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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 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

A high order characteristic discontinuous Galerkin scheme for advection on unstructured meshes

A new characteristic discontinuous Galerkin (CDG) advection scheme is presented. In contrast to standard discontinuous Galerkin schemes, the test functions themselves follow characteristics in order to ensure conservation and the edges of each element are also traced backwards along characteristics in order to create a swept region , which is integrated in order to determine the mass flux across the edge. Both the accuracy and performance of the scheme are greatly improved by the use of large Courant–Friedrichs–Lewy numbers for a shear flow test case and the scheme is shown to scale sublinearly with the number of tracers being advected, outperforming a standard flux corrected transport scheme for 10 or more tracers with a linear basis. Moreover the CDG scheme may be run to arbitrarily high order spatial accuracy and on unstructured grids, and is shown to give the correct order of error convergence for piecewise linear and quadratic bases on regular quadrilateral and hexahedral planar grids. Using a modal Taylor series basis, the scheme may be made monotone while preserving conservation with the use of a standard slope limiter, although this reduces the formal accuracy of the scheme to first order. The second order scheme is roughly as accurate as the incremental remap scheme with nonlocal gradient reconstruction at half the horizontal resolution. Furthermore, the scheme is being developed for implementation within the Model for Prediction Across Scales (MPAS) Ocean model, an unstructured grid finite volume ocean model.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS1989

AMTEC recirculating test cell component testing and operation

Alkali metal thermoelectric converter operation in a recirculating test cell (RTC), which requires a small electromagnetic pump (EM) and a high-temperature beta-double-prime alumina-solid-electrolyte (BASE)-to-metal seal, is discussed. The design of a pump and an active metal braze seal and the initial operation of a cell using these components are described. The pump delivered 0.25 cu cm/min against a 28-psia head. A braze seal system was selected after shear strength tests of Ta or Nb brazed to BASE by a variety of fillers including TiCuNi, TiNi, and TiNiCr. The TiCuNi filler was chosen for environment cell testing and showed no failure or observable degradation after short-term tests up to 1055 K. The pump and the Nb/TiCuNi/BASE seal were used in a test that demonstrated all the operational functions of the RTC for the first time. An increase in the radiation reduction factor at constant input power was observed, indicating that the condenser was being wet by sodium resulting in an increased reflectivity.

Underwood, M. L.↗
NASA NTRS1977

Experimental studies of graphite-epoxy and boron-epoxy angle ply laminates in shear

The nonlinear/inelastic response under inplane shear of a large variety of graphite-epoxy and boron-epoxy angle-ply laminates was tested. Their strength allowables were obtained and the mechanisms which govern their mode of failure were determined. Two types of specimens for the program were chosen, tested, and evaluated: shear panels stabilized by an aluminum honeycomb core and shear tubes. A modified biaxially compression/tension loaded picture frame was designed and utilized in the test program with the shear panels. The results obtained with this test technique categorically prefer the shear panels, rather than the tubes, for adequate and satisfactory experimental definition of the objectives. Test results indicate the existence of a so-called core-effect which ought to be considered when reducing experimental data for weak in shear laminates.

Weller, T.↗
NASA NTRS2005

The Effects of Elevated Temperatures on the Response of Resins Under Dynamic and Static Loadings

The overall objective of the research is to experimentally study the combined effects of temperature and strain rate on the response of two resins that are commonly used for the matrix material in composites. The resins are loaded at various temperatures in shear and in tension over a wide range of strain rates. These two types of loadings provide an opportunity to examine also the effect that temperature might have on the effects of the hydrostatic stress component on the material response. The experimental data provide the information needed for NASA scientists for the development of a nonlinear, strain rate, and temperature dependent deformation and strength models for composites that can subsequently be used in design. This year effort was directed into the development and testing of the epoxy resin at elevated temperatures. Two types of epoxy resins were tested in shear at high strain rates of about 10(exp-4)/s and elevated temperatures of 50 and 8OC. The results show that the temperature significantly affects the response of epoxy.

