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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Reinforced matrix for molten carbonate fuel cell and method for manufacturing the same

A reinforced electrolyte matrix for a molten carbonate fuel cell includes a porous ceramic matrix, a molten carbonate salt provided in the porous ceramic matrix, and at least one reinforcing structure comprised of at least one of yttrium, zirconium, cerium or oxides thereof. The reinforcing structure does not react with the molten carbonate salt. The reinforced electrolyte matrix separates a porous anode and a porous cathode in the molten carbonate fuel cell.

Surendranath, Arun↗
DOE OSTI2023

Additively manufactured structure with reinforced access opening

A method and system of additively-manufacturing a structure having a reinforced access opening includes printing, via an additive printing device having at least one printer head, a portion of the structure adjacent to a support surface. The portion of the structure is printed of a cementitious material, and the printed portion of the structure defines an access opening for the structure. Moreover, the method includes providing a void of the cementitious material at a top boundary of the access opening, placing one or more reinforcement members in the void such that the one or more reinforcement members extend across the void, and continuing to print the printed portion of the structure around the void to build up the structure. Thus, the method also includes backfilling the void with a backfill material to incorporate the one or more reinforcement members within the void into the printed portion of the structure.

Li, Xiaopeng↗
DOE OSTI2023

Low-Velocity Impact Performances of Healed Polymer Fiber Reinforced Plastics

Extending the lifecycle of traditional carbon or glass fiber-reinforced plastics is a complicated problem. The lack of sustainability limits the applications of the traditional composite materials in the vehicle industries where recycling and repurposing are critical issues. Alternatives for the low-stressed structural components are polymer fiber-reinforced plastics (PFRPs). In PFRPs, both the fibers and matrix are composed of thermoplastic polymers (e.g. polypropylene or polyethylene). They are lightweight, easy to manufacture, and cost-effective. Additionally, recycling and repurposing thermoplastic polymers are well understood. Therefore, the PFRPs have strong advantages compared to the traditional fiber-reinforced composites in low-stressed structural applications. In this study, we investigated the low-velocity impact (LVI) performances of the PFRPs and compared them with carbon fiber-reinforced plastics (CFRPs). A semi-spherical impactor was dropped to flat, square panels, and the absorbed impact energy was measured. The damage mechanisms were examined using a Xray µCT scan. The PFRPs outperformed the CFRPs in terms of perforation energy normalized by plate thickness and density. After the perforation, we healed the fractured plates by leveraging the recyclability of the thermoplastic polymers. The healing process of the panels was identical to the initial panel manufacturing process. No additional materials were added during the healing process. The healed PFRP panels were impacted again and substantially recovered energy absorption capability. We also conducted the repeated-impact test with several different impact energies. Unlike the CFRPs where the impact peak load decreased as the impacts repeated, the PFRPs showed an increasing trend. Such a unique mechanism was due to the strain-hardening behavior of the polymer fibers and matrix. As a result, the repeated-impact life of the PFRPs was significantly enhanced. These results are particularly interesting in the automotive or aerospace industries where repeated LVI is frequently observed.

Ko, Seunghyun↗
DOE OSTI2024

Low-velocity impact resistance and failure characteristics of all thermoplastic woven polymer-fiber-reinforced plastic composites

This study addresses the impact performances of recyclable composites made of all thermoplastic polymer-fiber-reinforced plastics (PFRPs), where the reinforcing fibers and matrix are made of thermoplastic polymers. Three woven PFRPs systems were evaluated, including polypropylene fibers, polypropylene matrix, and high-density polyethylene matrix. In low-velocity impact scenario with an impactor speed of less than 6 m/s, our results demonstrate the energy absorption capabilities of the flat laminate PFRPs compared to woven carbon fiber-reinforced plastics (CFRPs) and aluminum alloy 5052. For the systems studied, the PFRPs can reach the specific energy absorption 89% to 115% of the CFRPs. Even compared with the aluminum alloy 5052, the PFRPs can reach up to 97%. We investigate the failure morphologies of the PFRPs using X-ray µCT scans. They reveal the PFRPs’ unique ductile failure morphologies compared to common CFRPs. In addition, we heal the perforated region in the PFRPs by applying the manufacturing process identical to the initial curing process. The healed panels are perforated again, and they recovered 30% to 38% of their original specific energy absorption, a recovery not achievable with CFRPs. This study provides valuable experimental results, and concrete insights into the potential applications of recyclable PFRPs in various engineering fields. It emphasizes their excellent energy-absorbing capability and repairability.

