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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1988

Technological hurdles to the application of intercalated graphite fibers

Before intercalated graphite fibers can be developed as an effective power material, there are several technological hurdles which must be overcome. These include the environmental stability, homogeneity and bulk properties, connection procedures, and costs. Strides were made within the last several years in stability and homogeneity of intercalated graphite fibers. Bulk properties and connection procedures are areas of active research now. Costs are still prohibitive for all but the most demanding applications. None of these problems, however, appear to be unsolvable, and their solution may result in wide spread GOC application. The development of a relatively simple technology application, such as EMI shielding, would stimulate the solution of scale-up problems. Once this technology is developed, then more demanding applications, such as power bus bars, may be possible.

Gaier, James R.↗
DOE OSTI2025

TRISO Particle Isolation and Graphite Removal Using SRNL Vapor Digestion Technology

Tri-structural isotropic fueled reactors are planned to come online in the next decade, but there is not currently a widely agreed upon disposition pathway for this new fuel stream. For long term used nuclear fuel storage, there would be a significant benefit if the waste volume could be reduced or mitigated. Most of the volume from used TRISO fuel contains graphite. SRNL currently has an active patent which describes one pathway to digest the graphite. One benefit in the utilization of this pathway is that multiple cylindrical pieces can be stacked end-to-end in a reaction tube, then nitric acid and water vapor can be flowed through the tube, and the weight change of the individual cores can provide both a reaction profile and overall oxidant use efficiency. The reaction of nitric acid and graphite passes through a series of intermediate products – NO 2 , NO, and N 2 O – from reaction and decomposition to eventually form N2. The data shows that NO2 grows in with increasing temperature between 500-600°C and then decreases by way of either reaction with graphite or decomposition. Nitric oxide, a reaction and thermal decomposition product of NO 2 , exhibits a consistent decline as a function of temperature, which is consistent with the literature. Similarly, the concentrations of N 2 O and N 2 increase as a function of temperature as their reactions with graphite become more favorable.

Advanced Reactors↗
NASA NTRS1972

Graphite epoxy reflector support truss for applications technology satellite /ATS/.

The design, development, fabrication, and qualification load testing of the reflector support truss for Applications Technology Satellites F and G are described. Because the truss is stability-critical, high modulus graphite epoxy composite was used to provide a minimum weight structure. The work was performed under the sponsorship of the NASA Goddard Space Flight Center with Fairchild Industries as the prime contractor.

Randolph, R. E.↗
NASA NTRS1983

Orthotic devices using lightweight composite materials

Potential applications of high strength, lightweight composite technology in the orthotic field were studied. Several devices were designed and fabricated using graphite-epoxy composite technology. Devices included shoe plates, assistive walker devices, and a Simes prosthesis reinforcement. Several other projects having medical application were investigated and evaluations were made of the potential for use of composite technology. A seat assembly was fabricated using sandwich construction techniques for the Total Wheelchair Project.

Harrison, E., Jr.↗
NASA NTRS1984

Status and New Directions for Solid Lubricant Coatings and Composite Materials

At one time, solid lubricants were used almost entirely in aerospace applications. Today there is a pronounced trend to use them over a much broader range of applications. For example, self-lubricating polymer-based composites have displaced traditional oil-lubricated, metallic composites for many journal bearings and thrust, washers in applications as diverse as earthmoving machinery and snow blowers to aircraft applications. For moderate temperatures below 200° C, glass filament-wound epoxy bearings with PTFE lubricating liners are useful; for temperatures up to 350° C, graphite fiber reinforced polyimide bearing materials are finding applications. Molybdenum disulfide, graphite, and PTFE are the most widely known and used solid lubricants, and there is increasing interest in the relatively new solid lubricant graphite fluoride. Advanced technology engines such as the adiabatic diesel and the small, efficient gas turbine have severe lubrication and wear problems at temperatures beyond the capabilities of any of these lubricants. Here, self-lubricating ceramics and inorganic composites for use at I000° C or higher are of interest. However, perhaps the most significant new direction for solid lubricant coatings and self-lubricating composites is their steadily increasing use in dry bearings for large volume, moderate temperature applications. This can be attributed to their simplicity of use (no supporting lubricant system needed), light weight, convenience, and general cost effectiveness.

