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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Dimensionality effect of conductive carbon fillers in LiNi 1/3 Mn 1/3 Co 1/3 O 2 cathode

Developing advanced electrode architectures through modifying active materials, conductive fillers, binders, and electrolytes as well as processing methods has drawn significant research interest. Due to the insufficient electrical conductivity of many active materials, adding conductive carbon fillers to composite electrodes provides the necessary electrical conductivity. The dimensionality effect among different conductive fillers has a significant impact on electrochemistry, which can be associated with morphological and chemical heterogeneities of electrodes. In this study, synchrotron X-ray mosaic nanotomography and X-ray spectroscopy nanoimaging provided direct three-dimensional (3D) visualization and quantification capabilities to investigate the dimensionality effects of Super P (SP) and single-walled carbon nanotube (SWCNT) fillers on the capacity retention of LiNi 1/3 Mn 1/3 Co 1/3 O 2 (NMC111). The results indicate that NMC/SWCNT electrodes, with a wrapping effect from the SWCNTs, exhibited more homogeneous particle size distributions, morphological changes, and chemical states than NMC/SP electrodes, without the wrapping effect. This work developed a framework of 3D quantification methods to study the capacity fading behavior associated with morphological and chemical heterogeneities and paved the way toward designing electrodes for high rate energy storage applications.

25 ENERGY STORAGE↗
DOE OSTI2023

Irradiation-assisted cracking of SA508-304L weldments with 308L groove filler and 309L butter in hot water immersion constant rate extension tests

Low alloy SA508 bainitic steel is often welded to 300 series austenitic stainless steel in nuclear power plants. These dissimilar metal weldments use 309L butter applied to the low alloy steel and 308L groove filler material to join the 309L to austenite. High alloy steels (such as the 308L and 309L material used here) have been identified as having greater susceptibility to irradiation-assisted stress corrosion cracking (IASCC). Evidence is presented here of cracking under tensile loads in 309L weldment butter in LWR hydrothermal conditions that correlates irradiation induced changes at δ ferrite–γ austenite phase boundaries and γ–γ grain boundaries; specifically intergranular Cr 23 C 6 precipitates. Cracking is not observed in irradiated 308L groove filler under the same conditions. Both the 309L butter and 308L filler material have a duplex or mixed δ–γ phase microstructure due to solidification during the welding procedure. We have performed constant extension rate autoclave immersion tests in BWR normal water chemistry hot water (288 °C, 10 MPa, 2000 wt. ppb dissolved oxygen, <100 nS/cm conductivity, neutral pH) of proton irradiated (2 MeV, approximately 3 displacements per atom at a depth of 10 μm) tensile specimens. Proton irradiation to the dpa levels used here induced Cr 23 C 6 carbide precipitation at γ–γ grain boundaries and δ–γ phase boundaries in the 309L butter but not the 308L filler. Cracking was observed in the proton-irradiated volume of 309L at these interfaces in the vicinity of the Cr 23 C 6 precipitates. We hypothesis the SA508 is the source of carbon in the 309L butter. Cr depletion at γ–γ grain boundaries was also observed and may also be a root cause of cracking. Furthermore, the 309L butter is under significant tensile residual stress in the weldment that adds to applied tensile loads and this too may be a contributing factor.

309L weld butter↗
NASA NTRS1980

Improved fiber retention by the use of fillers in graphite fiber/resin matrix composites

A variety of matrix fillers were tested for their ability to prevent loss of fiber from graphite fiber/PMR polyimide and graphite fiber/epoxy composites in a fire. The fillers tested included powders of boron, boron carbide lime glass, lead glass, and aluminum. Boron was the most effective and prevented any loss of graphite fiber during burning. Mechanical properties of composites containing boron filler were measured and compared to those of composites containing no filler.

Gluyas, R. E.↗
NASA NTRS1982

Prolonging the Life of Refractory Fillers

Useful life of refractory glass-cloth gap filler is increased by coating it with a suspension of silicon carbide in butanol and polyethylene. Coating is applied to refractory-fiber cloth filler that seals gaps between insulating tiles on Space Shuttle orbiter. Tests showed that cloth fibers would be embrittled by extreme temperatures encountered on reentry into Earth's atmosphere and that only 25 percent of the thousands of fillers would be reusable after a mission. With coating, 85 percent of fillers would be reusable.

Schomburg, C.↗
NASA NTRS1981

Polyvinyl alcohol battery separator containing inert filler

A cross-linked polyvinyl alcohol battery separator is disclosed. A particulate filler, inert to alkaline electrolyte of an alkaline battery, is incorporated in the separator in an amount of 1-20% by weight, based on the weight of the polyvinyl alcohol, and is dispersed throughout the product. Incorporation of the filler enhances performance and increases cycle life of alkaline batteries when compared with batteries containing a similar separator not containing filler. Suitable fillers include titanates, silicates, zirconates, aluminates, wood floor, lignin, and titania. Particle size is not greater than about 50 microns.

