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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Fabrication of Advanced Nanocarbon-Metal Composites for Improved Energy Efficiency

We fabricated nanocarbon metal composites (NCMC) of Al alloys with a process called “electrocharging assisted process” (EAP). This method consists of the application of a high current to a mixture of liquid metal and carbon particles. We investigated aluminum alloys (6061 and 1350) and used activated carbon and graphite powder as the source of carbon. The high current induces the formation of carbon chains and ribbons in the liquid metal. Upon solidification of the metal an epitaxial relation between the carbon nanostructures and the metal lattice is produced. The purpose of the project was to find the parameters during the reaction that would give rise to a high density of nanoribbons extending throughout the metal such that the electrical conductivity and the mechanical strength of the composite increased and that the method could be extended to large scale manufacturing. For this purpose, we designed two reactors for the incorporation of nanocarbon ribbons in aluminum metal. The first reactor was designed to have more control of the region with the high current density. However, there were problems with getting good mixing of the carbon in small volumes. A second reactor was designed with a stirrer that allowed for better mixing of the carbon by the introduction of argon gas through the shaft of the stirrer. NCMC were fabricated with a series of parameters to understand the role of current, time of applied current, type and shape of the cathode electrode and stirring speed of the mixture. We analyzed the composites by Raman scattering to gain information on the crystallite size of the nanocarbon, XRD to obtain the crystal structure of the composite, SEM and TEM to characterize the grain size of the aluminum grains and the quality of the crystal structure. We also measured the electrical conductivity and mechanical properties of selected samples. The nanocomposites showed increase in crystallite size of the nanocarbon with a linear dependence of the crystallite size on the duration of the applied current. There is a minimum current density necessary for the crystallite size to increase compared to the ~ 10 nm size of the activated carbon source used in the fabrication. The electrical conductivity of the nanocomposites increased with crystallite size of the nanocarbon and with the concentration of converted carbon. The maximum increase in electrical conductivity was 5.7% above the baseline for samples with ~ 4 wt % nanocarbon with crystallite size larger than 30 nm. These samples presented a hardness ~ 8% higher than the baseline samples with no carbon.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS1998

Ionic Polymer-Metal Composites (IPMCs) as Biomimetic Sensors, Actuators and Artificial Muscles: A Review

This paper presents an introduction to ionic polymer-metal composites and some mathematical modeling pertaining to them. It further discusses a number of recent findings in connection with ion-exchange polymer-metal composites (IPMCS) as biomimetic sensors and actuators. Strips of these composites can undergo large bending and flapping displacement if an electric field is imposed across their thickness. Thus, in this sense they are large motion actuators. Conversely by bending the composite strip, either quasi-statically or dynamically, a voltage is produced across the thickness of the strip. Thus, they are also large motion sensors. The output voltage can be calibrated for a standard size sensor and correlated to the applied loads or stresses. They can be manufactured and cut in any size and shape. In this paper first the sensing capability of these materials is reported. The preliminary results show the existence of a linear relationship between the output voltage and the imposed displacement for almost all cases. Furthermore, the ability of these IPMCs as large motion actuators and robotic manipulators is presented. Several muscle configurations are constructed to demonstrate the capabilities of these IPMC actuators. This paper further identifies key parameters involving the vibrational and resonance characteristics of sensors and actuators made with IPMCS. When the applied signal frequency varies, so does the displacement up to a critical frequency called the resonant frequency where maximum deformation is observed, beyond which the actuator response is diminished. A data acquisition system was used to measure the parameters involved and record the results in real time basis. Also the load characterizations of the IPMCs were measured and it was shown that these actuators exhibit good force to weight characteristics in the presence of low applied voltages. Finally reported are the cryogenic properties of these muscles for potential utilization in an outer space environment of a few Torrs and temperatures of the order of - 140 degrees Celsius. These muscles are shown to work quite well in such harsh cryogenic environments and thus present a great potential as sensors and actuators that can operate at cryogenic temperatures.

Shahinpoor, M.↗
DOE OSTI2021

Silver-carbon-nanotube composite metallization for increased durability of silicon solar cells against cell cracks

One of the ways to reduce the cost of solar electricity is to reduce the degradation rate of solar modules and extend their lifetime well beyond 30 years. The extended module lifetime translates to increased bankability of utility-scale PV projects. In this work, we specifically address cell-crack-induced degradation by introducing crack-tolerant metallization. Herein, we make use of low-cost, multi-walled carbon nanotubes embedded in commercial screen-printable silver pastes as a highly integratable engineering solution. When the carbon nanotubes are appropriately functionalized and incorporated into commercial silver pastes, the resulting metal contacts on solar cells, after screen-printing and firing, show exceptional fracture toughness. These composite metal contacts possess increased ductility, electrical gap-bridging capability greater than 50 µm, and “self-healing” to regain electrical continuity even after cycles of complete electrical failure under large strain. While providing crack-tolerant mechanical properties, the composite paste delivers similar beginning-of-life cell performance as the conventional silver paste.

