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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

Near net shape processing: A necessity for advanced materials applications

High quality discrete parts are the backbones for successful operation of equipment used in transportation, communication, construction, manufacturing, and appliances. Traditional shapemaking for discrete parts is carried out predominantly by machining, or removing unwanted material to produce the desired shape. As the cost and complexity of modern materials escalates, coupled with the expense and environmental hazards associated with handling of scrap, it is increasingly important to develop near net shape processes for these materials. Such processes involve casting of liquid materials, consolidation of powder materials, or deformation processing of simple solid shapes into the desired shape. Frequently, several of these operations may be used in sequence to produce a finished part. The processes for near net shape forming may be applied to any type of material, including metals, polymers, ceramics, and their composites. The ability to produce shapes is the key to implementation of laboratory developments in materials science into real world applications. This seminar presents an overview of near net shapemaking processes, some application examples, current developments, and future research opportunities.

Kuhn, Howard A.↗
NASA NTRS1971

Apollo 14 composite casting demonstration

The purpose of the demonstration was to show that mixtures of materials of different specific gravities would remain stable in the liquid state and during freezing in low g and not segregate as they do on earth. An inflight demonstration was performed on the Apollo 14 mission during the translunar and and transearth coast periods. The apparatus consisted of an electrical heater, a heat sink device for cooling, and sealed metal capsules containing matrix materials having a low-melting point and dispersants. The evaluation of the demonstration samples was accomplished by comparing space processed (flight) samples with (control) samples processed on the ground under otherwise similar conditions. In the low q environment of space flight the dispersions of particles, fibers, and gases in a liquid metal matrix were maintained during solidification. Dispersions of normally immiscible liquids were also maintained during solidification.

Yates, I. C., Jr.↗
DOE OSTI2021

Solvent-Cast Solid Electrolyte Membranes Based on a Charged Rigid-Rod Polymer and Ionic Liquids

Solid-state electrolytes are attractive for use in electrochemical devices because they remove the need for a flammable liquid electrolyte while contributing to the structural integrity of the device. We have recently developed a class of solid electrolytes, termed molecular ionic composites (MICs), composed of ionic liquids (ILs) and a rigid-rod polyelectrolyte, poly(2,2'-disulfonyl-4,4'-benzidine terephthalamide) (PBDT). MIC materials, originally obtained through an ion-exchange process between IL and PBDT aqueous solution, possess an unprecedented combination of high ionic conductivity, high thermal stability, low flammability and widely tunable tensile storage moduli. Here we present a facile solvent casting method for preparing MIC membranes. These membranes are uniform, flexible, and tough, with tunable composition and thickness (≥ 40 μm). Unlike the previous ion-exchange method, which only allowed incorporation of hydrophilic ILs, we can now incorporate hydrophobic ILs to prepare MIC membranes for, e.g. battery electrolytes. A sodium (Na) metal symmetric cell constructed with a PBDT-Pyr 14 TFSI membrane as the solid electrolyte shows long-term stable cycling (> 500 h.) at 60 °C. Furthermore, the ability to prepare MICs using both hydrophilic and hydrophobic ILs initiates a wider range of MIC materials and broadens the array of applications accessible by MIC membranes.

