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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 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

LightMAT: Continous Fiber Malleable Thermoset Composites with sub-1-minute dwell times; validation of impact performance and evaluation of the efficacy of the compression forming process

Recent major advances in polymer chemistry are enabling a paradigm shift in the area of processing and re-processing/recycling of advanced composite materials. Inexpensive compression molding with short cycle times, traditionally available for thermoplastic composites only, are now possible for the thermoset resins based on polyimine chemistry. Participant will collaborate with the LightMAT consortium Labs ORNL, SNL, and PNNL to non-destructively characterize microscopic structural defects (such as voids and resin-rich areas), and perform high speed impact characterization of its malleable thermoset CFRP's. This work is critical to the validation and adoption of these materials for the automotive market and towards DOE-VTO lightweighting mission objectives.

36 MATERIALS SCIENCE↗
NASA NTRS2017

Modeling the Extremely Lightweight Zerodur Mirror (ELZM) Thermal Soak Test

Exoplanet science requires extreme wavefront stability (10 pm change/10 minutes), so every source of wavefront error (WFE) must be characterized in detail. This work illustrates the testing and characterization process that will be used to determine how much surface figure error (SFE) is produced by mirror substrate materials' CTE distributions. Schott's extremely lightweight Zerodur mirror (ELZM) was polished to a sphere, mounted, and tested at Marshall Space Flight Center (MSFC) in the X-Ray and Cryogenic Test Facility (XRCF). The test transitioned the mirror's temperature from an isothermal state at 292K to isothermal states at 275K, 250K and 230K to isolate the effects of the mirror's CTE distribution. The SFE was measured interferometrically at each temperature state and finite element analysis (FEA) has been completed to assess the predictability of the change in the mirror's surface due to a change in the mirror's temperature. The coefficient of thermal expansion (CTE) distribution in the ELZM is unknown, so the analysis has been correlated to the test data. The correlation process requires finding the sensitivity of SFE to a given CTE distribution in the mirror. A novel hand calculation is proposed to use these sensitivities to estimate thermally induced SFE. The correlation process was successful and is documented in this paper. The CTE map that produces the measured SFE is in line with the measured data of typical boules of Schott's Zerodur glass.

Brooks, Thomas E.↗
DOE OSTI2023

Functionally Designed Ultra-Lightweight Carbon Fiber Reinforced Thermoplastic Composites Door Assembly (Final Scientific/Technical Report)

This is the final technical report for a project that developed an ultra-lightweight carbon fiber reinforced thermoplastics composite door assembly for a mid-size SUV. The project was able achieve a weight reduction of at least 42.5% while maintaining or exceeding the fit, function, safety, stiffness, and crash performance requirements of the current baseline door. Additionally, the target cost was set at less than $5 per pound of weight saved. To accomplish these goals, the project team employed a systems approach that involves redesigning the door assembly, exploring novel materials, optimizing the design, and utilizing advanced manufacturing technologies.

42 ENGINEERING↗
DOE OSTI2020

Tuning martensitic transformations via coherent second phases in nanolaminates using free energy landscape engineering

In this work we explore the possibilities and limitations of using a coherent second phase to engineer the thermo-mechanical properties of a martensitic alloy by modifying the underlying free energy landscape that controls the transformation. We use molecular dynamics simulations of a model atomistic system where the properties of a coherent, nanoscale second phase can be varied systematically. With a base martensitic material that undergoes a temperature-induced transformation from a cubic austenite to a monoclinic martensite, simulations show significant ability to engineer the transformation temperatures, from a ~50% reduction to a ~200% increase, with 50 at.% of the cubic second phase. We establish correlations between the properties of the second phase, the transformation characteristics, and the microstructure via the free energy landscape of the twophase systems. Coherency stresses have a strong influence on the martensitic variants observed and can even cause the non-martensitic second phase to undergo a transformation. Reducing the stiffness of the second phase increases the transformation strain and modifies the martensitic microstructure, increasing the volume fraction of the transformed material. This increase in transformation strain is accompanied by a significant increase in Af and thermal hysteresis, while Ms remains unaltered. Our findings on the tunability of martensitic transformations can be used for informed searches of second phases to achieve desired material properties, such as achieving room temperature, lightweight shape memory alloys.

