Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “filler”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Epoxy as Filler or Matrix for Polymer Composites

Epoxy is a widely used polymer because of its ease of processing, high adhesiveness, and high chemical resistance. Epoxy-based composites are commonly used in aerospace, automotive, and marine applications. The epoxy type, function, curing agent, and curing process are discussed in this chapter. Epoxy is used as either a filler or polymer matrix in composite applications. As a filler, the epoxy modification on the fiber is discussed. As a polymer matrix, the epoxy is reinforced by natural and synthetic fibers. The manufacturing process and the fabricated epoxy-based composites’ performance (e.g., mechanical and thermal properties) are investigated. The advantages and disadvantages of epoxy’s function are discussed and summarized. Epoxy modification is an effective approach to improve the composites’ performance.

Zhao, Xianhui↗
DOE OSTI2022

Method for eliminating runout of braze filler metal during active brazing

Nanometers thick conformal coatings deposited by atomic-layer deposition (ALD) onto the metal surface of an active braze joint modifies the surface chemistry to eliminate excess braze filler metal flow. Unlike other means used to prevent braze filler metal runout, the thin ALD coating does not hinder next assembly processes, does not require post-braze cleaning, and does not alter the base material mechanical properties.

Goeke, Ronald S.↗
DOE OSTI2022

Method and system for recovering filler material

A method of recovering filler material from a polymer material comprises (a) heating the polymer material to a first temperature; (b) heating the polymer material to a second temperature higher than the first temperature resulting in a pyrolyzed material; (c) elutriating the pyrolyzed material to obtain a separated mixture; and (d) filtering the separated mixture to obtain the filler material.

Williams, Benjamin↗
DOE OSTI2023

Application of Interparticle Spacing Model to Maximize Filler Content in Cementitious Pastes

One of the most impactful ways to reduce embodied carbon of concrete in the near term is by partially replacing Portland cement with supplementary cementitious materials and/or fillers. This article describes an approach to reduce cement content in concrete through the development of high filler, low water (HFLW) cementitious pastes. Pastes with cement content as low as 50% (% weight of fines) were designed by applying models that maximize the packing density of the granular system and that consider the characteristics of the materials to calculate interparticle spacing (IPS), thereby allowing to obtain pastes with higher solids concentration and lower water demand. Strong correlations were found between IPS, the consistency index of the Herschel-Bulkley rheological model, and cement hydration kinetic parameters of binary and ternary pastes containing a Portland limestone cement and up to two different types of ground limestone. The approach showed to be feasible for the design of HFLW concrete paste fraction.

Antunes da Silva, Denise↗
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 OSTI2023

An examination of the precipitation behavior of proton irradiated dual phase 308L weldment filler materials

Voids, G phase particles, and Ni-Si rich clusters in proton irradiated dual phase 308L groove filler of a SA508–304 L dissimilar metal weldment are analyzed using advanced characterization techniques. These weldments are often used in light water nuclear reactors and are subject to enhanced corrosion and associated stress corrosion cracking (SCC). Radiation damage is known to accelerate SCC. Ni-Si enriched clusters were observed in proton irradiated γ austenite, while G phase M 6 Ni 16 Si 7 (where M transition metal element) precipitates were observed in proton irradiated δ ferrite. Compositional analysis of the G phase precipitates and Ni-Si clusters from STEM-EDS and APT are compared. Unlike G phase particles in proton irradiated δ ferrite, Ni-Si clusters in proton irradiated γ austenite are not rich in Mn. Both STEM-EDS and APT line-scan profiles of the Ni-Si clusters show that the Fe and Cr concentration gradient between matrix γ austenite and the Ni-Si clusters is not as sharp as those between matrix δ ferrite and G phase. Further, HR-STEM imaging indicates that the lattice parameter of the Ni-Si clusters is commensurate with γ austenite and the clusters do not represent the precipitation of a second phase. Finally, our analysis demonstrates the density and volume fraction of G phase particles and the density of voids scales with proton irradiation damage and the energy to recoils.

308L groove filler↗
DOE OSTI2022

Effect of natural carbon filler on thermo-oxidative degradation of thermoplastic-based composites

Here thermo-oxidative degradation of thermoplastic-based composites filled with two types of carbon filler including bituminous (Pittsburgh No.8, P8) and sub-bituminous (Powder River Basin, PRB) coals were investigated using differential scanning calorimetry (DSC) and thermogravimetric analysis. Oxidation induction time (OIT) and activation energy (AE) for coal plastic composites (CPCs), HDPE, and commercially available wood plastic composites (WPCs) were determined using isothermal and isoconversional kinetic methods. OIT values for CPC increased with coal content, indicating higher thermo-oxidative stability. AE values obtained using isothermal method were 52–116 kJ/mol for all CPC formulations, 32 kJ/mol for HDPE, and 33–114 kJ/mol for WPCs. AEs for CPCs obtained using isoconversional methods were not constant but rather dependent on the degree of degradation with CPC/ P8 coal possessing higher overall AE. Incorporating coal into HDPE increased thermo-oxidative stability of the resulting composite, indicating coal potentially acts as a natural primary and secondary antioxidant for polymer materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Composite coatings from polycarbosilane derived SiC and Al/SiC cermet active fillers as protective barriers against steel corrosion

