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At least 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Environmentally Friendly Use of Carbon Ore for Advanced Building Materials for Homes and Commercial Buildings

Through this effort, X-MAT CCC sought to confirm the utility and commercialization potential of carbon-derived building materials (CDBM) technology licensed from our partner, Semplastics. These CDBM products contain at least 52% coal-derived carbon by mass. Including the binders within the resin, the products contain at least 71% carbon by mass overall, meeting a key criterion for DE-FOA-0002185 – Area of Interest (AOI) 5 – Design Research and Development, Validation, and Fabrication of a Prototype Carbon-Based Building. The Phase II project has resulted in a technology demonstrator prototype structure, a detailed design for a carbon-based building, and updated techno-economic analysis (TEA) including detailed market surveys to show the commercial viability of CDBM products. We pursued the following objectives in Phase II: (1) construction of a partial building shell as a technology demonstrator, (2) testing of CDBM products, individually and in assemblies, (3) demonstration of bonding of CDBM and traditional building materials (TBM) in structural applications, (4) production of a detailed design for a carbon-based building, and (5) an update of the TEA that was performed in Phase I. In Phase II, X-MAT CCC and our industry team performed the development and testing needed to improve the maturity of the technology from a Technology Readiness Level (TRL) of 5 to TRL 6. CDBM have been shown by our partner Semplastics to exhibit a number of high-performance characteristics, including high strength (five times the flexure strength of the best commercial brick, and more than twice the compressive strength of construction-grade concrete block), lower density, improved mechanical durability and abrasion resistance, very high temperature stability, and resistance to chemicals, acids, salts, and water. These properties offer significant improvements over conventional building materials. Phase II built upon the work accomplished in Phase I by performing technical and economic research and development to confirm the viability of CDBM as commercial products in various markets. Acknowledgment: This material is based upon work supported by the Department of Energy under Award Number DE-FE0031985.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS2012

Use of Statistical Analysis of Acoustic Emission Data on Carbon-Epoxy COPV Materials-of-Construction for Enhanced Felicity Ratio Onset Determination

Broadband modal acoustic emission (AE) data were acquired during intermittent load hold tensile test profiles on Toray T1000G carbon fiber-reinforced epoxy (C/Ep) single tow specimens. A novel trend seeking statistical method to determine the onset of significant AE was developed, resulting in more linear decreases in the Felicity ratio (FR) with load, potentially leading to more accurate failure prediction. The method developed uses an exponentially weighted moving average (EWMA) control chart. Comparison of the EWMA with previously used FR onset methods, namely the discrete (n), mean (n (raised bar)), normalized (n%) and normalized mean (n(raised bar)%) methods, revealed the EWMA method yields more consistently linear FR versus load relationships between specimens. Other findings include a correlation between AE data richness and FR linearity based on the FR methods discussed in this paper, and evidence of premature failure at lower than expected loads. Application of the EWMA method should be extended to other composite materials and, eventually, composite components such as composite overwrapped pressure vessels. Furthermore, future experiments should attempt to uncover the factors responsible for infant mortality in C/Ep strands.

Abraham, Arick Reed A.↗
DOE OSTI2024

Reactive Carbon Capture: Cooperative and Bifunctional Adsorbent-Catalyst Materials and Process Integration for a New Carbon Economy

