The retrofitted airframe was crash tested under combined forward and vertical velocity conditions onto soil, which is characterized as a sand/clay mixture. Finite element models were developed of all test articles and simulations were performed using LS-DYNA, a commercial nonlinear explicit transient dynamic finite element code. Test-analysis results are presented for each energy absorber as comparisons of time-history responses, as well as predicted and experimental structural deformations and progressive damage under impact loading for each evaluation level.
Jackson, Karen E.↗
The Development of Two Composite Energy Absorbers for Use in a Transport Rotorcraft Airframe Crash Testbed (TRACT 2) Full-Scale Crash Test
Two composite energy absorbers were developed and evaluated at NASA Langley Research Center through multi-level testing and simulation performed under the Transport Rotorcraft Airframe Crash Testbed (TRACT) research program. A conical-shaped energy absorber, designated the conusoid, was evaluated that consisted of four layers of hybrid carbon-Kevlar plain weave fabric oriented at [+45deg/-45deg/-45deg/+45deg] with respect to the vertical direction. A sinusoidal-shaped energy absorber, designated the sinusoid, was developed that consisted of hybrid carbon-Kevlar plain weave fabric face sheets, two layers for each face sheet oriented at +/-45deg with respect to the vertical direction, and a closed-cell ELFOAM P200 polyisocyanurate (2.0-lb/cu ft) foam core. The design goal for the energy absorbers was to achieve average floor-level accelerations of between 25- and 40-g during the full-scale crash test of a retrofitted CH-46E helicopter airframe, designated TRACT 2. Variations in both designs were assessed through dynamic crush testing of component specimens. Once the designs were finalized, subfloor beams of each configuration were fabricated and retrofitted into a barrel section of a CH-46E helicopter. A vertical drop test of the barrel section was conducted onto concrete to evaluate the performance of the energy absorbers prior to retrofit into TRACT 2. The retrofitted airframe was crash tested under combined forward and vertical velocity conditions onto soft soil. Finite element models were developed of all test articles and simulations were performed using LS-DYNA, a commercial nonlinear explicit transient dynamic finite element code. Test-analysis results are presented for each energy absorber as comparisons of time-history responses, as well as predicted and experimental structural deformations and progressive damage under impact loading for each evaluation level.
Littell, Justin D.↗
Fire Station #2, Former Sewage Treatment Plant #17, and Towway Area-SWMU 114 PFAS Site Assessment Progress Report Kennedy Space Center, Florida
This PFAS Site Assessment Progress Report (SAPR) presents the findings of the 2022 PFAS investigation conducted from November 2021 through August 2022 at Solid Waste Management Unit (SWMU) 114 located within Kennedy Space Center (KSC), Florida. SWMU 114 includes area around Fire Station #2, Former Sewage Treatment Plant #17, the southern portion of the Shuttle Landing Facility Runway, Remote Launch Vehicle Hangar, and the Towway area. Fire Station #2 was constructed in 2008 and is currently active, housing fire station personnel and equipment, including aqueous film forming foam (AFFF). Releases of AFFF has occurred at SWMU 114. Previous environmental assessments have been performed at SWMU 114, including soil, groundwater, and surface water sampling for volatile organic compounds, polycyclic aromatic hydrocarbons, total petroleum hydrocarbons, and metals. No active remediation has been performed at the SWMU 114. PFAS site assessment field activities were conducted at SWMU 114 from November 2021 through August 2022. During the 2021-2022 Site Assessment, 124 direct-push samples were collected from 27 locations, 17 surface water samples were collected from 15 locations, 41 groundwater samples were collected from 37 newly installed monitoring wells, five concrete samples were collected from four locations, and one asphalt sample was collected. Additionally, two soil borings were advanced to 60 feet for lithologic descriptions, ten staff gauges were installed, and one round of water level measurements were collected from monitoring wells and staff gauges for groundwater flow determination. All groundwater and surface water samples were analyzed for 25 PFAS analytes by USEPA Method 537M. Concrete, and asphalt samples were analyzed by synthetic precipitation leaching procedure (SPLP) PFAS analysis by USEPA Modified Method 537M. Groundwater results were compared to the most recent Regional Screening Levels (RSLs) published by USEPA for residential tap water (USEPA, 2022a) to determine the extent of PFAS contamination at SWMU 114 for six PFAS analytes (PFOA, PFNA, PFBS, PFHxS, PFOS, and GenX). Surface water results were compared to the FDEP surface water screening levels (SW SLs) (FDEP, 2020) for PFOA and PFOS. The PFAS investigation concluded that groundwater exceeding RSLs extends east and south to Banana Creek and west to approximately the center of the SLF runway. The extent of PFAS is approximated to the north, to an area between Sharkey Road and Astronaut Road, where samples below the RSLs do not fully bound SWMU 114. At least two distinct PFAS source areas are located near Fire Station #2 and along Towway, at S114-MW0007S, within SWMU 114. Groundwater head measurements indicate that flow at SWMU 114 is generally similar across the shallow and intermediate water tables. A northeast to southwest trending groundwater divide is located near the middle of Towway where groundwater southeast of the divide flows to the south and groundwater northwest of the divide flows to the west. The groundwater divide generally separates the two areas of higher PFAS concentrations. Surface water samples indicated concentrations of PFOS above the SW SLs in surface water bodies across the site. Further assessment and sampling are required to better understand the interaction between groundwater and surface water at SWMU 114. Concrete and asphalt samples collected confirm that a significant release of AFFF occurred near the stormwater pond northwest of Fire Station #2. Additional concrete samples surrounding Fire Station #2 and at the northwest and southeast edges of the SLF tarmac indicate elevated PFOS concentrations. These results indicate that discharges of AFFF in these locations have infiltrated into asphalt and concrete and may act as a continuing source of PFAS to groundwater and surface water after rain events. Additional direct-push samples are required to delineate PFAS at SWMU 114. Samples may need to extend beyond the Former SLF Rescue Building and Morpheous Test Site to delineate PFAS in groundwater. Monitoring wells should be sampled and gauged quarterly to determine if seasonal impacts are observable, especially in shallow wells near surface water features. Furthermore, surface water samples should be collected from additional ditches to further define the extent of surface water impacts at SWMU 114 and extending along the SLF runway. Staff gauges should be gauged quarterly with groundwater gauging to determine surface water flow and interaction with groundwater. The PFAS sampling results and path forward for SWMU 114 were presented to the KSC Remediation Team in October 2022. Once the PFAS SAPR is approved, it will be submitted to the Florida Department of Environmental Protection.
Howard Franklin Fowler↗