Continuous Production of Carbon Foam from Carbon Ore
Not Available
Gula, Caleb (ORCID:0009000102460751)↗
SEARCH · Search NASA
Results for “carbon foam”
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Examining astrophysical gas cloud collapse using an optical depth-scaled, x-ray-irradiated, carbon-foam sphere
When stellar radiation interacts with a molecular cloud, the cloud's fate depends on the strength of the incident radiation and the radiation's mean-free-path within the cloud [F. Bertoldi, Astrophys. J. 346, 735–755 (1989)]. Under the right conditions, the radiation compresses the cloud and a star formation may occur. Where and when the stellar formation occurs in the cloud's collapse are open questions. Direct observation of the complete star–cloud lifecycle is nearly impossible due to the immense timescales and distances over which the interaction occurs. Laboratory astrophysics offers a way to investigate such a system by scaling the important astrophysical parameters to the laboratory. This work describes laboratory experiments to study the radiation-driven implosion of clouds, using x rays from a laser-irradiated, thin, gold foil as a surrogate star and a carbon-foam sphere as a surrogate cloud. An optically thick system, theoretically corresponding to a star-forming regime, was selected by choice of the foam density. Gold foil and sphere motions were imaged by x-ray radiography. Radiographic images show the formation of an interface between rarefied gold and carbon plasmas, a shock moving into the sphere, and a blunting of the initial sphere's shape. Measurements show that the shock moved linearly around 64 μm/ns into the sphere, and the gold–carbon interface formed by 2 ns at the sphere edge remained stationary. The deformation of the sphere was driven by the incident radiation and not by mechanical pressures applied by gold plasma. The blunting of the sphere was likely due to the geometric reduction of flux near the sphere's poles. Higher x-ray flux near the sphere's equator caused high compression and a faster shock, which flattened the sphere. We will discuss the results and implications of our observations.
VanDervort, R. W. [University of Michigan 1 , Ann ↗
Infiltrated carbon foam composites
An infiltrated carbon foam composite and method for making the composite is described. The infiltrated carbon foam composite may include a carbonized carbon aerogel in cells of a carbon foam body and a resin is infiltrated into the carbon foam body filling the cells of the carbon foam body and spaces around the carbonized carbon aerogel. The infiltrated carbon foam composites may be useful for mid-density ablative thermal protection systems.
Lucas, Rick D.↗
Evaluating the Physisorption and Chemisorption of Iodine on Bismuth-Functionalized Carbon Foams
Bismuth-containing carbon materials have been shown to be highly promising sorbents for the capture of radioiodine. However, there is still a need to understand the effects of carbon and bismuth on the iodine sorption mechanism. In this study, we show the relationship between the physical and chemical sorption of iodine under different bismuth loading conditions. Here, highly porous and non-friable conductive carbon foams were prepared and bismuth was electrodeposited to provide strong iodine binding sites. For pure carbon foams, equal ratios of physisorbed and chemisorbed iodine-carbon phases were detected before desorption. As the concentration of bismuth increased, the chemisorption between bismuth and iodine dominated the total capture mechanism and physisorption was almost completely eliminated. Additionally, chemisorption of iodine depended upon the size and specific surface area of the bismuth particles present within the framework of the foam.
36 MATERIALS SCIENCE↗
Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure
The objective is to develop continuous processing of carbon foam products made from coal at atmospheric pressure. Both carbon foam panels and lightweight carbon foam aggregates have been developed. A successful outcome would: 1) significantly reduce the cost to manufacture carbon foam through reductions in capital and labor costs, 2) significantly reduce the manufacturing time from weeks to hours, and 3) enable the manufacture of much larger volumes of carbon foam. All of these features are expected to enable carbon foam to enter much larger markets and create meaningful demand for U.S. coal.
