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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Fused filament fabrication of thermoplastic polyurethane composites with microencapsulated phase-change material

Here, the present study examines the thermal energy storage (TES) effectiveness and printability of microencapsulated phase-change material (MEPCM) combined with thermoplastic polyurethane (TPU) for fused filament fabrication (FFF). Two formulations were assessed: 24D MEPCM, which changes phase at 24 ° C, compounded with TPU pellets and 43D MEPCM, which changes phase at 43 ° C, integrated with TPU powder. These combinations are designed to evaluate the effectiveness of the form of the TPU (pellets versus powder) in the FFF process. The investigation includes a comprehensive analysis of thermal characteristics, encompassing phase-change temperature, latent heat of fusion, thermal conductivity, and thermal decomposition, which are assessed through differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). Additionally, mechanical properties, including stress-strain behavior, are examined to evaluate material suitability for TES applications, while microstructural visualization is used to provide deeper insights into material performance, structural integrity, and the quality of printed components. The 24D MEPCM and TPU pellets formulation experienced a significant loss of approximately 39.6% of PCM during filament extrusion and printing, resulting in a reduced effective latent heat. Therefore, further characterization of the pellet formulation was discontinued due to excessive leakage. In contrast, the 43D MEPCM and TPU powder formulation demonstrated minimal PCM loss, with the 60 wt.% composition achieving an effective latent heat of 132 J/g. This value represents the highest effective latent heat currently documented in the literature for PCM-polymer-composite materials produced using an FFF-based additive manufacturing process.

25 ENERGY STORAGE↗
DOE OSTI2022

Processing Compressed Expanded Natural Graphite for Phase Change Material Composites

Phase change materials (PCMs) are used in various thermal energy storage applications but are limited by their low thermal conductivity. One method to increase conductivity involves impregnating organic PCMs into highly porous conductive matrix materials. Of these materials, compressed expanded natural graphite (CENG) matrices have received the most attention. Despite this attention, the effect that CENG processing has on PCM saturation and overall matrix thermal conductivity has not been fully investigated. Therefore, the effect of the heat treatment process used to expand intercalated graphite flakes is evaluated here. Higher heat treatment temperatures yielded higher saturation rates and overall saturation at similar matrix porosities. For example, increasing temperature from 300 °C to 700 °C resulted in approximately 60%-70% increase in pore saturation after 100 minutes of soaking. The exposure time to heat treatment had less of an effect on PCM saturation. The exposure time had negligible effect above 30 min and above 500 °C heating temperatures. However, because the expanded graphite was found to oxidize around 700 °C, the use of longer exposure time in manufacturing applications can be beneficial if a shortened impregnation time is needed. Heat treatment conditions did not impact thermal conductivity. The composite latent heat of fusion was also reduced approximately proportionally to the PCM mass fraction. A local maximum in axial thermal conductivity was observed at around 83% porosity, which is similar to previous studies. The observed conductivity at this maximum was a factor of 81 times greater than the conductivity of the PCM.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Thermal and mechanical performance of gypsum composites containing fly ash cenosphere encapsulated phase change materials

Utilizing phase change materials (PCMs) within construction materials improves the thermal energy storage capabilities in the built environment. Notably, integrating PCMs into drywalls presents a promising avenue to reduce building energy use. However, incorporating PCMs into drywalls poses challenges, particularly reduced mechanical properties and workability limitations as it can adversely affect the hardening and cohesiveness of gypsum composites. To address these challenges, this study explores a novel strategy to incorporate PCMs into gypsum composites through fly ash cenosphere-encapsulated PCM, namely CenoPCM, aiming to enhance the mechanical properties and thermal conductivity over existing commercial counterparts. An experimental program was conducted to study the impact of the inclusion of CenoPCM on the mechanical and thermal performance of gypsum composites, and the results were compared to those of commercially available polymerencapsulated PCM benchmark (Micronal). The findings highlighted that PCM-charged samples exhibited up to 95.90 J/g (CenoPCM) of latent heat with 70 % CenoPCM loading. The results of mechanical tests also showed that CenoPCM outperformed its polymer-encapsulated counterpart, achieving 55 % higher mechanical strength on average. Here, this improvement is attributed to the rigid shell of fly ash cenosphere (FAC) serving as a PCM carrier, providing a skeleton-like structure to gypsum composites for higher load-bearing capacity. Additionally, hotbox tests demonstrated that the CenoPCM-charged wall panels yielded a 20 % higher thermal conductivity and a 22 % increased time lag compared to Micronal PCM-charged panels, indicating its potential to shift the peak load in buildings.

