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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 487 records · Page 27

All sources NASA NTRS DOE OSTI

NASA NTRS2014

Recent Progress in Adjustable X-ray Optics for Astronomy

Two adjustable X-ray optics approaches are being developed for thin grazing incidence optics for astronomy. The first approach employs thin film piezoelectric material sputter deposited as a continuous layer on the back of thin, lightweight Wolter-I mirror segments. The piezoelectric material is used to correct mirror figure errors from fabrication, mounting/alignment, and any ground to orbit changes. The goal of this technology is to produce Wolter mirror segment pairs corrected to 0.5 arc sec image resolution. With the combination of high angular resolution and lightweight, this mirror technology is suitable for the Square Meter Arc Second Resolution Telescope for X-rays (SMART-X) mission concept.. The second approach makes use of electrostrictive adjusters and full shell nickel/cobalt electroplated replication mirrors. An array of radial adjusters is used to deform the full shells to correct the lowest order axial and azimuthal errors, improving imaging performance from the 10 - 15 arc sec level to ~ 5 arc sec. We report on recent developments in both technologies. In particular, we discuss the use of insitu strain gauges on the thin piezo film mirrors for use as feedback on piezoelectric adjuster functionality, including their use for on-orbit figure correction. We also report on the first tests of full shell nickel/cobalt mirror correction with radial adjusters.

Reid, Paul B.↗

NASA NTRS1984

Predicting Moisture Absorption in Composite Materials

Heat transport programs adaptable for absorption analysis. Lightweight sandwich panel specimen used for comparison of water absorption measurements with program predictions. In program model, moisture -- like heat in heat-transport problem moves through variety of materials and structures along complex paths.

Haines, J. R.↗

NASA NTRSDate not supplied

Polymer Aerogels for Lunar Survivability (PALS)

As the Space Community endeavors to reach new heights of exploration, materials for extreme environment are on the forefront of research. One such material would include polymer aerogels; lightweight solids with nano-scale pore size (10-20 nm), high internal surface area (500-850 m2/g), low thermal conductivity (~20 mW/K), low density ( 0.15-0.05 g/cm3) and extremely high porosities (>95%). Due to these interesting properties, aerogels are ideal as thermal insulators and are by no means limited to this application. The high porosity combined with high surface area, make aerogels an ideal host system for particle incorporation for applications such as IR filtration, sensor platforms, as well as vibro-acoustic, dust, and radiation mitigation materials.

Stephanie Vivod↗

DOE OSTI2024

Parameter extraction approaches for compact modeling of thermoelectric modules

Thermoelectric (TE) cooling has experienced rapid advancements with the foundational understanding of TE materials. TE modules, compact and lightweight devices, have become the prevalent approach for implementing TE technologies. Accurately quantifying TE physical parameters (Seebeck coefficient α, thermal conductivity κ, and thermal resistance ρ) is challenging due to the dynamic temperature changes in operation. Furthermore, extracting lumped property parameters is crucial for designing energy systems using TE modules. Existing research has several limitations, such as lack of comparative analysis between prevalent formulae, reliance on potentially inaccurate vendor-supplied data, disregard for fundamental assumptions, and absence of empirical measurements. Further, this study addresses these gaps by conducting TE material characterization, comparing three existing formulae using vendor datasheets, designing a laboratory test facility for model validation and refinement, and outlining a structured data extraction procedure. The study's novelty lies in multiple key contributions: (1) a detailed comparative analysis of existing formulae for extracting TE property parameter; (2) executing experimental work in a laboratory setting to validate the model and elucidate its limitations; (3) highlighting potential risks; (4) clarifying possible assumptions from both material and engineering perspectives; and (5) considering temperature differential impacts. This comprehensive approach addresses the current research gaps and provides valuable insights into the design and application of TE modules in various energy systems.

36 MATERIALS SCIENCE↗

NASA NTRS1980

Graphite composite truss welding and cap section forming subsystems. Volume 2: Program results

The technology required to develop a beam builder which automatically fabricates long, continuous, lightweight, triangular truss members in space from graphite/thermoplastics composite materials is described. Objectives are: (1) continue the development of forming and welding methods for graphite/thermoplastic (GR/TP) composite material; (2) continue GR/TP materials technology development; and (3) fabricate and structurally test a lightweight truss segment.