36 MATERIALS SCIENCE↗
NASA NTRS1983

Metal matrix composite structural panel construction

Lightweight capped honeycomb stiffeners for use in fabricating metal or metal/matrix exterior structural panels on aerospace type vehicles and the process for fabricating same are disclosed. The stiffener stringers are formed in sheets, cut to the desired width and length and brazed in spaced relationship to a skin with the honeycomb material serving directly as the required lightweight stiffeners and not requiring separate metal encasement for the exposed honeycomb cells.

Mcwithey, R. R.↗
NASA NTRS2016

NIAC Phase I Study Final Report on Large Ultra-Lightweight Photonic Muscle Space Structures

The research goal is to develop new tools support NASA's mission of understanding of the Cosmos by developing cost effective solutions that yield a leap in performance and science data. 'Maikalani' in Hawaiian translates to, "knowledge we gain from the cosmos." Missions like Hubble have fundamentally changed humanity's view of the cosmos. Last year's Nobel prize in physics was a result of astronomical discoveries. $9B class JWST size (6.5 meter diameter) space telescopes, when launched are anticipated to rewrite our knowledge of physics. Here we report on a neoteric meta-material telescope mirror technology designed to enable a factor of 100 or more reduction in areal density, a factor of 100 reduction in telescope production and launch costs as well as other advantages; a leap to enable missions to image the cosmos in unprecedented detail, with the associated gain in knowledge. Whether terahertz, visible or X-ray, reflectors used for high quality electromagnetic imaging require shape accuracy (surface figure) to far better than 1 wavelength (lambda) of the incident photons, more typically lambda/10 or better. Imaging visible light therefore requires mirror surfaces that approximate a desired curve (e.g. a sphere or paraboloid) with smooth shape deviation of th less than approximately 1/1000 the diameter of a human hair. This requires either thick high modulus material like glass or metal, or actuators to control mirror shape. During Phase I our team studied a novel solution to this systems level design mass/shape tradespace requirement both to advance the innovative space technology concept and also to help NASA and other agencies meet current operational and future mission requirements. Extreme and revolutionary NASA imaging missions such as Terrestrial Planet Imager (TPI) require lightweight mirrors with minimum diameters of 20 to 40 meters. For reference, NASA's great achievement; the Hubble space telescope, is only 2.4 meters in diameter. What is required is a way to make large inexpensive deployable mirrors where the cost is measured in millions, not billions like current efforts. For example we seek an interim goal within 10 years of a Hubble size (2.4m) primary mirror weighing 1 pound at a cost of 10K in materials. Described here is a technology using thin ultra lightweight materials where shape can be controlled simply with a beam of light, allowing imaging with incredibly low mass yet precisely shaped mirrors. These " Photonic Muscle" substrates will eventually make precision control of giant s p a c e apertures (mirrors) possible. OCCAM substrates make precision control of giant ultra light-weight mirror apertures possible. This technology is posed to create a revolution in remote sensing by making large ultra lightweight space telescopes a fiscal and material reality over the next decade.

Cosmos↗
NASA NTRS2017

Relationship of Cure Temperature to Mechanical, Physical, and Dielectric Performance of PDMS Glass Composite for Electric Motor Insulation

Achieving NASAs aggressive fuel burn and emission reduction for N-plus-3 aircraft will require hybrid electric propulsion system in which electric motors driven by either power generated from turbine or energy storage system will power the fan for propulsion. Motors designed for hybrid electric aircraft are expected to operate at medium to high voltages over long durations in a high altitude service environment. Such conditions have driven research toward the development of wire insulation with improved mechanical strength, thermal stability and increased breakdown voltage. The silicone class of materials has been considered for electric wire insulation due to its inherent thermal stability, dielectric strength and mechanical integrity. This paper evaluates the dependence of these properties on the cure conditions of a polydimethyl-siloxane (PDMS) elastomer; where both cure temperature and base-to-catalyst ratio were varied. The PDMS elastomer was evaluated as a bulk material and an impregnation matrix within a lightweight glass veil support. The E-glass support was selected for mechanical stiffness and dielectric strength. This work has shown a correlation between cure conditions and material physical properties. Tensile strength increased with cure temperature whereas breakdown voltage tended to be independent of process variations. The results will be used to direct material formulation based on specific insulation requirements.

