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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 OSTI2021

Textile-Grade Carbon Fiber-Reinforced Polycarbonate Composites: Effect of Epoxy Sizing

In this work, epoxy-sized textile-grade polyacrylonitrile (PAN) carbon fiber (TCF) with 450 K filaments (CFTF, ORNL) was reinforced in the polycarbonate (PC) matrix using a compression molding technique. The epoxy sizing effect on the surface, thermal, and mechanical properties of TCF–PC was investigated. X-ray photoelectron spectroscopy and Fourier transform infrared spectroscopy results of the TCF–PC composite show the absence of an oxirane group (epoxy-sized TCF), which suggests a covalent bond formation between the oxirane ring and carbonyl groups from TCF and PC. Dynamic mechanical analysis results confirm a strong immobilized interface (b > 1) present between TCF and PC. The tensile, flexure, compression, and interlaminar shear strength of TCF–PC composites were 323 ± 53, 371 ± 31, 397 ± 87, and 36 ± 3 MPa, correspondingly. The fracture analysis through scanning electron microscopy shows good wettability between TCF and the PC matrix which validates the results obtained from surface and thermal characterization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Solventless Dual‐Cure Liquid Resins Via Circular Use of Phthalic Anhydride for Recyclable Composite Applications

Abstract Fiber‐reinforced composites (FRCs) possess a remarkable strength‐to‐weight ratio, making them ideal light‐weighing alternative materials of metals used in automotive, aerospace, and outdoor equipment applications, but their recycling is challenging. Chemically recyclable thermoset polymers can enable fiber recovery and reuse; however, challenges remain in the separation and purification of depolymerized small molecules for efficient polymer recycling. To this end, a series of liquid resins for chemically recyclable polymer networks is designed based on phthalic anhydride, a widely produced and inexpensive chemical. The straightforward sublimation of phthalic anhydride is leveraged to enable a simple and efficient separation process for polymer recycling. To liquefy phthalic anhydride, five mono‐acryloyl‐phthalates are synthesized to obtain stable liquid resins together with phthalic diglycidyl ester. These liquid resins undergo dual‐cure reactions that comprise photopolymerization of acrylate and, subsequently, heat‐mediated epoxy‐acid polymerization reactions. These liquid resins exhibit moderate viscosities (2600–6400 cP @ 22 °C), fast curing, and robust thermomechanical properties (T g s from 71 to 116 °C). It is demonstrated that hydrolysis of the dual‐cured polymers completes within 2 h at 80 °C, and direct sublimation produces phthalic anhydride with 82% yield. This resin system is expected to provide a cost‐competitive, highly efficient platform for recyclable FRCs.

Polymer Science↗
DOE OSTI2023

Functionally Designed Ultra-Lightweight Carbon Fiber Reinforced Thermoplastic Composites Door Assembly (Final Scientific/Technical Report)

This is the final technical report for a project that developed an ultra-lightweight carbon fiber reinforced thermoplastics composite door assembly for a mid-size SUV. The project was able achieve a weight reduction of at least 42.5% while maintaining or exceeding the fit, function, safety, stiffness, and crash performance requirements of the current baseline door. Additionally, the target cost was set at less than $5 per pound of weight saved. To accomplish these goals, the project team employed a systems approach that involves redesigning the door assembly, exploring novel materials, optimizing the design, and utilizing advanced manufacturing technologies.

42 ENGINEERING↗
DOE OSTI2020

Composite materials with self-regulated infrared emissivity and environment responsive fibers

A composite fabric having self-regulating Infrared emissivity includes meta fibers formed with optical nanostructures and an environment (temperature and/or moisture) responsive mechanism configured to adjust a relative disposition between the optical structures to control the electromagnetic coupling therebetween, thus regulating the infrared emissivity of the composite fabric to maintain a user of the fabric in a temperature/moisture comfort zone. The environment responsive mechanism may include a temperature responsive polymer layer on the fiber capable of expansion/shrinkage depending on the applied temperature, or a moisture responsive fiber changing its shape depending on the moisture level to affect spacing between the optical nanostructures.