CFRPs↗
DOE OSTI2023

Photo-Curing 3D Printing of Thermosetting Sacrificial Tooling for Fabricating Fiber-Reinforced Hollow Composites

Carbon fiber-reinforced hollow composites play a vital role in lightweighting modern cars and aircrafts. Fabrication of such hollow composites with seamless internal finish requires sacrificial tooling that can be used under pressure and high temperature. For the very first time, high performance sacrificial tooling that can be used to fabricate fiber-reinforced hollow composites is produced using photocuring 3D printing technology. This is achieved by developing UV-curable resins containing highly soluble yet hydrolysable acetal acrylate cross-linker and hydrophilic 4-acryloylmorpholine monomer. It is found that the cross-linker content greatly affects the printing speed. Further, the widely adopted UV post-curing method is found to have negligible impact on improving the thermal-mechanical properties of printed structures. Additionally, after thermal post-treatment, printed sacrificial tooling exhibits a heat deflection temperature of 112 °C at 0.455 MPa and an average coefficient of linear thermal expansion of 59 ppm °C -1 between 30 and 100 °C. As a result, printed tooling enables fabrication of carbon fiber-reinforced hollow composites with complex geometry, which shows a tensile strength of 802 MPa and an elastic modulus of 50.2 GPa.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Glass-Fiber Reinforcement as a Means of Recycling Polymers from Post-Consumer Applications

A major barrier to the recycling of post-consumer plastics is the commingled nature of these materials with consequent poor and variable mechanical, thermal and flow properties. Using polymers from end-of-life electronics, this comprehensive study demonstrates that glass-reinforcement is a viable method for reusing post-consumer plastics. In this work, a twin screw extruder was used to incorporate short glass fibers into polycarbonate containing varying amounts of polymeric impurities. The mechanical and melt flow properties of the compounded polycarbonate, having as much as 50% impurity, were studied. It was observed that, in the presence of 15 wt% short glass fibers, the measured mechanical and flow properties of the glass-reinforced material containing 25% impurity in the matrix phase, were indistinguishable from the corresponding properties of the virgin polymer and containing the same amount of glass reinforcement but no impurities. The effectiveness of this approach was confirmed by obtaining similar mechanical property data on a variety of other glass-filled thermoplastics.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Preparation of Chitin Nanofiber-Reinforced Xanthan Gum Hydrogels

In this study, chitin was nanofibrillated, cationized, and then used as a reinforcing agent for xanthan gum hydrogels. Amidinated chitin nanofibers (CNFs), which were prepared by partial deacetylation of the nanofibrillated chitin and the subsequent reaction of the generated amino groups with N,N-dimethylacetamide dimethyl acetal, were converted into an amidinium chitin bicarbonate with nanofiber morphology by CO{sub 2} gas bubbling and ultrasonic treatments in water. Xanthan gum hydrogels, which were prepared by exchange of disperse media from xantham gum ion gels with 1-butyl-3-methylimidazolium chloride, were then soaked in the resulting cationic CNF aqueous dispersions with different degrees of substitution (DSs) of amidinium groups to progress composition, giving rise to the CNF-reinforced xanthan gum hydrogels. The presence of CNFs in the hydrogels was confirmed by SEM measurement of the lyophilized samples. The amounts of CNFs in the hydrogels increased with increasing the DS values. The compression testing of the hydrogels suggested the reinforcing effect of CNFs, which were induced by electrostatic interaction owing to anionic nature of xanthan gum.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2019

Synthesis and Performance Evaluation of Unsaturated Polyester Blends of Resins and Its Application on Non-woven/Fabric Jute Fibers Reinforced Composites

The present study focuses on the generation of eco-friendly value added product by utilizing bio-based material as reinforced and matrix phase. Processing of soy and alkyd resin as matrix was carried out by utilization of soy flour and Ricinodendron heudelotii oil, followed essential modification in few inferior properties of soy flour resin by blending with alkyd resin. Separate sets of resin were prepared by maintaining 0%, 5% and 10% of alkyd resin in 100 g of soy flour resin respectively in each set to attain a comparative study on performance of prepared sets of resin blend. Subsequently, performance evaluation of polyester blends was evaluated by processing with non-woven/fabric jute fibers reinforced composites. The blend of R. heudelotii oil based alkyd and soy-flour resin in processing of composites was the noval approach of the study. The resins blend were characterized by FT–IR, viscosity and zeta potential measurements while thermo-mechanical analyses, water absorbancy and surface analyses were performed in composites. Significant increases noticed in the viscosity of blend, the blend containing 10% alkyd resin is two times more viscous compared to soy-flour resin. Furthermore, improvement in properties including water absorption, thermo-mechanical properties and better fiber-matrix interfacial adhesion of the composite could be observed. Higher glass transition temperature T{sub g} value i.e. 126.8 °C obtained for composites with 10% blend as matrix might emphasizes on increase of the degree of cross linking provided by the α-eleostearic fatty acid chain moiety. The enhancements in properties indicate extending opportunities for fiber-reinforced composites in several industries including building material, furniture, aerospace, nano etc.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Liquid-free covalent reinforcement of carbon nanotube dry-spun yarns and free-standing sheets

