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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Casting inorganic structures with DNA molds

Here we report a general strategy for designing and synthesizing inorganic nanostructures with arbitrarily prescribed three-dimensional shapes. Computationally designed DNA strands self-assemble into a stiff “nano-mold” that contains a user-specified three-dimensional cavity and encloses a nucleating gold “seed”. Under mild conditions, this seed grows into a larger cast structure that fills and thus replicates the cavity. We synthesized a variety of nanoparticles with three nanometer resolution: three distinct silver cuboids with three independently tunable dimensions, silver and gold nanoparticles with diverse cross sections, and composite structures with homo-/heterogeneous components. The designer equilateral silver triangular and spherical nanoparticles exhibited plasmonic properties consistent with electromagnetism-based simulations. Our framework is generalizable to more complex geometries and diverse inorganic materials, offering a range of applications in biosensing, photonics, and nanoelectronics.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2019

Degradation of E-glass fiber mechanical properties during composite sheet molding compound production for automotive applications

Research into pyrolysis-based recycling of sheet molding compounds (SMCs) to recover glass fiber for reuse has indicated significant pre-existing tensile strength damage in the shredded recycling input materials. Here, this loss in mechanical durability inherently hurts the value proposition of recycled glass fiber by limiting reuse of the fiber for reinforcement. In this study, the mechanical properties of glass fibers at each step in the first lifecycle of an SMC material are measured to assess the extent of cumulating fiber damage prior to recycling and identify potential causes of this degradation to maximum fiber tensile performance.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Silicone Molding and Lifetime Testing of Peripheral Nerve Interfaces for Neuroprostheses

Implantable peripheral nerve cuffs have a large application in neuroprostheses as they can be used to restore sensation to those with upper limb amputations. Modern day prosthetics, while lessening the pain associated with phantom limb syndrome, have limited fine motor control and do not provide sensory feedback to patients. Sensory feedback with prosthetics requires communication between the nervous system and limbs, and is still a challenge to accomplish with amputees. Establishing this communication between the peripheral nerves in the arm and artificial limbs is vital as prosthetics research aims to provide sensory feedback to amputees. Peripheral nerve cuffs restore sensation by electrically stimulating certain parts of the nerve in order to create feeling in the hand. Cuff electrodes have an advantage over standard electrodes as they have high selective stimulation by bringing the electrical interface close to the neural tissue in order to selectively activate targeted regions of a peripheral nerve. In order to further improve the selective stimulation of these nerve cuffs, there is need for finer spatial resolution among electrodes. One method to achieve a higher spatial resolution is to increase the electrode density on the cuff itself. Microfabrication techniques can be used to achieve this higher electrode density. Using L-Edit, a layout editor, microfabricated peripheral nerve cuffs were designed with a higher electrode density than the current model. This increase in electrode density translates to an increase in spatial resolution by at least one order of magnitude. Microfabricated devices also have two separate components that are necessary to understand before implantation: lifetime of the device and assembly to prevent nerve damage. Silicone molding procedures were optimized so that devices do not damage nerves in vivo, and lifetime testing was performed on test microfabricated devices to determine their lifetime in vivo. Future work of this project would include fabricating some of the designed devices and seeing how they compare to the current cuffs in terms of their electrical performance, lifetime, shape, and mechanical properties.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2016

Development of a Preventive Maintenance Program for Tooling Used in Powder Slush Molding

ORNL collaborated with Faurecia Interior Systems to investigate the feasibility of developing a thermomagnetic preventive maintenance program for nickel tooling used in powder slush molding. It was found that thermal treatments at temperatures greater than 500°C can anneal strain hardening in nickel tooling and a range of temperatures and times for effective thermal annealing were identified. It was also observed that magnetic fields applied during thermal annealing do not alter the kinetics of strain hardening annealing. The results obtained in this investigation provide a foundation for establishing a preventive maintenance program for nickel tooling.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Predictive Engineering Tools for Injection-Molded Long-Carbon-Thermoplastic Composites: Weight and Cost Analyses

