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All sources NASA NTRS DOE OSTI

DOE OSTI2024

Hybrid metal additive/subtractive machine tools and applications

Additive manufacturing creates parts by depositing a preform, typically layer by layer. Subtractive manufacturing involves removing material from a preform to create parts. Hybrid machine tools combine both additive and subtractive processes in the same workspace. They can be used to create parts that meet functional tolerance and surface finish requirements, or to create features that are difficult to produce using additive or subtractive processes alone. Here, this paper describes hybrid metal additive/subtractive machine tools. It covers design considerations, sensors and controls, process management, programming and software, and the impact on the design space. It also identifies future research challenges.

42 ENGINEERING↗

DOE OSTI2022

Zinc aluminate (ZnAl 2 O 4 ) refractory aggregates: Dilatometric sintering studies and thermal expansion coefficient

ZnAl 2 O 4 has recently been reported to enhance thermomechanical properties and slag corrosion resistance of refractory castables. The pore generation and deleterious expansion during in situ ZnAl 2 O 4 formation can limit their amount in a refractory composition. A comprehensive dilatometric study is presented, identifying the optimum raw materials and processing conditions. Preformed ZnAl 2 O 4 refractory aggregates were synthesized from industrial ZnO and reactive Al 2 O 3 by two-stage firing at 1050 °C and 1700 °C resulting in 0% open porosity. The ZnAl 2 O 4 powder calcined at 1050 °C is also a good refractory matrix material as it has better sinterability than preformed refractory-grade MgAl 2 O 4 and calcined alumina. The thermal expansion coefficient of ZnAl 2 O 4 aggregate in the range of 70–1600 °C was found to be 10.7 × 10 –6 K –1 , which is similar to tabular Al 2 O 3 (10.3 × 10 –6 K –1 ) and MgAl 2 O 4 (10.3 × 10 –6 K –1 ), but lower than dead burned MgO (16.4 × 10 –6 K –1 ), creating the possibility of developing thermal shock resistant refractories by utilizing this mismatch.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Electronic nature of the pseudogap in electron-doped Sr 2 IrO 4

In high-temperature ($T_c$) cuprate superconductors, many exotic phenomena are rooted in the enigmatic pseudogap state, which has been interpreted as consisting of preformed Cooper pairs or competing orders or a combination thereof. Observation of pseudogap phenomenologically in electron-doped Sr 2 IrO 4 —the 5d electron counterpart of the cuprates, has spurred intense interest in the strontium iridates as a testbed for exploring the exotic physics of the cuprates. Here, we examine the pseudogap state of electron-doped Sr 2 IrO 4 by angle-resolved photoemission spectroscopy (ARPES) and parallel theoretical modeling. Our analysis demonstrates that the pseudogap state of Sr 2 IrO 4 appears without breaking the particle–hole symmetry or inducing spectral broadening which are telltale signatures of competing orders in the cuprates. We find quasiparticle dispersion and its temperature dependence in the pseudogap state of Sr 2 IrO 4 to point to an electronic order with a zero scattering wave vector and limited correlation length. Particle–hole symmetric preformed Cooper pairs are discussed as a viable mechanism for such an electronic order. The potential roles of incommensurate density waves are also discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Using small angle x-ray scattering to examine the aggregation mechanism in silica nanoparticle-based ambigels for improved optical clarity

Silica-based aerogels are a promising low-cost solution for improving the insulation efficiency of single-pane windows and reducing the energy consumption required for space heating and cooling. Two key material properties required are high porosity and small pore sizes, which lead to low thermal conductivity and high optical transparency, respectively. However, porosity and pore size are generally directly linked, where high porosity materials also have large pore sizes. This is unfavorable as large pores scatter light, resulting in reduced transmittance in the visible regime. In this work, we utilized preformed silica colloids to explore methods for reducing pore size while maintaining high porosity. Further, the use of preformed colloids allows us to isolate the effect of solution conditions on porous gel network formation by eliminating simultaneous nanoparticle growth and aggregation found when using typical sol–gel molecular-based silica precursors. Specifically, we used in situ synchrotron-based small-angle x-ray scattering during gel formation to better understand how pH, concentration, and colloid size affect particle aggregation and pore structure. Ex situ characterization of dried gels demonstrates that peak pore widths can be reduced from 15 to 13 nm, accompanied by a narrowing of the overall pore size distribution, while maintaining porosities of 70%–80%. Optical transparency is found to increase with decreasing pore sizes while low thermal conductivities ranging from 95 +/− 13 mW/m K are maintained. Mechanical performance was found to depend primarily on effective density and did not show a significant dependence on solution conditions. Overall, our results provide insights into methods to preserve high porosity in nanoparticle-based aerogels while improving optical transparency.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Three-Dimensional Permeability of Thick-Section Glass Fabric Reinforced Polymer Composite by Vacuum-Assisted Resin Infusion Molding