01 COAL, LIGNITE, AND PEAT↗
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↗
Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure
CFOAM LLC has been manufacturing vitreous carbon foam from coal in panel form for several years. The process is currently set up in batch mode as two steps, where the first step is conducted at very high pressure. In order to reduce cost and increase capacity, a new process for making carbon foam is being developed that can be performed at atmospheric pressure. This advance in turn would enable the development of a continuous manufacturing process, which is also being pursued. Both carbon foam panels and light weight aggregates are being investigate. Construction of the pilot scale manufacturing plant has been completed and results of processing, microstructure, properties and performance of carbon foam products made using this new process will be discussed. This project is being 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↗
Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure
CFOAM LLC has been manufacturing vitreous carbon foam from coal in panel form for several years. The process is currently set up in batch mode as two steps, where the first step is conducted at very high pressure. In order to reduce cost and increase capacity, a new process for making carbon foam is being developed that can be performed at atmospheric pressure. This advance in turn would enable the development of a continuous manufacturing process, which is also being pursued. Both carbon foam panels and light weight aggregates are being investigate. Progress on the evolution of the pilot scale manufacturing plant and initial results of processing, microstructure, properties and performance of carbon foam products made using this new process will be discussed. This project is being 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↗
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↗
Multifunctional Carbon Foams for Aerospace Applications
Carbon foams produced by the controlled thermal decomposition of inexpensive coal extracts exhibit a combination of structural and thermal properties that make them attractive for aerospace applications. Their thermal conductivity can be tailored between 0.5 and 100 W/mK through precursor selection/modification and heat treatment conditions; thus, they can serve in either thermal protection or heat transfer systems such as heat exchangers. Because their structure is essentially a 3D random network of graphite-like members, they also can be considered low-cost, easily fabricated replacements for multi-directional structural carbon fiber preforms. Strengths of over 4000 psi in compression are common. Their density can be designed between 0.1 and 0.8 g/cc, and they can be impregnated with a variety of matrices or used, unfilled, in sandwich structures. These foams also exhibit intriguing electrochemical properties that offer potential in high-efficiency fuel cell and battery applications, mandrels and tooling for composite manufacture, ablative performance, and fire resistance. This paper presents the results of research conducted under NASA SBIR Topic 99.04.01, General Aviation Technology, supported from Langley Research Center. The potential of foam design through precursor selection, cell size and density control, density grading, and heat treatment is demonstrated.
Rogers, D. K.↗
Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure
CFOAM LLC has been manufacturing CFOAM® vitreous carbon foam from coal in panel form for several years. The process is currently set up in batch mode as two steps, where the first step is conducted at very high pressure. In order to reduce cost and increase capacity, a new process for making carbon foam is being developed that can be performed at atmospheric pressure. This advance in turn would enable the development of a continuous manufacturing process, which is also being pursued. Both carbon foam panels and light weight aggregates are being investigate. Progress on the evolution of the pilot scale manufacturing plant and initial results of processing, microstructure, properties and performance of carbon foam products made using this new process will be discussed. This project is being 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↗
Macroscale Fabrication of Lightweight and Strong Porous Carbon Foams through Template-Coating Pair Design
Manufacturing of low-density-high-strength carbon foams can benefit the construction, transportation, and packaging industries. One successful route to lightweight and mechanically strong carbon foams involves pyrolysis of polymeric architectures, which is inevitably accompanied by drastic volumetric shrinkage (usually >98%). As such, a challenge of these materials lies in maintaining bulk dimensions of building struts that span orders of magnitude difference in length scale from centimeters to nanometers. Here, this work demonstrates fabrication of macroscale low-density-high-strength carbon foams that feature exceptional dimensional stability through pyrolysis of robust template-coating pairs. The template serves as the architectural blueprint and contains strength-imparting properties (e.g., high node density and small strut dimensions); it is composed of a low char-yielding porous polystyrene backbone with a high carbonization-onset temperature. The coating serves to imprint and transcribe the template architecture into pyrolytic carbon; it is composed of a high char-yielding conjugated polymer with a relatively low carbonization-onset temperature. The designed carbonization mismatch enables structural inheritance, while the decomposition mismatch affords hollow struts, minimizing density. The carbons synthesized through this new framework exhibit remarkable dimensional stability (≈80% dimension retention; ≈50% volume retention) and some of the highest specific strengths (≈0.13 GPa g -1 cm 3 ) among reported carbon foams derived from porous polymer templates.
36 MATERIALS SCIENCE↗
Continuous manufacturing of carbon foam structures at atmospheric pressure
A method of manufacturing essentially crack-free carbon foam structures and carbon foam structures made in single-piece flow through a continuous kiln under inert atmosphere at atmospheric pressure. This process greatly reduces the cost to manufacture by reducing manufacturing time and increasing the ability to integrate automation equipment.
Olson, III, Rudolph Andrew↗
Fractal Loop Heat Pipe Performance Comparisons of a Soda Lime Glass and Compressed Carbon Foam Wick
This study compares heat flux performance of a Loop Heat Pipe (LHP) wick structure fabricated from compressed carbon foam with that of a wick structure fabricated from sintered soda lime glass. Each wick was used in an LHP containing a fractal based evaporator. The Fractal Loop Heat Pipe (FLHP) was designed and manufactured by Mikros Manufacturing Inc. The compressed carbon foam wick structure was manufactured by ERG Aerospace Inc., and machined to specifications comparable to that of the initial soda lime glass wick structure. Machining of the compressed foam as well as performance testing was conducted at the United States Naval Academy. Performance testing with the sintered soda lime glass wick structures was conducted at NASA Goddard Space Flight Center. Heat input for both wick structures was supplied via cartridge heaters mounted in a copper block. The copper heater block was placed in contact with the FLHP evaporator which had a circular cross-sectional area of 0.88 cm(sup 2). Twice distilled, deionized water was used as the working fluid in both sets of experiments. Thermal performance data was obtained for three different Condenser/Subcooler temperatures under degassed conditions. Both wicks demonstrated comparable heat flux performance with a maximum of 75 W/cm observed for the soda lime glass wick and 70 W /cm(sup 2) for the compressed carbon foam wick.