This project proposed to integrate, optimize and validate the fiber orientation and length distribution models previously developed and implemented in the Autodesk Simulation Moldflow Insight (ASMI) package for injection-molded long-carbon-fiber thermoplastic composites into a cohesive prediction capability. The current effort focused on rendering the developed models more robust and efficient for automotive industry part design to enable weight savings and cost reduction. The project goal has been achieved by optimizing the developed models, improving and integrating their implementations in ASMI, and validating them for a complex 3D LCF thermoplastic automotive part (Figure 1). Both PP and PA66 were used as resin matrices. After validating ASMI predictions for fiber orientation and fiber length for this complex part against the corresponding measured data, in collaborations with Toyota and Magna PNNL developed a method using the predictive engineering tool to assess LCF/PA66 complex part design in terms of stiffness performance. Structural three-point bending analyses of the complex part and similar parts in steel were then performed for this purpose, and the team has then demonstrated the use of stiffness-based complex part design assessment to evaluate weight savings relative to the body system target (≥ 35%) set in Table 2 of DE-FOA-0000648 (AOI #1). In addition, starting from the part-to-part analysis, the PE tools enabled an estimated weight reduction for the vehicle body system using 50 wt% LCF/PA66 parts relative to the current steel system. Also, from this analysis an estimate of the manufacturing cost including the material cost for making the equivalent part in steel has been determined and compared to the costs for making the LCF/PA66 part to determine the cost per “saved” pound.

42 ENGINEERING↗
DOE OSTI2017

Rapid Tooling for Functional Prototype of Metal Mold Processes Final Report CRADA No. TC-1032-98

Production inserts for die-casting were generally fabricated from materials with sufficient strength and· good wear properties at casting temperatures for long life. Frequently tool steels were used and machining was done with a combination of. conventional and Electric Discharge Machining (EDM) with some handwork, an expensive and time consuming process, partilly for prototype work. We proposed electron beam physical vapor deposition (EBPVD) as a process for rapid fabrication of dies. Metals, ranging from low melting point to refractory metals (Ta, Mo, etc.), would be evaporated and deposited at high rates (-2mm/hr.). Alloys could be easily evaporated and deposited if their constituent vapor pressures were similar and with more difficulty if they were not. Of course, layering of different materials was possible if required for a specific application. For example, a hard surface layer followed by a tough steel and backed by a high thermal conductivity (possibly cooled) copper layer could be fabricated. Electron-beam deposits exhibited 100% density and lull strength when deposited at a substrate (mandrel) temperature that was a substantial fraction of the deposited material's melting point. There were several materials that could have the required high temperature properties and ease of fabrication required for such a mandrel. We had successfully used graphite, machined from free formed objects with a replicator, to produce aluminum-bronze test molds. There were several parting layer materials of interest, but the ideal material depended upon the specific application.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Evaluation of Dissolvable Additively Manufactured Molds and Supports for Electroimpacts Innovative Additive Manufacturing Process

Electroimpact inc. has developed a new additive manufacturing process involving continuous fiber reinforcement along with high-strength thermoplastics. A unique part of this process includes using additive manufacturing to print a base geometry that is then used as a tool for continuous fiber placement. Ideally the tool should be disposable and cost effective. After printing the base tool, continuous fiber is printed on top of the tool using a secondary additive head on the same system to create the final printed part. After continuous fiber printing is completed, the tool is removed and disposed of to leave only the final desired structure. Materials used for the base tool have several requirements that must be met in order to complete this process. First, the material must be rigid and strong enough to support the loads from the secondary printing operation (continuous fiber printing). In addition, the material must be able to adhere to the secondary process material as well be capable of being removed such that the only remaining structure is continuous fiber composite. Using innovative soluble materials allows for parts to be produced through additive with molds that are produced as non-reusable one-off shapes and sizes.

