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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
NASA NTRS1980

Microstructure of the combustion zone: Thin-binder AP-polymer sandwiches

Experimental results are summarized for systematic quench-burning tests on ammonium perchlorate-HC binder sandwiches with binder thicknesses in the range 10 - 150 microns. Tests included three binders (polysulfide, polybutadiene-acrylonitrile, and hydroxy terminated polybutadiene), and pressures from 1.4 to 14 MPa. In addition, deflagration limits were determined in terms of binder thickness and pressure. Results are discussed in terms of a qualitative theory of sandwich burning consolidated from various sources. Some aspects of the observed results are explained only speculatively.

Price, E. W.↗
NASA NTRS1967

Polymer Research

Network density of filled composites, nitroso compound reactions with hydrocarbons, cryogenic bladder bag materials, thermoplastic rubbers as binders, and other polymer research studies

COMPOSITE MATERIAL↗
NASA NTRS1967

Polymer research

Stress-strain distribution in elastomers, and chemical and physical properties of prepolymers, rigid urethane foam, and thermoplastic rubbers for composite solid propellant binders

ELASTOMER↗
DOE OSTI2026

Covalent adaptable networks for electrolyte–binder integration in recyclable lithium metal batteries

Lithium-metal batteries (LMBs) are considered a promising next-generation energy storage technology due to their exceptionally high energy density. However, the development of solid polymer electrolytes and cathode binders for LMBs faces critical challenges, including interfacial instability, poor recyclability, and growing environmental concerns. In particular, current systems often rely on non-recyclable components featuring permanently crosslinked networks and polyfluoroalkyl substances (PFAS), such as poly(vinylidene fluoride) (PVDF), which cause battery waste and environmental harm. Herein, we introduce a multifunctional covalent adaptable network (CAN) platform based on thermally reversible Diels–Alder (DA) chemistry, designed for dual functionality as a CAN-based electrolyte (CAE) and a CAN-based cathode binder. The CAE achieves high ionic conductivity and strong storage modulus (1.4 mS cm −1 and ∼ 10 5 Pa at room temperature, respectively) and enables stable long-term cycling in symmetric Li||Li cells for over 2000 h with low overpotential. When it is applied as a cathode binder in LiFePO 4 (LFP) composite electrodes (C-LFP), the CAN matrix significantly reduces interfacial resistance and enhances discharge capacity compared to conventional PVDF-based systems. Thermal treatment induces self-healing at the cathode–electrolyte interface, further improving contact and yielding a discharge capacity of 150 mAh g −1 at 0.5 C. Moreover, the dynamic CAN architecture allows efficient recovery and reuse of lithium salts from spent electrolytes through retro-DA reactions under mild conditions (∼80 °C), establishing a low-energy, cost-effective recycling pathway. In conclusion, this work presents a scalable and sustainable strategy for high-performance LMBs by integrating recyclability, interfacial healing, and PFAS-free design, offering a holistic solution aligned with circular economy principles and next-generation battery demands.

Diels–Alder↗
DOE OSTI2023

Polycarbonate‐Based Solid‐Polymer Electrolytes for Solid‐State Sodium Batteries

Solid-polymer electrolytes comprised of polypropylene carbonate (PPC) and varied sodium bis(fluorosulfonyl)imide (NaFSI) salt concentrations are investigated for implementation as a conductive solid polymer electrolyte into solid-state cathode composites utilizing a sodium-layered oxide active material. The ionic conductivity generally increases with NaFSI salt content, reaching ≈1 mS cm −1 at 80 °C at the highest salt concentration (PPC:NaFSI = 0.5:1). Through an all-in-one slurry casting method, Na 2/3 Ni 1/3 Mn 2/3 O 2 cathode composites are fabricated in which the dispersed PPC electrolyte acts as the primary binder. Enabled by a bilayer polymer electrolyte system, cycling performance with the PPC cathode electrolyte is optimized with respect to salt concentration and anode material. The best cyclability is achieved with a moderate salt concentration electrolyte (PPC:NaFSI = 5:1), showcasing an initial capacity of 83 mA h g −1 with a remarkable 80% capacity retention after 150 cycles at C/5 rate and 60 °C. The superior performance of the lower salt concentration electrolyte is attributed to better electrochemical stability, as confirmed by linear sweep voltammetry and online electrochemical mass spectrometry measurements. In conclusion, these results underscore the potential of carbonate-based polymer electrolytes and the importance of balancing electrolyte conductivity and stability in cell design.