Sheibley, D. W.↗
NASA NTRS1981

Adjustable high emittance gap filler

A flexible, adjustable refractory filler is disclosed for filling gaps between ceramic tiles forming the heat shield of a space shuttle vehicle, to protect its aluminum skin during atmospheric reentry. The easily installed and replaced filler consists essentially of a strip of ceramic cloth coated, at least along both its longitudinal edges with a room temperature vulcanizable silicone rubber compound with a high emittance colored pigment. The filler may have one or more layers as the gap width requires. Preferred materials are basket weave aluminoborosilicate cloth, and a rubber compounded with silicon tetraboride as the emittance agent and finely divided borosilicate glass containing about 7.5% B2O3 as high temperature binder. The filler cloth strip or tape is cut to proper width and length, inserted into the gap, and fastened with previously applied drops of silicone rubber adhesive.

Leiser, D. B.↗
DOE OSTI2025

Compression Response of Silicone-Based Composites with Integrated Multifunctional Fillers

Polydimethylsiloxane (PDMS) is known for its exceptional mechanical properties, chemical stability, and flexibility. Recent advancements have focused on developing functional PDMS composites by integrating various functional fillers, including polymers, ceramics, and metals, for advanced applications such as electronics, medical devices, and aerospace. Consequently, there is a growing need to investigate PDMS composites to achieve higher filler loadings offering enhanced mechanical performance. This study addresses this need by utilizing the high molecular weight (MW) PDMS resin we have developed, offering its high elongation capacity of up to >6500%. We incorporated boron (B), hollow glass microballoons (HGMs), and tungsten-coated hollow glass microballoons (WHGMs) into the developed high MW PDMS. The resulting composites demonstrated excellent elastic properties and significant compression resilience (35–80%) and elastic modulus (1.28–10.15 MPa) at high filler loadings (~60 vol.%). Specifically, B/PDMS composites achieved up to 67.6 vol.% of B, HGM/PDMS composites held up to 68.6 vol.% of HGM, and WHGM/PDMS composites incorporated up to 54.0 vol.% of WHGM. These findings highlight the potential of high MW PDMS for developing high-performance PDMS composites suitable for advanced applications such as aerospace, automotive, and medical devices.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Effect of the filler morphology on the crystallization behavior and dielectric properties of the polyvinylidene fluoride‐based composite

Abstract Ceramic/polymer composites can be chemically stable, mechanically strong, and flexible, which make them candidates for electric devices, such as pressure or temperature sensors, energy storage or harvesting devices, actuators, and so forth. Depending on the application, various electrical properties are of importance. Polymers usually have low dielectric permittivity, but increased dielectric permittivity can be achieved by the addition of the ceramic fillers with high dielectric constant. With the aim to enhance dielectric properties of the composite without loss of flexibility, 5 wt% of BaTiO 3 ‐Fe 2 O 3 powder was added into a polyvinylidene fluoride matrix. The powder was prepared by different synthesis conditions to produce core/shell structures. The effect of the phase composition and morphology of the BaTiO 3 ‐Fe 2 O 3 core/shell filler on the structure and lattice dynamics of the polymer composites was investigated. Based on the results of the thermal analysis, various parameters of ceramic/polymer composites were determined. Differences in the phase composition and morphology of the filler have an influence on the formation of various polyvinylidene fluoride allomorphs and the degree of crystallinity. Furthermore, the dielectric performances of pure polyvinylidene fluoride and the polymer/ceramic composites were measured.

Polymer Science↗
DOE OSTI2021

Ionic conductivity optimization of composite polymer electrolytes through filler particle chemical modification

The addition of filler particles to polymer electrolytes is known to increment their ionic conductivity (IC). A detailed understanding of how the interactions between the constituent materials are responsible for the enhancement remains to be developed. A significant contribution is ascribed to an increment of the polymer amorphous fraction, induced by the fillers, resulting in the formation of higher ionic conductivity channels in the polymer matrix. However, the dependence of IC on the particle weight load and its composition on the polymer morphology is not fully understood. This work investigates Li-ion transport in composite polymer electrolytes (CPE) comprising Bi-doped LLZO particles embedded in PEO:LiTFSI matrixes. We find that the IC optimizes for very low particle weight loads (5-10%) and that both its magnitude and the load are required, strongly dependent on the garnet particle composition. Based on structural characterization results and electrochemical impedance spectroscopy, a mechanism is proposed to explain these findings. It is suggested that the Li-molar content in the garnet particle controls its interactions with the polymer matrix, resulting at the optimum loads reported, in the formation of high ionic conductivity channels. We propose that filler particle chemical manipulation of the polymer morphology is a promising avenue for the further development of composite polymer electrolytes.