Source record↗

DOE OSTI2026

Structural and Mechanical Analysis of Individual Mineralized Collagen Fibrils Using In Situ Transmission Electron Microscopy

Bone serves as an example of nature’s architectured material with its characteristic blend of strength and toughness, all at a lightweight design. Given the hierarchical nature of these materials, it is essential to understand the governing mechanisms and organization of their constituents across length scales for bioinspired structural design. Despite recent advances in transmission electron microscopy (TEM) that have allowed us to witness the hierarchical arrangement of bone at micro-down to the nanoscale, we are still missing the details about the structural organization and mechanical properties of the main building blocks of bone─mineralized collagen fibrils (MCFs). Here, we present a method to extract individual MCFs from nature’s model material, mineralized turkey leg tendon, using a dropcasting procedure. By isolating the MCFs onto TEM supporting grids, we visualized the arrangement of organic and mineral phases within individual MCFs at the nanoscale. Using a four-dimensional scanning transmission electron microscopy (4D-STEM) approach, the orientation of individual mineral crystals within the MCFs was examined. Furthermore, we conducted in situ tensile experiments, revealing exceptional tensile strains of at least 8%, demonstrating the intricate relationship between structural organization and the mechanical behavior of MCFs. These insights into the ultrastructure of mineralized tissue building blocks, as well as the proposed sample-extraction method compatible with in situ mechanical testing, provide a strong basis for research into nature-inspired material design.

4D-STEM↗

DOE OSTI2021

Lightweight, strong, moldable wood via cell wall engineering as a sustainable structural material

Turning wood into honeycombs Wood is an attractive material for structural applications, but it usually works best as boards or sheets. Xiao et al . have developed a process for engineering hardwood that allows these sheets to be manipulated into complex structures (see the Perspective by Tajvidi and Gardner). The key is to manipulate the cell wall structure by shrinking and blasting open the fibers and vessels by drying and “water-shocking” them. This process creates a window wherein the wood can be manipulated without ripping or tearing. Honeycomb, corrugated, or other complex structures are locked in once the wood dries. —BG

Science & Technology - Other Topics↗

NASA NTRS1999

Mechanical Behavior of Fabric-Film Laminates

Inflatable structures are gaining wide support in planetary scientific missions as well as commercial applications. For such applications a new class of materials made of laminating thin homogenous films to lightweight fabrics are being considered us structura1 gas envelops. The emerging composite materials are a result of recent advances in the manufacturing cf 1ightweight, high strength fibers, fabrics and scrims. The lamination of these load-carrying members with the proper gas barrier film results in wide range of materials suitable for various loading and environmental conditions. Polyester - based woven fabrics laminated to thin homogeneus film of polyester (Maylar) is an example of this class. This fabric/ film laminate is being considered for the development a material suitable for building large gas envelopes for use in the NASA Ultra Long Duration Balloon Program (ULDB). Compared to commercial homogeneus films, the material provides relatively high strength to weight ratio as well as better resistance to crack and tear propagation. The purpose of this papers is to introduce the mechanical behavior of this class of multi-layers composite and to highlight some of the concerns observed during the characterization of these laminate composites.

Said, Magdi S.↗

NASA NTRS2009

Machined Titanium Heat-Pipe Wick Structure

Wick structures fabricated by machining of titanium porous material are essential components of lightweight titanium/ water heat pipes of a type now being developed for operation at temperatures up to 530 K in high-radiation environments. In the fabrication of some prior heat pipes, wicks have been made by extruding axial grooves into aluminum unfortunately, titanium cannot be extruded. In the fabrication of some other prior heat pipes, wicks have been made by in-situ sintering of metal powders shaped by the use of forming mandrels that are subsequently removed, but in the specific application that gave rise to the present fabrication method, the required dimensions and shapes of the heat-pipe structures would make it very difficult if not impossible to remove the mandrels due to the length and the small diameter. In the present method, a wick is made from one or more sections that are fabricated separately and assembled outside the tube that constitutes the outer heat pipe wall. The starting wick material is a slab of porous titanium material. This material is machined in its original flat configuration to form axial grooves. In addition, interlocking features are machined at the mating ends of short wick sections that are to be assembled to make a full-length continuous wick structure. Once the sections have been thus assembled, the resulting full-length flat wick structure is rolled into a cylindrical shape and inserted in the heatpipe tube (see figure). This wick-structure fabrication method is not limited to titanium/water heat pipes: It could be extended to other heat pipe materials and working fluids in which the wicks could be made from materials that could be pre-formed into porous slabs.