25 ENERGY STORAGE↗
NASA NTRS1972

Polymeric binder for explosives

Chemical reaction for producing a polymer which can be mixed with explosives to produce a rigid material is discussed. Physical and chemical properties of polymers are described and chemical structure of the polymer is illustrated.

Bissell, E. R.↗
NASA NTRS1979

Low-temperature elastomer production and curing

Thermally and chemically stable polymers are needed for materials applications, particularly highly-stable elastomers for solid propellant binders where initial high temperature required for dissolving anhydride in polymer is deerimental. Solvent reactant system allows polymerization without condensation of products under low heat. Solvents utilized were dimethylacetamide, dimethyflormamide, etc.

Ingham, J. D.↗
DOE OSTI2025

LiNi0.8Mn0.1Co0.1O2 Thin Films Prepared by Polymer-Assisted Deposition for the Study of Cathode-Electrolyte Interphases in Lithium-Ion Batteries

High-nickel layered oxide cathodes such as LiNi0.8Mn0.1Co0.1O2 (NMC811) are critical for next-generation lithium-ion batteries (LIBs) due to their superior energy density and reduced reliance on cobalt. However, many Ni-rich cathodes suffer from rapid capacity fade and structural instability originating from complex interfacial reactions at the cathode-electrolyte interface. Traditional composite electrodes exhibit degradation mechanisms that are challenging to quantitatively understand due to additives, including binders and carbon black. In this study, we demonstrate a new synthesis approach for binder- and additive-free NMC811 thin films using polymer-assisted deposition (PAD). PAD-NMC811 are model thin-film cathodes for investigating interfacial phenomena that can be obscured in composite cathodes. Structural and chemical characterization by X-ray diffraction, soft X-ray absorption spectroscopy, and atomic force microscopy show that PAD-NMC811 films possess high phase purity, crystallinity, chemical homogeneity, and morphological uniformity. Electrochemical analyses using cyclic voltammetry and galvanostatic cycling revealed electrochemical behavior consistent with that of composite electrodes, along with a moderate capacity fade indicative of cathode-electrolyte interphase (CEI) formation. Our findings illustrate the effectiveness of PAD synthesis of thin films tailored for detailed mechanistic studies, which offer critical insights into CEI evolution and cathode degradation pathways.

25 ENERGY STORAGE↗
NASA NTRS1980

Development of a solvent processed insensitive propellant

Two types of low vulnerability propellants are studied which are distinguished by whether the binder is a rubber, such as polyurethane or CTBN, or a plasticizable polymer such as ethyl cellulose or cellulose acetate. The former propellants are made by a partial cure extrusion process while the latter are made by the conventional solvent process. Emphasis is given to a cellulose binder (plasticizer) RDX composition. The type of binder used, the particle size of the RDX and the presence of small quantities of nitrocellulose in the solvent processed compositions have important influences on the mechanical and combustion characteristics of the propellant. The low temperature combustion is of particular concern because of potential breakup of the grains that can lead to instability.

Trask, R.↗
NASA NTRS1979

Lunar building materials: Some considerations on the use of inorganic polymers

The use of inorganic polymer systems synthesized from the available lunar chemical elements, viz., silicon, aluminum, and oxygen to make adhesives, binders, and sealants needed in the fabrication of lunar building materials and the assembly of structures is considered. Inorganic polymer systems, their background, status, and shortcomings, and the use of network polymers as a possible approach to synthesis are examined as well as glassy metals for unusual structural strength, and the use of cold-mold materials as well as foam-sintered lunar silicates for lightweight shielding and structural building materials.

