Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Multimaterial”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Polymeric multimaterials by photochemical patterning of crystallinity

An organized combination of stiff and elastic domains within a single material can synergistically tailor bulk mechanical properties. However, synthetic methods to achieve such sophisticated architectures remain elusive. We report a rapid, facile, and environmentally benign method to pattern strong and stiff semicrystalline phases within soft and elastic matrices using stereo-controlled ring-opening metathesis polymerization of an industrial monomer, cis -cyclooctene. Dual polymerization catalysis dictates polyolefin backbone chemistry, which enables patterning of compositionally uniform materials with seamless stiff and elastic interfaces. Visible light–induced activation of a metathesis catalyst results in the formation of semicrystalline trans polyoctenamer rubber, outcompeting the formation of cis polyoctenamer rubber, which occurs at room temperature. This bottom-up approach provides a method for manufacturing polymeric materials with promising applications in soft optoelectronics and robotics.

Science & Technology - Other Topics↗
DOE OSTI2022

Stochastic Modeling in a Multimaterial Continuum Mixture Shock Physics Code

Stochastic modelling approaches are presented to capture random effects at multiple time and length scales. Random processes that occur at the microscale produce nondeterministic effects at the macroscale. Here we present three stochastic modeling approaches that describe random processes at microscopic length scales and map these processes to the macroscopic length scale. The first stochastic modeling approach is based upon a particle based numerical technique to solve a Stochastic Differential Equation (SDE) using an arbitrary diffusion process to capture random processes at the microstructural level. The second approach prescribes a Probability Density Function (PDF) for the drift and diffusion of the random variable derived using the forward and backward Kolmogorov equations. This method requires mean and drift evolution PDF transport equations. The third approach is the coupling of multiple random variables which are dependent on each other. The relationship of the PDFs and a coupling function, known as a copula, produces a Joint Probability Density Function (JPDF). These stochastic modeling approaches are implemented into a Multiple Component (MC) shock physics computational code and used to model statistical fracture and reactive flow applications.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Development of Multimaterial Graded Structure from Superalloys to Refractory Alloys

This research focused on developing hybrid microstructures for extreme environments where zone-specific performance is essential. Traditional structural applications rely on single alloy compositions, often requiring compromises in cost, corrosion resistance, or high-temperature stability, while dissimilar welding leads to abrupt material transitions and potential mechanical weaknesses. By employing a combinatorial approach, this study enabled a gradual transition of chemistries across components, allowing site-specific tailoring of microstructures. Leveraging additive manufacturing’s flexibility, this concept facilitated multi-material alloying and optimized fabrication strategies, unlocking new capabilities in high-performance applications while reducing manufacturing costs.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Development of Multimaterial Graded Structure from Superalloys to Refractory Alloys

This research focused on developing hybrid microstructures for extreme environments where zone-specific performance is essential. Traditional structural applications rely on single alloy compositions, often requiring compromises in cost, corrosion resistance, or high-temperature stability, while dissimilar welding leads to abrupt material transitions and potential mechanical weaknesses. By employing a combinatorial approach, this study enabled a gradual transition of chemistries across components, allowing site-specific tailoring of microstructures. Leveraging additive manufacturing’s flexibility, this concept facilitated multi-material alloying and optimized fabrication strategies, unlocking new capabilities in high-performance applications while reducing manufacturing costs.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Multimaterial lamination as a means of retarding penetration and spallation failures in plates

Experimental data are presented which show that hypervelocity impact spallation and penetration failures of a single solid aluminum plate and of a solid aluminum plate spaced a distance behind a Whipple meteor bumper may be retarded by replacing the solid aluminum plate with a laminated plate. Four sets of experiments were conducted. The first set of experiments was conducted with projectile mass and velocity held constant and with polycarbonate cylinders impacted into single plates of different construction. The second set of experiments was done with single plates of various construction and aluminum spherical projectiles of similar mass but different velocities. These two experiments showed that a laminated plate of aluminum and polycarbonate or aluminum and methyl methacrylate could prevent spallation and penetration failures with a lower areal density than either an all-aluminum laminated plate or a solid aluminum plate. The aluminum laminated plate was in turn superior to the solid aluminum plate in resisting spallation and penetration failures. In addition, through an example of 6061-T6 aluminum and methyl methacrylate, it is shown that a laminated structure ballistically superior to its parent materials may be built. The last two sets of experiments were conducted using bumper-protected main walls of solid aluminum and of laminated aluminum and polycarbonate. Again, under hypervelocity impact conditions, the laminated main walls were superior to the solid aluminum main walls in retarding spallation and penetration failures.

