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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Chemical Recycling of Plastic Waste to Higher Value Lubricants

The aim of this project was to develop scalable methods to convert plastic waste to petrochemical-equivalent feedstocks and demonstrate their utility in lubricant base oil and wax applications. These objectives were partially accomplished, by scaling up the synthesis of platinum-on-strontium titanate catalysts to twenty gram batches, scaling up the conversion of plastic waste to twenty-five grams of plastic, producing high-melt waxes and characterizing their properties, and demonstrating the purification of high-melt waxes. High-melt waxes are one petrochemical-equivalent feedstock that can be made from plastic waste, consisting of a hard wax with a melt point above 65 C. They are used as ingredients in hot melt adhesives, coatings, and cosmetics. Producing a petrochemical-equivalent feedstock from plastic waste provides an advantage in lower carbon footprint and manufacturing cost, as the waste feedstock costs less than crude oil.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Infinitely Recyclable Network Polymers, Enabling Sustainable Manufacturing (CRADA Final Report)

This FLO Materials project was aimed at commercializing a new, infinitely recyclable material that can enable closed-loop lifecycles for hard-to-recycle plastics and plastic products. Four hundred million metric tons of virgin plastic is produced each year, yet less than 10% of this material is recycled. In the US alone, 2% of energy consumption is dedicated to the manufacture of virgin plastics, polymer resin, and synthetic rubbers. By keeping plastic materials in circulation longer, we can reduce waste, lower manufacturing costs, cut energy and oil consumption, and drastically reduce greenhouse gas (GHG) emissions. Specifically, FLO’s innovation overcomes the complications associated with salvaging difficult-to-recycle plastics (i.e., contaminated thermoplastic linear polymers, thermoset cross-linked network polymers), which represent at least 20% of total polymer global production, with a recycling rate of near 0%. Chemical recycling of these new polymers through depolymerization allows all additives to be easily removed at room temperature and the recovered monomers to be remanufactured into next generation materials with 100% recovery of mechanical performance and aesthetic quality.

36 MATERIALS SCIENCE↗
DOE OSTI2025

The Effect of a Carbon Fiber Layer Between the Cathode and the Current Collector on Battery Cell Performance

Contact resistance between the cathode active material (CAM) and the Al current collector can be reduced by applying carbon coatings to the Al current collector surface. However, this process requires an additional step of carbon layer coating on the current collector, which increases both manufacturing costs and processing time. In the present work, an interlayer of continuous unsized carbon fibers aligned in one direction (CF interlayer), is introduced between the Al current collector and the NMC811 cathode during cathode deposition on the Al current collector. This single-step approach eliminates the need for the additional carbon layer coating on the current collector. Additionally, this approach removes the use of toxic solvents and insulative polymers used for making the carbon coating. The CF interlayer improves the rate capability at higher C-rates. The CF interlayer lowers the contact resistance between the cathode particles and the current collector while improving the activation energy of charge transfer. The peel test showed that the CF interlayer does not affect the adhesion strength of the cathode layer with the current collector.

25 ENERGY STORAGE↗
DOE OSTI2022

Optimization of a Lightweight Floating Offshore Wind Turbine with Water Ballast Motion Mitigation Technology

Floating offshore wind turbines are a promising technology for addressing energy needs by utilizing wind resources offshore. The current state of the art is based on heavy, expensive platforms to survive the ocean environment. Typical design techniques do not involve optimization because of the computationally expensive time domain solvers used to model motions and loads in the ocean environment. However, this design uses an efficient frequency domain solver with a genetic algorithm to rapidly optimize the design of a novel floating wind turbine concept. The concept utilizes a liquid ballast mass to mitigate motions on a lightweight post-tensioned concrete platform. The simple cruciform-shaped design of the platform made of post-tensioned concrete is less expensive than steel, reducing the raw material and manufacturing cost. The use of ballast water to behave as a tuned mass damper allows a smaller platform to achieve the same motions as a much larger platform, thus reducing the mass and cost. The optimization techniques applied with these design innovations resulted in a design with a levelized cost of energy of USD 0.0753/kWh, roughly half the cost of the current state of the art.