14 SOLAR ENERGY↗
NASA NTRS1990

A creep model for metallic composites based on matrix testing: Application to Kanthal composites

An anisotropic creep model is formulated for metallic composites with strong fibers and low to moderate fiber volume percent (less than 40 percent). The idealization admits no creep in the local fiber direction and assumes equal creep strength in longitudinal and transverse shear. Identification of the matrix behavior with that of the isotropic limit of the theory permits characterization of the composite through uniaxial creep tests on the matrix material. Constant and step-wise creep tests are required as a data base. The model provides an upper bound on the transverse creep strength of a composite having strong fibers embedded in a particular matrix material. Comparison of the measured transverse strength with the upper bound gives an assessment of the integrity of the composite. Application is made to a Kanthal composite, a model high-temperature composite system. Predictions are made of the creep response of fiber reinforced Kanthal tubes under interior pressure.

Binienda, W. K.↗
DOE OSTI2023

Electrochemical performance of ionic polymer metal composite under tensile loading

Abstract Cracks in polymer composites can lead to premature failure, which can be disastrous for polymer-based energy storage devices. Detecting these cracks is essential to guarantee the reliability and safety of such devices. However, detecting cracks in composite polymers such as ionic polymer metal composites (IPMCs) is a challenging task, which makes it difficult to ensure their performance and safety. The overall goal of this study is to investigate the effect of cracks or damage caused by tensile loading on the mechanical properties and electrochemical characteristics of IPMC based capacitors. During tensile testing, the deformation of the IPMC strips causes changes in the ion distribution and concentration in the polymer matrix, influencing the performance of the material. The measurements were conducted utilizing electrochemical impedance spectroscopy at a room temperature ( 21 ∘ C ) and frequency range of 10 KHz to 1 Hz. The method utilized in this study proved to be easy and quick with consistent results. The IPMC capacitor was found to increase its capacitance after major cracking in the Pt electrodes from high tensile mechanical loads. Furthermore, at lower frequency range (<100 Hz), the real ( ε ′ ) and imaginary ( ε ′ ′ ) part of permittivity increase with the addition of loads. This displays that the dielectric property of the material is affected due to the increasing of the loads. It is concluded that, at frequencies above 100 Hz, the permittivity is weakly load dependent.

36 MATERIALS SCIENCE↗
NASA NTRS2005

The Effect of Metal Composition on Fe-Ni Partition Behavior between Olivine and FeNi-Metal, FeNi-Carbide, FeNi-Sulfide at Elevated Pressure

Metal-olivine Fe-Ni exchange distribution coefficients were determined at 1500 C over the pressure range of 1 to 9 GPa for solid and liquid alloy compositions. The metal alloy composition was varied with respect to the Fe/Ni ratio and the amount of dissolved carbon and sulfur. The Fe/Ni ratio of the metal phase exercises an important control on the abundance of Ni in the olivine. The Ni abundance in the olivine decreases as the Fe/Ni ratio of the coexisting metal increases. The presence of carbon (up to approx. 3.5 wt.%) and sulfur (up to approx. 7.5 wt.%) in solution in the liquid Fe-Ni-metal phase has a minor effect on the partitioning of Fe and Ni between metal and olivine phases. No pressure dependence of the Fe-Ni-metal-olivine exchange behavior in carbon- and sulfur-free and carbon- and sulfur-containing systems was found within the investigated pressure range. To match the Ni abundance in terrestrial mantle olivine, assuming an equilibrium metal-olivine distribution, a sub-chondritic Fe/Ni-metal ratio that is a factor of 17 to 27 lower than the Fe/Ni ratios in estimated Earth core compositions would be required, implying higher Fe concentrations in the core forming metal phase. A simple metal-olivine equilibrium distribution does not seem to be feasible to explain the Ni abundances in the Earth's mantle. An equilibrium between metal and olivine does not exercise a control on the problem of Ni overabundance in the Earth's mantle. The experimental results do not contradict the presence of a magma ocean at the time of terrestrial core formation, if olivine was present in only minor amounts at the time of metal segregation.