bismuth↗
DOE OSTI2023

Polyester-based epoxy vitrimer integrating spent coffee ground as a natural filler

Coffee is a widely consumed beverage, but approximately 80% mass of coffee cherry is discarded as waste. Here, in this study, spent coffee grounds (SCG) were recycled and used as a natural filler in a polyester-based epoxy matrix made from reactions of diglycidyl ethers of Bisphenol A and polyethylene glycol with methyl nadic anhydride. The properties of SCG/epoxy composites with various SCG contents up to 40% w/w were evaluated using various techniques such as FT-IR spectroscopy, tensile testing, optical microscopy, differential scanning calorimetry, and rheology. The SCG filled polyester-based epoxy matrix demonstrated excellent dimensional stability and retained a permanently crosslinked network, but re-shaping was possible at ~150 °C through transesterification, which occurred due to a dynamic chain exchange reaction between the ester group of the epoxy matrix and the hydroxyl group of the SCG fillers. The transesterification also improved the interfacial adhesion between the matrix and SCG fillers, resulting in tensile strength of over 20 MPa and a modulus of around 2.5 GPa, even with high SCG contents up to 40% w/w. While neat, cured epoxy shows thermoset behavior, filling the matrix with SCG enables reforming and origami-inspired spontaneous change in shape.

42 ENGINEERING↗
DOE OSTI2025

Advancements in active filler-contained polymer solid-state electrolytes for lithium-metal batteries: A concise review

Lithium-metal batteries (LMBs) usually are regarded as the pinnacle of next-generation energy storage due to the high specific capacity and low redox potential of the Li-metal anode. However, their development is hindered by safety hazards related to flammable electrolytes and uncontrolled side reactions within the battery. Both polymer and solid-state inorganic electrolytes, despite their potential, exhibit shortcomings that limit their practical applications. Active filler-containing polymer electrolytes (AFPEs) offer a promising solution by combining the benefits of both types. Enhanced by supramolecular interactions between the polymer matrix and active fillers, AFPEs demonstrate superior electrochemical performance over traditional polymer electrolytes. This review discusses the progress in active fillers and various polymer matrices, examining the factors that enhance performance, particularly ionic conductivity. It also outlines the future research directions of AFPEs, aiming to broaden the application of solid electrolytes in high-performance LMBs.

All solid-state batteries↗
DOE OSTI2025

Relationship Between Filler Type, Thermomechanical Properties, and Aging of RTV Silicone Foams

Room-temperature vulcanizing (RTV) silicone foams are used in many industrial applications that require the material to perform over long time periods. However, mechanical properties tend to deteriorate when these foams age under a compressive load. The chemical aging is attributed to the presence of unreacted functional groups of the prepolymers, residues from acid, and catalytically active tin (II) species. Here, an optimized thermal treatment of an RTV foam that achieves completion of curing reactions and deactivation of reactive species is proposed. Foams that were thermally aged for three months under compressive load showed no signs of compression set, indicative of the effectiveness of the implemented post-curing approach. In addition, the effects of fillers (diatomaceous earth, fumed silica, and carbon nanofibers) on thermomechanical properties were investigated. Tensile strength, tear strength, and thermal conductivity increased when these fillers were added to the unfilled RTV formulation, with carbon nanofibers (CNFs) being the most effective filler. Rheological studies of RTV formulations indicated that 2.5 wt.% of CNFs is the upper limit that can be added to the RTV formulation.

36 MATERIALS SCIENCE↗
NASA NTRS1975

Several braze filler metals for joining an oxide-dispersion-strengthened nickel-chromium-aluminum alloy

An evaluation was made of five braze filler metals for joining an aluminum-containing oxide dispersion-strengthened (ODS) alloy, TD-NiCrAl. All five braze filler metals evaluated are considered suitable for joining TD-NiCrAl in terms of wettability and flow. Also, the braze alloys appear to be tolerant of slight variations in brazing procedures since joints prepared by three sources using three of the braze filler metals exhibited similar brazing characteristics and essentially equivalent 1100 C stress-rupture properties in a brazed butt-joint configuration. Recommendations are provided for brazing the aluminum-containing ODS alloys.

Gyorgak, C. A.↗
NASA NTRS2001

Aluminum Lithium Alloy 2195 Fusion Welding Improvements with New Filler Wire

The objective of this research was to assess the B218 weld filler wire for Super Lightweight External Tank production, which could improve current production welding and repair productivity. We took the following approaches: (1) Perform a repair weld quick look evaluation between 4043/B218 and B218/B218 weld filler wire combinations and evaluation tensile properties for planished and unplanished conditions; and (2) Perform repair weld evaluation on structural simulation panel using 4043-B218 and B218/B218 weld filler wire combinations and evaluation tensile and simulated service fracture properties for planished and unplanished conditions.