Dibattista, J. D.↗
NASA NTRS1999

A Gas-Kinetic Scheme for Multimaterial Flows and Its Application in Chemical Reaction

This paper concerns the extension of the multicomponent gas-kinetic BGK-type scheme to multidimensional chemical reactive flow calculations. In the kinetic model, each component satisfies its individual gas-kinetic BGK equation and the equilibrium states of both components are coupled in space and time due to the momentum and energy exchange in the course of particle collisions. At the same time, according to the chemical reaction rule one component can be changed into another component with the release of energy, where the reactant and product could have different gamma. Many numerical test cases are included in this paper, which show the robustness and accuracy of kinetic approach in the description of multicomponent reactive flows.

Lian, Yongsheng↗
DOE OSTI2022

In-line mixing printhead for multimaterial aerosol jet printing

An aerosol jet printhead comprising an in-line static mixer can mix multiple aerosol streams for co-deposition from a single nozzle. A printhead was designed, fabricated, and tested, demonstrating in-plane functionally graded films. The inline mixing printhead can be used with a compact aerosol jet deposition system.

Secor, Ethan Benjamin↗
DOE OSTI2022

Emulsion stereolithography and 3D printing of multimaterials and nanoscale material gradients

A functionally graded material is formed by pipetting individual micro-or-nano-litter droplets with a variety of materials including multi-nanostructured material (nanowires, carbon nanotubes, enzymes, multi-element and/or multi-color, multi-biomolecules) and UV polymerization of the flat hydrogel meniscus surface formed at the carrier fluid interface. After step-by-step droplet pipetting and subsequent layer-by-layer UV polymerization via a digital mask, the complete fabricated part without supporting layers is taken out of the carrier fluid while the un-cured micro-litter residue is conveniently suctioned out of the carrier fluid.

Zheng, Xiaoyu↗
DOE OSTI2023

Multimaterial powder bed patterning for additive manufacturing method

The present disclosure relates to an additive manufacturing system. In one embodiment the system makes use of a reservoir for holding a granular material feedstock. A nozzle is in communication with the reservoir for releasing the granular material feedstock in a controlled fashion from the reservoir to form at least one layer of a part. An excitation source is included for applying a signal which induces a controlled release of the granular material feedstock from the nozzle as needed, to pattern the granular material feedstock as necessary to form a layer of the part.

Dudukovic, Nikola↗
DOE OSTI2025

Rotary Inertia Friction Welding of Dissimilar High-Strength 422 Martensitic Stainless Steel and 4140 Low Alloy Steel for Heavy-Duty Engine Piston Fabrication

AISI 422 martensitic stainless steel with superior high temperature performance (oxidation resistance and strength) is under evaluation for replacing current heavy-duty piston crown materials, AISI 4140 martensitic steel and micro alloyed steel (MAS) 38MnSiVS5, to fabricate a multimaterial piston. This multimaterial piston concept further improved power density and fuel economy by allowing heavyduty diesel engines to operate at higher temperatures and pressures. Joining AISI 422 steel piston crowns with AISI 4140 steel piston skirts is a key manufacturing step for this multimaterial piston. However, the significant differences in strength, elevated temperature flow stress, alloy chemistry, and temper resistance between these two martensitic steels cause some weldability issues (cracking) and metallurgical challenges (alloying element migration/segregation) when using conventional fusion-based welding processes. Rotary inertia friction welding (RIFW), a solid-state welding process, has been the preferred method to join 4140 crowns to 4140 skirts (and MAS crowns to MAS skirts) in high-volume production of current heavy-duty diesel engine pistons. It has been used to join these two materials with relatively comparable alloy chemistry to fabricate pistons with MAS skirts and 4140 crowns. Meanwhile, RIFW has also been a preferred method of dissimilar metal welding. However, RIFW of dissimilar high-strength martensitic steels has yet to be widely pursued. The interfacial microstructure complexities created by the thermomechanical process and highly nonequilibrium phase transformations during RIFW are a significant challenge for understanding and predicting their joining behavior and have not been reported in detail. Here, in this work, defect-free AISI 422 steel-AISI 4140 multimaterial pistons were successfully fabricated using the RIFW process. The interfacial microstructure and mechanical properties of dissimilar 422/4140 steel RIFW in the as-welded condition were experimentally studied in detail. The results provide critical baseline information for understanding RIFW mechanisms and guiding subsequent postweld heat treatment (PWHT) practice.