insulation↗
DOE OSTI2020

Top Loading Helium Cryostat Integrated with High-Pressure Cell with Fast Remote Pressure Control (Final Report for SBIR Phase 1)

A large number of physical phenomena, such as superconductivity and quantum critical phenomena, often appear only at very low temperatures below 5 K. There is an immense interest to investigate these phenomena at high pressure as a means of tuning interatomic distances, and thus the interaction parameters controlling these phenomena, in a continuous and controlled fashion. The current P-T condition for neutron scattering experiments are limited to either relatively low pressures of about 2 GPa at temperatures below 5 K, or to relatively high temperatures at pressures or tens of GPa. The purpose of this research is to develop neutron sample environment instrumentation for reaching 10-20 GPa at 1-2K with rapid and reliable online pressure and temperature control (i.e. without having to interrupt the experiment). The ultimate goal of the project is to design an integrated fast-cooling low-temperature sample environment cryogenic system compatible with state of the art neutron diamond anvil cells suitable for single-crystal neutron scattering experiments for temperatures down to 2K and pressures of several tens of GPa. The integrated system will consist of top-loading Helium flow cryostat with in-situ sample alignment mechanisms, large-volume diamond anvil cells (DAC) made from novel superalloy Pascalloy and optimized for fast cooling and heating, and a compact remote pressure control mechanism for the DAC based on a novel concept of inflatable bellows integrated with a lever-arm based force amplifier. In Phase I, we have designed, manufactured, and tested prototypes of the novel compact force-amplified pneumatic pressure control mechanism for Neutron Diamond Anvil Cell (nDAC), which allows to use pneumatic bellows system for smooth remote pressure control in the nDAC inside a top-loading cryostat with bore size of 70 mm or larger. This allows significant minimum temperature decrease in remotely controlled nDAC from 5-10 K down to 2 K. We also studied mechanical properties of a novel non-magnetic superalloy Pascalloy with different heat-treatment conditions and preliminary results indicate that up to date this is probably the strongest and most suitable material for making more compact and lightweight cryogenic nDACs for neuron scattering experiments at extreme conditions, allowing much faster cooling and heating. Potential applications: The new developments will allow to create a wide range of compact Diamond Anvil Cells for neutron diffraction which can reach several tens of GPA pressure at 2-4 K while preserving accurate remote pressure control capabilities. The new concepts can be used for developing sample environment instrumentation outside the neutron scattering field. The new development have very strong potential for expanding experimental capabilities in materials sciences and have high commercialization potential. The proposed new cryogenic high-pressure system or any of its individual components will be in high demand not only in neutron scattering facilities, but also at synchrotron beamlines and other high-pressure research facilities around the world.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Excellent antioxidizing, thermally insulating and flame resistance silica‐polybenzoxazine aerogels for aircraft ablative materials

Abstract High‐performance thermal protective composites with lightweight, micro‐ ablation and high‐efficient thermal insulation are urgently required for thermal protection systems in advanced hypersonic speed vehicles. However, the practical applications of thermal protective composites have long been hampered by the main issues such as low mass residual rate and poor long‐term antioxidation of the matrix in high‐temperature aerobic environments. Here, we report a novel silica‐polybenz oxazine (SiO 2 ‐PBO) aerogels with interpenetrated networks, possessing the ability to antioxidation, thermal insulation, and flame‐retardant properties. The resulting SiO 2 ‐PBO aerogels exhibit low density (0.25 g/cm 3 ), low thermal conductivity (0.035 W/(m·K)), and superior peak heat release rate value (15.3 W/g). Moreover, the mass residual rate is up to 70.46 wt% in the N 2 atmosphere and remains 57.83 wt% despite existing in the air atmosphere and experiencing the highest temperature of 800°C. Briefly, SiO 2 ‐PBO aerogels as‐prepared could be a potential matrix for a new gene ration of high‐performance thermal protective composites in the future.