Ceno PCM↗
DOE OSTI2023

Suppressing Structural Relaxation in Nanoscale Antimony to Enable Ultralow‐Drift Phase‐Change Memory Applications

Abstract Phase‐change random‐access memory (PCRAM) devices suffer from pronounced resistance drift originating from considerable structural relaxation of phase‐change materials (PCMs), which hinders current developments of high‐capacity memory and high‐parallelism computing that both need reliable multibit programming. This work realizes that compositional simplification and geometrical miniaturization of traditional GeSbTe‐like PCMs are feasible routes to suppress relaxation. While to date, the aging mechanisms of the simplest PCM, Sb, at nanoscale, have not yet been unveiled. Here, this work demonstrates that in an optimal thickness of only 4 nm, the thin Sb film can enable a precise multilevel programming with ultralow resistance drift coefficients, in a regime of ≈10 −4 –10 −3 . This advancement is mainly owed to the slightly changed Peierls distortion in Sb and the less‐distorted octahedral‐like atomic configurations across the Sb/SiO 2 interfaces. This work highlights a new indispensable approach, interfacial regulation of nanoscale PCMs, for pursuing ultimately reliable resistance control in aggressively‐miniaturized PCRAM devices, to boost the storage and computing efficiencies substantially.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1971

Phase change solidification dynamics

Phase change solidification phenomena in n- hexadecane for spacecraft thermal control systems, considering two or three dimensional models

Golden, J. O.↗
DOE OSTI2022

Sensitivity Study of Mini-Batch Size on a Long Short-Term Memory Network for In-situ Sensing of Core-to-shell Ratio of Microencapsulated Phase Change Materials

Microencapsulated phase change materials are being studied for applications for thermal energy storage in concentrated solar fields. During fabrication, the thickness of the encapsulation cannot be readily measured for real-time control. Therefore, a machine learning network, specifically a Long Short-Term Memory network, is being developed to estimate the ratio of the shell radius to core radius based on a one second temperature history. The mini-batch size determines how often the algorithm weights are updated during network training, and shuffle indicates whether the training data is shuffled during training. A general factorial design is used to analyze the effects of varying mini-batch size and shuffle, along with the core-to-shell ratio, on the RMSE of the response from the Long Short-Term Memory network. It was found that the network performed better for smaller core to shell ratios (less than 0.6) and had the lowest RMSE when the minibatch size was 128. The minimum RMSE found was 0.00501.

Shannon, Rebecca↗
NASA NTRS1976

Effective thermal property improves phase change paint data

The phase-change coating technique presents itself as a valuable tool in determining the heat transfer rate over the surface of small complex wind tunnel models. A numerical technique is described which shows that an effective thermophysical property - the square root of the product of thermal conductivity, density, and specific heat - may significantly improve the accuracy of the phase-change coating technique with allowance for model inhomogeneity and temperature dependency in a transient environment. Results of the measured steady-state variation of the effective thermophysical property with temperature and the effect of surface heating rate on the effective thermophysical property are plotted for a representative homogeneous model material and for an extreme nonhomogeneous model material. The use of an effective thermophysical property to reduce phase-change paint data is recommended. The analysis also confirms that the apparatus described by Corwin and Kramer (1975) can be used to measure directly this effective thermophysical property for use in wind tunnel model heat-transfer measurements.

Drummond, J. P.↗
NASA NTRS2009

Vibration damping and heat transfer using material phase changes

A method and apparatus wherein phase changes in a material can dampen vibrational energy, dampen noise and facilitate heat transfer. One embodiment includes a method for damping vibrational energy in a body. The method comprises attaching a material to the body, wherein the material comprises a substrate, a shape memory alloy layer, and a plurality of temperature change elements. The method further comprises sensing vibrations in the body. In addition, the method comprises indicating to at least a portion of the temperature change elements to provide a temperature change in the shape memory alloy layer, wherein the temperature change is sufficient to provide a phase change in at least a portion of the shape memory alloy layer, and further wherein the phase change consumes a sufficient amount of kinetic energy to dampen at least a portion of the vibrational energy in the body. In other embodiments, the shape memory alloy layer is a thin film. Additional embodiments include a sensor connected to the material.