Myre, David↗
Secondary electron emission for reticulated carbon foam surfaces using direct measurements and spectroscopic analysis
This study investigates secondary electron emission (SEE) characteristics of reticulated foams using direct measurements and analytical modeling. Total SEE was quantified, revealing suppression of up to 44% in carbon foam structures compared to planar graphite surfaces. An optimal geometric configuration was identified and supported by analytical models. SEE angular dependence experiments showed diverse behaviors: fiber-like behavior and directional dependence for pore and ligaments on the mm scale, with fuzz-like characteristics when the foam features are between 10–100 µm. Electron energy analyzer measurements showed that carbon foams preferentially suppress inelastic backscattered electrons (BSEs) more so than true secondary electrons (SEs). The analysis indicated a larger fraction of low-energy SE generation in foams compared to flat surfaces due to increased emission from curved fiber ligaments and tertiary SEs from high-energy BSEs. These findings have implications for design and optimization of materials with tailored electron emission properties for applications like plasma-facing components, spacecraft materials, and accelerator surfaces.
Auger↗
Experiments and simulations of isochorically heated warm dense carbon foam at the Texas Petawatt Laser
An experimental and simulation study of warm dense carbon foams at ambient density (n e ~10 21 cm –3 ) is presented. This study of isochorically heated foams is motivated by their potential application in carbon-atmosphere white-dwarf envelopes, where there are modeling uncertainties due to the equation of state. The foams are heated on an approximately picosecond time scale with a laser-accelerated proton beam. The cooling and expansion of the heated foams can be modeled with appropriately initialized radiation-hydrodynamics codes; xRAGE code is used in this work. The primary experimental diagnostic is the streaked optical pyrometer, which images a narrow band of radiation from the rear surface of the heated material. Presented are xRAGE modeling results for both solid aluminum targets and carbonized resorcinol-formaldehyde foam targets, showing that the foam appears to cool slowly on the pyrometer because of partial transparency. So that simulations of cooling foam are processed properly, it is necessary to account for finite optical depth in the photosphere calculation, and the methods for performing that calculation are presented in depth.
36 MATERIALS SCIENCE↗
Shock compression of a low-density carbon foam
Porous polymer foams are found in numerous applications where they may be subjected to dynamic compression. The shockwave properties of polymer foams have several features that make shock Hugoniot measurements and interpretation challenging. Here, we present a comparison of dynamic X-ray phase contrast imaging and traditional optical velocimetry approaches to measuring the shocked states for a low-density carbon foam. Overall, dynamic X-ray phase contrast imaging was found to reduce errors associated with the measured Hugoniot states. In this study, the foam exhibits anomalous compression as expected due to its high initial porosity arising from shock heating.
36 MATERIALS SCIENCE↗
Superior removal of As(III) and As(V) from water with Mn-doped β-FeOOH nanospindles on carbon foam
Arsenic pollution of water is one of the severest environmental challenges threatening human health. Iron-based nanomaterials have been demonstrated effective in arsenic removal. However, they generally suffer from low removal efficiency towards highly toxic As(III), loss of active sites owing to agglomeration, and poor reusability. Herein, we report a carbonized melamine foam supported Mn(IV)-doped β-FeOOH nanospindles(CF@Mn-FeOOH NSp) for tackling the technical hurdles. The designed CF@Mn-FeOOH NSp appears as a free-standing monolith through a low-cost and straightforward hydrothermal method. The atomic-scale integration of Mn(IV) into β-FeOOH enables an oxidation-adsorption bifunctionality, where Mn(IV) serves as oxidizer for As(III) and Fe(III) acts as adsorber for As(V). The maximal adsorption capacity for As(V) and As(III) can reach 152 and 107 mg g -1 , respectively. Meanwhile, As in simulated high arsenic groundwater can be decreased to below 10 μg L -1 within 24 h. By simple "filtrating-washing", 85% and 82% of its initial adsorption capacity for As(V) and As(III) can be easily recovered even after 5-cycles reuse. Kinetics and isotherm adsorption study indicate that the arsenic adsorption behavior is mainly through chemical bonding during single-layer adsorbing process. The as-prepared CF@Mn-FeOOH offers a scalable, efficient, and recyclable solution for arsenic removal in groundwater and wastewater from mines and industry.
63 RADIATION, THERMAL, AND OTHER ENVIRON. POLLUTAN↗