Abstract Determination of permeability of thick-section glass fabric preforms with fabric layers of different architectures is critical for manufacturing large, thick composite structures with complex geometry, such as wind turbine blades. The thick-section reinforcement permeability is inherently three-dimensional and needs to be obtained for accurate composite processing modeling and analysis. Numerical simulation of the liquid stage of vacuum-assisted resin infusion molding (VARIM) is important to advance the composite manufacturing process and reduce processing-induced defects. In this research, the 3D permeability of thick-section E-glass fabric reinforcement preforms is determined, and the results are validated by a comparison between flow front progressions from experiments and from numerical simulations using ansys fluent software. The orientation of the principal permeability axes were unknown prior to experiments. The approach used in this research differs from those in literature in that the through-thickness permeability is determined as a function of flow front positions along the principal axes and the in-plane permeabilities and is not dependent on the inlet radius. The approach was tested on reinforcements with fabric architectures which vary through-the-thickness direction, such as those in a spar cap of a wind turbine blade. The computational simulations of the flow-front progression through-the-thickness were consistent with experimental observations.

Engineering↗

DOE OSTI2020

Numerical simulation of terahertz radiation by laser-driven plasma dipole oscillation

Laser-plasma interactions have many theoretical and technological applications. One is the use of coherently accelerated electrons to provide novel sources of THz radiation. Our research focuses on simulating the cross/self-interactions between two high intensity, ultra-short, counter propagating and detuned laser pulses and an initial neutral target for controlled ionization. Unlike our previous studies of laser-matter interaction over preformed plasma, we explore the injection and collision of laser pulses to induce background plasma driven by the self-guided laser wakefield mechanism, which is then used to perturb the plasma resulting in induced dipole oscillations leading to transverse radiation. Inducing a cylindrical spatial plasma column within the laser beam radius regime provides a stable, spatially localized plasma channel. The emitted radiation from the plasma dipole oscillation (PDO) will not be affected by surrounding plasma absorption, resulting in effective radiation distribution. Finally, results include 3D EM-PIC simulations and a comparison of the self- ionizing plasma against the preformed plasma to assess the efficiency of the mechanisms.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2021

RapidClave® Technology Demonstrations – II Hat Stiffener

This project sought to evaluate the cost and performance of both polymeric and metallic tooling for use with the RapidClave® composite process. Teijin’s rapid cure carbon/epoxy prepreg, Q183, was selected to fabricate demonstration components, of aerospace design, which currently are fabricated via compression molding using matched steel tooling. The ability to fabricate components using this prepreg in the RapidClave®, and using low cost single sided tooling, could significantly reduce the cost of part manufacture and shorten production lead times for tooling fabrication. The component demonstration article was a “hat stiffener” geometry typically used to reinforce fuselage or wing skins of an aircraft. A rapid preforming process was demonstrated and rapid process cycle times similar to compression molding were achieved by placing the preform on hot tooling, thus avoiding the time and energy associated with typical thermal cycling. A 90% reduction in tooling cost was achieved through the use of single sided aluminum or polymeric additive tooling when compared to compression molding matched steel tooling. In addition to rapid cycle times, RapidClave® offers the ability to change out tooling in minutes such that multiple part geometries can be fabricated in one shift.

36 MATERIALS SCIENCE↗

DOE OSTI2025

A Novel Manufacturing Process of Lightweight Automotive Seats (Integration of Additive Manufacturing and Reinforced Polymer Composite)