Wang, Yuhuang↗
DOE OSTI2026

Hybrid Bio-Based Composites: Enabling Cellulose Nanofiber (CNF) Incorporation into Composites via Macroscale Natural Fiber Carriers

Cellulose nanofibers (CNFs) have significant potential in composites as additives to improve mechanical properties, melt rheology, and more. However, agglomeration of CNFs is a key challenge in composite melt processing as obtaining nano-level dispersion of CNFs often requires cost- and energy-intensive processes (e.g., solvent exchange or freeze drying) due to the strong hornification tendencies of CNF. Herein, we avoid these challenges by using a natural fiber carrier method to integrate CNF into thermoplastic composites. Fibers are co-dried to create a hybrid fiber feedstock for compounding in which natural fibers are decorated with dispersed nanofibers. The hybridized fibers result in up to a 24% increase in tensile strength and up to a 35% increase in Young’s modulus compared to composites only containing natural fibers. The lignocellulosic nanofibers are found to outperform their purely cellulosic counterpart, which is theorized to be due to either an increased propensity for fibrillation of the lignocellulosic fibers or the increased hydrophobicity of the fibers due to the presence of lignin. Surface analysis of fiber feedstocks, via streaming potential measurements and dynamic light scattering (DLS), confirmed a significant change in the feedstock hydrophobicity before and after hybridization. While mild additions of CNF (1 wt.% on the macroscale fiber) do not impact the composite melt viscosity, the viscosity is found to increase at higher CNF loadings (5 wt.% on the macroscale fiber), indicating its utility as a rheology modifier. Lastly, use of these materials as novel feedstocks for medium-scale additive manufacturing in high-fidelity part production was demonstrated.

bio-based↗
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 OSTI2021

Integrating helicoid channels for passive control of fiber alignment in direct-write 3D printing

3D printing of fiber-reinforced composites has been receiving increasing attention as an efficient additive approach enabling lightweight, functional, and high-performance components required for industrial applications. The properties of fiber composites significantly depend on internal microstructures, including fiber orientation, distribution, and degree of alignment. Although multiple strategies have been introduced for controlling the fiber composites microstructures, these strategies are mostly active approaches relying on additional control of mechatronics parts, external forces, or intentionally introduced unstable flows inside narrow nozzles. These methods suffer from higher risk of nozzle clogging and requiring extra parts in 3D printing. Here, we introduce helicoid channels into extrusion system as a passive approach to control the fiber alignment without any additional moving parts in direct-write 3D printing. The helicoid channels automatically guide the composite inks and align fibers before flowing into narrow nozzle space, avoiding clogging and improving printability. The analyses indicate that both helicoid surface to volume ratio and helix angle affect the pre-alignment of fibers, leading to tunable mechanical properties of printed fiber-reinforced composites with increased stiffness and strength up to 77.6% and 47.8%, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Elucidating the impact of fiber source on polypropylene/hemp composite performance for the automotive industry

Given their high strength-to-weight ratio, there is an ever-increasing volume of plastics being used in the automotive industry as plastics aid in the charge to lightweight vehicles for improved fuel efficiency. However, these plastics are often landfilled at their end-of-life, which has given rise to the demand for sustainable materials and waste management alternatives compared to purely synthetic systems. Natural fiber composites have been explored as a viable material option to reduce the environmental impact of plastic use in automobiles while simultaneously ensuring the part performance is not sacrificed. Herein, we explored the use of hemp/polypropylene (PP) composites in which US-sourced hemp is compared to internationally sourced and industrially available hemp. There appears to be a minimal impact on the composite properties regardless of fiber sourcing, and the addition of a natural filler to the PP matrix results in up to a 367% increase in Young's modulus, 126% increase in heat deflection temperature, and comparable water uptake performance. It should be noted that the natural filler addition does increase density by up to 13% due to the higher density of natural fibers compared to the low-density PP matrix. A modified rule of mixtures calculation revealed that the composite materials produced in this study demonstrated good agreement with analytical modeling. Finally, a screening analysis was performed exploring the transportation of hemp fibers, and the results build a strong case for regionalized manufacturing of automotive parts.

Hubbard, Amber M. [Oak Ridge National Laboratory (↗
DOE OSTI2022

An Advanced Meso-Scale Peridynamic Modeling Technology using High-Performance Computing for Cost-Effective Product Design and Testing of Carbon Fiber Reinforced Polymer Composites in Light-weight Vehicles

We study a peridynamic composite modeling technology based on the discontinuous Galerkin finite element method, implemented in the commercial LS-DYNA software, for modeling and prediction of failure in carbon fiber reinforced polymer composites. The proposed technology is developed for the material failure analysis at the meso-scale, which provides the prevailing fiber-matrix interaction mechanism, without adoption of the representative volume element method and thus avoiding complicated numerical calibration procedures. Three types of experimental tests—in-plane coupon test, out-of-plane coupon test, and a component crash test—are simulated in a high-performance computing environment to assess the performance of the proposed peridynamic composite modeling technology.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Additive Manufacturing of C/C-SiC Ceramic Matrix Composites by Automated Fiber Placement of Continuous Fiber Tow in Polymer with Pyrolysis and Reactive Silicon Melt Infiltration

