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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
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Finite Element Thermal Model for Ultrasonic Welding of Thermoplastic Composites

Ultrasonic welding, UW, is a fast and energy-efficient technique for joining thermoplastic composites. It involves the use of high-frequency mechanical vibrations and a static welding force to melt and join adherends. Ultrasonic welding is an enabling technology to reduce the cost and complexity of in-space construction because lightweight thermoplastic composite components can be packaged compactly for launch and then efficiently assembled using supervised autonomous robotic technologies on site. However, the temperatures in space present challenges to UW, and it is critical that the efficacy of process parameters selected for manufacturing in space is understood prior to launch. To this end, a three-dimensional finite element model is presented in this technical presentation. The model incorporates equations for effects of viscoelastic heating and heat transfer on the welding process. The proposed model is applied to predict the temperature distribution in single lap shear, SLS, samples composed of AS4/PEEK (TC1200) composite that were welded using a terrestrial machine as part of a comprehensive weldability study. Thermocouple and infrared spot sensor data from the SLS samples provide empirical temperature measurements for calibration and validation of the UW thermal model. Calibration and validation of the model is an important step given the significant uncertainties in material properties such as the loss modulus and necessary assumptions in the physics implementations which allow the model to converge in an acceptable amount of time. The validated thermal model can be used to simulate the process for the space environment. Future validation sample testing is planned in a vacuum chamber. The result will be a model capable of guiding process parameter selection to ensure acceptable weld bonds when manufacturing in space.

Josh Fody↗
DOE OSTI2013

Numerical Studies of Nucleation and Bubble Growth in Thermoplastic Foams at high Nucleation Rates

The influence volume approach (IVA) provides a coherent way of modeling the simultaneous nucleation and bubble growth during the foaming of thermoplastic polymers. In this work, a numerical model based on the influence volume approach is used to investigate the path to creating thermoplastic foams with nano-cellular structure. In particular, the diffusion of the blowing agent inside the polymer during the initial nucleation and later during bubble growth is analyzed. It is found that as the depressurization rate increases the gas diffusion becomes the limiting factor for bubble growth allowing for greater number of nuclei to be formed. However after a critical value of depressurization rate, further increase in depressurization rate appears to have no effect on the final bubble diameter. We comment on this critical depressurization rate based on classical nucleation theory.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Lignin-derived thermoplastic co-polymers and methods of preparation

The present invention relates to a crosslinked lignin comprising a lignin structure having methylene or ethylene linking groups therein crosslinking between phenyl ring carbon atoms, wherein said crosslinked lignin is crosslinked to an extent that it has a number-average molecular weight of at least 10,000 g/mol, is melt-processible, and has either a glass transition temperature of at least 100.degree. C., or is substantially soluble in a polar organic solvent or aqueous alkaline solution. Thermoplastic copolymers containing the crosslinked lignin are also described. Methods for producing the crosslinked lignin and thermoplastic copolymers are also described.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Verdant Power: Thermoplastic Blade Validation at Full Scale

For the first time in history, thermoplastic composite blades, which have the potential to revolutionize the marine energy industry, are being validated on a large-scale tidal power turbine. Thanks to funding from the U.S. Department of Energy's Water Power Technologies Office and a collaboration with Verdant Power, NREL researchers constructed thermoplastic composite turbine blades and are validating their performance on one of Verdant Power's tidal turbines deployed in New York City's East River.

HYDRO ENERGY↗
DOE OSTI2021

Thermoplastic welding apparatus and related methods

Thermoplastic welding apparatus and related methods are disclosed. An example method includes providing a smart susceptor between composite parts that are to be joined via thermoplastic welding. The example method includes positioning the composite parts and the smart susceptor on a tooling surface within a cavity of a tooling apparatus and applying a seal to the composite parts and the tooling surface to form a vacuum chamber between the composite parts and the tooling surface at a welding joint of the composite parts; producing a magnetic field at the welding joint. The example method includes providing a vacuum in the vacuum chamber during a welding operation.