Gilat, Amos↗
DOE OSTI2018

Study on Texture Evolution and Shear Behavior of an Al/Ni/Cu Composite

The microstructure, texture, and mechanical properties of the Al/Ni/Cu composite during various accumulative roll bonding (ARB) cycles were studied using optical microscopy, scanning electron microscopy, x-ray diffraction, shear punch test, and hardness test. In addition, ImageJ software and Rietveld software were used in order to study microstructure and dislocation density variations, respectively. It was found that Ni and Cu layers were fractured and distributed in the Al matrix due to differences in their mechanical properties. Fracture and distribution of Cu and Ni particles after cycle five led to the alteration of the composite structure from a layered to a particle-reinforced structure. ARB process leads to the formation of strong orientation along the β-fiber and also to pronounced copper and dillamore components in both Al and Cu phases. Furthermore, the shear yield stress and ultimate shear strength of the composite increased as the ARB process advanced; however, shear elongation presented a non-uniform variation. Investigation of the fracture surfaces revealed that the mechanical properties of the composite are affected not only by the strain hardening of the Cu layer, but also by the structural change in the composite during the initial ARB cycles. During the last stages of the process, however, changes in mechanical properties were mostly governed by reinforcement particles serving as strain concentration zones and the strain hardening of the Al matrix.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Melt Flow Behavior and Processability of Polylactic Acid/Polystyrene (PLA/PS) Polymer Blends

The present investigation dealt with the flow behavior and processability of polylactic acid/polystyrene (PLA/PS) polymer blends using a capillary rheometer. For this purpose, PLA/PS blends with different ratios of the concentrations were prepared using a single screw extruder. The shear viscosity, shear stress, shear rate, power-law index, viscous activation energy at a constant shear stress, and elongational stress were determined. PLA/PS blends exhibited a typical shear-thinning behavior over the entire range of shear rates tested, and the viscosity values of the blends would tend to decrease with increasing amount of PLA. In addition, the polymer blend of 70 % PLA and 30 % PS was found to be relatively less sensitive to the processing temperature, implying that the extrusion process was more desirable for fabrication of PLA/PS polymer blend than the injection process.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Adjustable rheology of fumed silica dispersion in urethane prepolymers: Composition-dependent sol and gel behaviors and energy-mediated shear responses

Variation of colloidal and interfacial interactions leads to a microstructural diversity in fumed silica dispersions exhibiting absolutely different sol- or gel-like rheological responses. In this study, fumed silicas with different surface areas (200–400 m{sup 2}/g) and surface characteristics (hydrophilic or hydrophobic) are dispersed into moisture-cured polyurethane. The microstructures investigated using transmission electron microscope are associated perfectly with three different rheological behaviors: (i) Sols with well-dispersed silica aggregates, (ii) weak gels with agglomerate-linked networks, and (iii) strong gels with concentrated networks of large agglomerates. Though sols and gels are well distinguished by shear thickening or sustained thinning response through steady shear flow test, it is interesting that the sols and weak gels exhibit a uniform modulus plateau-softening-hardening-softening response with increasing dynamic strain at frequency 10 rad s{sup −1} while the strong gels show a sustained softening beyond the linear regime. Furthermore, the onset of softening and hardening can be normalized: The two softening are isoenergetic at mechanical energies of 0.3 J m{sup −3} and 10 kJ m{sup −3}. On the other hand, the hardening is initiated by a critical strain of 60%. The mechanisms involved in the generation of the sol- and the gel-like dispersions and their structural evolutions during shear are thoroughly clarified in relation to the polyols, the characteristic and content of silica and the curing catalysts.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2015

Processing ultrasonic inspection data from multiple scan patterns for turbine rotor weld build-up evaluations