Xiao, Yunyun↗
DOE OSTI2022

Extreme hardness at high temperature with a lightweight additively manufactured multi-principal element superalloy

Materials are needed that can tolerate increasingly harsh environments, especially ones that retain high strength at extreme temperatures. Higher melting temperature alloys, like those consisting primarily of refractory elements, can greatly increase the efficiency of turbomachinery used in grid electricity production worldwide. Existing alloys, including Ni- and Co-based superalloys, used in components like turbine blades, bearings, and seals, remain a performance limiting factor due to their propensity, despite extensive optimization efforts, for softening and diffusion-driven elongation at temperatures often well above half their melting point. To address this critical materials challenge, we present results from integrating additive manufacturing and alloy design to guide significant improvements in performance via traditionally difficult-to-manufacture refractory alloys. We present an example of a multi-principal element alloy (MPEA), consisting of five refractory elements and aluminum, that exhibited high hardness and specific strength surpassing other known alloys, including superalloys. The alloy shows negligible softening up to 800°C and consists of four compositionally distinct phases, in distinction to previous work on MPEAs. Density functional theory calculations reveal a thermodynamic explanation for the observed temperature-independent hardness and favorability for the formation of this multiplicity of phases.

36 MATERIALS SCIENCE↗
NASA NTRS1976

Lightweight orthotic appliances

Graphite-filament reinforced polymer materials are used in applications requiring high tensile strength and modulus. Superior properties of graphite composite materials permit fabrication of supports that are considerably lighter, thinner, and stiffer than conventional components.

Baucom, R. M.↗
NASA NTRS2003

Impact Resistance of Lightweight Hybrid Structures for Gas Turbine Engine Fan Containment Applications

The ballistic impact resistance of hybrid composite sandwich structures was evaluated with the ultimate goal of developing new materials or structures for potential gas turbine engine fan containment applications. The sandwich structures investigated consisted of GLARE-5 laminates as face sheets with lightweight cellular metallic materials such as honeycomb, foam, and lattice block as a core material. The impact resistance of these hybrid sandwich structures was compared to GLARE-5 laminates and 2024-T3 Al sheet, which were tested as a function of areal weight (material thickness). The GLARE-5 laminates exhibited comparable impact properties to that of 2024-T3 Al at low areal weights, even though there were significant differences in the static tensile properties of these materials. The GLARE-5, however, did have a greater ballistic limit than straight aluminum sheet at higher areal weights. Furthermore, there is up to a 25% advantage in ballistic limit for the GLARE-5/foam sandwich structures compared to straight 2024-T3 Al. But no advantage in ballistic limit was observed between any of the hybrid sandwich structures and thicker versions of GLARE-5. Recommendations for future work are provided, based on these preliminary data.

Hebsur, Mohan G.↗
DOE OSTI2021

Evolution of elastic and thermal properties of cementitious composites containing micro-size lightweight fillers after exposure to elevated temperature

This work studies the evolution of elastic and thermal properties of cementitious composites containing micro-size lightweight fillers after exposure to elevated temperatures (up to 800 °C). A multiscale investigation is carried out to study the thermal degradation of cementitious composite materials at multiple scale levels: at cement past level, the dehydration kinetics of cement hydrates (i.e., C–S–H, CH and aluminate hydrates) and development of microcracks are studied as functions of exposure temperatures. The damage mechanism of the inclusion phases and damages within the interfacial transition zone (ITZ) under elevated temperature are also investigated. In addition, the change of mechanical (i.e., elastic moduli, compressive strengths) and thermal (thermal conductivities) properties are measured as functions of the exposure temperature. Based on the experimental studies, a multiscale thermal degradation model is developed where the thermal degradations of cement paste (including water composition, porosity, and solid phase changes), inclusion phases, and the interfaces are captured through a multiscale sub-stepping homogenization scheme. The thermal degradation model is validated through multiple sets of experimental data. Finally, the influence of key parameters including the particle size distribution of the inclusions, the chemical composition, as well as the effects of ITZ damage are studied.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Multiscale mechanical design of the lightweight, stiff, and damage-tolerant cuttlebone: A computational study