Matsen, Marc R.↗
DOE OSTI2024

Post-Deployment Characterization of Glass Fiber-Reinforced Thermoset and Thermoplastic Composite Tidal Turbine Blades: Preprint

In 2021, the National Renewable Energy Laboratory (NREL) supported Verdant Power with the most successful tidal energy deployment in U.S. history. Three of their tidal turbines were deployed as part of the Roosevelt Island Tidal Energy project. Initially, the three rotors were manufactured from glass fiber-reinforced epoxy composites. Midway through the deployment, one rotor was replaced with one manufactured at NREL. Instead, it was infused with a novel, infusible thermoplastic resin system. Since the deployment, one epoxy rotor and one thermoplastic rotor were returned to NREL for continued materials and manufacturing research. The two rotors underwent full-scale structural testing before being sectioned and cut into specimens for a variety of manufacturing quality tests, thermos-mechanical characterization, and evaluation of material performance in marine environments, to understand the key differences between the fiberglass reinforced epoxy and Elium composites used for the respective rotors. Matrix burnoff tests showed that the Elium blades had a considerably higher fiber volume fraction compared to the epoxy blades (61% vs. 49%). Environmental aging of the specimens showed that the epoxy laminates absorbed more water over the conditioning period, however, it was determined that the Elium laminates had higher diffusion coefficients, so initially absorbed water faster. Finally, one full epoxy blade and one full Elium blade were conditioned at ambient temperatures for up to 11 months, while taking periodic mass measurements. The datasets were extrapolated out to assume a full 20 year operational life span and it was determined that the blades would not reach full saturation during that time span.

composite manufacturing↗
DOE OSTI2024

Post-Deployment Characterization of Glass Fiber-Reinforced Thermoset and Thermoplastic Composite Tidal Turbine Blades

In 2021, the National Renewable Energy Laboratory (NREL) supported Verdant Power with the most successful tidal energy deployment in U.S. history. Three of their Gen5d 5 m turbines were deployed as part of the Roosevelt Island Tidal Energy project. Initially, the three deployed rotors were manufactured from glass fiber-reinforced epoxy composites. Midway through the deployment, one rotor was replaced with one manufactured at NREL. The new rotor utilized a novel infusible thermoplastic resin system (Elium from Arkema). Since the deployment, one epoxy rotor and one thermoplastic rotor were returned to NREL for continued materials and manufacturing research. The two rotors underwent full-scale structural testing before being sectioned and cut into specimens for a variety of manufacturing quality tests, thermomechanical characterization, and evaluation of material performance in marine environments to understand the key differences between the fiberglass-reinforced epoxy and Elium composites used for the respective rotors. Matrix burn-off tests showed that the Elium blades had a considerably higher fiber volume fraction compared to the epoxy blades (61% vs. 49%). Environmental aging of the specimens showed that the epoxy laminates absorbed more water over the conditioning period; however, it was determined that the Elium laminates had higher diffusion coefficients, so they initially absorbed water faster. Finally, one full epoxy blade and one full Elium blade were conditioned at ambient temperatures for up to 11 months, while periodic mass measurements were taken. The datasets were extrapolated to assume a full 20-year operational life span, and it was determined that the blades would not reach full saturation during that time span.

composite manufacturing↗
DOE OSTI2024

Supersoft Norbornene–Based Thermoplastic Elastomers with High Strength and Upper Service Temperature

With over 6 million tons produced annually, thermoplastic elastomers (TPEs) have become ubiquitous in modern society, due to their unique combination of elasticity, toughness, and reprocessability. Nevertheless, industrial TPEs display a tradeoff between softness and strength, along with low upper service temperatures, typically ≤100 °C. This limits their utility, such as in bio-interfacial applications where supersoft deformation is required in tandem with strength, in addition to applications that require thermal stability (e.g., encapsulation of electronics, seals/joints for aeronautics, protective clothing for firefighting, and biomedical devices that can be subjected to steam sterilization). Thus, combining softness, strength, and high thermal resistance into a single versatile TPE has remained an unmet opportunity. Through de novo design and synthesis of novel norbornene-based ABA triblock copolymers, this gap is filled. Ring-opening metathesis polymerization is employed to prepare TPEs with an unprecedented combination of properties, including skin-like moduli (<100 kPa), strength competitive with commercial TPEs (>5 MPa), and upper service temperatures akin to high-performance plastics (≈260 °C). Here, the materials are elastic, tough, reprocessable, and shelf stable (≥2 months) without incorporation of plasticizer. Structure–property relationships identified herein inform development of next-generation TPEs that are both biologically soft yet thermomechanically durable.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Ionic complexation of endblock-sulfonated thermoplastic elastomers and their physical gels for improved thermomechanical performance