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 crosslinkable 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. Furthermore, 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 in a wide variety of other hierarchical nanostructured ensembles.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Capillary transport of water through textile-reinforced concrete applied in repairing and/or strengthening cracked RC structures

The use of textile-reinforced concrete (TRC) has great potential for innovative solutions in repairing, protecting, and strengthening concrete and RC structures. The article at hand reports on an investigation on composite concrete specimens made of cracked ordinary concrete as substrate and textile-reinforced concrete (TRC) as a cover layer for its strengthening and repair. The TRC cover layer was assessed with regard to its effectiveness as a protective layer against the ingress of water through capillary action. Since in real applications such TRC layers may be cracked or presumed to be so, thereby activating the load-carrying function of the textile reinforcement, the TRC layer was cracked for purposes of this study. The water transport in the cracked ordinary concrete specimens without the TRC layer was used as a reference. Gravimetric measurements and neutron radiography served as the testing techniques. In ordinary concrete quick and deep ingress of water through relatively wide macro-cracks of approximately 100 μm width, followed by transport through the capillary pore system, caused saturation of large areas in a rather short time. TRC applied to the RC surface reduced the ingress of water to a large extent. Its small crack widths of 15 to 20 μm changed suction behaviour fundamentally. In the cracked substrate of ordinary concrete, capillary suction was prevented, and transport through the pore system of the matrix became the prevailing transport mechanism of capillary action. Not only was the mechanism altered, but the transport of water deep into inner regions was markedly retarded as well.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Monitoring reinforcement corrosion and corrosion-induced cracking by X-ray microcomputed tomography method

X-ray microcomputed tomography (X-ray μCT) method is proposed to trace steel corrosion and corrosion-induced cracking in cement paste. Experimental results show it can track the time-dependent development of steel corrosion and corrosion products, as well as the subsequent initiation and propagation of corrosion-induced cracks. Furthermore, the information of corrosion pits, corrosion products, and corrosion-induced cracks can be clearly obtained from the whole specimen by this novel method. Additionally, SEM/EDS results agree closely with image analyses by X-ray μCT. This method provides a new angle to investigate the reinforcement corrosion process and can help to improve the numerical analysis of corrosion-induced damage in reinforced concrete structures. - Highlights: • Reinforcement corrosion and corrosion-induced cracking is traced by X-ray μCT method. • The development of corrosion products can be determined as a function of time and space. • Subsequent initiation and propagation of corrosion-induced cracks can be monitored. • The time-dependent corrosion process can be quantitative analyzed by X-ray μCT measurement.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A closer look at corrosion of steel reinforcement bars in concrete using 3D neutron and X-ray computed tomography

Corrosion of reinforcing bars constitutes the largest threat to the durability of concrete structures. Thus, several studies have investigated the nature of the corrosion products, most using post-mortem analyses. However, corrosion products evolve when in contact with oxygen, hindering result interpretation. This work presents instead a state-of-the-art, non-destructive 3D method for the assessment of corrosion of embedded reinforcements. Multimodal neutron and X-ray tomography was used to observe, non-destructively, the characteristics of the corrosion products in two concrete samples, with the aim of investigating possible benefits of the use of this technique for reinforced concrete structures. One sample was naturally corroded, extracted from an 81-year-old bridge, the other was corroded via the galvanostatic method, resulting in corrosion-induced cracks. Quantitative and qualitative data was acquired, including the iron-to-rust volumetric ratio in macroscopic interfacial voids and the thickness of the corrosion layer at the steel concrete interface. The iron-to-rust volumetric ratio corresponded to large, soluble, corrosion products, forming in environments with low availability of oxygen for both samples.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Additive manufacturing of continuous carbon fiber-reinforced SiC ceramic composite with multiple fiber bundles by an extrusion-based technique