The study presents a data processing methodology for weld build-up using multiple scan patterns. To achieve an overall high probability of detection for flaws with different orientations, an inspection procedure with three different scan patterns is proposed. The three scan patterns are radial-tangential longitude wave pattern, axial-radial longitude wave pattern, and tangential shear wave pattern. Scientific fusion of the inspection data is implemented using volume reconstruction techniques. The idea is to perform spatial domain forward data mapping for all sampling points. A conservative scheme is employed to handle the case that multiple sampling points are mapped to one grid location. The scheme assigns the maximum value for the grid location to retain the largest equivalent reflector size for the location. The methodology is demonstrated and validated using a realistic ring of weld build-up. Tungsten balls and bars are embedded to the weld build-up during manufacturing process to represent natural flaws. Flat bottomed holes and side drilled holes are installed as artificial flaws. Automatic flaw identification and extraction are demonstrated. Results indicate the inspection procedure with multiple scan patterns can identify all the artificial and natural flaws.

42 ENGINEERING↗
DOE OSTI2023

Structure, Function, and Application of Self–Healing Adhesives from Mistletoe Viscin

Berries from the European Mistletoe (Viscum album) possess a sticky tissue called viscin that facilitates adhesion and germination onto host trees. Recent studies of viscin have demonstrated its adhesive capacity on a range of natural and synthetic surfaces including wood, skin, metals, and plastic. Yet, the underlying mechanisms remain poorly understood. Here, an investigation of the adhesive performance of mistletoe viscin is performed, demonstrating its hygroscopic nature and ability to self-heal following adhesive failure. It is identified that adhesion originates from a water-soluble adhesive component that can be extracted, isolated, and characterized independently. Lap shear mechanical testing indicates that the mistletoe adhesive extract (MAE) outperforms native viscin tissue, as well as gum arabic and arabinogalactan—common plant-based adhesives. Furthermore, humidity uptake experiments reveal that MAE can reversibly absorb nearly 100% of its mass in water from the atmosphere. In-depth spectroscopic and mass spectrometry investigations reveal a composition consisting primarily of an atypical arabinogalactan, with additional sugar alcohols. Finally, several proof-of-concept applications are demonstrated using MAE for hygro-responsive reversible adhesion between various surfaces including skin, plastic, PDMS, and paper, revealing that MAE holds potential as a biorenewable and reusable adhesive for applications in cosmetics, packaging, and potentially, tissue engineering.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Joining of Lightweight Dissimilar Materials by Friction Self-Piercing Riveting

In this work, we employed a unique solid-state joining process, friction self-piercing riveting (F-SPR), to join carbon fiber composites to the low-ductility magnesium alloy AZ31B. The localized frictional heat generated between the rotating rivet and the underside of the magnesium sheet softened and prevented crack generation in AZ31B. A consumable joining rivet was designed to join the selected material stacks by F-SPR. Lap shear tensile testing was used to assess the joint quality of specimens produced by F-SPR. The joint interface from the cross-sectioned F-SPR specimen was evaluated by optical microscopy.

Lim, Yong Chae↗
DOE OSTI2020

Joining of Thermoset Carbon Fiber Reinforced Polymer and AZ31 Magnesium Alloy Sheet Via Friction Stir Interlocking

A new technique called friction stir interlocking (FSI) was applied for lap-joining of AZ31 magnesium sheet and thermoset carbon fiber reinforced polymer (TS-CFRP) sheet. Instead of directly joining AZ31 and TS-CFRP, a series of magnesium interlocks were used to friction stir weld with AZ31 sheet to enable joining with TS-CFRP. Microstructural characterization of joint cross sections showed that a tool rotation rate of 800 rpm produced incomplete mixing of magnesium interlocks and the top AZ31 sheet, while 1200 rpm achieved sufficient material mixing to avoid unwelded regions. Mechanical property characterization showed that AZ31/TS-CFRP dissimilar joints failed through the magnesium interlock shanks during lap shear tensile testing, with a maximum normalized joint strength reaching ~100 MPa.