Russell, C.↗
NASA NTRS2003

Filler wire for aluminum alloys and method of welding

A weld filler wire chemistry has been developed for fusion welding 2195 aluminum-lithium. The weld filler wire chemistry is an aluminum-copper based alloy containing high additions of titanium and zirconium. The additions of titanium and zirconium reduce the crack susceptibility of aluminum alloy welds while producing good weld mechanical properties. The addition of silver further improves the weld properties of the weld filler wire. The reduced weld crack susceptibility enhances the repair weldability, including when planishing is required.

Bjorkman, Jr., Gerald W. O.↗
NASA NTRS2003

Stable, Thermally Conductive Fillers for Bolted Joints

A commercial structural epoxy [Super Koropon (or equivalent)] has been found to be a suitable filler material for bolted joints that are required to have large thermal conductances. The contact area of such a joint can be less than 1 percent of the apparent joint area, the exact value depending on the roughnesses of the mating surfaces. By occupying the valleys between contact peaks, the filler widens the effective cross section for thermal conduction. In comparison with prior thermal joint-filler materials, the present epoxy offers advantages of stability, ease of application, and -- as a byproduct of its stability -- lasting protection against corrosion. Moreover, unlike silicone greases that have been used previously, this epoxy does not migrate to contaminate adjacent surfaces. Because this epoxy in its uncured state wets metal joint surfaces and has low viscosity, it readily flows to fill the gaps between the mating surfaces: these characteristics affect the overall thermal conductance of the joint more than does the bulk thermal conductivity of the epoxy, which is not exceptional. The thermal conductances of metal-to-metal joints containing this epoxy were found to range between 5 and 8 times those of unfilled joints.

LeVesque, Raymond J., II↗
NASA NTRS2013

Development of a SMA-Based Slat-Cove Filler for Reduction of Aeroacoustic Noise Associated With Transport-Class Aircraft Wings

Airframe noise is a significant part of the overall noise produced by typical, transport-class aircraft during the approach and landing phases of flight. Leading-edge slat noise is a prominent source of airframe noise. The concept of a slat-cove filler was proposed in previous work as an effective means of mitigating slat noise. Bench-top models were deployed at 75% scale to study the feasibility of producing a functioning slat-cove filler. Initial results from several concepts led to a more-focused effort investigating a deformable structure based upon pseudoelastic SMA materials. The structure stows in the cavity between the slat and main wing during cruise and deploys simultaneously with the slat to guide the aerodynamic flow suitably for low noise. A qualitative parametric study of SMA-enabled, slat-cove filler designs was performed on the bench-top. Computational models were developed and analyses were performed to assess the displacement response under representative aerodynamic load. The bench-top and computational results provide significant insight into design trades and an optimal design.

Turner, Travis L.↗
NASA NTRSDate not supplied

Development of Slat-gap and Slat-cove Filler Treatments for Noise Reduction Assessment on the High Lift Common Research Model in the NASA LaRC 14x22

Airframe noise is an important issue during the approach and landing phases of flight because engines are throttled back, and airframe sources become an equal or greater contributor to environmental noise. The leading-edge slat component of the high-lift system for transport aircraft has been identified as a prominent source of airframe noise. Noise production mechanisms and potential treatments to mitigate airframe noise have been areas of active research for nearly three decades. Two promising technologies for slat noise reduction are the slat-gap filler (SGF) and slat-cove filler (SCF). Previous work was done using a 2D section of a transport class aircraft wing to demonstrate their feasibility via benchtop and computational models. A wind tunnel test campaign was recently undertaken to test the SGF and SCF technologies in a flight-like environment by installing dynamically scaled treatments on the 10%-scale High-Lift Common Research Model (CRM-HL), which is representative of a commercial twin-aisle transport aircraft. Advancement of the SGF and SCF technologies to overcome challenges of integration with 3D airframe structures, computational simulations of the CRM-HL predicting the aerodynamic and aeroacoustic performance and structural loads, and design of wind tunnel model hardware with features accommodating noise treatments were conducted in parallel. Details of innovations in the SGF and SCF technologies for 3D airframe feasibility will be described. The loads the treatments must sustain in flight and the influence of those loads on the design is also discussed. Finally, the design of wing leading-edge assemblies to treat the 10% CRM-HL with dynamically scaled SGF and SCF components is presented. The treatments were successfully tested in 2020/2021 providing a demonstration of leading-edge noise reduction using components that would allow slat articulation.

airframe noise reduction↗