Due to the high cost, complex preparation process and difficulty in structural design, the traditional methods for carbon fiber-reinforced SiC ceramic composite preparation have great limitations. This paper presents a technique for the additive manufacturing multiple continuous carbon fiber bundle-reinforced SiC ceramic composite with core-shell structure using an extrusion-based technique. A conventional nozzle system was modified to print simultaneously a water-based SiC paste with continuous carbon fibers. Different levels of binder contents were investigated to optimize the stickiness, viscosity, thixotropy and viscoelasticity of the paste. After sintering, SiC whiskers were generated on the surface of fiber, which is conjectured to be due to the reaction between SiO and carbon fiber at high temperature. The continuous carbon fiber-reinforced SiC ceramic composite exhibited non-brittle fracture. In conclusion, the flexural strength of the additively manufactured Cf/SiC composites improved from 162 MPa with no fiber bundles to a maximum of 219 MPa with three fiber bundles.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Discontinuous micro-fibers as intrinsic reinforcement for ductile Engineered Cementitious Composites (ECC)

Engineered Cementitious Composites (ECC) have demonstrated superior mechanical and durability performance than conventional concrete. In the micromechanical reinforcing system of ECC, fibers play a pivotal role in establishing the ultrahigh tensile ductility and autogenous crack width control. This article reviews the state-of-the-art of discontinuous micro-fibers as intrinsic reinforcement of ECC regarding technical performance as well as environmental and economic impacts. Mechanical properties of ECC made with different micro-fibers, man-made or natural, and their embodied energy, emissions and material cost, are comprehensively surveyed. Further, studies on fiber hybridization are discussed regarding the combination of different types of fibers to form synergetic reinforcements that mitigate total material cost, and potentially enhance the composite performance. Lastly, recommendations on fiber selections are highlighted and directions for future research are suggested.

42 ENGINEERING↗
DOE OSTI2025

Tunable structure and reinforcement of polyvinyl alcohol (PVA) hydrogels using fungal chitin particles

Polysaccharides, including chitin, are one of the most abundant biopolymers in nature and are increasingly recognized as a sustainable alternative to petroleum-derived plastics and synthetic fillers in polymer composites. Traditionally sourced from crustacean shells, chitin offers mechanical strength and biocompatibility with limitations also in processability and functionality. Fungal-derived chitin material represents a promising alternative, with advantages including scalable fermentation on low-cost substrates, absence of shellfish allergens, and tunable molecular architectures that vary by species, developmental stage, and growth environment. Here, in this study, we systematically examined chitinous materials obtained from taxonomically and functionally distinct fungi, Laccaria bicolor, Trichoderma reesei and Rhizopus oryzae, to assess their structural, chemical, and morphological properties as reinforcement agents in polymer composites. Mild alkaline pretreatment was employed to obtain mycelium chitin particles, thereby improving accessibility to chitin and co-occurring β-D-glucans while maintaining microparticle integrity. Comprehensive FTIR and solid-state NMR analyses revealed species-specific differences in chemical composition and microstructure, with R. oryzae exhibiting a unique spectral signature. These fungal-derived chitin were then incorporated into poly(vinyl alcohol) (PVA) hydrogels, where they acted as reinforcing fillers without the need for additional chemical crosslinkers. Comparative evaluation of hydrogel properties demonstrated that fungal chitin significantly enhanced mechanical performance, with all mycelium fillers mitigating the water weakening in PVA hydrogels. R. oryzae-derived composites tripled the hydrogel tensile strength while the submicron fibrous morphology in L. bicolor contributes to over 45 % tensile improvement in dry PVA composites. Our findings highlight the potential of fungal biomass as a tunable, sustainable platform for producing chitin-based reinforcing agents.

Chitin↗
DOE OSTI2013

Effect of heat treatment on microstructure and interface of SiC particle reinforced 2124 Al matrix composite