25 ENERGY STORAGE↗
NASA NTRS2009

Silica-Aerogel Composites Opacified with La(0.7)Sr(0.3)MnO3

As part of an effort to develop improved lightweight thermal-insulation tiles to withstand temperatures up to 1,000 C, silica aerogel/fused-quartz-fiber composite materials containing La0.7Sr0.3MnO3 particles as opacifiers have been investigated as potentially offering thermal conductivities lower than those of the otherwise equivalent silica-aerogel composite materials not containing La(0.7)Sr(0.3)MnO3 particles. The basic idea of incorporating opacifying particles into silica-aerogels composite to reduce infrared radiative contributions to thermal conductivities at high temperatures is not new: it has been reported in a number of previous NASA Tech Briefs articles. What is new here is the selection of La(0.7)Sr(0.3)MnO3 particles as candidate opacifiers that, in comparison with some prior opacifiers (carbon black and metal nanoparticles), are more thermally stable. The preparation of a composite material of the present type includes synthesis of the silica-aerogel component in a sol-gel process. The La(0.7)Sr(0.3)MnO3 particles, made previously in a separate process, are mixed into the sol, which is then cast onto fused-quartz-fiber batting. Then the aerogel-casting solution is poured into the mold, where it permeates the silica fiber felt. After the sol has gelled, the casting is aged and then subjected to supercritical drying to convert the gel to the final aerogel form. The separate process for making the La(0.7)Sr(0.3)MnO3 particles begins with the slow addition of corresponding proportions of La(CH3COOH)3, Mn(CH3COOH)3, and Sr(NO3)2 to a solution of H2O2 in H2O. The solution is then peptized by drop-wise addition of NH4OH to obtain a sol. Next, the sol is dried in an oven at a temperature of 120 C to obtain a glassy solid. The solid is calcined at 700 C to convert it to La(0.7)Sr(0.3)MnO3. Then La(0.7)Sr(0.3)MnO3 particles are made by ball-milling the calcined solid. The effectiveness of La(0.7)Sr(0.3)MnO3 particles as opacifiers and thermal-conductivity reducers depends on the statistical distribution of particle sizes as well as the relative proportions of La(0.7)Sr(0.3)MnO3 and aerogel. For experiments performed thus far, samples of aerogel/fiber composites were formulated to have, variously, silica target density of 0.07 or 0.14 g/cu cm and to contain 30 percent of La(0.7)Sr(0.3)MnO3 in average particle size of 0.3 or 3 microns. The thermal conductivities of the samples containing the 3 micron La(0.7)Sr(0.3)MnO3 particles were found to be lower than those of the samples containing the 0.3 micron La(0.7)Sr(0.3)MnO3 particles. The optimum particle size is believed to be between 1 and 5 microns.

Rhine, Wendell↗
DOE OSTI2021

Development of high B s Fe–Ni-based metal amorphous nanocomposite by optimization of glass-forming ability

Thermocalc simulations identified compositions with good glass-forming ability (GFA) by locating minima in liquidus temperature, and solidification range in (Fe 70 Ni 30 ) x (B-Si-Nb) 100-x alloys with x = 82% and x = 85%, increased compared to previously developed x = 80% alloys. 3 compositions in the x = 82% system and 1 in the x = 85% system were successfully cast as amorphous magnetic ribbon. Magnetic properties of as-cast alloys showed improvements in Curie temperature and saturation induction, especially for the 85% alloy. Crystallization behavior in the 85% alloy was determined to occur as a 2-step process. Annealing studies showed (Fe 70 Ni 30 ) 82 Nb 2 Si 0 B 16 and (Fe 70 Ni 30 ) 82 Nb 3 Si 0 B 15 alloys to exhibit low coercivity and high B s with annealing. TEM results show significant crystallization in as-cast ribbon. The (Fe 70 Ni 30 ) 85 Nb 0.5 Si 0 B 14.5 alloy as-cast has small, uniformly distributed grains, allowing a useful nanocrystalline alloy to be produced as cast. Lastly, the parameter ΔT xg , the temperature range in which the material can be thermomechanically processed, was in the range of 12–23 °C.

36 MATERIALS SCIENCE↗
NASA NTRS1982

Method of bonding plasticized elastomer to metal and articles produced thereby

Plasticized elastomer was securely bonded to a metal surface by interposing between the adhesive-coated metal surface and the elastomer sheet of material obtained by combining adhesive with a portion of the elastomer that was treated to remove plasticizers therefrom and heating the assembly in a mold under pressure. The sheet material is made up by dissolving a portion of the plasticized elastomer in an organic solvent, casting the solution, exposing it to a vacuum to remove the solvent and plasticizers, dissolving the deplasticized material in liquid adhesive and casting and drying the resulting liquid.

White, W. T.↗
NASA NTRS1988

Dendritic solidification in binary alloys

Alloys generally solidify dendritically, and associated with that is the microsegregation of impurities. Pure metals also solidify in dendritic form as 'thermal' dendrites, which actually segregate the system's enthalpy. In this investigation, small additions of solute to succinonitrile have been studied and dendritic growth observed in a supercooled melt. This free dendritic growth-mode is similar to that experienced by equiaxed dendrites found in alloy castings. Observations of these free dendrites include measurement of velocity and tip radius of the dendrites at different supercoolings and solute concentrations.