Ramsay, William↗
NASA NTRS1965

An evaluation of a quick release fluid coupling having identical mating halves

A new quick disconnect fluid coupling features identical halves that provide male/female mating. Advantages are reduction of inventory and renewal of defective seals without installing new ones. Two designs were evaluated: A hermaphroditic connector (coupling half converts from one sex to another), and a nonconvertible coupling using a face or but type coupling- to-coupling seal. The hermaphroditic coupling was found superior. Advantages are (1) fewer seals used, reducing leakage, and (2) defective seals quickly replaced by simply converting both halves from one sex to another. Seals are standard O-rings and protected against contamination. The contributing factors to a low manufacturing cost are the shutoff valve and latching method.

Coupling↗
NASA NTRS1970

Low stress integral coverslips

Low stress integral coverslips deposition by high vacuum ion beam sputtering for solar cell manufacturing cost reduction

Bartels, F. T. C.↗
NASA NTRS1972

Memory reduction through higher level language hardware

Application of large scale integration in computers to reduce size and manufacturing costs and to produce improvements in logic function is discussed. Use of FORTRAN 4 as computer language for this purpose is described. Effectiveness of method in storing information is illustrated.

Kerner, H.↗
NASA NTRS1972

Ablator manufacturing

Studies are being conducted to determine how manufacturing-induced defects affect the performance of ablative heat shields. If commonly occurring defects do not affect material performance, simpler manufacturing techniques can be used, quality control requirements can be relaxed, repair and rework operations can be held to a minimum, and thus the total manufacturing cost can be reduced.

Pittman, C. M.↗
NASA NTRS1971

The generation of pollution-free electrical power from solar energy.

Projections of the U.S. electrical power demands over the next 30 years indicate that the U.S. could be in grave danger from power shortages, undesirable effluence, and thermal pollution. An appraisal of nonconventional methods of producing electrical power is conducted, giving particular attention to the conversion of solar energy into commercial quantities of electrical power by solar cells. It is found that 1% of the land area of the 48 states could provide the total electrical power requirements of the U.S. in the year 1990. The ultimate method of generating vast quantities of electrical power would be from a series of synchronous satellites which beam microwave power back to earth to be used wherever needed. Present high manufacturing costs of solar cells could be substantially reduced by using massive automated techniques employing abundant low cost materials.

Cherry, W. R.↗
NASA NTRS1972

Composites - Lighter and cheaper.

Composite engineering materials have two distinct parts, including the load-bearing filaments and the matrix. Fibers can range from glass to boron and graphite. Matrix constituents include epoxies for lower temperatures and metals for higher temperatures. Composites appear as tape or combined with metal in structural shapes. The increased use of composites will reduce over-all per pound manufacturing costs. Two major deterrents to further application of composites in advanced commercial transports include a shortage of cost-effective structural design concepts and a lack of confidence in the life characteristics. A program has been outlined by NASA that will, if implemented, provide considerable in-service life experience with structural components on commercial transports.

Goble, R. L.↗
NASA NTRS1972

Program for establishing long-time flight service performance of composite materials in the center wing structure of C-130 aircraft. Phase 1: Advanced development

Areas where selective reinforcement of conventional metallic structure can improve static strength/fatigue endurance at lower weight than would be possible if metal reinforcement were used are discussed. These advantages are now being demonstrated by design, fabrication, and tests of three boron-epoxy reinforced C-130E center wing boxes. This structural component was previously redesigned using an aluminum build-up to meet increased severity of fatigue loadings. Direct comparisons of relative structural weights, manufacturing costs, and producibility can therefore be obtained, and the long-time flight service performance of the composite reinforced structure can be evaluated against the wide background of metal reinforced structure.

