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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Materials for the biorefinery: high bio-content, shape memory Kraft lignin-derived non-isocyanate polyurethane foams using a non-toxic protocol

Polyurethanes are among the top six polymers produced in the world and are widely used in the automotive, furniture, construction and appliance industry for their light weight, impact resistance, and insulating properties. However, the use of hazardous diisocyanates used in polyurethane formulations has led many to search for more sustainable alternatives. The lignin component of biomass has been targeted to replace the often toxic and petroleum-derived precursors to polymer synthesis in support of the biorefinery concept where natural materials are used as the feedstock for commodity plastics. The use of lignin is often hampered due to its low reactivity, heterogeneity and the necessity of employing extensive purification and/or functionalization measures to ensure materials are of comparable quality. In this report, a unique method is presented for the synthesis and processing of a non-toxic, non-isocyanate polyurethane foam utilizing unmodified Kraft lignin and a biobased curing agent. Here, raw Kraft lignin is functionalized with green organic carbonates and a non-toxic approach is taken to solubilize the precursors with a curing agent from renewable fatty acids enabling rapid gel-times. For the first time, a NIPU foam from lignin is synthesized while the structure–property relationship of different reaction mixtures is studied demonstrating shape memory capacity and 100% biobased carbon content.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Linear simulations of a wide pedestal quiescent H-mode plasma with the extended-MHD code NIMROD

We present linear simulations of a Wide Pedestal QH (WPQH)-mode DIII-D plasma with the NIMROD code to address the role of ion multispecies collisionality on WPQH-modes. We use a full extended-MHD model that captures Alfvénic and magnetoacoustic waves, including two-fluid, ion gyroviscosity and cross heat flux. We show that two-fluid and ion gyroviscous effects destabilize electron-directed peeling–ballooning modes in the pedestal. The linear growth rates of the modes decrease when carbon (C) is added to a deuterium plasma because the multispecies collisional effects increase the plasma resistivity. When replacing C with tungsten (W), the multispecies collisional effects increase the resistivity further, as well as the stabilizing effect on the instabilities. The resistivity impact on mode stability is reversed when both two-fluid and ion gyroviscous effects are ignored, which is consistent with previous works, proving that multispecies collisional effects, together with two-fluid and ion gyroviscosity, should be considered to address the stability of plasmas with significant impurity content.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Deformation and failure of the CrCoNi medium-entropy alloy subjected to extreme shock loading

The extraordinary work hardening ability and fracture toughness of the face-centered cubic (fcc) high-entropy alloys render them ideal candidates for many structural applications. Here, the deformation and failure mechanisms of an equiatomic CrCoNi medium-entropyalloy (MEA) were investigated by powerful laser-driven shock experiments. Multiscale characterization demonstrates that profuse planar defects including stacking faults, nanotwins, and hexagonal nanolamella were generated during shock compression, forming a three-dimensional network. During shock release, the MEA fractured by strong tensile deformation and numerous voids was observed in the vicinity of the fracture plane. High defect populations, nanorecrystallization, and amorphization were found adjacent to these areas of localized deformation. Molecular dynamics simulations corroborate the experimental results and suggest that deformation-induced defects formed before void nucleation govern the geometry of void growth and delay their coalescence. Our results indicate that the CrCoNi-based alloys are impact resistant, damage tolerant, and potentially suitable in applications under extreme conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2022

On the optimized 3D printing and post-processing of PETG materials

Glycol-modified polyethylene terephthalate (PETG) is a reliable middle ground between polylactic acid and acrylonitrile butadiene styrene due to its light weight, impact resistance, toughness, flexibility, and cost-effectiveness. However, during 3D printing, the filament form is prone to oozing and stringing. In this study, we optimized the PETG printability via g-code setting and printing parameter modification, and consideration of filament quality, build plate temperature and leveling, and printing design complexity. Printed PETGs were thermally and chemically annealed, and post-processing conditions including annealing time, temperature, and solvent use were investigated. Mechanical properties were evaluated in terms of print parameter changes and post-processing techniques.

36 MATERIALS SCIENCE↗
DOE OSTI2021

RapidClave Technology Demonstrations-II Kevlar Composite Vehicle Floor

This Demonstration’s objective was to develop enhanced methods to produce a complex preform comprised of Kevlar fabric and thermoplastic adhesive and rapidly consolidate the preform into the desired functional shape of a vehicular floor protection system. The approach and outcome goals were to reduce the tooling cost by 50% and shorten the processing time by 50% using the RapidClave® to consolidate the part rather than an autoclave. UDRI partnered with O’Gara Armoring who currently produces one piece Kevlar floor composite laminates that offer enhanced impact resistance at lighter weights as compared to steel. These laminates are constructed by hand layup of 3000 denier K29 fiber in a plain weave architecture with a thermoplastic film adhesive layer manufactured by Barrday and will be referred to as semi-preg throughout this paper. The current process is labor intensive and costly. Current production rates are only about one per month but an improved process is expected to enable product growth. A 50% reduction in tooling cost was achieved through the use of additive tooling, and the RapidClave® process enabled a 60% reduction in cycle time. Further cost savings were realized through the implementation of a preforming process that resulted in a 65% reduction in labor hours. This new approach for manufacturing reinforced vehicle floors has been partially implemented by O’Gara with plans to continue work on additional vehicle models. The cost savings has potential for increasing O’Gara’s production to reach new markets, and lead to job creation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