An additive manufacturing process for fabricating ceramic matrix composites has been developed based on the C/C-SiC system. Automated fiber placement of the continuous carbon fibers in a polyether ether ketone matrix was performed to consolidate the carbon fibers into a printed preform. Pyrolysis was performed to convert the polymer matrix to porous carbon, and then Si was introduced by reactive melt infiltration to convert a portion of the carbon matrix to silicon carbide. The densities and microstructures were characterized after each step during the processing, and the mechanical properties were measured. The C/C-SiC composites exhibited a porosity of 10–20%, characteristic flexural strength of 234.91 MPa, and Weibull modulus of 3.21. The composites displayed toughness via a significant displacement to failure.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effects of mercerization and fiber sizing of coir fiber for utilization in polypropylene composites

The use of natural fibers as an alternative to synthetic fibers for reinforcing composites is increasing. However, the poor interfacial adhesion between natural fibers and polymer matrices limits their applications. Several approaches have been considered to improve fiber-matrix adhesion via chemical and/or physical treatment. However, the effectiveness of these treatments varies based on the type of fiber, its source, and its composition. Thus, it is imperative to understand the effectiveness of treatment conditions. In this study, we investigated the influence of alkali treatment and fiber sizing on the chemical, thermal, morphological, and mechanical properties of coir fibers and the interface between coir fiber and polypropylene matrix. Further, it was found that using a 5 wt% sodium hydroxide solution for 6 h at room temperature was the optimal treatment condition that led to an improvement in tensile strength by 58%, tensile modulus by 71%, and elongation at break by 37% compared to untreated fibers, and an increment in interfacial shear strength (IFSS) between coir fibers and polypropylene matrix by 32%. The alkali treatment removed the fiber surface impurities, made the fiber surface rough, and enhanced the fiber crystallinity. Sizing of the alkali-treated fiber led to an improvement in IFSS by 87% with no modification of the fiber’s mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Thickness threshold study of polyaniline-based lightning strike protection coating for carbon/glass fiber reinforced polymer composites

Different polyaniline (PANI) based lightning strike protection (LSP) coating thicknesses were tested against simulated lightning strike tests to evaluate the threshold thickness of the coating. A series of lightning strike tests were performed on carbon/glass fiber reinforced polymer (CFRP/GFRP) composites subjected to simulated lightning currents ranging from 40 to 100 kA. Five LSP-coated specimens were considered herein: two CFRP and three GFRP composites. A minimum of ~ 345 μm thick PANI-based LSP coating on CFRP and GFRP composites under a 40 kA peak current retained 83 % and 100 % residual strength, respectively. Additionally, GFRP specimens tested against 60 and 100 kA peak currents exhibited 100 % residual strength. Finally, this study proposes that a PANI-based LSP coating is suitable for protecting GFRP composites, while the careful design is necessary for CFRP composites to avoid any catastrophic failure.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Automatic identification and quantification of dense microcracks in high-performance fiber-reinforced cementitious composites through deep learning-based computer vision

Highlights: • A method is presented to detect, locate, quantify, and visualize dense microcracks in HPFRCC. • Quantification of dense microcracks is realized using deep learning method for the first time. • The presented method uses deep learning models that are trained using a realistic dataset size. • The presented method has a high computation efficiency for identifying and quantifying cracks. • The presented method provides crack width with errors up to 50 μm and a R{sup 2} value of 0.984. High-performance fiber-reinforced cementitious composites (HPFRCCs) feature high mechanical strengths, crack resistance, and durability. Under excessive loading, HPFRCCs demonstrate dense microcracks that are difficult to identify using existing methods. This study presents a computer vision method for identification, quantification, and visualization of microcracks in HPFRCCs based on deep learning. The presented method integrates multiple deep learning models and computer vision techniques in a hierarchical architecture. The crack pattern (e.g., number, width, and spacing of cracks) are automatically determined from pictures without human intervention. This study shows that the presented method achieves an accuracy of 0.992 for crack detection and an accuracy finer than 50 μm (R{sup 2} > 0.984) for quantification of crack width when deep learning models are trained using only 200 pictures of HPFRCCs and 200 pictures of conventional concrete with incorporation of data augmentation. The presented method is expected to be also applicable to other materials featuring complex cracks.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Degradation in interfacial shear strength of carbon fiber/ vinyl ester composites due to long-term exposure to seawater using push-out tests

