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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
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↗
NASA NTRS1973

Properties of solid polymer electrolyte fluorocarbon film

The ionic fluorocarbon film used as the solid polymer electrolyte in hydrogen/oxygen fuel cells was found to exhibit delamination failures. Polarized light microscopy of as-received film showed a lined region at the center of the film thickness. It is shown that these lines were not caused by incomplete saponification but probably resulted from the film extrusion process. The film lines could be removed by an annealing process. Chemical, physical, and tensile tests showed that annealing improved or sustained the water contents, spectral properties, thermo-oxidative stability, and tensile properties of the film. The resistivity of the film was significantly decreased by the annealing process.

Alston, W. B.↗
NASA NTRS1977

Imaging natural materials with a quasi-microscope

A Viking lander camera with auxilliary optics mounted inside the dust post was evaluated to determine its capability for imaging the inorganic properties of granular materials. During mission operations, prepared samples would be delivered to a plate positioned within the camera's field of view and depth of focus. The auxiliary optics would then allow soil samples to be imaged with an 11 pm pixel size in the broad band (high resolution, black and white) mode, and a 33 pm pixel size in the multispectral mode. The equipment will be used to characterize: (1) the size distribution of grains produced by igneous (intrusive and extrusive) processes or by shock metamorphism, (2) the size distribution resulting from crushing, chemical alteration, or by hydraulic or aerodynamic sorting; (3) the shape and degree of grain roundness and surface texture induced by mechanical and chemical alteration; and (4) the mineralogy and chemistry of grains.

Bragg, S.↗
NASA NTRS1978

An investigation of heat pipe meniscus heat transfer

The use of grooved evaporator surfaces in heat pipes has increased in popularity in the past few years primarily due to the reproducibility achievable with grooved walls and the relatively low costs of the threading or extrusion processes involved in their production. The present study combines both analyses and experiments on square groove geometries, with special emphasis on overcoming the limitations of earlier analyses with finite-difference methods and groove-fillet hydrodynamic simplifications. The groove fillet, which has in previous analyses been assumed constant in radius of curvature, is permitted to change in thickness and curvature consistent with hydrodynamics and heat loss from the groove. A model is developed for accurate determination of the effect of constriction resistance on groove performance. The grooved-surface tests to be conducted are briefly described which will provide data under closely controlled operation to allow comparison and verification of the analyses.

Saaski, E. W.↗
NASA NTRS1978

Development of Methods of Characterizing Coal in Its Plastic State

Coal in its plastic state (typically 400-460 C) was examined by the isothermal Gieseler plastometry of seven selected coals of widely varying plastic properties. Kinetic models were proposed for the isothermal plastometric curves. Plastic behavior was compared with a variety of laboratory analyses and characterizations of these coals, including classical coal analysis; mineral analysis; microstructural analysis (extractable fractions, surface area measurement, and petrographic analysis); and thermal analysis (thermogravimetric analysis, thermomechanical analysis, and differential scanning calorimetry). The phenomenon of a sharp, large, poorly reproducible exotherm in the differential scanning calorimetric analysis of coking coals was examined. Several coal extrudates show mineral distribution, organic maceral composition and overall calorific value to be little affected by 800 F extrusion. Volatile matter and plastic properties are moderately reduced, and the network structure (as gauged by extractables) appears to be slightly degraded in the extrusion process.

Lloyd, W. G.↗
NASA NTRS1981

Permanent magnet properties of Mn-Al-C between -50 C and +150 C

Anisotropic Mn-Al-C (Ni) magnets are potential substitutes for Alnico 5 and 8. The limited machinability of the alloy and the fact that it is cobalt-free made it particularly interesting. The low Curie point and the costly warm extrusion process needed for grain orientation are drawbacks. The objective of this study was a detailed magnetic characterization of the material for possible use in electric machinery. The principal subjects of the study were the largest extruded bars presently available, of 31 mm diameter. Easy and hard axis magnetization curves and second-quadrant recoil loop fields were measured at various temperatures ranging from -50 C to +150 C. Property variations over the cross section of a bar were also studied.

Abdelnour, Z. A.↗
NASA NTRS2000

Viscoelastic flow modeling in the extrusion of a dough-like fluid

This work attempts to investigate the effect of viscoelasticity and three-dimensional geometry in screw channels. The Phan-Thien Tanner (PTT) constitutive equation with simplified model parameters was solved in conjunction with the flow equations. Polyflow, a commercially available finite element code was used to solve the resulting nonlinear partial differential equations. The PTT model predicted one log scale lower pressure buildup compared to the equivalent Newtonian results. However, the velocity profile did not show significant changes for the chosen PTT model parameters. Past Researchers neglected viscoelastic effects and also the three dimensional nature of the flow in extruder channels. The results of this paper provide a starting point for further simulations using more realistic model parameters, which may enable the food engineer to more accurately scale-up and design extrusion processes.

NASA Discipline Life Support Systems↗
NASA NTRS2023

Moon-to-Mars Planetary Autonomous Construction Technology: MMPACT Material Screening

NASA’s Space Technology Mission Directorate “champions technologies needed to live on and explore the Moon” [1]. This includes capabilities that capitalize on existing lunar resources and carry out surface manufacturing and construction activities. The goal of the Moon-to-Mars Planetary Construction Technology (MMPACT) Project is to mature these two capabilities. The primary resource on the Moon and the primary feedstock for manufacturing and construction is regolith. In the past, astronauts launched, landed, and lived in a spacecraft. NASA envisions a future where we make living spaces on the lunar surface instead. The innovative technologies required for lunar surface construction may be something never seen before, or they may be adaptations of existing technologies. MMPACT must screen for the most feasible technologies with the earliest potential technology insertions given the ambitious goals of the Artemis campaign. This poster summarizes recent efforts to discover and document mechanical and thermal capabilities of various technologies: a laser-based vitreous material transformation from Texas-based ICON, a molten extrusion process from ICON, a mortar from MSFC, a mortar from an MSFC-Louisiana State University partnership, and a geopolymer from a MSFC-Pennsylvania State University partnership. Other testing and development activities are documented as well. [1] https://www.nasa.gov/directorates/spacetech/Lunar_Surface_Innovation_Initiative

In-situ Resource Utilization↗
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↗