Rosenfeld, John H.↗

NASA NTRS2019

Additive Manufacturing of Multi-Material Systems for Aerospace Applications

Additive manufacturing methods for producing single materials are rapidly improving. The resulting material properties and microstructures are becoming more comparable to those of conventionally fabricated materials. However, the need for multi-functional and complex structures and components requires additional innovations in manufacturing such as multi-material and hybrid additive manufacturing approaches. Additive manufacturing machines with multiple print capabilities and combinations of AM, machining, and conventional processing methods will further open up design spaces and possibilities. In this presentation, several examples of the needs and methods for multi-material fabrication will be discussed with a focus on aerospace applications. Direct printing of silver coils in conjunction with fused deposition modeling, machined parts, and, binder jetting is being developed for innovative stator designs. Binder jetting of silicon-based materials with powder bed additions is being developed for heat exchanger applications. Additive manufacturing of bi-material systems is being pursued to fabricate lightweight, integrated, multifunctional structures.

multi-materials↗

NASA NTRS2009

Polyimide/Glass Composite High-Temperature Insulation

Lightweight composites of RP46 polyimide and glass fibers have been found to be useful as extraordinarily fire-resistant electrical-insulation materials. RP46 is a polyimide of the polymerization of monomeric reactants (PMR) type, developed by NASA Langley Research Center. RP46 has properties that make it attractive for use in electrical insulation at high temperatures. These properties include high-temperature resistance, low relative permittivity, low dissipation factor, outstanding mechanical properties, and excellent resistance to moisture and chemicals. Moreover, RP46 contains no halogen or other toxic materials and when burned it does not produce toxic fume or gaseous materials. The U. S. Navy has been seeking lightweight, high-temperature-resistant electrical-insulation materials in a program directed toward reducing fire hazards and weights in ship electrical systems. To satisfy the requirements of this program, an electrical-insulation material must withstand a 3-hour gas-flame test at 1,600 F (about 871 C). Prior to the development reported here, RP46 was rated for use at temperatures from -150 to +700 F (about -101 to 371 C), and no polymeric product - not even RP46 - was expected to withstand the Navy 3-hour gas-flame test.

Pater, Ruth H.↗

DOE OSTI2023

A novel additive manufacturing compression overmolding process for hybrid metal polymer composite structures

Metal polymer composites combining low density, high strength composites with highly ductile and tough metals have gained traction over the last few decades as lightweight and high-performance materials for industrial applications. However, the mechanical properties are limited by the interfacial bonding strength between metals and polymers achieved through adhesives, welding, and surface treatment processes. In this paper, a novel manufacturing process combining additive manufacturing and compression molding to obtain hybrid metal polymer composites with enhanced mechanical properties is presented. Additive manufacturing enabled deposition of polymeric material with fibers in a predetermined pattern to form tailored charge or preform for compression molding. Here, a grade 300 maraging steel triangular lattice is first fabricated using AddUp FormUp350 laser powder bed system and compression overmolded with additively manufactured long carbon fiber-reinforced polyamide-6,6 (40% wt. CF/PA66) preform. The fabricated hybrid metal polymer composites showed high stiffness and tensile strength. The stiffness and failure characteristics determined from the uniaxial tensile tests were correlated to a finite element model within 20% deviation. Fractographic analyses was performed using microscopy to investigate failure mechanisms of the hybrid structures.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Fabrication of flexible perovskite solar cells via rapid thermal annealing

Adaptability, lightweight, and low cost of materials make flexible perovskite solar cells essential for the perovskite technology to breach commercial photovoltaic markets. Roll-to-roll manufacturing has great potential for high-throughput perovskite manufacturing; however, conventional annealing methods are not capable of producing flexible perovskite solar cells at scale. Conventional methods are time consuming and may compromise functionality of flexible substrates under tension. Here, we introduce a bladecoated perovskite thin film on flexible ITO-coated PET annealed via rapid thermal annealing (RTA) that reduces post-deposition processing time from ~150 s to ~14 s. As a result, performance was not sacrificed for scalability as a perovskite solar cell was produced with a power conversion efficiency (PCE) of 14.58%.

