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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Material efficiency and climate change mitigation of passenger vehicles

A transition to electric vehicles and renewable energy is currently underway but may not be rapid enough in order to reach ambitious climate change mitigation targets. Therefore, additional, preferably instantaneous, measures are needed for quick emissions reductions, which is where material efficiency (ME) could constitute a promising solution. ME strategies include but are not limited to vehicle lightweighting through material substitution, increased recycling of materials, reuse and remanufacturing of vehicle components, vehicle downsizing (switching to a smaller vehicle) and more intensive use by means of increased vehicle occupancy through sharing practices. While recent analyses have focused on a narrow subset of these, we find striking differences in the overall potential of different strategies to decrease vehicular carbon footprints. Downsizing and more intensive use offer the largest mitigation potential but strongly depend on consumer behavior and are highly sensitive to modeling assumptions. Combined, the analyzed strategies can achieve emission reductions of up to 57% over the life cycle of a single vehicle, which is comparable to up to 83% achieved through a shift to low-carbon energy supply. ME can cut carbon footprints of already efficient vehicles charging renewable electricity by half again. This makes ME both an excellent short-term solution for climate change mitigation targeting the light vehicle sector but also an important complementary strategy to the long-term transition towards electric vehicles and renewable energy supply.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1992

Composite materials microstructure for radiation shielding

Shielding against radiation is a concern for applications on earth, in space, and on extraterrestrial surfaces. On earth EMI is an important factor, while in space and on extraterrestrial surfaces particle (high charge-Z and high energy-E) radiation is a critical issue. Conventional metallic materials currently used for EMI shielding incur large weight penalties. To overcome this weight penalty, ultra-lightweight composite materials utilizing fillers ranging from carbon microballoons to silver coated ceramic microballoons are proposed. The crucial shielding requirement is conductivity of the constituent materials, while the hollow microballoon geometry is utilized to yield low weight. Methods of processing and composition effects are examined and these results are compared to the effectiveness of varying the conductive microballoon material. The resulting ultralightweight materials, developed for EMI shielding, can be tailored through the application of the understanding of the relative effects of variables such as those tested. Initial experimental results reveal that these tailored ultralightweight composite materials are superior to traditional aluminum shielding at only a small fraction of the weight.

Radford, Donald W.↗
DOE OSTI2022

Materials FY 2021 Annual Progress Report

The Materials Technology subprogram supports the VTO’s mission to accelerate the deployment of clean energy technology toward achieving net-zero emissions in the transportation sector. Lighter vehicles with more efficient powertrains reduce energy use, decrease greenhouse gas (GHG) emissions, and save consumers money.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Corrosion Protection and Dissimilar Material Joining for Next Generation Lightweight Vehicles

The Arconic Technology Center working with Honda R&D Americas, LLC and the Ohio State University evaluated the corrosion performance of several multi-material conditions and demonstrated the production worthiness of the Resistance Spot Riveting (RSR™) process. RSR is a new technology being developed by Howmet Fastening Systems (formerly Arconic, Inc.) that employs a fastener that is installed using conventional resistance spot welding equipment to produce multi-material joints. The goal of the 3-year project was to demonstrate the use of RSR to join aluminum to steel and aluminum to carbon fiber composites on a prototype scale. Deployment of this technology would help the automotive industry achieve an additional 10 to 20% weight reduction over high strength steels. These weight-savings to the body in white generally translates to 2.5-5.0% of overall vehicle curb weight. The resulting total weight-savings could provide a 1.5% to 3.0% total improvement in fuel efficiency for vehicles that incorporate RSR for multi-material joining. The RSR technology addresses several production barriers to achieving DOE’s fuel efficiency targets including eliminating the need of additional capital for new joining technologies and the flexibility to process conventional steel and multi-material structures with the same equipment. Additionally, the trend towards ultra-high strength steels limits the availability of conventional joining technologies that can effectively process these multi-material combinations. In order to accomplish these goals, the following program milestones were completed by the team: 1) Developed RSR process parameters, producing multi-material joints for mechanical testing and corrosion assessments. 2) Conducted corrosion evaluation of RSR and baseline joints assembled between automotive type aluminum alloys, steels, and carbon fiber using several corrosion mitigation strategies. 3) Developed a production ready feed system and integrate into a robotic resistance spot welding station to simulate automotive production conditions. 4) Produced demonstration assemblies for testing and evaluation.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Supercruiser Arrow HS-8