To say the least, releasing CO 2 into the atmosphere is reaping undue environmental consequences given the ever-present increase in severe global weather events over the past five years. However, it can be argued that–at least in the confines of current technological capabilities–the atmospheric release of CO 2 is somewhat unavoidable given that even shifting toward clean energy sources–such as solar, nuclear, wind, battery, or H 2 power–incurs an initial carbon requirement by way of manufacturing the very production abilities through which “clean” energy is generated. Even years from now, experts agree that energy production will be diversified and–as the global population continues to drive the growth of global energy consumption–thermal power derived from carbon combustion is likely to remain one intrinsic energetic source, of which CO 2 will always be a byproduct. In this context, it is the responsibility of the scientific community to devise improved pathways of carbon management such that (i) the consequences of combustion on the global environment are reduced and (ii) carbon fuels can be leveraged in a sustainable fashion. In this Account, we discuss a pivotal perspective shift on CO 2 emissions derived from a considerable breakthrough in material science from our work on shape engineering of nanoporous adsorbents and catalysts. This account details the development of materials which no longer vilify CO 2 emissions as a valueless combustion byproduct, instead providing a path for them to become a potential feedstock. In more specific terms, this work details the development of structured, cooperative “bifunctional” materials (BFMs) comprised of (i) a high-temperature adsorbent and (ii) a heterogeneous catalyst that enable single-bed CO 2 capture and utilization in oxidative ethane dehydrogenation (ODHE), oxidative propane dehydrogenation (ODHP), and dry methane reforming (DMR) processes. This Account begins with the conceptual development of the BFMs in the powdered state, followed by detailing the first-ever reports of structuring the materials into facile honeycomb contactors by 3D printing. The Account then summarizes the impressive performance of the 3D-printed BFMs, specifically focusing on how their catalysts (metal oxides and perovskites) influence their reactive CO 2 capture performances in ODHE, ODHP, and DMR processes. Such promise of CO 2 -as-fuel offers a glimpse into the future of a diversified energy economy, in which CO 2 /fuel looping can play an important role. A major factor in achieving this future is, of course, developing an appropriately active catalyst; an account of whose first breakthroughs in material science are detailed herein.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1981

Experimental determination of ablation vapor species from carbon phenolic heat-shield materials

The relative concentrations of vapors produced from carbon phenolic composites under thermal loadings approximating those expected at peak heating during vehicle entry into the atmospheres of the outer planets have been determined. The technique of vaporizing the surface of bulk samples by laser irradiation while measuring in situ the vapor species by mass spectrometry is described. Results show that vapor composition varies with irradiance level and with depth of heating (or extent of pyrolysis). Attempts are made to compare these experimental results with the theoretical predictions from computer codes.

Lincoln, K. A.↗
DOE OSTI2023

Tailoring biogenic straw insulation from additive manufacturing

In the pursuit of carbon-storing materials that could help accomplish high levels of building sustainability, wheat straw has emerged as a promising alternative to fossil fuel-based building materials. Straw is 100% biodegradable and abundant agricultural waste used in the construction 400 years ago, and it has been reported to have the lowest embodied carbon when measured against other typical insulating materials. Here, in this study, we report additive manufacturing of carbon-sequestration insulation panel materials by upcycling cellulose fibrils from wheat straw. Cellulose obtained from alkaline and 2,2,6,6-tetramethylpiperidine-1-oxyl radical-mediated oxidation shows thermal conductivity of 0.036 W m -1 K -1 , alongside elastic and flexural modulus of 900 MPa and 502 MPa, respectively. In addition, an in-situ hydrophobic treatment in the cellulose-based insulation panels is achieved with an average water contact angle of 133.7° Furthermore, the extrusion-based additive manufacturing of a 3D-printable ink obtained by mixing the cellulose and silica aerogel precursor is accomplished, with the printed material exhibiting structural integrity, thus showing great potential towards the development of state-of-the-art, sustainable materials for carbon-sequestration building applications.

36 MATERIALS SCIENCE↗
NASA NTRS1974

Raw Liquid Waste Treatment System and Process

A raw sewage treatment process is disclosed in which substantially all the non-dissolved matter, suspended in the sewage water is first separated from the water, in which at least organic matter remains dissolved. The non-dissolved material is pyrolyzed to form an activated carbon and ash material without the addition of any conditioning agents. The activated carbon and ash material is added to the water from which the non-dissolved matter was removed. The activated carbon and ash material adsorbs the organic matter dissolved in the water and is thereafter supplied in a counter flow direction and combined with the incoming raw sewage to at least facilitate the separation of the non-dissolved settleable materials from the sewage water. Carbon and ash material together with the non-dissolved matter which was separated from the sewage water are pyrolyzed to form the activated carbon and ash material.