Wang, Tianhao↗
DOE OSTI2019

Microstructure and Mechanical Behavior of MnO{sub 2}/Pb Nanocomposite

MnO{sub 2}/Pb nanocomposite was produced by solid-state accumulative roll-bonding (ARB) technique. Composites with different amounts of MnO{sub 2} were synthesized with the highest probable ARB cycles. The mechanical properties of composites were studied by tensile, microhardness and shear punch tests. It was observed that yield stress, tensile stress and elongation were improved by increasing the ARB cycles. On the other hand, increasing the amount of MnO{sub 2} up to 0.5 wt.% improved the mechanical properties of the composites. Tensile tests results revealed that the maximum tensile strength could be achieved in the composite containing 0.5 wt.% MnO{sub 2} after 10 passes (up to 4.35 times higher than control sample, Pb-10 pass). In comparison with Pb-10 pass, the hardness of 0.5 wt.% MnO{sub 2}/Pb nanocomposite was enhanced up to 7.5 times after 10 ARB passes. ARB process led to a proper distribution of MnO{sub 2} particles in Pb matrix with the mean size of less than 30 nm.

36 MATERIALS SCIENCE↗
DOE OSTI2017

The influence of substrate moisture preparation on bond strength of concrete overlays and the microstructure of the OTZ

The influence of substrate moisture preparation on the direct shear bond strength of composite substrate-overlay specimens was evaluated. The substrate surface was exposed to four different moisture conditions prior to overlay application. A quantitative analysis of backscattered electron images of the microstructure of the overlay transition zone was carried out to quantify its properties along the interface and help analyse the results of the shear bond testing. The results show that pre-wetting the substrate surface prior to application of the overlay provides no added benefit towards increasing the bond strength and may in some cases reduce bond strength significantly. The microstructural investigations confirmed that pre-saturated substrates increase the w/c ratio and the porosity in the overlay transition zone (OTZ), which was found to have a thickness of about 100 μm. The OTZ in overlays cast on dry substrate surfaces had lower porosity and an increased amount of anhydrous cement.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Friction Stir Dovetailing of AA7099 to Steel with AA6061 Interlayer for Reduced Zn Embrittlement at Dissimilar Interface

Joining of high strength Al alloy (AA7099) to steel (rolled homogeneous armor) with and without AA6061 interlayer was achieved using a friction stir dovetailing (FSD) method. Detailed investigations were conducted to establish correlations between mechanical performance and microstructural evolution of FSD joints. Lap shear tensile testing revealed that incorporation of the AA6061 interlayer combined with tailored processing methodology significantly improved both mechanical interlocking and load transmission across the dovetail interface. Following incorporation of the interlayer, the maximum load carrying capacity and peak extension (of the AA7099/AA6061/steel joint) are 60% and 210% higher, respectively, than results obtained from an AA7099/steel joint without an interlayer. Without an AA6061 interlayer, formation of zinc rich intermetallic compounds led to brittle interfacial failure of the AA7099-steel FSD joint. Incorporation of novel tool and joint configuration eliminated asymmetric joint performance as a function of loading direction, which is generally observed in friction stir lap welding. The efficacy of the use of an AA6061 interlayer in joining AA7099 to steel was demonstrated through mechanical testing as well as high resolution analytical electron microscopy characterization.

Dissimilar metal joining, Friction stir dovetailin↗
DOE OSTI2015

Friction stir welding joint of dissimilar materials between AZ31B magnesium and 6061 aluminum alloys: Microstructure studies and mechanical characterizations