Kloucek, Petr↗
DOE OSTI2023

Mechanical and Thermal Characterization of Phase-Change Material and High-Density Polyethylene Functional Composites for Thermal Energy Storage

Abstract Phase-change materials (PCMs) can be used to develop thermal energy storage systems as they absorb large amount of latent heat nearly at a constant temperature when changing phase from a solid to a liquid. To prevent leakage when in a liquid state, PCM is shape stabilized in a polymer matrix of high-density polyethylene (HDPE). The present research explores the injection-molded mechanical and thermal properties of different PCM/HDPE composite ratios. The tensile strength and modulus of elasticity at room temperature and with the PCM fully melted within the composite are measured. Additionally, the hardness, latent heat of fusion, phase-change temperature, and thermal conductivity are investigated. An analysis of microstructures of the composite is used to support the findings. The PCM within the PCM/HDPE composite gives it the benefit of thermal storage but causes a decrease in mechanical properties.

Energy & Fuels↗
DOE OSTI2025

Self‐Strain Suppression of the Metal‐to‐Insulator Transition in Phase‐Change Oxide Devices

Strongly correlated materials exhibiting phase transitions which can be controlled through external stimuli, such as electric fields, are promising for future computing technologies beyond conventional semiconductor transistors. Devices that take advantage of structural phase transitions have inherent built‐in memory, reminiscent of synapses and neurons, and are thus natural candidates for neuromorphic computing. Of particular interest are phase‐change oxides, which allow for control over the metal‐to‐insulator transition. Here, X‐ray nano‐diffraction structural imaging of micro‐devices fabricated with the archetypal phase‐change material vanadium sesquioxide (V 2 O 3 ) is reported. The devices contain a Ga ion‐irradiated region where the metal‐to‐insulator transition critical temperature is lowered, a useful feature for controlling neuron‐like spiking behavior. Results show that strain, induced by crystal lattice mismatch between the pristine and irradiated material, leads to a suppression of the metal‐to‐insulator‐transition. Suppression occurs within the irradiated region or along its edges, depending on the defect‐distribution and the size of the region. The observed self‐straining effect can extend to other phase‐change oxides and dominate as device dimensions are reduced and become too small to dissipate strain within the irradiated region. The findings are important for phase engineering in phase‐change devices and highlight the necessity to study phase transitions at the nanoscale.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2021

Impact of size and thermal gradient on supercooling of phase change materials for thermal energy storage

Phase change material based thermal energy storage has many current and potential applications in the heating and cooling of buildings, battery and electronics thermal management, thermal textiles, and dry cooling of power plants. However, connecting lab scale thermal data obtained with differential scanning calorimetry (DSC) to the performance of large-scale practical systems has been a major challenge primarily due to the dependence of supercooling on the size and temperature gradient of the system. Here we show how a phase change material’s supercooling behavior can be characterized experimentally using common lab scale thermal analysis techniques. We then develop a statistics based theoretical model that uses the lab-scale data on small samples to quantitatively predict the supercooling performance for a general thermal energy storage application of any size, including also allowing for the possibility of temperature gradients. Finally, we validate the modeling methodology by comparing to experimental results for solid-solid phase change in neopentyl glycol, which shows how the model successfully predicts the changes in supercooling temperature across a large range of cooling rates (2 orders of magnitude) and volumes (3 orders of magnitude). By accounting for thermal gradients, the model avoids ~2x error incurred by lumped approximations.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Thermal Cycle and Capacitance Testing of Mezzo Industries Phase Change Material Heat Capacitor

A phase change material heat capacitor prototype, designed and built under a NASA Small Business Innovation Research grant by Mezzo Technologies, was tested through coolant thermal cycling within the expected flow rates and temperature range of the Orion spacecraft’s propylene glycol-water mixture coolant system. Testing was performed with the phase change material contained under sealed conditions after a degassing procedure and exposed to atmosphere without prior degassing. The useful heat storage capacitance was measured and compared to Orion spacecraft requirements and theoretical N-Pentadecane storage capacity.

Propylene Glycol Water↗
DOE OSTI2024

Low-cost fin-tube heat exchanger design for building thermal energy storage using phase change material

Heat transfer in phase change materials (PCMs) is complex because the melting and freezing fronts change as functions of stored or released heat. In prior attempts to optimize heat exchangers (HXs) in one or two dimensions, complex geometry has often been used to maximize the melt and freeze front area. This complex geometry is difficult and hence expensive to construct. This paper proposes a multiple-scale 3D finite element modeling approach to design fin-tube HXs for low-cost latent thermal energy storage applications. Further, the optimal fin and tube designs were determined at three scales (unit-scale, medium-scale, and large-scale) by modeling the melt and freeze front in three dimensions and using measured bulk thermal properties. The finite element model was validated by comparing it with the experimental data for a referenced design of a similar type. The results indicate that commercially available organic PCMs with low conductivity (<0.3 W/m·K) can have charge and discharge times appropriate for building thermal energy storage (i.e., 4–5 h) with fin-tube HX designs at costs <$26/kWh, even when the temperature difference (5.56°C) between the heat transfer fluid and the PCM phase change temperature is small. However, as the HX increases in length, the temperature reduction along the tube limits some larger-scale designs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRSDate not supplied