Holzheid, Astrid↗
DOE OSTI2024

Predicting Electrical Conductivity in Bi-Metal Composites

Generating high magnetic fields requires materials with not only high electric conductivity but also good strength properties in order to withstand the necessarily strong Lorentz forces. A number of bi-metal composites, most notably Cu/Nb, are considered to be good candidates for this purpose. Here, we generalize our previous work on Cu/Nb in order to predict, from theory, the dependence of electric conductivity on the microstructure and volume fraction of the less conductive component for a number of other bi-metal composites. Together with information on strength properties (taken from previous literature), the conductivity information we provide in this work can help to identify new promising candidate materials (such as Cu/Nb, Cu/Ag, Cu/W, …) for magnet applications with the highest achievable field strengths.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Residual elastic strain evolution due to thermal cycling of a ceramic-metal composite (WC-Cu) via high energy X-ray diffraction and analytical modeling

Residual stress, when superimposed with in-service loading, can significantly reduce the lifetime and performance of a component. Ceramic-metal composites are susceptible to residual stresses due to the thermal expansion mismatch of the ceramic and metallic phases. The WC-Cu composite explored in the present study provides a promising combination of thermal conductivity and strength properties, while exhibiting counterintuitive improvements in strength and ductility after thermal cycling. Further, this work quantifies the evolution of the residual elastic strains as a result of processing and cyclic thermal loading in a co-continuous WC-Cu composite through experimental high energy X-ray diffraction and kinetics-based modeling. Both analyses indicate that processing-induced residual tensile stress in the copper phase is relieved upon subsequent thermal cycling, with kinetics modeling revealing the cyclic-dependent nature of the active power-law creep mechanisms. The results indicate that, through stress relaxation, this material system maintains structural stability during thermal cycling. The illustrated kinetics of relaxation can inform general material processors and designers of ceramic-metal composites to minimize detrimental residual stress and improve performance of these material systems.

36 MATERIALS SCIENCE↗
NASA NTRS1999

Electrical Impedance of Ionic Polymeric Metal Composites

In recent years the use of ionic polymer metal composites such as Nafion-based platinum ionomers have emerged as electroactive polymer materials with great potential for robotics and other applications. An effective activation of these materials requires understanding of their mechanism of operation. Generally, the material needs to be maintained hydrated to assure its electromechanical activity. To allow the control of the response of the material, a study is underway to investigate the electrical response. Particular emphasis is placed on possible electrochemical reactions and deviations from linear dielectric behavior. Currently, efforts are made to determine the necessary drive characteristics of the source to allow low power operation (< or = 1.0 W) of the material as an actuator.

Leary, S.↗
NASA NTRS1965

Fiber-metal composites

Law-of-mixtures relationship applied to fiber-metal composites - Determination of yield strengths, tensile strengths, and other properties of composites

FIBER↗
NASA NTRS1990

Creep and creep rupture of strongly reinforced metallic composites

A creep and creep damage theory is presented for metallic composites with strong fibers. Application is to reinforced structures in which the fiber orientation may vary throughout but a distinct fiber direction can be identified locally (local transverse isotropy). The creep deformation model follows earlier work and is based on a flow potential function that depends on invariants reflecting stress and the material symmetry. As the focus is on the interaction of creep and damage, primary creep is ignored. The creep rupture model is an extension of continuum damage mechanics and includes an isochronous damage function that depends on invariants specifying the local maximum transverse tension and the maximum longitudinal shear stress. It is posited that at high temperature and low stress, appropriate to engineering practice, these stress components damage the fiber/matrix interface through diffusion controlled void growth, eventually causing creep rupture. Experiments are outlined for characterizing a composite through creep rupture tests under transverse tension and longitudinal shear. Application is made to a thin-walled pressure vessel with reinforcing fibers at an arbitrary helical angle. The results illustrate the usefulness of the model as a means of achieving optimal designs of composite structures where creep and creep rupture are life limiting.

Robinson, D. N.↗
NASA NTRS2019

Polymer Infused Composite Metal Foam as a Potential Aircraft Leading Edge Material

The leading edge of the aircraft wings must be free from three-dimensional disturbances caused by insect adhesion, ice accretion, and particle wear in order to improve flight performance, safety, and fuel efficiency of the aircraft. An innovative solution was explored in this work by infusing stainless steel composite metal foam (SS CMF) with a hydrophobic epoxy resin system. S-S CMF was made with 100% stainless steel using a powder metallurgy technique. The infused epoxy filled the macro- and microporosities, unique to SS CMF’s structure, creating a product with a density similar to that of aluminum. The contact angle, wear rate, erosion resistance, and insect adhesion of the novel infused composite metal foam were measured and compared to aluminum, epoxy and stainless steel. The infusion process was determined to fill up to 88% of the pores within the SS CMF and was found to reduce wettability and insect residue accretion. The contact angle of the infused SS CMF was 43% higher than its parent material, stainless steel, and 130% higher than aluminum. Insect residue maximum height and areal coverage were reduced by 60 and 30%, respectively, compared to aluminum. Grit blast experiments to simulate erosion resulted in a greater roughness increase for aluminum than for the parent epoxy resin or the resin-infused SS CMF. These results suggest that the durability and performance of infused SS CMF was superior compared to aluminum, which is the current leading edge material of choice. Based on the promising results under relevant wear and erosion conditions, it is concluded that the infused SS CMF can offer a potential tailored replacement to aluminum leading edge material.

Jacob C. Marx↗