Harold E Sliney↗
NASA NTRS1991

Industrial Applications of Graphite Fluoride Fibers

Based on fluorination technology developed during 1934 to 1959, and the fiber technology developed during the 1970s, a new process was developed to produce graphite fluoride fibers. In the process, pitch based graphitized carbon fibers are at first intercalated and deintercalated several times by bromine and iodine, followed by several cycles of nitrogen heating and fluorination at 350 to 370 C. Electrical, mechanical, and thermal properties of this fiber depend on the fluorination process and the fluorine content of the graphite fluoride product. However, these properties are between those of graphite and those of PTFE (Teflon). Therefore, it is considered to be a semiplastic. The physical properties suggest that this new material may have many new and unexplored applications. For example, it can be a thermally conductive electrical insulator. Its coefficient of thermal expansion (CTE) can be adjusted to match that of silicon, and therefore, it can be a heat sinking printed circuit board which is CTE compatible with silicon. Using these fibers in printed circuit boards may provide improved electrical performance and reliability of the electronics on the board over existing designs. Also, since it releases fluorine at 300 C or higher, it can be used as a material to store fluorine and to conduct fluorination. This application may simplify the fluorination process and reduce the risk of handling fluorine.

Hung, Ching-Cheh↗
NASA NTRS2005

Poco Graphite Mirror Metrology Report

Recently a lightweight mirror technology was tested at Marshall Space Flight Center's Space Optic Manufacturing Technology Center (MSFC, SOMTC). The mirror is a Poco Graphite CVD Si clad SiC substrate. It was tested for cryogenic (cryo) survivability to 20deg Kelvin in SOMTC's X-ray Calibration and Cryogenic Test Facility. The surface figure of the mirror was measured before and after cry0 cycling. The test technique and results are discussed.

Kester, Thomas J.↗
DOE OSTI2023

A novel method for quantifying irradiation damage in nuclear graphite using Raman spectroscopy

Raman spectroscopy has long been used in studying irradiation damage in carbon/graphite materials. It is however unclear if the measurements from different types of materials are directly comparable. Further, decoupling the contribution from irradiation temperature and fluence to the total damage in nuclear graphite possessing irradiation damage gradient is currently not readily feasible as it requires a complete set of test reactor irradiation experiments over the relevant temperature and fluence range. A novel methodology has therefore been proposed and developed to quantify total irradiation damage evolution at crystal level based on graphite Raman G-band position shift. Specifically, G-band positions derived from a large number of spectra collected from the fractured surface of microfine-grained POCO ZXF-5Q graphite possessing proton irradiation damage gradient were plotted with open literature Raman data on HOPG, BEPO (AXGP graphite), PCEA and IG-110 graphite as a function of dpa. The total damage level within 2σ beam radius in this POCO graphite was estimated to be equivalent to ~2–5 dpa at ~350–370 °C. Derived G-band positions were then mapped to the three-stage amorphization trajectory model indicating beam centre area has entered the second stage, i.e., transitioning from nanocrystalline graphite into amorphous carbon. G-band position relative shift (ΔG) curve with a ‘turn-around’ peak as a function of total damage can be used for in-service lifetime prediction. Importantly, the developed methodology has the potential to ‘unify’ total damage levels across different grades of nuclear graphite caused by ion, neutron and proton irradiation at different temperatures.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Graphite for Advanced Nuclear Reactors: Deployment Readiness Review

Historically, graphite has been used in numerous reactor technologies, including research/test reactors and, commercially, in advanced gas reactors. These non-metallic materials can play a key role as internal core structures, reflectors, or neutron moderators, making them important for deployment of certain advanced reactor technologies. This report explores the industry readiness for graphite material deployment, documenting Codes and Standards applicable to their design, qualification, and manufacturing. Discussions also examine the manufacturing processes, aging/degradation, inspection techniques, and disposal options. The report covers the current status, documents gaps, and proposes some conclusions about approaches to managing some of the current gaps.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1974

Carbon composites in space vehicle structures

Recent developments in the technology of carbon or graphite filaments now provide the designer with greatly improved materials offering high specific strength and modulus. Besides these advantages are properties which are distinctly useful for space applications and which provide feasibility for missions not obtainable by other means. Current applications include major and secondary structures of communications satellites. A number of R & D projects are exploring carbon-fiber application to rocket engine motor cases, advanced antenna systems, and space shuttle components. Future system studies are being made, based on the successful application of carbon fibers for orbiting space telescope assemblies, orbital transfer vehicles, and very large deployable energy generation systems. Continued technology development is needed in analysis, material standards, and advanced structural concepts to exploit the full potential of carbon filaments in composite materials.

Mayer, N. J.↗
NASA NTRS1978

Transition from glass to graphite in manufacture of composite aircraft structure

The transition from fiberglass reinforced plastic composites to graphite reinforced plastic composites is described. Structural fiberglass design and manufacturing background are summarized. How this experience provides a technology base for moving into graphite composite secondary structure and then to composite primary structure is considered. The technical requirements that must be fulfilled in the transition from glass to graphite composite structure are also included.