The microstructure and interface between metal matrix and ceramic reinforcement of a composite play an important role in improving its properties. In the present investigation, the interface and intermetallic compound present in the samples were characterized to understand structural stability at an elevated temperature. Aluminum based 2124 alloy with 10 wt.% silicon carbide (SiC) particle reinforced composite was prepared through vortex method and the solid ingot was deformed by hot rolling for better particle distribution. Heat treatment of the composite was carried out at 575 °C with varying holding time from 1 to 48 h followed by water quenching. In this study, the microstructure and interface of the SiC particle reinforced Al based composites have been studied using optical microscopy, scanning electron microscopy (SEM) coupled with energy dispersive X-ray spectroscopy (EDS), electron probe micro-analyzer (EPMA) associated with wavelength dispersive spectroscopy (WDS) and transmission electron microscopy (TEM) to identify the precipitate and intermetallic phases that are formed during heat treatment. The SiC particles are uniformly distributed in the aluminum matrix. The microstructure analyses of Al–SiC composite after heat treatment reveal that a wide range of dispersed phases are formed at grain boundary and surrounding the SiC particles. The energy dispersive X-ray spectroscopy and wavelength dispersive spectroscopy analyses confirm that finely dispersed phases are CuAl{sub 2} and CuMgAl{sub 2} intermetallic and large spherical phases are Fe{sub 2}SiAl{sub 8} or Al{sub 15}(Fe,Mn){sub 3}Si. It is also observed that a continuous layer enriched with Cu and Mg of thickness 50–80 nm is formed at the interface in between Al and SiC particles. EDS analysis also confirms that Cu and Mg are segregated at the interface of the composite while no carbide is identified at the interface. - Highlights: • The composite was successfully heat treated at 575°C for 1-48 hrs. • A layer of 50-75 nm is formed at interface after heat treatment. • No Carbide formation and SiC dissolution is observed at this temperature. • MgAl{sub 2}O{sub 4}, CuMgAl{sub 2} phases are segregated at interface of Al-SiC composite. • Mg and Cu are also segregated at near to the grain boundary.

36 MATERIALS SCIENCE↗
DOE OSTI2018

On the reinforcement homogenization in CNT/metal matrix composites during severe plastic deformation

Highlights: • Carbon nanotube-reinforced composites were processed by severe plastic deformation. • The evolution of the second phase distribution homogeneity is thoroughly analyzed. • The analysis is carried out with increasing equivalent strains. • A combination of two methods is applied and discussed. • A model that predicts the equivalent strain necessary for homogeneity is proposed. - Abstract: Carbon nanotube (CNT)-reinforced nickel matrix composites with different concentrations were processed by high pressure torsion (HPT). We thoroughly characterized the CNT agglomerates' spatial arrangement at different stages of deformation in order to extract information valuable for the optimization of the processing parameters and to elucidate the mechanisms involved during the processing of particle reinforced metal matrix composites by HPT. From the electron micrographs taken on the radial direction with increasing equivalent strains, we observed that CNT agglomerates debond by relative sliding between CNT during HPT, becoming spherical at higher stages of deformation. Furthermore, we introduced a model for the prediction of the minimum strain required for a homogeneous distribution of a second phase during HPT, which can be correlated to the material's three-dimensional structure and agrees well with the experimental data.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Synergistic role of carbonaceous reinforcements on multi length scale tribology of electrophoretically deposited nickel-boron nitride coatings

Highlights: • Electrophoretic deposition of Ni-BN coating. • Reinforcement of Ni-BN with carbon allotropes (diamond, carbon nanotubes and graphene). • Enhanced hardness and elastic modulus in Ni-BN-D than Ni-BN-CNT and Ni-BN-Gr. • High wear resistance (0.45 × 10{sup −8} m{sup 3}) from fretting and micro-scratch testing of Ni-BN-D. • High compressive stress (−601 MPa) exist in Ni-BN-D coating which restricts wear. - Abstract: Electrophoretically deposited Ni-BN composite coating was strengthened with graphene (Ni-BN-Gr), carbon nanotubes (Ni-BN-CNT) and diamond (Ni-BN-D) carbonaceous reinforcements. Highest hardness (2.0 GPa) and elastic modulus (133.5 GPa) of Ni-BN-D coating than Ni-BN-CNT (1.96 GPa and 102.1 GPa, respectively), Ni-BN-Gr (1.94 GPa and 92.0 GPa respectively) and also from Ni-BN (1.89 GPa and 91.5 GPa, respectively) coatings was linked through high compressive stress (−601 MPa), dislocation density (8.9 × 10{sup 15} m{sup −2}) and yield strength (4.4 GPa). The micro-scratching damage was contributed by ploughing and adhesion components, which were compared with that of experimental frictional values. Addition of graphene, CNT and diamond in Ni-BN composite showed a decrease in wear volume (from 1.66 × 10{sup −8} m{sup 3} to 0.45 × 10{sup −8} m{sup 3}) due to the synergetic lubricating effect of BN and carbonaceous reinforcements. Thus, Ni-BN-D restrict inception of multiscale wear and can be a potential three phase metal-ceramic coating for engineering and industrial applications.

36 MATERIALS SCIENCE↗