Technology in aeronautics has advanced dramatically since the last design of a production High Speed Civil Transport (HSCT) aircraft. Newly projected requirements call for a new High Speed Civil Transport aircraft with a range of approximately 550 nm and at least 275 passenger capacity. The aircraft must be affordable and marketable. The new HSCT must be able to sustain long-duration flights and to absorb the abuse of daily operation. The new aircraft must be safe and simple to fly and require a minimum amount of maintenance. This aircraft must meet FAA certification criteria of FAR Part 25 and environmental constraints. Several design configurations were examined and two designs were selected for further investigation. The first design employs the delta planform wings and conventional empennage layout. The other design uses a swing wing layout and conventional empennage. Other engineering challenges, including materials and propulsion are also discussed. At a cruise flight speed between Mach 2.2 and Mach 3.0, no current generation of materials can endure the thermal loading of supersonic flight and satisfy the stringent weight requirements. A new generation of lightweight composite materials must be developed for the HSCT. With the enforcement of stage 3 noise restrictions, these new engines must be able to propel the aircraft and satisfy the noise limit. The engine with the most promise is the variable cycle engine. At low subsonic speeds the engine operates like a turbofan engine, providing the most efficient performance. At higher speeds the variable cycle engine operates as a turbojet power plant. The two large engine manufacturers, General Electric and Pratt & Whitney in the United States, are combining forces to make the variable cycle engine a reality.

Lord, Paul↗
NASA NTRS2003

Electron Radiation Effects on Candidate Solar Sail Material

Solar sailing is a unique form of propulsion where a spacecraft gains momentum from incident photons. Solar sails are not limited by reaction mass and provide continual acceleration, reduced only by the lifetime of the lightweight film in the space environment and the distance to the Sun. Once thought to be difficult or impossible, solar sailing has come out of science fiction and into the realm of possibility. Any spacecraft using this propulsion method would need to deploy a thin sail that could be as large as many kilometers in extent. The availability of strong, ultra lightweight, and radiation resistant materials will determine the future of solar sailing. The National Aeronautics and Space Administration's (NASA) Marshall Space Flight Center (MSFC) is concentrating research into the utilization of ultra lightweight materials for spacecraft propulsion. The Space Environmental Effects Team at MSFC is actively characterizing candidate solar sail material to evaluate the thermo-optical and mechanical properties after exposure to space environmental effects. This paper will describe the irradiation of candidate solar sail materials to energetic electrons, in vacuum, to determine the hardness of several candidate sail materials.

Edwards, David L.↗
NASA NTRS2005

Performance of a Light-Weight Ablative Thermal Protection Material for the Stardust Mission Sample Return Capsule

New tests and analyses are reported that were carried out to resolve testing uncertainties in the original development and qualification of a lightweight ablative material used for the Stardust spacecraft forebody heat shield. These additional arcjet tests and analyses confirmed the ablative and thermal performance of low density Phenolic Impregnated Carbon Ablator (PICA) material used for the Stardust design. Testing was done under conditions that simulate the peak convective heating conditions (1200 W/cm2 and 0.5 atm) expected during Earth entry of the Stardust Sample Return Capsule. Test data and predictions from an ablative material response computer code for the in-depth temperatures were compared to guide iterative adjustment of material thermophysical properties used in the code so that the measured and predicted temperatures agreed. The PICA recession rates and maximum internal temperatures were satisfactorily predicted by the computer code with the revised properties. Predicted recession rates were also in acceptable agreement with measured rates for heating conditions 37% greater than the nominal peak heating rate of 1200 W/sq cm. The measured in-depth temperature response data show consistent temperature rise deviations that may be caused by an undocumented endothermic process within the PICA material that is not accurately modeled by the computer code. Predictions of the Stardust heat shield performance based on the present evaluation provide evidence that the maximum adhesive bondline temperature will be much lower than the maximum allowable of 250 C and an earlier design prediction. The re-evaluation also suggests that even with a 25 percent increase in peak heating rates, the total recession of the heat shield would be a small fraction of the as-designed thickness. These results give confidence in the Stardust heat shield design and confirm the potential of PICA material for use in new planetary probe and sample return applications.