Humphrey, M. F.↗
DOE OSTI2024

Carbon Management with Advanced Materials: An Assessment of Experimental and Computational Capabilities at the University of California-Riverside

The major goals of this project were to conduct an R&D scoping study and self-assessment to evaluate how the current capabilities, expertise, personnel, and facilities/equipment of UC Riverside (UCR) align with Fossil Energy and Carbon Management (FECM) objectives. This scoping study particularly focused on the Materials Science & Engineering program since it encompasses faculty from nearly all the engineering and science departments in UCR with expertise in experimental and computational areas of potential interest to FECM. In addition, this assessment identified gaps in capabilities and provided a discussion on what would enable UCR to be better prepared for potential future competitive solicitations focused on FECM-supported technologies.

36 MATERIALS SCIENCE↗
NASA NTRS1980

Raw liquid waste treatment process

A raw sewage treatment process is disclosed in which substantially all the non-dissolved matter, which is suspended in the sewage water is first separated from the water, in which at least organic matter is dissolved. The non-dissolved material is pyrolyzed to form an activated carbon and ash material without the addition of any conditioning agents. The activated carbon and ash material is added to the water from which the non-dissolved matter was removed. The activated carbon and ash material absorbs organic matter and heavy metal ions, it is believed, are dissolved in the water and is thereafter supplied in a counter current flow direction and combined with the incoming raw sewage to facilitate the separation of the non-dissolved settleable materials from the sewage water. The used carbon and ash material together with the non-dissolved matter which was separated from the sewage water are pyrolyzed to form the activated carbon and ash material.

Humphrey, Marshall F.↗
NASA NTRS2012

Overview of C/C-SiC Composite Development for the Orion Launch Abort System

Past and present efforts by the authors to further understanding of the ceramic matrix composite (CMC) material used in the valve components of the Orion Launch Abort System (LAS) Attitude Control Motor (ACM) will be presented. The LAS is designed to quickly lift the Orion Crew Exploration Vehicle (CEV) away from its launch vehicle in emergency abort scenarios. The ACM is a solid rocket motor which utilizes eight throttleable nozzles to maintain proper orientation of the CEV during abort operations. Launch abort systems have not been available for use by NASA on manned launches since the last Apollo ]Saturn launch in 1975. The CMC material, carbon-carbon/silicon-carbide (C/C-SiC), is manufactured by Fiber Materials, Inc. and consists of a rigid 4-directional carbon-fiber tow weave reinforced with a mixed carbon plus SiC matrix. Several valve and full system (8-valve) static motor tests have been conducted by the motor vendor. The culmination of these tests was the successful flight test of the Orion LAS Pad Abort One (PA ]1) vehicle on May 6, 2010. Due to the fast pace of the LAS development program, NASA Marshall Space Flight Center assisted the LAS community by performing a series of material and component evaluations using fired hardware from valve and full ]system development motor tests, and from the PA-1 flight ACM motor. Information will be presented on the structure of the C/C-SiC material, as well as the efficacy of various non ]destructive evaluation (NDE) techniques, including but not limited to: radiography, computed tomography, nanofocus computed tomography, and X-ray transmission microscopy. Examinations of the microstructure of the material via scanning electron microscopy and energy dispersive spectroscopy will also be discussed. The findings resulting from the subject effort are assisting the LAS Project in risk assessments and in possible modifications to the final ACM operational design.