Chopra, M. A.↗
NASA NTRS2000

Ultrasonic Assessment of Impact-Induced Damage and Microcracking in Polymer Matrix Composites

The main objective of this NASA FAR project is to conduct ultrasonic assessment of impact-induced damage and microcracking in polymer matrix composites at various temperatures. It is believed that the proposed study of impact damage assessment on polymer matrix composites will benefit several NASA's missions and current interests, such as ballistic impact testing of composite fan containment and high strain rate deformation modeling of polymer matrix composites. Currently, impact-induced delamination and fracture in 6061-T6 aluminum/cast acrylic sandwich plates adhered by epoxy were generated in an instrumented drop-weight impact machine. Although only a small dent was produced on the aluminum side when a hemispherical penetrator tup was dropped onto it from a couple of inches, a large ring of delamination at the interface was observed. The delamination damage was often accompanied by severe shattering in the acrylic substratum. Damage patterns in the acrylic layer include radial and ring cracks and, together with delamination at the interface, may cause peeling-off of acrylic material from the sandwich plate. Theory of stress-wave propagation can be used to explain these damage patterns. The impact tests were conducted at various temperatures. The results also show clearly that temperature effect is very important in impact damage. For pure cast acrylic nil-ductile transition (NDT) occurs between 185-195 F Excessive impact energy was dissipated into fracture energy when tested at temperature below this range or through plastic deformation when tested at temperature above the NDT temperature. Results from this study will be used as baseline data for studying fiber-metal laminates, such as GLARE and ARALL for advanced aeronautical and astronautical applications.

Liaw, Benjamin↗
NASA NTRS2000

Impact Delamination and Fracture in Aluminum/Acrylic Sandwich Plates

Impact-induced delamination and fracture in 6061-T6 aluminum/cast acrylic sandwich plates adhered by epoxy were generated in an instrumented drop-weight impact machine. Although only a small dent was produced on the aluminum side when a hemispherical penetrator tup was dropped onto it from a couple of inches, a large ring of delamination at the interface was observed. The delamination damage was often accompanied by severe shattering in the acrylic substratum. Damage patterns in the acrylic layer include radial and ring cracks and, together with delamination at the interface, may cause peeling-off of acrylic material from the sandwich plate. Theory of stress-wave propagation can be used to explain these damage patterns. The impact tests were conducted at various temperatures. The results also show clearly that temperature effect is very important in impact damage. For pure cast acrylic nil-ductile transition (NDT) occurs between 185-195 F. Excessive impact energy was dissipated into fracture energy when tested at temperature below this range or through plastic deformation when tested at temperature above the NDT temperature. Results from this study will be used as baseline data for studying fiber-metal laminates, such as GLARE and ARALL for advanced aeronautical and astronautical applications.

Liaw, Benjamin↗
NASA NTRS2021

The Effect of Composition on Microstructure and Properties for Additively Manufactured Superalloy 718

Additive manufacturing (AM) represents an exciting new approach towards producing metallic aerospace components. The ability to make complex geometries that were impossible to create using conventional manufacturing methods has sparked interest from the aerospace community, including NASA. The use of AM components for crucial and human rated space missions necessitates a full characterization of the differences between AM and more conventional wrought and cast processes. For this study, sixteen different commercially available superalloy 718 powder feedstocks were obtained, built using laser powder bed fusion(L-PBF), and microstructurally and mechanically analyzed. These measurements revealed a wide range of build qualities and microstructures despite all powder lots falling within the 718chemical specification and being processed using the same prescribed build and heat treatment parameters. Statistical analysis found a strong correlation of the amount of carbon in the powder with the final grain size and strength of the heat-treated 718 part. Ultimately, this study highlights the need of a refined superalloy 718 chemical specification for powder lots to be used in AM.