Harvill, W. E.↗
NASA NTRS1973

Effect of a reduction in blade thickness on performance of a single stage 20.32 centimeter mean diameter turbine

As part of a program to reduce the manufacturing costs of a small gas-turbine engine, the turbine blading was reduced in thickness to facilitate coining. Tests were made to determine the effect of this modification on turbine performance. The working fluid was air at nominal inlet total conditions of 535 deg F and 20.0 psia. Performance results are presented and compared for four stator-rotor combinations in terms of equivalent torque, mass flow, and efficiency at equivalent design speed and at inlet-total to exit-static pressure ratios of 1.8 to 3.8

Nusbaum, W. J.↗
NASA NTRS1973

Design of thermal protection system for 8 foot HTST combustor

The combustor in the 8-foot high temperature structures tunnel at the NASA-Langley Research Center has encountered cracking over a period of 50-250 tunnel tests within a limited range of the required operating envelope. A program was conducted which analyzed the failed combustor liner hardware and determined that the mechanism of failure was vibratory fatigue. A vibration damper system using wave springs located axially between the liner T-bar and the liner support was designed as an intermediate solution to extend the life of the current two-pass regenerative air-cooled liner. The effects of liner wall thickness, cooling air passage height, stiffener ring geometry, reflective coatings, and liner material selection were investigated for these designs. Preliminary layout design arrangements including the external water-cooling system requirements, weight estimates, installation requirements and preliminary estimates of manufacturing costs were prepared for the most promissing configurations. A state-of-the-art review of thermal barrier coatings and an evaluation of reflective coatings for the gasside surface of air-cooled liners are included.

Moskowitz, S.↗
NASA NTRS1974

Lunar module voice recorder

A feasibility unit suitable for use as a voice recorder on the space shuttle was developed. A modification, development, and test program is described. A LM-DSEA recorder was modified to achieve the following goals: (1) redesign case to allow in-flight cartridge change; (2) time code change from LM code to IRIG-B 100 pps code; (3) delete cold plate requirements (also requires deletion of long-term thermal vacuum operation at 0.00001 MMHg); (4) implement track sequence reset during cartridge change; (5) reduce record time per cartridge because of unavailability of LM thin-base tape; and (6) add an internal Vox key circuit to turn on/off transport and electronics with voice data input signal. The recorder was tested at both the LM and shuttle vibration levels. The modified recorder achieved the same level of flutter during vibration as the DSEA recorder prior to modification. Several improvements were made over the specification requirements. The high manufacturing cost is discussed.

Source record↗
NASA NTRS1975

Conceptual design study of advanced acoustic-composite nacelles

Conceptual studies were conducted to assess the impact of incorporating advanced technologies in the nacelles of a current wide-bodied transport and an advanced technology transport. The improvement possible in the areas of fuel consumption, flyover noise levels, airplane weight, manufacturing costs, and airplane operating cost were evaluated for short and long-duct nacelles. Use of composite structures for acoustic duct linings in the fan inlet and exhaust ducts was considered as well as for other nacelle components. For the wide-bodied transport, the use of a long-duct nacelle with an internal mixer nozzle in the primary exhaust showed significant improvement in installed specific fuel consumption and airplane direct operating costs compared to the current short-duct nacelle. The long-duct mixed-flow nacelle is expected to achieve significant reductions in jet noise during takeoff and in turbo-machinery noise during landing approach. Recommendations were made of the technology development needed to achieve the potential fuel conservation and noise reduction benefits.

Nordstrom, K. E.↗
NASA NTRS1974

Earth resources technology satellite /ERTS/ data collection and transmission buoys for inland, neritic and oceanic waters

As a result of a consortium of several industries and organizations, an economical, versatile, and stable data collection and transmission buoy has been designed, developed, and deployed to gather and transmit water quality data to a ground receiving station at three-minute intervals and to the earth resources technology satellite (ERTS) as it passes over the deployed buoy every 12 hours. The buoy system, designed for both fresh and salt water application, gathers data inclusive of temperature measurement, conductivity, relative acidity, dissolved oxygen, current speed, and direction. The mechanical design philosophy used to determine and satisfy boundary conditions involving stability, ease of deployment, servicing and maintenance, minimal manufacturing costs, and fresh and salt water installation capability is discussed. The development of peripheral handling equipment and anchoring systems is described.

Chapman, W. S.↗