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components. However, fabricating these metal polymer composite structures through traditional manufacturing processes limits their mechanical properties due to limited design freedom, lack of control over fiber orientation in composite parts, and poor interfacial bonding between the constituent materials. It is essential to develop a novel manufacturing process to enable high throughput production of lightweight automotive seats using metal and polymer composites. As such it is important to design the automotive seat suitable for manufacturing via this process and perform mechanical characterization on various subcomponents of the seat to ensure that the design and performance requirements provided by the auto manufacturer are met. The aim of this project is to develop a novel manufacturing technique to produce lightweight automotive seat by combining AM with conventional manufacturing processes. The car seat back panel will be designed via topology optimization and numerical simulations to minimize the overall weight while ensuring it meets all the performance requirements. The optimization of the seat back structure will be based on computational stress analysis to maximize the stiffness and minimize the weight. Materials currently used by Ford Motor Company will be adopted for a few subcomponents while the in-house composite materials will be used for the rest of the seat back. The composite and metallic materials will be tested to determine their mechanical properties as these are necessary for simulations. A novel manufacturing process will be developed to integrate AM metal inserts with discontinuous reinforced composite through large scale additive manufacturing and compression overmolding processes. The developed manufacturing technique will be used to fabricated various subcomponents suitable for the seat back design and mechanically tested to determine their properties. The manufacturing of the lightweight seat back design through this process involves integrated AM metal inserts with the composite structure for recliner connection. The manufacturing of the entire seat back which is lightweight through the novel manufacturing process will be discussed. The performance of the designed seat back will be investigated through numerical simulations and shown to meet all the requirements provided by the auto manufacturer. The final goal of developing a novel manufacturing process for lightweight automotive seats is met through design optimization of seat back, manufacturing of subcomponents, mechanical characterization, and validation through numerical simulations. The routes to achieve the final goal of the project and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. The project resulted in the development of a novel manufacturing process to integrate metal inserts with tailored polymer composite preforms through overmolding. Leveraging this proven manufacturing process, a lightweight seat back was designed through topology optimization and numerical simulations. The designed seat back uses AM metal inserts and compression overmolding of tailored polymer composite preforms obtained via large scale additive manufacturing. The metal polymer composite structures fabricated through this process exhibited enhancement in stiffness and improved ductility upon testing. Overall, the project provided an alternative design and manufacturing technique for automotive seat back that enables weight saving while meeting the safety and performance requirements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Additively Manufactured Carbon Fiber-Reinforced Siliconized Silicon Carbide Composites Using Carbon Fiber-Reinforced Poly-Ether-Ether-Ketone (PEEK) as a Precursor

Herein, we report a method to additively manufacture carbon fiber-reinforced siliconized silicon carbide composites. The process involves the pyrolysis of a 3D-printed carbon fiber-reinforced poly-ether-ether-ketone (PEEK) composite to produce a porous carbon fiber-reinforced carbon matrix composite preform, which is subsequently infiltrated with molten silicon to obtain a carbon fiber-reinforced siliconized silicon carbide composite. A key aspect of the method is limiting polymer melt flow during pyrolysis of PEEK, which is achieved by thermally annealing the 3D-printed carbon fiber-reinforced PEEK preform in air at a temperature below PEEK’s melting temperature. Rheological and differential scanning calorimetry (DSC) measurements demonstrate that the thermal annealing treatment altered the melting behavior of PEEK, while NMR and FTIR measurements provided a mechanistic explanation for the structural changes responsible for the behavior. It was also found that dimensional changes during pyrolysis were anisotropic with greater shrinkage in the stacking direction of the material.

Yoon, Bola [ORNL] (ORCID:0000000260875373)↗

DOE OSTI2021

The interpretation of temperature and salinity variables in numerical ocean model output and the calculation of heat fluxes and heat content

Abstract. The international Thermodynamic Equation of Seawater 2010 (TEOS-10) defined the enthalpy and entropy of seawater, thus enabling the global ocean heat content to be calculated as the volume integral of the product of in situ density, ρ, and potential enthalpy, h0 (with reference sea pressure of 0 dbar). In terms of Conservative Temperature, Θ, ocean heat content is the volume integral of ρcp0Θ, where cp0 is a constant “isobaric heat capacity”. However, many ocean models in the Coupled Model Intercomparison Project Phase 6 (CMIP6) as well as all models that contributed to earlier phases, such as CMIP5, CMIP3, CMIP2, and CMIP1, used EOS-80 (Equation of State – 1980) rather than the updated TEOS-10, so the question arises of how the salinity and temperature variables in these models should be physically interpreted, with a particular focus on comparison to TEOS-10-compliant observations. In this article we address how heat content, surface heat fluxes, and the meridional heat transport are best calculated using output from these models and how these quantities should be compared with those calculated from corresponding observations. We conclude that even though a model uses the EOS-80, which expects potential temperature as its input temperature, the most appropriate interpretation of the model's temperature variable is actually Conservative Temperature. This perhaps unexpected interpretation is needed to ensure that the air–sea heat flux that leaves and arrives in atmosphere and sea ice models is the same as that which arrives in and leaves the ocean model. We also show that the salinity variable carried by present TEOS-10-based models is Preformed Salinity, while the salinity variable of EOS-80-based models is also proportional to Preformed Salinity. These interpretations of the salinity and temperature variables in ocean models are an update on the comprehensive Griffies et al. (2016) paper that discusses the interpretation of many aspects of coupled Earth system models.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1973

Molding process for imidazopyrrolone polymers

A process is described for producing shaped articles of imidazopyrrolone polymers comprising molding imidazopyrrolone polymer molding power under pressure and at a temperature greater than 475 C. Moderate pressures may be employed. Preferably, prior to molding, a preform is prepared by isostatic compression. The preform may be molded at a relatively low initial pressure and temperature; as the temperature is increased to a value greater than 475 C., the pressure is also increased.