Covington, M. A.↗
NASA NTRS2002

Higher-Order Theory: Structural/MicroAnalysis Code (HOTSMAC) Developed

The full utilization of advanced materials (be they composite or functionally graded materials) in lightweight aerospace components requires the availability of accurate analysis, design, and life-prediction tools that enable the assessment of component and material performance and reliability. Recently, a new commercially available software product called HOTSMAC (Higher-Order Theory--Structural/MicroAnalysis Code) was jointly developed by Collier Research Corporation, Engineered Materials Concepts LLC, and the NASA Glenn Research Center under funding provided by Glenn's Commercial Technology Office. The analytical framework for HOTSMAC is based on almost a decade of research into the coupled micromacrostructural analysis of heterogeneous materials. Consequently, HOTSMAC offers a comprehensive approach for analyzing/designing the response of components with various microstructural details, including certain advantages not always available in standard displacement-based finite element analysis techniques. The capabilities of HOTSMAC include combined thermal and mechanical analysis, time-independent and time-dependent material behavior, and internal boundary cells (e.g., those that can be used to represent internal cooling passages, see the preceding figure) to name a few. In HOTSMAC problems, materials can be randomly distributed and/or functionally graded (as shown in the figure, wherein the inclusions are distributed linearly), or broken down by strata, such as in the case of thermal barrier coatings or composite laminates.

Arnold, Steven M.↗
NASA NTRS2003

Characterization of Candidate Solar Sail Material Exposed to Space Environmental Effects

Solar sailing is a unique form of propulsion where a spacecraft gains momentum from incident photons. Solar sails are not limited by reaction mass and provide continual acceleration, reduced only by the lifetime of the lightweight film in the space environment and the distance to the Sun. Once thought to be difficult or impossible, solar sailing has come out of science fiction and into the realm of possibility. Any spacecraft using this method would need to deploy a thin sail that could be as large as many kilometers in extent. The availability of strong, ultra lightweight, and radiation resistant materials will determine the future of solar sailing. The National Aeronautics and Space Administration's Marshall Space Flight Center (MSFC) is concentrating research into the utilization of ultra lightweight materials for spacecraft propulsion. The Space Environmental Effects Team at MSFC is actively characterizing candidate solar sail material to evaluate the thermo-optical and mechanical properties after exposure to space environmental effects. This paper will describe the exposure of candidate solar sail materials to emulated space environmental effects including energetic electrons, combined electrons and Ultraviolet radiation, and hypervelocity impact of irradiated solar sail material. This paper will describe the testing procedure and the material characterization results of this investigation.

Edwards, David↗
NASA NTRS2003

Impedance-Based Structural Health Monitoring for Composite Laminates at Cryogenic Environments

One of the important ways of increasing the payload in a reusable launch vehicle (RLV) is to replace heavy metallic materials by lightweight composite laminates. Among various parts and systems of the RLV, this project focuses on tanks containing cryogenic fuel. Historically, aluminum alloys have been used as the materials to construct fuel tanks for launch vehicles. To replace aluminum alloys with composite laminates or honeycomb materials, engineers have to make sure that the composites are free of defects before, during, and after launch. In addition to robust design and manufacturing procedures, the performance of the composite structures needs to be monitored constantly.In recent years, the impedance-based health monitoring technique has shown its promise in many applications. This technique makes use of the special properties of smart piezoelectric materials to identify the change of material properties due to the nucleation and progression of damage. The piezoceramic patch serves as a sensor and an actuator simultaneously. The piezoelectric patch is bonded onto an existing structure or embedded into a new structure and electrically excited at high frequencies. The signature (impedance or admittance) is extracted as a function of the exciting frequency and is compared with the baseline signature of the healthy state. The damage is quantified using root mean square deviation (RMSD) in the impedance signatures with respect to the baseline signature. A major advantage of this technique is that the procedure is nondestructive in nature and does not perturb the properties and performance of the materials and structures. This project aims at applying the impedance-based nondestructive testing technique to the damage identification of composite laminates at cryogenic temperature.