Thermoplastic elastomers (TPEs) composed of nonpolar triblock copolymers constitute a broadly important class of (re)processable network-forming macromolecules employed in ubiquitous commercial applications. Physical gelation of these materials in the presence of a low-volatility oil that is midblock-selective yields tunably soft TPE gels (TPEGs) that are suitable for emergent technologies ranging from electroactive, phase-change and shape-memory responsive media to patternable soft substrates for flexible electronics and microfluidics. Many of the high-volume TPEs used for these purposes possess styrenic endblocks that are inherently limited by a relatively low glass transition temperature. To mitigate this shortcoming, we sulfonate and subsequently complex (and physically crosslink) the endblocks with trivalent Al3+ ions. Doing so reduces the effective hydrophilicity of the sulfonated endblocks, as evidenced by water uptake measurements, while concurrently enhancing the thermomechanical stability of the corresponding TPEGs. Chemical modification results, as well as morphological and property development, are investigated as functions of the degree of sulfonation, complexation and TPEG composition. (C) 2020 Published by Elsevier Inc.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Multiple‐Repeated Plasma Surface Treatments for Significantly Improving Bonding Performance of Metal‐Carbon‐Fiber‐Reinforced Thermoplastic Polymer Dissimilar Adhesive Joints

This work investigates how multiple‐repeated plasma surface treatments can significantly enhance adhesively bonded metal‐carbon‐fiber‐reinforced thermoplastic polymer (CFRTP) dissimilar joints, a topic that has been rarely investigated compared to other parameters during the plasma treatment process. By conducting double cantilever beam tests on adhesively bonded AA6061‐carbon‐fiber‐reinforced polyphthalamide (CFRPPA) dissimilar joints, it is shown that the average Mode I specific fracture energy after 20 repetitions of the same plasma treatment, using processing parameters without noticeably changing surface roughness, can be improved and saturated up to almost 2000% compared to non‐treated joints and almost 240% compared to a single plasma treatment commonly used in the literature. The improvement can be attributed to the enhanced chemical bonding at the CFRPPA‐adhesive interface. This study is important for achieving strong bonding performance of CFRTP‐related structural joints using multiple plasma treatments, a simple and effective method.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Infusible acrylic thermoplastic resins: Tailoring of chemorheological properties

Infusible liquid resins that polymerize into a thermoplastic are desirable for many applications. Similar to unsaturated and vinylester thermosetting systems, they consist of polymers dissolved in reactive monomer. This work presents a method to decrease cycle time by tuning the molecular weight and concentration of the predissolved polymer in the resin. Variation of these properties allows precise control of the viscosity which in turn controls the time at which peak exotherm is reached, the maximum temperature for a given part thickness, and cure time. In this work, predictive models for the viscosity dependence on molecular weight, polymer concentration, shear rate, and temperature are developed. Two fiberglass panels are fabricated and tested; one with a lower molecular weight ($M_w$~30 kg mol –1 ) poly(methyl methacrylate) dissolved in methyl methacrylate and the second with higher molecular weight ($M_w$~500 kg mol –1 ) predissolved polymer in the resin. Mechanical properties are indistinguishable but the lower molecular weight panel cures up to three times faster.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Fine grinding of thermoplastics by high speed friction grinding assisted by guar gum