Johnson, C. L.↗

NASA NTRS1981

Hot forming graphite/polyimide structures

Hot forming process has been developed in which structural shapes and panels are fabricated directly from stabilized graphite/polyimide preforms. Process can be used with thermosetting polymers that have high-temperature melt phase just before final cure. This phase allows fibers to move without destroying matrix-to-fiber adhesion. One of key advantages of this process is that prestages preforms are very stable and do not require refrigerated storage.

Baucom, R. M.↗

NASA NTRS1980

Fabrication and evaluation of low fiber content alumina fiber/aluminum composites

The mechanical fabrication of low volume percent fiber, polycrystalline alumina fiber reinforced aluminum composites was accomplished. Wire preform material was prepared by liquid-metal infiltration of alumina fiber bundles. The wires were subsequently encapsulated with aluminum foil and fabricated into bulk composite material by hot-drawing. Extensive mechanical, thermal and chemical testing was conducted on preform and bulk material to develop a process and material data base. In addition, a preliminary investigation of mechanical forming of bulk alumina fiber reinforced aluminum composite material was conducted.

Hack, J. E.↗

NASA NTRS1984

Changes in atmospheric CO2 - Influence of the marine biota at high latitude

Approximately half of the nitrogen and phosphorus entering deep waters of the contemporary ocean are transported from the surface in inorganic form as preformed nutrients. A simple model for ocean chemistry is presented and shown to account for the present level of atmospheric CO2. Fluctuations in preformed nutrients, modulated by changes in insolation and circulation at high latitudes, can result in significant variations in CO2. It is suggested that these changes may account for the apparent control on climate exercised by secular variations in the orbital parameters of the earth.

Knox, F.↗

NASA NTRS1984

Thermoplastic-carbon fiber hybrid yarn

Efforts were directed to develop processing methods to make carbon fiber/thermoplastic fiber preforms that are easy to handle and drapeable, and to consolidate them into low void content laminates. The objectives were attained with the development of the hybrid yarn concept; whereby, thermoplastic fiber can be intimately intermixed with carbon fiber into a hybrid yarn. This was demonstrated with the intermixing of Celion 3000 with a Celanese liquid crystal polymer fiber, polybutylene terepthalate fiber, or polyetheretherketone fiber. The intermixing of the thermoplastic matrix fiber and the reinforcing carbon fiber gives a preform that can be easily fabricated into laminates with low void content. Mechanical properties of the laminates were not optimized; however, initial results indicated properties typical of a thermoplastic/carbon fiber composites prepared by more conventional methods.

Ketterer, M. E.↗

NASA NTRS1987

Method of preparing fiber reinforced ceramic material

Alternate layers of mats of specially coated SiC fibers and silicon monotapes are hot pressed in two stages to form a fiber reinforced ceramic material. In the first stage a die is heated to about 600 C in a vacuum furnace and maintained at this temperature for about one-half hour to remove fugitive binder. In the second stage the die temperature is raised to about 1000 C and the layers are pressed at between 35 and 138 MPa. The resulting preform is placed in a reactor tube where a nitriding gas is flowed past the preform at 1100 to 1400 C to nitride the same.

Bhatt, Ramakrishna T.↗

NASA NTRS1988

Thermoplastic coating of carbon fibers

Now that quantities of prepreg were made on the thermoplastic coating line, they are being formed into both textile preform structures and directly into composite samples. The textile preforms include both woven and knitted structures which will be thermoformed into a finished part. In order to determine if the matrix resin is properly adhering to the fibers or if voids are being formed in the coating process, the tensile strength and modulus of these samples will be tested. The matrix uniformity of matrix distribution in these samples is also being determined using an image analyzer.

Edie, D. D.↗

NASA NTRS1992

Modified Spot Welder Solders Flat Cables

Soldering device, essentially modified spot welder, melts high-melting-temperature solders without damaging plastic insulation on flat electrical cables. Solder preform rests on exposed conductor of cable, under connector pin. Electrodes press pin/preform/conductor sandwich together and supply pulse of current to melt preform, bonding pin to conductor. Anvil acts as support and heat sink. Device used to solder flexible ribbon cables to subminiature pin connectors.

Haehner, Carl L.↗