Lee, S. M.↗
NASA NTRS1977

Electrically Conductive Paints for Satellites

A program was conducted to develop and test electrically conductive paint coatings for spacecraft. A wide variety of organic and inorganic coatings were formulated using conductive binders, conductive pigments, and similar approaches. Z-93, IITRI's standard specification inorganic thermal control coating, exhibits good electrical properties and is a very space-stable coating system. Several coatings based on a conductive pigment (antimony-doped tin oxide) in silicone and silicate binders offer considerable promise. Paint systems using commercially available conductive polymers also appear to be of interest, but will require substantial development. Evaluations were made based on electrical conductivity, paint physical properties, and the stability of spectral reflectance in space environment testing.

Gilligan, J. E.↗
DOE OSTI2025

Water Sorption Study of Various Polymers and Polymeric Composites

In the formulations of many composite materials, polymeric materials are often used as binder materials to enhance processability, functionality, and safety during manufacturing. For instance, poly(ester urethane), such as Estane® 5703, is used in the formulation of PBX 9501, and vinyl copolymer elastomer (VCE) is used in the formulation of VCE/filler compos ites. The stability of these binders directly impacts the overall stability and performance of their composites. Estane and VCE are prone to hydrolytic degradation, with water sorption behavior playing a significant role in their long-term stability and aging behavior. Hence, it is critical to study their water sorption behavior under various humidity and tempera ture conditions. To improve the accuracy and reduce labor-intensive work involved in water sorption experiments, an automated Dynamic Vapor Sorption (DVS) system was employed, which can generate large datasets. To efficiently process and analyze these datasets, Python scripts were developed. These scripts not only streamlined data processing, but also accu rately derived the Arrhenius parameters related to water diffusion and sorption properties for the tested materials. This approach offers a robust framework for evaluating water trans port and sorption processes in polymeric materials and adds valuable capabilities to future water sorption testing efforts.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Sandwich-structured paper composite with water and oil resistance for food packaging and tableware applications

The growing environmental challenges posed by plastic waste from disposable tableware highlight the urgent need for sustainable alternatives. Traditional plastics decompose over centuries, generating microplastics that threaten ecosystems and human health. While lignin has emerged as a promising material for plastic replacement, its inherent dark brown color and processing challenges in paper-based products have limited its application, particularly in food-contact materials. Here, to address these limitations, we have developed biodegradable sandwich-structured paper composites comprising parchment paper as surface layers and a lignin-polymer core with polyvinyl alcohol (PVA) and polylactic acid (PLA). This innovative structure eliminates the need for binders, minimizing potential food contamination, and enables direct application as packaging or molded tableware. Lignin micro- and nano-particles (LMNP) enhances durability and provides natural water and oil resistance without harmful additives, such as per- and polyfluoroalkyl substances (PFAS), while PVA and PLA improve the composite's tenacity. The resulting material, composed of 65 wt% lignin, demonstrates excellent water and oil resistance, with no penetration exceeding 1 h, and exhibits enhanced tensile strength (45 MPa), making it a viable and eco-friendly alternative for disposable tableware.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Binder-Stabilized Carbon Fiber Hosts for High-Utilization Sodium–Polysulfide Flow Catholytes

Sodium-sulfur (Na-S) batteries hold promise as high-energy-density batteries for long-duration energy storage due to their high open circuit voltage and Earth-abundant active materials. However, low utilization of the sulfur active material limits the achievable specific capacity, especially when a liquid polysulfide catholyte is utilized. High-surface-area carbon materials demonstrate promise to increase sulfur utilization in a Na-S battery. To make the carbon host material applicable for a flow battery application, a binder is required to bind the carbon materials together and to a porous substrate. Here, we utilize a composite carbon paper electrode coated by polymer,carbon nanofibers (CNFs) and carbon black (CB). By varying the mass ratios of CNF to CB, we found that a 70/20/10 mass ratio of CNF/CB/binder provided the highest capacity (260 mAh g −1 compared to the baseline of 156 mAh g −1 ) and stable battery performance over 100 cycles. Analysis of the composite electrode and full cells reveals that the amount of CB in the composite electrode influences binder distribution, cell resistance, and full cell performance.

Lehmann, Michelle L. [Oak Ridge National Laborator↗