High speed friction grinding has been used to grind plant and food substances in water but never been explored for grinding of thermoplastics like polylactic acid (PLA), low and high density polyethylene and polypropylene. Such grinding was investigated in this work and was made possible by using 0.5% guar gum solution instead of just water because increasing the viscosity of water reduced their settling and the speed of passing through the grinder. Additionally, tensile, flexural, and impact strengths of the plastics were studied and higher grinding efficiency of PLA could be explained by its low elongation-at-break compared to low density polyethylene, high density polyethylene, and polypropylene. The microplastics (2000–45 μm) were studied for mass and particle size distributions and by scanning electron microscopy, 13 C CP/MAS NMR, Fourier transform infrared spectroscopy, differential scanning calorimetry, and thermogravimetric analysis. In addition, viscosity of guar gum and contact angles was measured. This new technology can produce finely ground microplastics (710–45 μm) for a variety of applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Process Variability Effects on Tensile Response in Injection Molded, Fluorinated Thermoplastics

The mechanical properties of fluorinated thermoplastics (i.e., tensile strength and elongation) can vary with changes in injection molding processing parameters. Four fluoropolymers are examined: poly(vinylidene fluoride) (PVDF) and random poly(vinylidene fluoride-co-chlorotrifluoroethylene) (PVDF-CTFE) with three CTFE concentrations. Dog bones were manufactured with various cylinder dwell times and mold cooling times to assess the manufacturing sensitivity to the tensile response. Dwell and cooling times increasingly impact mechanical performance as CTFE concentration increases. Specimens exhibit higher tensile strength as a function of injection order. The first injected specimen exhibits the lowest tensile strength and highest elongation in all copolymers. This trend becomes more pronounced among fluoropolymers with higher CTFE concentration and lower weight-averaged molecular weight. Parallel plate rheology was used to obtain the zero-shear viscosity as a function of material type, process, and injection order. We found that in the copolymers, the first injected sample exhibited a lower zero-shear viscosity than the next, which indicates a lower molecular weight in the first injected specimen. This phenomenon was not presented for the PVDF homopolymer. Copolymer mechanical uncertainties are hypothesized to result from the shorter molecular weight chains extruding out of the specimens' sides as a flash due to higher mobility with CTFE segments.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Design and Synthesis of Multigraft Copolymer Thermoplastic Elastomers: Superelastomers

Thermoplastic elastomers (TPEs) have been widely studied because of their recyclability, good processibility, low production cost, and unique performance. The building of graft-type architectures can greatly improve mechanical properties of TPEs. This review focuses on the advances in different approaches to synthesize multigraft copolymer TPEs. Anionic polymerization techniques allow for the synthesis of well-defined macromolecular structures and compositions, with great control over the molecular weight, polydispersity, branch spacing, number of branch points, and branch point functionality. Progress in emulsion polymerization offers potential approaches to commercialize these types of materials with low production cost via simple operations. Moreover, the use of multigraft architecturesprovides a solution to the limited elongational properties of all-acrylic TPEs, which can greatly expand their potential application range. The combination of different polymerization techniques, the introduction of new chemical compositions, and the incorporation of sustainable sources are expected to be further investigated in this area in coming years.

36 MATERIALS SCIENCE↗
DOE OSTI2019

An Ionomeric Renewable Thermoplastic from Lignin-Reinforced Rubber

An ionomeric, leathery thermoplastic with high mechanical strength is prepared by a new thermal processing method from a soft, melt-processable rubber. Compositions made by incorporation of equal-mass lignin, a renewable oligomeric feedstock, in an acrylonitrile-butadiene rubber often yield weak rubbers with large lignin domains (1–2 µm). The addition of zinc chloride (ZnCl2) in such a composition based on sinapyl alcohol-rich lignin during a solvent-free synthesis induces a strong interfacial crosslinking between lignin and rubber phases. This compositional modification results in finely interspersed lignin domains (<100 nm) that essentially reinforce the rubbery matrix with a 10–22 °C rise in the glassy-to-rubbery transition temperature. The ion-modified polymer blends also show improved materials properties, like a 100% increase in ultimate tensile strength and an order of magnitude rise in Young's modulus. Coarse-grained molecular dynamics (MD) simulations verify the morphology and dynamics of the ionomeric material. The computed result also confirms that the ionomers have glassy characteristics.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Morphological Studies of Solution-Crystallized Thermoplastic Elastomers with Polyethylene Endblocks and a Random-Copolymer Midblock