New Phase Change Materials for Active Photonics

Phase change materials or PCMs are truly remarkable compounds whose unique switchable properties have fueled an explosion of emerging applications in electronics and photonics. Nonetheless, if we discount their use in optical discs, PCMs’ immense application potential in photonics beyond data recording has only begun to unfold in the past decade. While the material requirements for optical or electronic data storage have been succinctly summarized as five key elements “writability, archival storage, erasability, readability, and cyclability” decades ago, these requirements are not universally relevant to the diverse set of photonic applications now being explored. It also comes as no surprise that existing PCMs, which have been heavily vetted for data storage, are not necessarily the optimal compositions for different use cases in optics and photonics. PCMs with their attributes custom-tailored for specific applications are therefore in demand as phase-change photonics continue to expand. Here we discuss the PCM selection and design strategies specifically for photonic applications as well as our recent work developing active integrated photonic devices and metasurface optics based on new PCMs tailored for photonics.

phase change materials↗
NASA NTRS1991

A finite element model of conduction, convection, and phase change near a solid/melt interface

Detailed understanding of heat transfer and fluid flow is required for many aerospace thermal systems. These systems often include phase change and operate over a range of accelerations or effective gravitational fields. An approach to analyzing such systems is presented which requires the simultaneous solution of the conservation laws of energy, momentum, and mass, as well as an equation of state. The variable property form of the governing equations are developed in two-dimensional Cartesian coordinates for a Newtonian fluid. A numerical procedure for solving the governing equations is presented and implemented in a computer program. The Galerkin form of the finite element method is used to solve the spatial variation of the field variables, along with the implicit Crank-Nicolson time marching algorithm. Quadratic Langrangian elements are used for the internal energy and the two components of velocity. Linear Lagrangian elements are used for the pressure. The location of the solid/liquid interface as well as the temperatures are determined form the calculated internal energy and pressure. This approach is quite general in that it can describe heat transfer without phase change, phase change with a sharp interface, and phase change without an interface. Analytical results from this model are compared to those of other researchers studying transient conduction, convection, and phase change and are found to be in good agreement. The numerical procedure presented requires significant computer resources, but this is not unusual when compared to similar studies by other researchers. Several methods are suggested to reduce the computational times.

Viterna, Larry A.↗
NASA NTRS2016

A Liquid-Liquid Thermoelectric Heat Exchanger as a Heat Pump for Testing Phase Change Material Heat Exchangers

The primary objective of the Phase Change HX payload on the International Space Station (ISS) is to test and demonstrate the viability and performance of Phase Change Material Heat Exchangers (PCM HX). The system was required to pump a working fluid through a PCM HX to promote the phase change material to freeze and thaw as expected on Orion's Multipurpose Crew Vehicle. Due to limitations on ISS's Internal Thermal Control System, a heat pump was needed on the Phase Change HX payload to help with reducing the working fluid's temperature to below 0degC (32degF). This paper will review the design and development of a TEC based liquid-liquid heat exchanger as a way to vary to fluid temperature for the freeze and thaw phase of the PCM HX. Specifically, the paper will review the design of custom coldplates and sizing for the required heat removal of the HX.

Sheth, Rubik B.↗
NASA NTRS1995

Mantle plume interaction with an endothermic phase change

High spatial resolution numerical simulations of mantle plumes impinging from below on the endothermic phase change at 660-km depth are used to investigate the effects of latent heat release on the plume-phase change interaction. Both axisymmetric and planar upflows are considered, and the strong temperature dependence of mantle viscosity is taken into account. For plume strengths considered, a Clapeyron slope of -4 MPa/K prevents plume penetration of the phase change. Plumes readily penetrate the phase change for a Clapeyron slope of -2 MPa/K and arrive in the upper mantle considerably hotter than if they had not traversed the phase change. For the same amount of thermal drive, i.e., the same excess basal temperature, axisymmetric plumes are hotter upon reaching the upper mantle than are planar upwellings. Heating of plumes by their passage through the spinel-perovskite endothermic phase change can have important consequences for the ability of the plume to thermally thin the lithosphere and cause melting and volcanism.

Schubert, Gerald↗