36 MATERIALS SCIENCE↗
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]↗
DOE OSTI2025

Enabling Industrial Re-Use of Large-Format Additive Manufacturing Molding and Tooling

Large-format additive manufacturing (LFAM) is an enabling manufacturing technology capable of producing large parts with highly complex geometries for a wide variety of applications, including automotive, infrastructure/construction, and aerospace mold and tooling. In the past decade, the LFAM industry has seen widespread use of bio-based, glass, and/or carbon fiber reinforced thermoplastic composites which, when printed, serve as a lower-cost alternative to metallic parts. One of the highest-volume materials utilized by the industry is carbon fiber (CF)-filled polycarbonate (PC), which in out-of-autoclave applications can achieve comparable mechanical performance to metal at a significantly lower cost. Previous work has shown that if this material is recovered at various points throughout the manufacturing process for both the lab and pilot scale, it can be mechanically recycled with minimal impacts on the functional performance and printability of the material while significantly reducing the feedstock costs. End-of-life (EOL) CF-PC components were processed through industrial shredding, melt compounding, and LFAM equipment, followed by evaluation of the second-life material properties. Experimental assessments included quantitative analysis of fiber length attrition, polymer molecular weight degradation using gel permeation chromatography (GPC), density changes via pycnometry, thermal performance using dynamic mechanical analysis (DMA), and mechanical performance (tensile properties) in both the X- and Z-directions. Results demonstrated a 24.6% reduction in average fiber length compared to virgin prints, accompanied by a 21% decrease in X-direction tensile strength and a 39% reduction in tensile modulus. Despite these reductions, Z-direction tensile modulus improved by 4%, density increased by 6.8%, and heat deflection temperature (HDT) under high stress retained over 97% of its original value. These findings underscore the potential for integrating mechanically recycled CF-PC into industrial LFAM applications while highlighting the need for technological innovations to mitigate fiber degradation and enhance material performance for broader adoption. This critical step toward circular material practices in LFAM offers a pathway to reducing feedstock costs and environmental impact while maintaining functional performance in industrial applications.

additive manufacturing↗
DOE OSTI2024

Filaments of the Slime Mold Cosmic Web and How They Affect Galaxy Evolution

Abstract We present a novel approach for identifying cosmic web filaments within theDisPerSEstructure identification framework, using cosmic density field estimates from the Monte Carlo Physarum Machine (MCPM), inspired by the slime mold organism. We apply our method to the IllustrisTNG (TNG100) cosmological simulations and investigate the impact of filaments on galaxies. The MCPM density field is superior to the Delaunay tessellation field estimator in tracing the true underlying matter distribution and allows filaments to be identified with higher fidelity, finding more low-prominence/diffuse filaments. Using our new filament catalogs, we find that ≳90% of galaxies are located within ∼1.5 Mpc of a filamentary spine, with little change in the median star formation activity with distance to the nearest filament. Instead, we uncover a differential effect of the local filament line density, Σ fil (MCPM)—the total MCPM overdensity per unit length along a filament segment—on galaxy formation: most galaxies are quenched and gas-poor near high-line density filaments atz≤ 1. At earlier times, the filamentary environment appears to have no effect on galactic gas supply and quenching. Atz= 0, quenching in log ( M * / M ⊙ ) ≳ 10.5 galaxies is mainly driven by mass, while lower-mass galaxies are significantly affected by the filament line density. Satellites are far more susceptible to filaments than centrals. The local environments of massive halos are not sufficient to account for the effect of filament line density on gas removal and quenching. Our new approach holds great promise for observationally identifying filaments from galaxy surveys such as SDSS and DESI.

Astronomy & Astrophysics↗
NASA NTRS1965

Cork is used to make tooling patterns and molds

Sheet and waste cork are cemented together to provide a tooling pattern or mold. The cork form withstands moderately high temperatures under vacuum or pressure with minimum expansion, shrinkage, or distortion.

Hoffman, F. J.↗