Friction stir welding is an efficient manufacturing method for joining dissimilar alloys, which can dramatically reduce grain sizes and offer high mechanical joint efficiency. Lap FSW joints between dissimilar AZ31B and Al 6061 alloy sheets were made at various tool rotation and travel speeds. Rotation and travel speeds varied between 560–1400 r/min and 16–40 mm/min respectively, where the ratio between these parameters was such that nearly constant pitch distances were applied during welding. X-ray diffraction pattern (XRD), optical microscopy images (OM), electron probe microanalysis (EPMA) and scanning electron microscopy equipped with an energy-dispersive X-ray spectroscopy (SEM-EDS) were used to investigate the microstructures of the joints welded. Intermetallic phases including Al{sub 12}Mg{sub 17} (γ) and Al{sub 3}Mg{sub 2} (β) were detected in the weld zone (WZ). For different tool rotation speeds, the morphology of the microstructure in the stir zone changed significantly with travel speed. Lap shear tensile test results indicated that by simultaneously increasing the tool rotation and travel speeds to 1400 r/min and 40 mm/min, the joint tensile strength and ductility reached a maximum. Microhardness measurements and tensile stress–strain curves indicated that mechanical properties were affected by FSW parameters and mainly depended on the formation of intermetallic compounds in the weld zone. In addition, a debonding failure mode in the Al/Mg dissimilar weld nugget was investigated by SEM and surface fracture studies indicated that the presence of intermetallic compounds in the weld zone controlled the failure mode. XRD analysis of the fracture surface indicated the presence of brittle intermetallic compounds including Al{sub 12}Mg{sub 17} (γ) and Al{sub 3}Mg{sub 2} (β). - Highlights: • Dissimilar Al/Mg joint was obtained by lap friction stir welding technique. • Effect of rotation and travel speeds on the formation of intermetallic compounds • Microstructure and chemical studies including metallography, XRD, SEM-EDS, and EPMA • Mechanical property tests such as stress–strain curves, failure load and hardness • IMCs as Al{sub 3}Mg{sub 2} and Al{sub 12}Mg{sub 17} were identified in weld nugget and at Al/Mg interface.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Comparison of microstructural and mechanical properties of friction stir spot welded ultra-high strength dual phase and complex phase steels

Highlights: • The microstructure and mechanical properties of FSSW of ultra high strength DP and CP steels are compared. • The stir zone (SZ) of CP steel mainly consists of bainite and martensite; no bainite is identified in the SZ of DP steel. • The cooling was not fast enough for the CP steel to suppress the effect of chemical composition on phase transformation. - Abstract: The microstructure and mechanical properties of friction stir spot welding of ultrahigh strength dual phase (DP) and complex phase (DP) steels are compared based on the experimental results. For both DP and CP steels, FSSW joints are successfully fabricated using the same process parameter set. While the microstructure of joints are characterized in detail using scanning electron microscopy, electron back scattered diffraction, and transmission electron microscopy, the mechanical property of joints are evaluated by shear tensile tests. The result of the microstructural analysis shows that the stir zone (SZ) of CP steel mainly consists of bainite and martensite, while no bainite is identified in the SZ of DP steel. The existence of bainite in the SZ of CP steel suggests that the cooling rate, which is nearly identical for both CP and DP steels, was not fast enough to suppress the effect of the alloying composition, particularly that of Mn, on the phase transformation. The result of the present study contributes to the development of solid state joining process of the ultrahigh strength steels.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Passive sensing of a microparticle modified hybrid, fiber-reinforced composite

The widespread commercial adoption of high-performance, fiber-reinforced composites has pushed research interests toward the next generation of composites. These new composites are tasked with integrating additional functionalities into the structures without causing a trade-off in mechanical performance. One such functionality that has received significant interest is sensing. This is especially important for composites using high-performance fibers (e.g., carbon fiber) because their strain-to-failure is relatively low, resulting in brittle fracture. Besides, fiber damage can be hidden within the composite, potentially leading to premature catastrophic failure if not detected. In prior research, we demonstrated continuous feed-through deposition of ceramic nanoparticles on carbon fiber’s surface that simultaneously enhanced both the piezoresistive response and interlaminar shear strength. In this work, a similar continuous feed-through deposition process was used to demonstrate passive sensing and energy harvesting by integrating ferroelectric microparticles on the surface of electrically nonconductive fibers. The sensing and energy harvesting capabilities were characterized by mechanically straining composite beams and measuring the power generated. The improvements in mechanical properties are shown through interlaminar shear strength tests. Therefore, this research aims to demonstrate a high throughput, commercially scalable approach to coat fibers with ferroelectric microparticles that enable passive sensing as well as improved mechanical performance when fabricated into a fiber-reinforced composite.

Bowland, Christopher↗