Timothy M Smith↗
NASA NTRS1997

Fundamentals of Mold Free Casting: Experimental and Computational Studies

Researchers are developing the technology of 'Ballistic Particle Manufacturing' (BPM) in which individual drops are precisely layered onto a substrate, and the drops are deposited so as to prevent splatting. These individual drops will ultimately be combined to form a net-shape, three-dimensional object. Our understanding of controlled drop deposition as applied to BPM is far from complete. Process parameters include the size and temperature of the liquid metal drop, its impact velocity and trajectory, and the condition and temperature of the substrate. Quantitative knowledge of the fluid mechanics and heat transfer of drop deposition and solidification are necessary to fully optimize the manufacturing process and to control the material microstructure of the final part. The object of this study is to examine the dynamics of liquid metal drops as they impinge upon a solid surface and solidify under conditions consistent with BPM (i.e. conditions which produce non-splatting drops). A program of both numerical simulations and experiments will be conducted. Questions this study will address include the following: How do the deformation and solidification of the drop depend on the properties of the fluid drop and the solid substrate? How does the presence of previously deposited drops affect the impingement and solidification process? How does the impingement of the new drop affect already deposited material? How does the cooling rate and solidification of the drops influence the material microstructure?

Tryggvason, Gretar↗
DOE OSTI2024

Evaluation of Sb-Nd and Te-Nd phases within the U-Zr fuel matrix and their interactions with HT9 alloy

Antimony (Sb) and tellurium (Te) were investigated as potential additives for U-10Zr (wt.%) metallic fuel to limit the fuel-cladding chemical interaction (FCCI) with HT-9 alloy. Neodymium (Nd) was utilized to simulate the formation of lanthanide-based solid fission products which are known to play a detrimental role in FCCI. Fuel alloys of U-Zr-Sb-Nd and U-Zr-Te-Nd were evaluated in their annealed condition and compared against their as-cast conditions. Isothermal diffusion couple experiments were performed between U-Zr-Nd, U-Zr-Sb-Nd, and U-Zr-Te-Nd against the cladding alloy HT9 to evaluate the effectiveness of the additives to stabilize Nd within the fuel alloys, as well as investigate the interaction regions that form between the different fuel alloys and HT9. Further, SbNd and Sb 3 Nd 4 , and TeNd are found to be the primary neodymium-based phases formed in the U-Zr-Sb-Nd and U-Zr-Te-Nd alloys, respectively. The zirconium-based phase, Zr 2 Sb, is also found to form within the former alloy. All phases were found to remain stable through the diffusion experiments and exhibited no interaction with HT9 constituent elements. Preferential interaction between Nd with additivities Te and Sb compared to constituting elements in HT9 was further verified based on density functional theory (DFT) calculated enthalpy of mixing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Two-layer cathode architecture for high-energy density and high-power density solid state batteries

Solid state batteries with high-energy density and high-power density require the development of thick and energy dense cathodes. Structured cathode electrodes with a double-layer configuration were enabled using a freeze tape casting technique. A bottom dense layer was utilized to enhance the energy density whereas a top porous layer with vertically aligned walls was utilized to enhance the power density. The porous structure of the power layer was achieved by ice templating this layer on top of the densified energy layer of the cathode. This configuration was found to better utilize the active material of the cathodes and was optimized using numerical simulation and computer modeling. Cells with Li metal anode and LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) at approximately 5 and 20 mg/cm 2 were cycled at 70 °C at different C-rates. Poly(ethylene oxide) (PEO) with lithium bis-trifluoromethanesulfonimide (LiTFSI) was used for the catholyte and the solid-state electrolyte. The structured cathodes exhibited more than double capacity values as well as better Coulombic efficiency compared to non-structured (single-layer) thick cathodes. In conclusion, synchrotron X-ray tomography and scanning electron microscopy were used to characterize the microstructure of the cathodes.

25 ENERGY STORAGE↗
DOE OSTI2023

Improved Productivity with Multilaser Rotary Powder Bed Fusion Additive Manufacturing