Styrenic thermoplastic elastomers (TPEs) in the form of triblock copolymers possessing glassy endblocks and a rubbery midblock account for the largest global market of TPEs worldwide, and typically rely on microphase separation of the endblocks and the subsequent formation of rigid microdomains to ensure satisfactory network stabilization. In this work, the morphological characteristics of a relatively new family of crystallizable TPEs that instead consist of polyethylene endblocks and a random-copolymer midblock composed of styrene and (ethylene-co-butylene) moieties are investigated. Copolymer solutions prepared at logarithmic concentrations in a slightly endblock-selective solvent are subjected to crystallization under different time and temperature conditions to ascertain if copolymer self-assembly is directed by endblock crystallization or vice versa. According to transmission electron microscopy, semicrystalline aggregates develop at the lowest solution concentration examined (0.01 wt%), and the size and population of crystals, which dominate the copolymer morphologies, are observed to increase with increasing aging time. Real-space results are correlated with small- and wide-angle X-ray scattering to elucidate the concurrent roles of endblock crystallization and self-assembly of these unique TPEs in solution.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Hygrothermal aging and recycling effects on mechanical and thermal properties of recyclable thermoplastic glass fiber composites

Abstract Glass fiber‐reinforced polymer composites are widely used in marine applications, including renewable energy devices and submarines, due to their strength‐to‐weight ratios and corrosion resistance. As sustainability becomes more important, recyclable thermoplastic composites are gaining attention in marine energy applications. These materials face harsh conditions such as high chloride water, UV radiation, pressurization, and thermal cycling, which can affect their durability and recyclability. This study examines the impact of hygrothermal aging on the recyclability of an Elium glass fiber (GF) composite. Samples were mechanically ground for recycling, and mechanical and thermal properties were compared between aged and unaged samples. After seawater aging, the tensile strength and modulus of the unaged composite dropped by 25% and 13% respectively, due to water ingress along the fiber‐matrix interface. The recycled composite showed reduced flexural strength as the long fiber composite was converted into short fibers during the process. Differential scanning calorimetry (DSC) revealed no change in glass transition temperature after aging. Weight loss (25%) was attributed to the thermal stability of the glass fibers. Dynamic mechanical analysis (DMA) showed that the storage modulus increased with aging, and fracture analysis confirmed a mixed mode of failure for aged composites. Highlights Hygrothermal aging lowers mechanical performance of Elium® GF composites. Failure mechanism tends to be matrix cracking and interface bonding. Glass transition temperature is not reduced by hygrothermal aging. Fractured composite was successfully recycled via thermoforming. Flexural strength of the recycled composite is lower.

17 WIND ENERGY↗
DOE OSTI2016

A Thermoplasticity Model for Oil Shale

Several regions of the world have abundant oil shale resources, but accessing this energy supply poses a number of challenges. One particular difficulty is the thermomechanical behavior of the material. When heated to sufficient temperatures, thermal conversion of kerogen to oil, gas, and other products takes place. This alteration of microstructure leads to a complex geomechanical response. In this work, we develop a thermoplasticity model for oil shale. The model is based on critical state plasticity, a framework often used for modeling clays and soft rocks. The model described here allows for both hardening due to mechanical deformation and softening due to thermal processes. In particular, the preconsolidation pressure—defining the onset of plastic volumetric compaction—is controlled by a state variable representing the kerogen content of the material. As kerogen is converted to other phases, the material weakens and plastic compaction begins. We calibrate and compare the proposed model to a suite of high-temperature uniaxial and triaxial experiments on core samples from a pilot in situ processing operation in the Green River Formation. In conclusion, we also describe avenues for future work to improve understanding and prediction of the geomechanical behavior of oil shale operations.

04 OIL SHALES AND TAR SANDS↗