Piecing together carbon nanotubes (CNTs) into assemblies has so far failed to achieve the same elite strength performance metrics as individual CNTs, highlighting a critical deficiency in understanding the effects that the processing of individual nanostructures have on the performance of their derived macroscale assemblies, thereby hindering the development of a process-structure-performance map for these materials. In this work, we propose a method to decouple the distribution orientation of nanoscale tortuosity and the microscale twist of CNT dry-spun yarns under applied loads via in situ soft X-ray probing at high energy (1200 eV) and low energy (280 eV), respectively. With this decoupling enabled by in situ soft X-ray scattering, we acquired a deeper understanding of the deformation mechanisms of these yarns. We found that for untreated yarns, the twist angle of collective CNT bundles at the macroscale is more sensitive to applied stress than the nanoscale alignment distribution. We also found that increasing nominal twist densities of yarns as well as increased strengthening via plasma treatments and polymer infiltration act to decrease the yarns' sensitivity to realignment at the nanoscale and prevent failure by the slip mechanism.

A persistent lack of detailed and quantitative structural analysis of these hierarchical carbon nanotube (CNT) ensembles precludes establishing processing-structure-property relationships that are essential to enhance macroscale performance (e.g., in mechanical, electrical, thermal applications). Here, we use scanning transmission X-ray microscopy (STXM) to analyze the hierarchical, twisted morphology of dry-spun CNT yarns and their composites, quantifying key structural characteristics such as density, porosity, alignment, and polymer loading. As the yarn twist density increases (15,000 to 150,000 turns per meter), the yarn diameter decreased (4.4-1.4 μm) and density increased (0.55-1.26 g·cm-3), as intuitively expected. Yarn density, ρ, ubiquitously scaled with diameter d according to ρ ∼ d-2 for all parameters studied here. Spectromicroscopy probes with 30 nm resolution and elemental specificity were employed to analyze the radial and longitudinal distribution of the oxygen-containing polymer content (∼30% weight fraction), demonstrating nearly perfect filling of the voids between CNTs with a vapor-phase polymer coating and cross-linking process. These quantitative correlations highlight the intimate connections between processing conditions and yarn structure with important implications for translating the nanoscale properties of CNTs to the macroscale.

Carbon nanotubes (CNTs) possess exceptional mechanical properties, surpassing stiffness and strength metrics of common materials such as steel alloys by 100× at the nanoscale. However, when myriads of individual CNTs are bundled together into macroscopic ensembles like fibers or sheets, the result is a 100-fold drop in strength compared to its individual components. Here we present a general strategy aimed to close this gap in property scaling. By using vapor-phase polymerization of a cross-linkable polymer, we reinforced the weak interlinkages among individual CNTs within both yarns and sheets to promote a better transference of mechanical load across the structure. After the treatment, dry-spun, low-density 2.3 μm thin yarns increased their elastic moduli by at least 300%, and free-standing CNT sheets exhibited a 10× boost. In-situ synchrotron small-angle X-ray scattering revealed that polymer-reinforced yarns undergo limited CNT bundle rearrangement when subjected to tensile loads compared to pristine yarns. This evidence supports the hypothesis that the polymer hinders CNTs slippage, the root cause of the poor scaling of mechanical properties in these materials. While we demonstrated this reinforcement method for CNT structures, it is not specific to CNTs and could be used to reinforce a wide variety of hierarchical nanostructured ensembles.

The aerogels industry has been growing with a market capacity of 909 billion USD in 2019. Silica aerogels are the most extensively used due to their ease of synthesis. It can possess many useful properties such as high optical transparency, high-surface area, low thermal conductivity, and a wide accessible density range. However, silica aerogels are brittle and friable, making them unsuitable for many applications. Polymeric aerogels are typically much more robust but lack the uniform fine nanostructure which gives silica its exceptional properties. Herein, mechanically robust polyimide (PI) aerogels with uniform <20 nm porosity and exceptional transparency are demonstrated. Optimization was achieved by minimizing the phase separation during gelation, minimizing the light scattering, and yielding the exceptionally transparent aerogels. The aromatic PI backbone results in a high modulus while retaining a low thermal conductivities and high thermal stability. We demonstrate methods for inducing phase separation to increase the pore size and the effects on bulk properties. This study presents a better understanding of the route to producing transparent polymer aerogels.