Allen, Lee R.↗
NASA NTRS1989

Damage-tolerant composite materials produced by stitching carbon fibers

NASA-Langley has undertaken the investigation of composite damage-tolerance enhancement and fabrication economies-maximization via reinforcement-stitching, in combination with resin transfer molding. Attention is given to results obtained by an experimental evaluation of composites tailored for damage tolerance by stitching layers of dry carbon-fiber fabric with closely-spaced threads, in order to furnish through-the-thickness reinforcement. Various stitching patterns and thread materials have been evaluated, using flat-plate specimens; blade-stiffened structural elements have been fabricated and tested. The results presented indicate that stitched laminates furnish damage tolerance performance comparable to that of more expensive, toughened-matrix composites.

Dow, Marvin B.↗
NASA NTRS1998

Carbon-Carbon Turbocharger Housing Unit for Intermittent Combustion Engines

An improved, lightweight, turbine housing unit for an intermittent combustion reciprocating internal combustion engine turbocharger is prepared from a lay-up or molding of carbon-carbon composite materials in a single-piece or two-piece process. When compared to conventional steel or cast iron, the use of carbon-carbon composite materials in a turbine housing unit reduces the overall weight of the engine and reduces the heat energy loss used in the turbocharging process. This reduction in heat energy loss and weight reduction provides for more efficient engine operation.

Northam, G. Burton↗
NASA NTRS1999

Process for Making Carbon-Carbon Turbocharger Housing Unit for Intermittent Combustion Engines

An improved. lightweight, turbine housing unit for an intermittent combustion reciprocating internal combustion engine turbocharger is prepared from a lay-up or molding of carbon-carbon composite materials in a single-piece or two-piece process. When compared to conventional steel or cast iron, the use of carbon-carbon composite materials in a turbine housing unit reduces the overall weight of the engine and reduces the heat energy loss used in the turbo-charging process. This reduction in heat energy loss and weight reduction provides for more efficient engine operation.

Northam, G. Burton↗
DOE OSTI2023

Effect of tension during sulfonation stabilization for UHMWPE-derived carbon fibers

Polyethylene is a promising low-cost alternative precursor material for carbon fiber production, but it has yet to show mechanical properties near or surpassing polyacrylonitrile-derived carbon fibers. The high molecular weight and order of ultra-high molecular weight polyethylene (UHMWPE) may offer a pathway to realizing this promise by enabling long-range graphitic structure formation and superior mechanical properties. The tension applied during the precursor stabilization process is crucial to maintaining the shape of the fibers during the conversion process, but no published study has yet probed the relationship between sulfonation tension and carbon fiber microstructure and mechanical properties. In this work, a logarithmic sweep of tensile stress was applied to UHMWPE fibers during the stabilization process followed by carbonization. Increasing tension significantly reduced fiber shrinkage, resulted in straighter fibers with less severe kink bands, and greatly improved the mechanical properties of the fibers. Raman spectroscopy and X-ray diffraction revealed that in all cases the carbon fibers were largely amorphous, but increasing tension resulted in increased size and alignment of the turbostratic crystallites with the fiber axis. Large voids were present in the sample fibers, so the Griffith-Irwin relation was employed to predict the potential ultimate tensile strength of the fibers with voids reduced to sizes comparable to commercially produced fibers. Furthermore, this work demonstrates the importance of tension applied during the stabilization of polyethylene fibers for carbon fiber production and establishes a framework for achieving high mechanical properties from these precursors.

36 MATERIALS SCIENCE↗
NASA NTRS1978

High-purity silicon for solar cell applications

The article discusses the production of solar cells from high-purity silicon. The process consists of reducing the level of impurities in the raw materials, preventing material contamination before and after entering the furnace, and performing orders-of-magnitude reduction of metal impurity concentrations. The high-purity raw materials are considered with reference to carbon reductants, silica, and graphite electrodes. Attention is also given to smelting experiments used to demonstrate, in an experimental-scale furnace, the production of high-purity SoG-Si. It is found that high-purity silicon may be produced from high-purity quartz and chemically purified charcoal in a 50-kVA arc furnace. The major contamination source is shown to be impurities from the carbon reducing materials.