14 SOLAR ENERGY↗

DOE OSTI2020

Thermal Activation of a Copper-Loaded Covalent Organic Framework for Near-Ambient Temperature Hydrogen Storage and Delivery

Copper(II) formate is efficiently incorporated into the pores of a 2D imine-based covalent organic framework (COF) via coordination with the phenol and imine groups. The coordinated metal ion is then reduced to Cu(I) with a thermal treatment that evolves CO 2 . After loading with hydrogen gas, the majority of H 2 desorbs from the coordinatively saturated Cu(II) COF at temperatures < -100 degrees C. However, the activated Cu(I) COF retains adsorbed H 2 above room temperature. Adsorption/desorption of H 2 was highly reversible. Diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) strongly supports a molecular hydrogen interaction with Cu(I). A Kissinger analysis of variable ramp rate desorption experiments estimates the enthalpy of H 2 desorption from Cu(I) at 15 kJ mol -1 . The results represent an advance toward practical H 2 storage and delivery in a lightweight, stable, and highly versatile material.

08 HYDROGEN↗

DOE OSTI2024

Epoxy Coating of Biofiber: An Effective Modifier of Biofiber Physical and Flow Properties for Improved Tensile Behavior of Biofiber-Reinforced Biocomposite

Biocomposites combine renewable, plant-based fibers with degradable polymers and are an attractive option for sustainable, lightweight, and cost-effective materials with a low carbon footprint, especially for large-scale additive manufacturing. One of the major challenges in the widespread adoption of biocomposites is that their mechanical performance is significantly inferior to that of synthetic composites. Surface treatment is a common and effective technique to improve the mechanical properties of the biofibers used in biocomposites. This study aims to investigate the physical and flow properties of surface-treated biofibers, as well as the tensile properties of their PLA-based biocomposite, to gain insights into how surface treatment changes the fiber‘s characteristics and biocomposite‘s mechanical properties. Surface treatment was created using a two-component epoxy system by reacting poly(bisphenol A-co-epichlorohydrin) glycidyl end-capped (PBG) and dicyandiamide (DICY). The treatment was tested on two different biofibers (loblolly pine and corn stover fibers) with three different PBG/DICY molar ratios (0.25, 0.5, and 2). Results showed that surface-treated fibers improved the tensile strength and Young‘s modulus of the biocomposites. Loblolly pine biocomposites from fibers treated with a PBG/DICY ratio of 0.25 exhibited the best tensile properties. The surface treatment resulted in a more loosely dispersed fiber bulk structure, as evidenced by less fiber agglomeration into smaller particle sizes, higher fiber sphericity, and lower loose bulk density. This can enhance stress distribution and the overall mechanical performance of the biocomposites. Additionally, surface-treated fibers exhibited better dynamic flow properties.

36 MATERIALS SCIENCE↗

NASA NTRS1972

NERVA turbopump bearing retainer fabrication on nonmetallic retainer

The need for a low-wear, lightweight, high strength bearing retainer material with a radiation degradation threshold of 10 to the 9th power rads (C) prompted development of nonmetallic reinforced polymers of the following types: (1) polybenzimidazole, (2) polyimide, and (3) polyquinoxaline. Retainers were machined from tubular laminates (billets), including reinforcement by either glass or graphite fabric or filament. Fabrication of billets involves hot preimpregnation of the reinforcement fabric or filament with polymer followed by wrapping this prepreg over a heated mandrel to form a tube with the required thickness and length.

Accinelli, J. B.↗

NASA NTRS1981

A new family of fire-resistant foams

Need for lightweight flame-resistant, nonsmoking materials in interiors of spacecraft has spawned family of foams that could find applications in aircraft and other vehicles. Polyimide-based foams are being developed as resilient fillers for seat cushions, as rigid, low-density wall panels, as high-strength sheets for floors, and as thermal and acoustical insulation.

Gagliani, J.↗

NASA NTRS1984

Low-Shock Pyrotechnic Actuator

Miniature 1-ampere, 1-watt pyrotechnic actuator enclosed in flexible metal bellows. Bellows confines outgassing products, and pyrotechnic shock reduction achieved by action of bellows, gas cushion within device, and minimum use of pyrotechnic material. Actuator inexpensive, compact, and lightweight.

Lucy, M. H.↗