A novel, to the best of our knowledge, method of wet chemical etching of sapphire workpieces (such as optics, wafers, windows, and cones), called the sapphire advanced mitigation process (or sapphire AMP), has been developed that exposes sub-surface mechanical damage created during the optical fabrication process and significantly enhances the surface laser damage resistance ($ \gt {2{\times}}$>2×) and mechanical strength (up to $\sim{2.6{\times}}$∼2.6×). Sapphire AMP involves first treating the workpiece with a mixture of sulfuric and phosphoric acid $([{\rm H_{2}{\rm SO_{4}}}]:[{\rm H_{3}{\rm PO_{4}}}]=1:3)$([H2SO4]:[H3PO4]=1:3) at 220°C, followed with phosphoric acid at 160°C, then with sodium hydroxide base (NaOH) and surfactant at 40°C, and finally with a high-pressure deionized water spray rinse. Sapphire AMP has been demonstrated on both A- and C-plane sapphire workpieces. The mechanism of this etch process involves the reaction of the sapphire $({\rm Al_{2}}{\rm O_{3}})$(Al2O3) surface with sulfuric acid $({\rm H_{2}}{\rm SO_{4}})$(H2SO4) forming aluminum sulfate $[{{\rm Al}_2}{({{\rm SO}_4})_3}]$[Al2(SO4)3], which has low solubility. The high phosphoric acid content in the first and second steps of sapphire AMP results in the efficient conversion of ${{\rm Al}_2}{({{\rm SO}_4})_3}$Al2(SO4)3 to aluminum phosphate $({\rm AlPO_{4}})$(AlPO4), which is very soluble, greatly reducing reaction product redeposition on the workpiece surface. Sapphire AMP is shown to expose sub-surface mechanical damage on the sapphire surface created during the grinding and polishing processes, whose etched morphology has either isotropic or anisotropic evolution depending on the nature of the initial surface damage. Sapphire AMP was also designed to remove the key known surface, laser absorbing precursors (namely, foreign chemical impurities, the fracture surface layer of preexisting sub-surface damage, and reaction product or foreign species redeposition or precipitation). Static and sliding indention induced surface microfractures on sapphire are shown after sapphire AMP to have a significant decrease in the fast photoluminescence intensity (a known metric for measuring the degree of laser damaging absorbing precursors). In addition, the onset of laser damage (at 351 nm 3 ns) on sapphire AMP treated workpieces was shown to increase in fluence from $\sim{4}$∼4 to $ \gt {9}.{5}\;{{\rm J/cm}^2}$>9.5J/cm2. Finally, biaxial ball-on-ring mechanical tests on sapphire disks showed an increase in the failure stress from 340 MPa (with pre-existing 28 µm flaws) to $\sim{900}\;{\rm MPa}$∼900MPa after sapphire AMP, which is attributed to the blunting of the surface microfractures.

The Carbon Nanotube (CNT) fiber for the ICF capsule support is developed at the Fusion Target Development Facility (B298 Rm126). The goal of this report is to document the processes developed for the production of CNT fiber. Final CNT fiber dimensions are 2 inches in length and ~2-4 μm in diameter.

Experiments at the National Ignition Facility (NIF) using targets containing a deuterium-tritium (D-T) fuel layer have, until recently, required that a high-quality layer of solid D-T (herein referred to as an ice layer) be formed in the capsule. The development of a process to line the inner surface of a target capsule with a foam layer of a thickness that is typical of ice layers has resulted in the ability to field targets with liquid layers wetting the foam. Successful fielding of liquid-layer targets on NIF required not only a foam-lined capsule but also changes to the capsule filling process and the manner with which the inventory is maintained in the capsule. Additionally, changes to target heater power and the temperature drops across target components were required in order to achieve the desired range of shot temperatures. These changes and the target's performance during four target shots on NIF are discussed.