Tseng, Kevin↗
DOE OSTI2025

Pultrusion and Vitrimer Composites: Emerging Pathways for Sustainable Structural Materials

Pultrusion is a manufacturing process used to produce fiber-reinforced polymer composites with excellent mechanical, thermal, and chemical properties. The resulting materials are lightweight, durable, and corrosion-resistant, making them valuable in aerospace, automotive, construction, and energy sectors. However, conventional thermoset composites remain difficult to recycle due to their infusible and insoluble cross-linked structure. This review explores integrating vitrimer technology a novel class of recyclable thermosets with dynamic covalent adaptive networks into the pultrusion process. As only limited studies have directly reported vitrimer pultrusion to date, this review provides a forward-looking perspective, highlighting fundamental principles, challenges, and opportunities that can guide future development of recyclable high-performance composites. Vitrimers combine the mechanical strength (tensile strength and modulus) of thermosets with the reprocessability and reshaping of thermoplastics through dynamic bond exchange mechanisms. These polymers offer high-temperature reprocessability, self-healing, and closed-loop recyclability, where recycling efficiency can be evaluated by the recovery yield retention of mechanical properties and reuse cycles meeting the demand for sustainable manufacturing. Key aspects discussed include resin formulation, fiber impregnation, curing cycles, and die design for vitrimer systems. The temperature-dependent bond exchange reactions present challenges in achieving optimal curing and strong fiber–matrix adhesion. Recent studies indicate that vitrimer-based composites can maintain structural integrity while enabling recycling and repair, with mechanical performance such as flexural and tensile strength comparable to conventional composites. Incorporating vitrimer materials into pultrusion could enable high-performance, lightweight products for a circular economy. The remaining challenges include optimizing curing kinetics, improving interfacial adhesion, and scaling production for widespread industrial adoption.

Fiber composites↗
NASA NTRS1985

Applications of spherical shells

A new technique of producing hollow spheres of many materials at a very rapid rate, at very low cost, and with high reproducibility of shell diameter and wall thickness has been developed. Shells formed of metal or of other solid materials are expected to find numerous technical and industrial applications. For example, metal shells might be used as inertial confinement fusion targets, or as the principal constituents in lightweight structural materials for NASA Space Stations or DOD large antennas and mirrors, or be employed as containers for phase-change heat-storage media, or serve as containers for hazardous materials, or be employed as catalytic surface agents.

Wang, T. G.↗
NASA NTRS2010

MSFC Thermal Protection System Materials on MISSE-6

The Lightweight Nonmetallic Thermal Protection Materials Technology (LNTPMT) program studied a number of ceramic matrix composites, ablator materials, and tile materials for durability in simulated space environment. Materials that indicated low atomic oxygen reactivity and negligible change in thermo-optical properties in ground testing were selected to fly on the Materials on International Space Station Experiment (MISSE)-6. These samples were exposed for 17 months to the low Earth orbit environment on both the ram and wake sides of MISSE-6B. Thermo-optical properties are discussed, along with any changes in mass.

Finckenor, Miria M.↗
NASA NTRS2013

Conducting nanotubes or nanostructures based composites, method of making them and applications

An electromagnetic interference (EMI) shielding material includes a matrix of a dielectric or partially conducting polymer, such as foamed polystyrene, with carbon nanotubes or other nanostructures dispersed therein in sufficient concentration to make the material electrically conducting. The composite is formed by dispersing the nanotube material in a solvent in which the dielectric or partially conducting polymer is soluble and mixing the resulting suspension with the dielectric or partially conducting polymer. A foaming agent can be added to produce a lightweight foamed material. An organometallic compound can be added to enhance the conductivity further by decomposition into a metal phase.