HYBRID COMPOSITES VIA CO-EXTRUSION ADDITIVE MANUFACTURING-COMPRESSION MOLDING FOR PERFORMANCE OPTIMIZATION

The growing demand for hybrid polymer composites with multifunctional properties has led to the development of various hybridization techniques, such as multi-material compounding and controlled laminate stacking sequence. In this study, a novel hybrid manufacturing approach was used by integrating a multiplexing extrusion system (MExS) based on additive manufacturing with subsequent compression molding process. This technique enabled the co-extrusion of different materials during the additive manufacturing process to fabricate composites with tailored performance. The developed hybrid composite featured a skin layer of glass fiberreinforced polycarbonate (PC/GF) encapsulating a carbon fiber-reinforced acrylonitrile butadiene styrene (CF/ABS) core. The structure was engineered to promote improved thermal and impact resistance at the surface, supported by a stiff core for enhanced overall mechanical integrity. Mechanical, thermal and morphological properties of the hybrid composites were investigated to understand trade-offs in performance compared to a single-material system. The results demonstrate that this approach enables the production of multifunctional composites suitable for applications such as automotive body panels and protective housings, where a balance of weight, mechanical strength, and thermal performance is essential.

Wasti, Sanjita [ORNL]↗
NASA NTRS1967

The heat sterilizable battery.

Sealed heat sterilizable high impact resistant battery for space missions, grafting acrylic acid and polyethylene by irradiation for separator

SPACECRAFT POWER SUPPLY↗
NASA NTRS1970

Radioisotope thermionic generator /RTIG/

Impact resistant power packages for unmanned planetary probe landers, discussing radioisotope thermionic multiconverter array optimal configuration

Rouklove, P.↗
NASA NTRS1972

Design properties of randomly reinforced fiber composites

The pseudoisotropic-laminate analogy is used in conjunction with fiber composite micro- and macromechanics to predict the thermal and mechanical properties of planar randomly reinforced fiber composites (PRRFC). Theoretical results are presented for boron/aluminum, boron/epoxy, Thornel-50/epoxy, and S-glass/epoxy PRRFC. The results show that the thermal and elastic properties depend on both constituent materials and the fiber volume ratio. The strength depends also on the type of applied stress. In general, no simple ratio exists between the properties of unidirectional fiber composites and those of PRRFC. The data are presented in convenient graphical form to serve as an aid for design and/or analysis and also for further research in PRRFC. The residual stresses and the impact resistance are also theoretically examined.

Chamis, C. C.↗
NASA NTRS1973

Factors affecting miniature Izod impact strength of tungsten-fiber-metal-matrix

The miniature Izod and Charpy impact strengths of copper, copper-nickel, and nickel-base superalloy uniaxially reinforced with continuous tungsten fibers were studied. In most cases, impact strength was increased by increasing fiber or matrix toughness, decreasing fibermatrix reaction, increasing test temperature, hot working, or heat treating. Notch sensitivity was reduced by increasing fiber content or matrix toughness. An equation relating impact strength to fiber and matrix properties and fiber content was developed. Program results imply that tungsten alloy-fiber/superalloy matrix composites can be made with adequate impact resistance for turbine blade or vane applications.

Winsa, E. A.↗
NASA NTRS1974

High strength nickel base alloy, WAZ-16, for applications up to 2200 F

Alloy product is high strength, high temperature nickel base material with higher incipient melting temperature than all known nickel base alloys. It is microstructurally stable and has high impact resistance both before and after prolonged thermal exposure. It contains relatively few alloying constitutents and low content of expensive and rare metals.

Waters, W. J.↗
NASA NTRS1974

Boron/aluminum-graphite/resin advanced fiber composite hybrids

An investigation was conducted to determine the fabrication feasibility and to assess the potential of adhesively-bonded metal and resin matrix fiber composite hybrids as an advanced material, for aerospace and other structural applications. The results of fabrication studies and of evaluation of physical and mechanical properties show that using this hybrid concept it is possible to design a composite which, when compared to nonhybrid composites, has improved transverse strength, transverse stiffness, and impact resistance with only a small penalty on density and longitudinal properties. The results also show that laminate theory is suitable for perdicting the structural response of such hybrids. The sequence of fracture modes indicates that these types of hybrids can be readily designed to meet fail-safe requirements.

Chamis, C. C.↗
NASA NTRS1974

Strengthening silicon carbide by quenching

Quenching was used to form compressive surface layers in hot-pressed silicon carbide. The presence of the compressive stresses was verified by slotted rod tests. The slotted rod tip deflection was retained at temperatures to at least 1380 C, showing that the stresses are not relieved immediately at elevated temperatures. The flexural strength and impact resistance of specimens quenched from moderate temperatures (2000 C) were increased. Frequently, specimens quenched from higher temperatures were weakened by thermal shock damage.

Gruver, R. M.↗
NASA NTRS1975

Boron/aluminum graphite/resin advanced fiber composite hybrids

Fabrication feasibility and potential of an adhesively bonded metal and resin matrix fiber-composite hybrid are determined as an advanced material for aerospace and other structural applications. The results show that using this hybrid concept makes possible a composite design which, when compared with nonhybrid composites, has greater transverse strength, transverse stiffness, and impact resistance with only a small penalty on density and longitudinal properties. The results also show that laminate theory is suitable for predicting the structural response of such hybrids. The sequence of fracture modes indicates that these types of hybrids can be readily designed to meet fail-safe requirements.

Chamis, C. C.↗
NASA NTRS1974

High temperature polyimide foams for shuttle upper surface thermal insulation

Polyimide foams developed by Monsanto Company were examined for use as upper surface space shuttle thermal insulation. It was found that postcured polyimide foams having a density of 64 kg/cu m (4 lb/cu ft) had acceptable physical properties up to and exceeding 700 K (800 F). Physical tests included cyclic heating and cooling in vacuum, weight and dimensional stability, mechanical strength and impact resistance, acoustic loading and thermal conductivity. Molding and newly developed postcuring procedures were defined.

Ball, G. L., III↗