Here, in this study, single fiber (~7-μm diameter) push-out tests are conducted to evaluate hygrothermal effects on the interfacial shear strength (IFSS) of carbon fiber/vinyl ester (CF/VE) composites. Hygrothermal conditioning is achieved by saturating samples in simulated seawater at 40 °C for two years. An investigation has been conducted on the preparation, validity, and interpretation of the push-out test results. First, the authors present a polishing methodology that results in thin films of CF/VE composites in the thickness range of 15–120 μm and produces an average 41.2% drop in IFSS due to long-term hygrothermal exposure. Using scanning electron microscopy (SEM), we show that during the push-out tests, the failure initiates locally at the zone of minimum bond strength at the bottom (away from the indenter), then propagates along the length of the interface. The influence of radial tensile stresses originating due to bending is found to be negligible. Using the SEM imaging of the pushed-out fibers, we validate the failure of the interface to be the primary source of failure. The associated results are found to depend on the thickness of the interface. We then reevaluate the results using the Weibull distribution, knowing that the failure mechanism is analogous to the weakest link theory. The results show a 25.5% drop in the IFSS of the CFVE composite, measured at an infinitesimal scale due to long-term to hygrothermal conditioning at 40 °C. A significant drop in IFSS was observed after reheating above glass transition temperature (T g ) and cooling.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Quality Investigation of Pultruded Carbon Fiber Panels Subjected to Four-Point Flexure via Fiber Optic Sensing

Pultruded carbon fiber-reinforced composites are attractive to the wind energy industry due to the rapid production of highly aligned unidirectional composites with enhanced fiber volume fractions and increased specific strength and stiffness. However, high volume carbon fiber manufacturing remains cost-prohibitive. This study investigates the feasibility of a pultruded low-cost textile carbon fiber-reinforced epoxy composite as a promising material in spar cap production was undertaken based on mechanical response to four-point flexure loading. As spar caps are primarily subjected to flexural loading, large-span four-point flexure was considered, and coupon testing was restricted to tensile modulus and compression strength assessment. High-resolution spatial fiber optic strain sensing was utilized to determine spatial strain distribution during four-point flexure, revealing consistent strain along the length of the part and proved to be an excellent option for process manufacturing quality examination. Additionally, holes with diameters of 2.49 mm, 5.08 mm, and 1.93 mm were drilled through the thickness of full-width parts to determine the feasibility of structural health monitoring of pultruding parts internal to wind blades via fiber optic strain sensing.

Chemistry↗
DOE OSTI2026

Microfibril orientation and compositional heterogeneity in fiber and vessel cell walls of poplar xylem studied by AFM-IR and SFG spectroscopy

Understanding the structural organization of cellulose microfibrils (CMFs) within individual plant cell walls is essential for connecting cell wall architecture to its mechanical and physiological functions. However, due to the complex hierarchical structure and nanoscale heterogeneity of cell walls, it remains technically challenging to resolve detailed compositional and orientational information at subcellular levels of individual cell walls. This study investigates the internal 3D structure, chemical composition, and sublayer organization of fiber and vessel cell walls in the xylem tissue of a two-year-old field-grown hybrid poplar tree (Populus alba × P. glandulosa) using photothermal atomic force microscopy coupled with infrared spectroscopy (AFM-IR) and sum frequency generation (SFG) hyperspectral microscopy. AFM-IR provided nanoscale chemical imaging, revealing localized compositional heterogeneity, including variations between adjacent cell walls and transitional layers beyond the traditional S1, S2, and S3 sublayers. SFG microscopy revealed that CMFs in fiber walls are highly aligned along the stem axis, consistent with their role in mechanical support, while vessel cell walls exhibited slightly tilted CMFs, reflecting their function in hydraulic transport. Together, these results offer new insights into cell-type-specific CMF organization and compositional gradients in hybrid poplar xylem. These findings highlight the structural and chemical complexity of secondary cell walls in woody plants and demonstrate the value of AFM-IR and SFG spectroscopy in elucidating plant cell wall architecture.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Mechanical Characterization of High-Temperature Carbon Fiber-Polyphenylene Sulfide Composites for Large Area Extrusion Deposition Additive Manufacturing

Additive manufacturing (AM) is evolving from rapid prototyping to production of structural components. The widespread application of AM demands a high level of mechanical performance from these components, and it is therefore essential to improve feedstock material in order to meet these mechanical expectations. However, compared to traditional manufacturing techniques, the mechanical properties of AM materials and their resulting components are not well understood. In this study, we investigated the processability, microstructure, and mechanical performance of twin-screw compounded short carbon fiber reinforced polyphenylene sulfide (PPS) pellets as a feedstock material for big area AM (BAAM). The performance of the AM components was compared to that of traditional processing methods, namely injection molding (IM) and extrusion-compression molding (ECM). It was found that the AM composites exhibited 118% lower tensile strength and 55% lower tensile modulus when compared to traditional injection molding composite specimens; however, AM composites exhibited comparable properties to ECM composites. This response was attributed to highly aligned fibers in IM and AM samples. However, the AM composites contained porosity (15.5% volume), which reduced their mechanical properties in comparison to ECM composites. Finally, the IM process showed the maximum amount of fiber attrition with minimum porosity (0.007% volume), while the ECM process exhibited the least fiber attrition with 4.3% volume porosity.

36 MATERIALS SCIENCE↗