36 MATERIALS SCIENCE↗
DOE OSTI2020

High-performance molded composites using additively manufactured preforms with controlled fiber and pore morphology

Here, large-scale multimaterial preforms produced by additive manufacturing (AM) underwent compression molding (CM) to produce high-performance thermoplastic composites reinforced with short carbon fibers. AM and CM techniques were integrated to control the fiber orientation (microstructure) and to reduce void content for the improved mechanical performance of the composite. The new integrated manufacturing technique is termed “additive manufacturing-compression molding” (AM-CM). For the present study, the most common materials were used for large-scale printing, i.e., acrylonitrile butadiene styrene (ABS), carbon fiber (CF)–filled ABS (CF/ABS) and glass fiber (GF)–filled ABS (GF/ABS). Three different manufacturing processes; (a) AM (b) extrusion compression molding (ECM), and (c) AM-CM were used to prepare four different panel configurations: (1) neat ABS, (2) CF/ABS, (3) overmold (CF/ABS over neat ABS), and (4) sandwich (neat ABS between two CF/ABS layers). The mechanical properties (tensile and flexural strength and modulus, and Izod impact energy) of samples prepared via all three manufacturing processes were compared. X-ray microcomputer tomography was employed to evaluate the fiber orientation distribution and the volumetric porosity content. The preform maintained high fiber alignment (≈ 82% of fibers within the range of 0–20° in the deposition direction), and the volumetric porosity was reduced by 50% from 3.79% to 1.91% after compression. The alignment of long pores along the deposition direction was also observed. The mechanical properties are discussed with correlation to the fiber alignment and void content in the samples. CF/ABS samples prepared by AM-CM showed significant improvement of 11.15%, 35.27%, 28.6%, and 74.3% in the tensile strength, tensile modulus, flexural strength, and flexural modulus, respectively, when compared with samples prepared by ECM. Unique aspects of this study are the demonstration of large-scale multimaterial AM and the use of multimaterials as preforms to make high-performance composites.

36 MATERIALS SCIENCE↗
DOE OSTI2021

MADE3D: Enabling the next generation of high-torque density wind generators by additive design and 3D printing

Direct-drive wind turbine generators are increasing in popularity, thanks to recent project developments—especially offshore, where reliability and efficiency are major cost drivers. Yet, high capital costs are forcing many original equipment manufacturers to consider lightweight, high-torque density generators for next-generation multi-megawatt turbines that may be difficult to realize by traditional design or manufacturing methods. In this study, we present a new design framework enabled by advanced machine learning and multimaterial additive manufacturing to perform a magnetic topology optimization that maximizes the torque per rotor active mass for a 15-megawatt direct-drive permanent magnet wind generator. A comparison of the proposed approach against conventional topology optimization demonstrated a significant increase in computational efficiency and accuracy in performance predictions. Results using single and multimaterial compositions for rotor core and magnets identify a wider choice of 3D printable designs for a given specification. A hybrid combination of sintered and dysprosium-free polymer-bonded magnets shows good potential for torque performance by saving material costs up to 8.75%. More than 30% improvement in rotor torque densities is identified which can marginally improve the overall generator torque density. With the rapid evolution of multipowder deposition technolgies, this study can greatly inspire a new paradigm for design-driven manufacturing with novel material compositions and lightweight, low-cost, high-strength multimaterial geometries that were previously unexplored for direct-drive generators.

17 WIND ENERGY↗