Stainless steel is used throughout the world as a structural material. However, it undergoes corrosion damage when exposed to extremely corrosive media, such as the marine environment. An alternative to solve this problem lies in the development of coatings that can withstand extreme conditions but also be easily deposited with inherently corrosion-resistant materials such as silicon carbide (SiC). The present study shows a simple method to produce Al/SiC cermet powders by attrition milling. The resulting cermet powders with a metallic matrix and hemispherical morphology, were employed as fillers in polycarbosilane (PCS) solutions that were sprayed on A304 stainless steel substrates. Al/SiC composite coatings were produced after heating the sprayed suspensions at 700 °C for 1 h in Ar atmosphere. The resulting composite coatings exhibited low surface energies (< 35 mN/m), water contact angles of 53°, and adhesion strength of up to 30 MPa. Finally, corrosion tests were performed in a cyclic corrosion test chamber, showing that these coatings effectively reduced the corrosion rate of stainless steel by 87%, reaching corrosion rate values of 0.007 g/cm 2 year.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Quest for environmentally sustainable materials: A case for animal-based fillers and fibers in polymeric biocomposites

This review explores the potential of animal-based fillers and fibers as eco-friendly alternatives to conventional synthetic ones. Examining materials such as wool, silk, feather, hair and beak, the review elucidates their chemistry, structure, properties and sources, emphasizing biodegradability and renewability. It also discusses the compatibility of these materials with polymer matrices and their mechanical, acoustic and thermal performances. Further, the review critically analyzes environmental and ethical implications, presenting challenges and opportunities in the emerging field. By addressing ecological and performance aspects, it contributes to global efforts in fostering sustainability in materials science. Future research to address gaps and enhance the design, manufacture and application of animal-based reinforcements in various industries are clearly outlined at the end of the review.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Influence of oxygen on performance of multi-principal element alloy as braze filler for Ni-base alloys

In manufacturing of multi-principal element alloys (MPEAs), the casting process is often a primary point of oxygen introduction to the material system, which was demonstrated by the laboratory scale button arc-melting process. Oxygen introduction raises concerns for the mechanical performance of these alloys if employed as structural materials alone or in engineering applications, such as serving as filler materials to enable joining of similar or dissimilar alloy pairs that are conventionally considered difficult to join. In this work, oxide inclusions in an as-cast off-equiatomic MnFeCoNiCu MPEA and Ni-base alloy braze joints made with this MPEA were evaluated by synchrotron x-ray diffraction mapping and electron microscopy. MnO was found to be prevalent throughout the cast MPEA and was chemically reduced during brazing by trace Al from the base material, Ni-base Alloy 600. Incomplete reaction of the MnO with Al, and some alternative reaction with Cr, left a mixture of MnO, Al 2 O 3 , and Cr 2 O 3 in the as-brazed joint, with the oxides concentrated near the braze centerline due to directional solidification. Further, in the braze joints, the non-oxide constituent phases detected were an FCC matrix and particles of Cr 23 C 6 , Cr 7 C 3 , and TiN which are all native to Alloy 600. The evolution of oxides within the brazed joints at elevated service temperatures of 600-800°C was also evaluated. While MnO and Al 2 O 3 were stable during high-temperature service, Cr 2 O 3 particles grew to several hundred microns, with dissolved oxygen in the MPEA providing a significant source for oxide growth. Comparing tensile performance of the as-brazed condition with post-service conditions showed that the evolution of oxide particles contributed to an increase in strength and decrease in ductility of the brazed joints. Evaluating particle morphologies among fracture surfaces of individual specimens demonstrated that large Cr 2 O 3 particles and continuous cluster networks of Al 2 O 3 were the features most detrimental to total elongation. Hence, unmitigated evolution of oxygen-containing species during brazing and service conditions is detrimental to the ductility of the brazed joints, which highlights the importance of oxygen control in initial manufacturing of MPEAs for engineering applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Modified microstructures in proton irradiated dual phase 308L weldment filler material