Laser powder bed fusion (LPBF) enables the fabrication of intricate, geometrically complex structures with a sufficiently fine surface finish for many engineering applications with a diversity of available feedstock metals. However, the production rate of LPBF systems is not well suited for mass production in comparison to traditional manufacturing methods. LPBF systems measure their deposition rates in 100's of grams per hour, while other processes measure in kilograms per hour or even in the case of processes such as forming, stamping, and casting, 100's of kilograms per hour. To be widely adopted in industry for mass production, LPBF requires a new scalable architecture that enables many orders of magnitude improvement in deposition rate, while maintaining the geometry freedom of additive manufacturing. This article explores concepts that could achieve as much as four orders of magnitude increase in the production rate through the application of (1) rotary table kinematic arrangements; (2) a dramatic number of simultaneously operating lasers; (3) reductions of laser optic size; (4) improved scanning techniques; and (5) an optimization of toroidal build plate size. To theoretically demonstrate the possibilities of production improvements, a productivity analysis is proposed for synchronous reluctance motors with relevance to the electric vehicle industry, given the recent increase in the diversity of printable soft magnetic alloys. The analysis provides insights into the impact of the architecture and process parameters necessary to optimize rotary powder bed fusion for mass production.

36 MATERIALS SCIENCE↗
NASA NTRS1971

Test and evaluation of Apollo 14 composite casting demonstration specimens and flight and control samples

The results of experiments 1, 2, and 10 of the Apollo 14 composite casting demonstration are discussed. The purpose of the demonstration, with regard to samples 1 and 2, was to obtain preliminary data on the liquid phase sintering process in a weightless environment. With regard to sample 10, the purpose was to obtain preliminary information on how to achieve uniform dispersion of dense particles on a metal matrix by employing shaking modes or forces in the system when the metal matrix is molten. Results of the demonstrations were interpreted in a quantitative and qualitative manner. For experiment 1 it was found that the tungsten particles were redistributed more uniformly in the flight sample than in the control sample. Experiment 2 results indicate that complete melting may not have occured and thus a high degree of significance cannot be associated with the qualitative results relating to particle redistribution data. The particle-matrix system of experiment 10 was found to be nonwetting.

Fabiniak, R. C.↗
NASA NTRS2003

The Application of Metal Matrix Composite Materials in Propulsion System Valves

Metal Matrix Composite (MMC) materials have been developed and used in many applications to reduce the weight of components where weight and deflection are the driving design requirement. MMC materials are being developed for use in some propulsion system components, such as turbo-pumps and thrust chambers. However, to date, no propulsion system valves have been developed that take advantage of the materials unique properties. The stiffness of MMC's could help keep valves light or improve life where deflection is the design constraint (such as seal and bearing locations). The low CTE of the materials might allow the designer to reduce tolerances and clearances producing better performance and lighter weight valves. Using unique manufacturing processes allow parts to be plated/coated for longer life and allow joining either by welding or threading/bolting. Additionally, casting of multi part pre-forms to form a single part can lead to designs that would be hard or impossible to manufacture with other methods. Therefore, NASA's Marshall Space Flight Center (MSFC) has developed and tested a prototype propulsion system valve that utilizes these materials to demonstrate these advantages. Through design and testing, this effort will determine the best use of these materials in valves designed to achieve the goal of a highly reliable and lightweight propulsion system. This paper is a continuation of the paper, The Application of Metal Matrix Composite Materials In Propulsion System Valves, presented at the JANNAF Conference held in April, 2002. Fabrication techniques employed, valve development, and valve test results will be discussed in this paper.

Laszar, John↗
DOE OSTI2024

Advanced Fabrication Techniques of Metal Hydrides for Science and Technology Applications (Abbreviated Final Report)

Lithium Hydride (LiH) atomic properties make it an excellent candidate for thermal energy storage, hydrogen storage, and nuclear reactor technology. High Energy Density (HED) experiments on LiH at the National Ignition Facility (NIF) can also provide critical Equation of State (EOS) and Hugoniot data. Density requirements for LiH vary per application and therefore physical and structural requirements for LiH are non-uniform. Historical production of LiH relies on casting processesthat are limited by density and grain-size control, which leads to unfavorable machinable characteristics. LiH manufacturing is further hindered due to its chemical reactivity and propensity to readily react with moisture. This work aimed at exploring advanced fabrication techniques for LiH such as 1) uniaxial powder pressing methods and 2) laser powder bed fusion (L-PBF) additive manufacturing. Uniaxial powder compaction offers advantageous tailorable mechanical and physical properties via density control, and L-PBF can produce net-shaped complex parts with unique microstructure. Uniaxial pressing proved successful in readily producing LiH with density control.

36 MATERIALS SCIENCE↗