Gupta, Mool C.↗
NASA NTRS2013

Optical Characterization of Window Materials for Aerospace Applications

An optical metrology laboratory has been developed to characterize the optical properties of optical window materials to be used for aerospace applications. Several optical measurement systems have been selected and developed to measure spectral transmittance, haze, clarity, birefringence, striae, wavefront quality, and wedge. In addition to silica based glasses, several optical lightweight polymer materials and transparent ceramics have been investigated in the laboratory. The measurement systems and selected empirical results for non-silica materials are described. These measurements will be used to form the basis of acceptance criteria for selection of window materials for future aerospace vehicle and habitat designs.

Tedjojuwono, Ken K.↗
NASA NTRS2017

Lightweight ZERODUR: Validation of Mirror Performance and Mirror Modeling Predictions

Upcoming spaceborne missions, both moderate and large in scale, require extreme dimensional stability while relying both upon established lightweight mirror materials, and also upon accurate modeling methods to predict performance under varying boundary conditions. We describe tests, recently performed at NASA's XRCF chambers and laboratories in Huntsville Alabama, during which a 1.2 m diameter, f/1.2988% lightweighted SCHOTT lightweighted ZERODUR(TradeMark) mirror was tested for thermal stability under static loads in steps down to 230K. Test results are compared to model predictions, based upon recently published data on ZERODUR(TradeMark). In addition to monitoring the mirror surface for thermal perturbations in XRCF Thermal Vacuum tests, static load gravity deformations have been measured and compared to model predictions. Also the Modal Response(dynamic disturbance) was measured and compared to model. We will discuss the fabrication approach and optomechanical design of the ZERODUR(TradeMark) mirror substrate by SCHOTT, its optical preparation for test by Arizona Optical Systems (AOS). Summarize the outcome of NASA's XRCF tests and model validations

technology↗
NASA NTRS2014

Solar and Drag Sail Propulsion: From Theory to Mission Implementation

Solar and drag sail technology is entering the mainstream for space propulsion applications within NASA and around the world. Solar sails derive propulsion by reflecting sunlight from a large, mirror- like sail made of a lightweight, reflective material. The continuous sunlight pressure provides efficient primary propulsion without the expenditure of propellant or any other consumable, allowing for very high V maneuvers and long-duration deep space exploration. Drag sails increase the aerodynamic drag on Low Earth Orbit (LEO) spacecraft, providing a lightweight and relatively inexpensive approach for end-of-life deorbit and reentry. Since NASA began investing in the technology in the late 1990's, significant progress has been made toward their demonstration and implementation in space. NASA's Marshall Space Flight Center (MSFC) managed the development and testing of two different 20-m solar sail systems and rigorously tested them under simulated space conditions in the Glenn Research Center's Space Power Facility at Plum Brook Station, Ohio. One of these systems, developed by L'Garde, Inc., is planned for flight in 2015. Called Sunjammer, the 38m sailcraft will unfurl in deep space and demonstrate solar sail propulsion and navigation as it flies to Earth-Sun L1. In the interim, NASA MSFC funded the NanoSail-D, a subscale drag sail system designed for small spacecraft applications. The NanoSail-D flew aboard the Fast Affordable Science and Technology SATellite (FASTSAT) in 2010, also developed by MSFC, and began its mission after it was was ejected from the FASTSAT into Earth orbit, where it remained for several weeks before deorbiting as planned. NASA recently selected two small satellite missions as part of the Advanced Exploration Systems (AES) Program, both of which will use solar sails to enable their scientific objectives. Lunar Flashlight, managed by JPL, will search for and map volatiles in permanently shadowed Lunar craters using a solar sail as a gigantic mirror to steer sunlight into the shaded craters. The Near Earth Asteroid (NEA) Scout mission will use the sail as primary propulsion allowing it to survey and image one or more NEA's of interest for possible future human exploration. Both are planned for launch in 2017. As the technology matures, solar sails will increasingly be used to enable science and exploration missions that are currently impossible or prohibitively expensive using traditional chemical and electric rockets. For example, the NASA Heliophysics Decadal Survey identifies no less than three such missions for possible flight before the mid-2020's. Solar sail propulsion technology is no longer an intesting theoretical possibility; it has been demonstrated in space and is now a critical technology for science and solar system exploration.

Johnson, Les↗