In this study, the effect of proton irradiation on the microstructure of δ ferrite—γ austenite mixed phase 308L filler material in a 508–304 dissimilar metal weldment was investigated over a depth of 0 to 10 µm. Ni–Si–Mn G-phase precipitates were observed with SEM and TEM in δ ferrite but not in γ austenite. Our density functional theory based calculations show that the G/Fe interface energy in δ-Fe is significantly lower than that in γ-Fe (0.35 versus 1.25 J/m 2 ), which provides a thermodynamics-based explanation for our experimental observations of preferential formation of G-phase in δ ferrite. STEM-EDS, TEM dark field imaging, and diffraction patterns confirmed the Ni–Si–Mn enriched precipitates were G-phase precipitates with a stoichiometry of Mn 6 Ni 16 Si 7 . Intragranular voids and Ni–Si enriched clusters were observed in irradiated γ austenite. Additionally, Ni and Si segregation was observed along the void interfaces. In both cases, Ni–Si clusters and segregation to voids, selected area diffraction patterns did not reveal the existence of a second phase. Proton irradiation induced Cr depletion and Si and Ni enrichment at γ-γ austenite grain boundaries that was characterized with STEM/EDS.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Hierarchically structured metal carbides as conductive fillers in thermo-responsive polymer nanocomposites for battery safety

Integrating thermo-responsive polymer switching materials (TRPS) into lithium-ion batteries (LIBs) has been recognized as one of the most effective strategies to prevent thermal runaway under various abuse scenarios. However, the current methods to obtain TRPS cannot satisfy different practical applications. Herein, we develop a versatile strategy for the preparation of various metal carbides (e.g., tungsten carbide, molybdenum carbide) with controllable hierarchical structure that is featured with surface protrusion structure, which is critical for high conductivity and rapid thermal response. Systematic studies of the phase and morphology evolutions by advanced characterizations illustrate that the reducing agent and reduction rate are critical for developing the specific morphology. In conclusion, by using the above-mentioned carbides as the conductive fillers of TRPS, the resulting TRPS with a specially controlled shape exhibits over 5 order of conductivity improvement compared with common carbides with particulate morphology, in addition to reversible shutdown performance and effective thermal abuse protections toward safe LIB operation.

25 ENERGY STORAGE↗
DOE OSTI2026

Nonlocal Effect of Percolated Particle Networks on Viscoelasticity of Polymer–Filler Nanocomposites: A Mesoscale Simulation Study

With nanoparticles (NPs) as fillers, polymer nanocomposites (PNCs) usually exhibit enhanced mechanical properties. However, a direct connection between the microscopic structural relaxation and macroscopic mechanical properties of PNCs remains to be established. To investigate the micro-to-macro connection, we develop a mesoscale model, in which the NPbridging polymer chains are represented by a dynamic bonded interaction between NPs, and the bulk polymer matrix is implicitly modeled by overdamped Langevin dynamics. Extensive equilibrium simulations are performed to quantify the microscopic dynamics of model PNCs. Systematic analyses of modified Rouse dynamics, dynamic structure factor, and relaxation modulus uncover that the microscopic relaxation dynamics of PNCs are significantly decelerated across different length scales because of nonlocal effects of percolated particle networks a phenomenon that has not been adequately captured in prior simulation studies. We find that NPvolume- fraction and NP-bonding-energy barrier are the two critical variables that affect bulk viscoelasticity the most. The proposed mesoscale model is versatile and provides a powerful framework for studying structure−property relations of different PNCs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Gel composite electrolyte – an effective way to utilize ceramic fillers in lithium batteries

Achieving synergy between ion-conducting polymers and ceramics in a composite electrolyte has been proven to be difficult as the complicated ceramic/polymer interface presents challenges to understand and control. In this work, we report a strategy to utilize discrete ceramic fillers to form a gel composite electrolyte with enhanced transport properties for lithium metal batteries. The matrix of the composite membrane is crosslinked poly(ethylene oxide) with bis(trifluoromethane)sulfonimide lithium salt (LiTFSI). The membrane is plasticized with tetraethylene glycol dimethyl ether (TEGDME). The incorporation of doped-lithium aluminum titanium phosphate particles (LICGC™) into the membrane greatly improves the membrane's cycling characteristics against the lithium electrode, exhibiting lower interfacial impedance, lower overpotential and higher rate capability. The underpinnings of the superior performance of the gel composite electrolyte are discussed in depth. LICGC™ can immobilize the TFSI - anions in the polymer matrix and simultaneously promote Li+ transport by increasing the plasticizer to Li + ratio. Further, the transport enhancement is achieved without sacrificing mechanical properties. The composite membrane shows significantly improved handleability and processability. This work sheds light on the design strategy for a safe electrolyte towards stable Li metal batteries.