Dosaj, V. D.↗
NASA NTRS2010

Experimental Constraints on the Stability of Clinopyroxene (+) Magnesite in Iron Bearing Planetary Mantles: Implications for Nakhlite Formation

Carbon is present in various forms in the Earth s upper mantle (carbonate- or diamond-bearing mantle xenoliths, carbonatite magmas, CO2 emissions from volcanoes...). Moreover, there is enough carbon in chondritic material to stabilize carbonates into the mantles of Mars or Venus as well as in the Earth. However, the interactions with iron have to be constrained, because Fe is commonly thought to buffer oxygen fugacity into planetary mantles. [1] and [2] show evidences of the stability of clinopyroxene Ca(Mg,Fe)Si2O6 + magnesite (Mg,Fe)CO3 in the Earth s mantle around 6GPa (about 180km). The stability of oxidized forms of carbon (like magnesite) depends on the oxygen fugacity of the system. In the Earth s mantle, the maximum carbon content is 10000 ppm [3]. The fO2 parameter varies vertically as a function of pressure, but also laterally because of geodynamic processes like subduction. Thus, carbonates, graphite, diamond, C-rich gases and melts are all stable forms of carbon in the Earth s mantle. [4] show that the fO2 variations observed in SNC meteorites can be explained by polybaric graphite-CO-CO2 equilibria in the Martian mantle. [5] inferred from thermodynamic calculations that the stable form of carbon in the source regions of the Martian basalts should be graphite (and/or diamond). After [6], a metasomatizing agent like a CO2-rich melt may infiltrate the mantle source of nakhlites. However, according to [7] and [8], the FeO wt% value in the Martian bulk mantle is more than twice that of the Earth s mantle (KLB-1 composition by [9]). As iron and carbon are two elements with various oxidation states, Fe/C interaction mechanisms must be considered.

Martin, Audrey M.↗
DOE OSTI2021

A scalable metal-organic framework as a durable physisorbent for carbon dioxide capture

A hydrophobic CO 2 physisorbent Most materials for carbon dioxide (CO 2 ) capture of fossil fuel combustion, such as amines, rely on strong chemisorption interactions that are highly selective but can incur a large energy penalty to release CO 2 . Lin et al . show that a zinc-based metal organic framework material can physisorb CO 2 and incurs a lower regeneration penalty. Its binding site at the center of the pores precludes the formation of hydrogen-bonding networks between water molecules. This durable material can preferentially adsorb CO2 at 40% relative humidity and maintains its performance under flue gas conditions of 150°C. —PDS

Science & Technology - Other Topics↗
DOE OSTI2025

Spatial distribution of sp 3 defects in carbon fibers via time-of-flight secondary ion mass spectrometry

Defects play a significant role in the material properties of carbon fibers (CF). Several defects result in the formation of sp 3 bonds in an otherwise sp 2 -dominant graphitic structure. Understanding the distribution of these defects within CF provides insight into their properties and the effect of manufacturing conditions. Reports showed time-of-flight secondary ion mass spectrometry (ToF-SIMS) is capable of characterizing the spatial distribution of sp 2 and sp 3 content in carbon materials. Here, ToF-SIMS was utilized to investigate the spatial distribution of sp 3 defects in T700, T1000, and M46 CF. M46 had the lowest sp 3 content. Center-to-edge analysis revealed that T700 CF had a gradient of sp 3 defects starting from the center and increasing to the edge, whereas M46 CF had a sudden increase in sp 3 defects roughly 1 μm from the edge. Comparatively, T1000 CF had a relatively uniform radial distribution of sp 3 defects, except for a newly identified sp 2 rich region at 0.8 μm from the center. This is hypothesized to originate from a skin–core structure that forms during CF manufacturing. As a result, this work demonstrates the utility of ToF-SIMS for characterizing the spatial distribution of sp 3 defects within CF, establishing new ways to understand CF formation.

Carbon fibers↗