Buffum, H. E.↗
DOE OSTI2023

Upgrading of Raw Coal and Coal Waste for Coal-Derived Graphene Process

Conference presentation at 47th International Technical Conference on Clean Energy (Clearwater Clean Energy Conference), Clearwater, Florida, July 23–27, 2023. The University of North Dakota Energy & Environmental Research Center (EERC) conducted a laboratory-scale coal-derived graphene (CDG) project focused on developing a technological process for making graphite from four U.S. domestic coals and coal wastes. Coal and coal waste preprocessing methods were developed and applied to clean and upgrade the coal precursors prior to graphitization and subsequent conversion to graphene products. Carbonization and graphitization of these preprocessed coals and coal wastes has produced graphite, which was used to make graphene oxide (GO) and reduced graphene oxide (rGO). Graphene quantum dots (GQDs) were also made from the raw and upgraded coal precursors.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1994

Lightning Protection

Kit-built airplanes are more affordable because they are assembled by the owner and do not require Federal Aviation Administration (FAA) certification. The Glasair III, is an advanced technology homebuilt, constructed of a fiberglass and graphite fiber composite material, and equipped with digital instruments. Both technologies make the airplane more susceptible to lightning effects. When Glasair manufacturer, Stoddard-Hamilton, decided that lightning protection would enable more extensive instrument flight and make the plane more marketable, they proposed a joint development program to NASA Langley Research Center (LAR). Under a Small Business Innovation Research (SBIR) contract, Langley contractors designed and tested a lightning protection system, and the Glasair III-LP became the first kit-built composite aircraft to be lightning tested and protection-verified under FAA guidelines for general aviation aircraft.

Source record↗
DOE OSTI2025

Development of the technological process for the IGR reactor's highly-enriched irradiated uranium-graphite fuel immobilization

The immobilization of irradiated highly enriched uranium (HEU) fuel is a critical component of nuclear waste management and non-proliferation efforts. In Kazakhstan, at National Nuclear Center of the Republic of Kazakhstan special attention is given to managing legacy HEU fuel from research reactors. One such case involves the IGR research reactor, whose first core containing irradiated HEU uranium-graphite fuel was operated from 1961 to 1966 and removed following reactor modernization. This fuel now requires a reliable and secure immobilization strategy. Here, this paper presents the development of a technological process for immobilizing this fuel to reduce its enrichment to below 20 % in terms of 235U content. The proposed method involves down-blending irradiated HEU fuel with depleted uranium, followed by encapsulation in a Portland cement matrix. Full-scale experiments were conducted to assess the uniformity of uranium distribution within the matrix. The results confirm the effectiveness of this approach, ensuring reliable immobilization of fuel in accordance with international requirements, including IAEA standards and Kazakhstan's regulatory framework. These findings contribute to the broader effort of adapting immobilization strategies for the safe management of spent fuel from research reactors.

12 - MGMT OF RADIOACTIVE AND NON-RADIOACTIVE WASTE↗
DOE OSTI2026

Status on Microstructural Studies of Nuclear Graphite

This report documents the completion of the Advanced Reactor Technologies (ART) Level 3 Milestone (M3AT-26OR0605054), “Provide status on microstructural studies of nuclear graphite,” due May 1, 2026. The contents of this report summarize recent progress in the development of the Nuclear Graphite Microstructure Library, including datasets that have been generated, curated, and submitted for publication, as part of the broader effort to establish and integrate the library within the NDMAS platform.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Friction and wear of nuclear graphite exposed to molten FLiNaK salt environment

This report formally documents the completion of the Advanced Reactor Technologies Level 3 Milestone (M3TG-25OR0501104), “Initiate graphite wear studies of graphite samples exposed to molten salt environment,” due August 1, 2025. The report summarizes the ongoing activities aimed at characterizing the friction and wear behavior of graphite in molten LiF–NaF–KF (FLiNaK) salt environment. The wear and friction behavior of self-mated ET-10 nuclear graphite were tested at varying temperatures (550°C and 650°C), contact loads (40 and 80 N) and sliding speeds (1 and 10 mm/s) in a controlled argon environment. The results were compared to the wear and friction behavior of the same graphite material in a dry argon environment. This report presents initial studies on the friction and wear behavior of graphite in sliding contact mode, with future work focused on investigating the graphite matrix materials, as well as rolling and impact contact modes. The outcomes of this report could provide insights into assessing the integrity of the graphitic components of pebble-bed fluoride salt–cooled high-temperature reactors (PB-FHRs) to enhance their safe operation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