25 ENERGY STORAGE↗
DOE OSTI2025

Effect of calcite filler on carbonation behavior in a synthesized C‐S‐H binder

Widespread implementation of portland limestone cements (PLC) in industry has raised new questions about their carbonation resistance due to higher initial limestone content than ordinary portland cement. While carbonation of portland cement and each of its hydrate phases has been studied at a fundamental level, the integral role of how limestone fillers interact chemically or physically during carbonation necessitates further study. In this study, a C-S-H binder comprised of a highly reactive zeolite pozzolan and lime was used to evaluate the effect of varying calcite additions on carbonation behavior at a microstructural level. Fundamental insight into hydration kinetics and carbonation mechanisms of hydraulic binders was obtained via analysis of the C-S-H and calcite microstructure. X-ray microcomputed tomography (X-ray CT) was used to quantify microstructural changes, and the results showed a decrease in shrinkage for increased calcite dosages, with a ∼50% reduction observed for a 45% wt. calcite replacement level. Crystallographic and thermal analyses measured compositional changes in the binder and confirmed that shrinkage was related to the decalcification of C-S-H. Furthermore, the addition of calcite to the C-S-H binder effectively reduced the liquid-to-solid ratio, porosity, and amount of C-S-H present in these binders. Ultimately, these results help elucidate how the carbonation risks of PLC can be mitigated by proportioning the mixture water only to the reactive component of the binder.

C-S-H↗
DOE OSTI2022

Using Crystallization to Control Filler Dispersion and Vice Versa in Polymer Nanocomposites

Our overall goal was to exploit our ability to control the spatial dispersion of spherical nanoparticles in a semicrystalline polymer matrix to tune the properties of the resulting nanocomposite. In particular, our two tasks were: Hierarchically organize spherical nanoparticles into unique morphologies by varying the ratio of the polymer crystallization rate to the filler diffusion rate during matrix solidification. Organize nanoparticles in the matrix melt into superstructrues as a means to tailor polymer crystallization rates, and potentially the crystal structure and/or morphology of the semicrystalline matrix.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Cryo-GCMS Outgassing Screening: Thermal Filler Materials

A study was conducted to investigate the outgassing characteristics of four thermal filler materials. The purpose of this screening was to identify any outgassing products that might be considered reactive, specifically compounds that could result in corrosion in the systems where these materials are used. A range of compounds was observed in the sample headspaces, though most do not stand out as being known reactive species of concern. However, several halogenated compounds and sulfurous compounds- classes compounds known to facilitate corrosion reactions under certain conditions- were observed in low concentrations. The TFLEX 760 exhibited the highest total outgassing, while the GR130 had the lowest. Therm-a-Gap75 and the Si thermal grease exhibited very similar outgassing profiles. It is difficult to predict the extent to which any given compound observed in an analysis of this type might pose a risk in an actual system; factors such as temperature, system geometry, concentration, and gas conductance all play a role in the kinetics governing chemical reactions. It is recommended that the results of these analyses are shared with pertinent materials SMEs familiar with the system(s) in question to evaluate potential risks.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Design and Gas Separation Performance of Imidazolium Poly(ILs) Containing Multivalent Imidazolium Fillers and Crosslinking Agents

This work introduces a series of vinyl-imidazolium-based polyelectrolyte composites, which were structurally modified via impregnation with multivalent imidazolium-benzene ionic liquids (ILs) or crosslinked with novel cationic crosslinkers which possess internal imidazolium cations and vinylimidazolium cations at the periphery. A set of eight [C4vim][Tf2N]-based membranes were prepared via UV-initiated free radical polymerization, including four composites containing di-, tri-, tetra-, and hexa-imidazolium benzene ILs and four crosslinked derivatives which utilized tri- and tetra- vinylimidazolium benzene crosslinking agents. Structural and functional characterizations were performed, and pure gas permeation data were collected to better understand the effects of “free” ILs dispersed in the polymeric matrix versus integrated ionic crosslinks on the transport behaviors of these thin films. These imidazolium PIL:IL composites exhibited moderately high CO2 permeabilities (~20–40 Barrer), a 4–7× increase relative to corresponding neat PIL, with excellent selectivities against N2 or CH4. The addition of imidazolium-benzene fillers with increased imidazolium content were shown to correspondingly enhance CO2 solubility (di- < tri- < tetra- < hexa-), with the [C4vim][Tf2N]: [Hexa(Im+)Benz ][Tf2N] composite showing the highest CO2 permeability (PCO2 = 38.4 Barrer), while maintaining modest selectivities (αCO2/CH4 = 20.2, αCO2/N2 = 23.6). Additionally, these metrics were similarly improved with the integration of more ionic content bonded to the polymeric matrix; increased PCO2 with increased wt% of the tri- and tetra-vinylimidazolium benzene crosslinking agent was observed. This study demonstrates the intriguing interactions and effects of ionic additives or crosslinkers within a PIL matrix, revealing the potential for the tuning of the properties and transport behaviors of ionic polymers using ionic liquid-inspired small molecules.

36 MATERIALS SCIENCE↗