Cuttlebone, the endoskeleton of cuttlefish, offers an intriguing biological structural model for designing low-density cellular ceramics with high stiffness and damage tolerance. Cuttlebone is highly porous (porosity ~93%) and lightweight (density less than 20% of seawater), constructed mainly by brittle aragonite (95 wt%), but capable of sustaining hydrostatic water pressures over 20 atmospheres and exhibits energy absorption capability under compression comparable to many metallic foams (~4.4 kJ/kg). Here, in this work, we computationally investigate how such remarkable mechanical efficiency is enabled by the multiscale structure of cuttlebone. Using the common cuttlefish, Sepia Officinalis, as a model system, we first conducted high-resolution synchrotron micro-computed tomography (µ-CT) and quantified the cuttlebone's multiscale geometry, including the 3D asymmetric shape of individual walls, the wall assembly patterns, and the long-range structural gradient of walls across the entire cuttlebone (ca. 38 chambers). The acquired 3D structural information enables systematic finite-element simulations, which further reveal the multiscale mechanical design of cuttlebone: at the wall level, wall asymmetry provides optimized energy absorption while maintaining high structural stiffness; at the chamber level, variation of walls (number, pattern, and waviness amplitude) contributes to progressive damage; at the entire skeletal level, the gradient of chamber heights tailors the local mechanical anisotropy of the cuttlebone for reduced stress concentration. Our results provide integrated insights into understanding the cuttlebone's multiscale mechanical design and provide useful knowledge for the designs of lightweight cellular ceramics.

36 MATERIALS SCIENCE↗
NASA NTRS1990

The development of composite materials for spacecraft precision reflector panels

One of the critical technology needs for large precision reflectors required for future astrophysics and optical communications is in the area of structural materials. Therefore, a major area of the Precision Segmented Reflector Program at NASA is to develop lightweight composite reflector panels with durable, space environmentally stable materials which maintain both surface figure and required surface accuracy necessary for space telescope applications. Results from the materials research and development program at NASA Langley Research Center are discussed. Advanced materials that meet the reflector panel requirements are identified. Thermal, mechanical and durability properties of candidate materials after exposure to simulated space environments are compared to the baseline material.

Tompkins, Stephen S.↗
NASA NTRS1990

Making Lightweight Structures By Vapor Deposition

Technique developed for fabrication of stiff, strong, lightweight structures of silicon carbide or other materials by any of several deposition processes. Structures made by method can have complicated shapes. Ability to manufacture complex shape from pure deposited SiC useful and leads to new products in several fields. These lightweight structures used as backup structures for optical components, as structural components in automotive, aerospace, and outer space applications, and as lightweight parts of furniture for outer space.

Goela, Jitendra S.↗
NASA NTRS1995

Carbon-Fiber/Epoxy Tube Lined With Aluminum Foil

Carbon-fiber/epoxy composite tube lined with welded aluminum foil useful as part of lightweight heat pipe in which working fluid ammonia. Aluminum liner provides impermeability for vacuum seal, to contain ammonia in heat pipe, and to prevent flow of noncondensable gases into heat pipe. Similar composite-material tubes lined with foils also incorporated into radiators, single- and two-phase thermal buses, tanks for storage of cryogenic materials, and other plumbing required to be lightweight.

Gernet, Nelson J.↗
NASA NTRSDate not supplied

Materials for Power Transmission in Extreme Environments

NASA’s goal for a sustained human presence on the Moon and a future Lunar economy requires the development of novel power transmission materials for extreme environments. As an increasing number of public and private entities set their sights towards a future on the Moon, the demand for surface power will dramatically increase – potentially up to megawatt levels. A Lunar economy is envisioned to include a human habitat, manned and unmanned science exploration assets, excavation rovers and systems, and large-scale infrastructure construction such as solar arrays and power grids. A NASA trade study estimated that 1 to 3 km of power transmission lines (1 to 3 KV ac and dc) will be needed over time. Current high power and voltage SOA cables/wire can easily exceed 1 kg/m where mass is not as critical. Connectors, deployment spools and robots further increase the subsystem mass significantly increasing costs. On the other hand, advances in aeronautics provides path towards space missions. The operating environment on the Moon presents substantial risk to safe and reliable power transmission due to space weathering and degradation. These challenges include cosmic and UV radiation, extreme temperatures swings, the electrostatic Lunar exosphere, and the electrostatic and abrasive lunar regolith. The critical need for lightweight, safe and reliable power cables/wires materials is evident. In this presentation, the extreme high altitude and lunar environments and recent materials development from NASA Glenn Research Center’s High Voltage Materials team towards meeting NASA’s objectives and goals for aeronautics and space missions.

Cu/CNT conductors↗