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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 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Long-term hygrothermal effects on damage tolerance of hybrid composite sandwich panels

A sandwich construction, composed of hybrid carbon-glass fiber-reinforced plastic skins and a syntactic foam core, was selected as the design concept for a wind tunnel compressor blade application, where high damage tolerance and durability are of major importance. Beam specimens were prepared from open-edge and encapsulated sandwich panels which had previously been immersed in water at different temperatures for periods of up to about two years in the extreme case. Moisture absorption and strength characteristics, as related to time of exposure to hygrothermal conditions, were evaluated for the sandwich specimens and their constituents (skins and foam). After different exposure periods, low-velocity impact damage was inflicted on most sandwich specimens and damage characteristics were related to impact energy. Eventually, the residual compressive strengths of the damaged (and undamaged) beams were determined flexurally. Test results show that exposure to hygrothermal conditions leads to significant strength reductions for foam specimens and open-edge sandwich panels, compared with reference specimens stored at room temperature. In the case of skin specimens and for beams prepared from encapsulated sanwich panels that had previously been exposed to hygrothermal conditions, moisture absorption was found to improve strength as related to the reference case. The beneficial effect of moisture on skin performance was, however, limited to moisture contents below 1% (at 50 C and lower temperatures). Above this moisture level and at higher temperatures, strength degradation of the skin seems to prevail.

Ishai, Ori↗
DOE OSTI2025

Feasibility of Algal Biochar, a Byproduct of Biofuel Production, as a Supplemental Cementitious Material

Algal biochar, as the solid residue of biofuel production from algal biomass, is reported to explore disposition options, aiming to lessen the liability or obstacles to biofuel production processes. However, landfills and open combustion lead to adverse environmental impacts. One way to add value to such wastes is to use them as admixtures in cementitious construction materials. This study aims to investigate the feasibility of algae-derived biochar as supplementary cementitious materials (SCM) at different water contents and mixture ratios. Algal biochar-cement composites were prepared with different algal biochar content as well as different water-to-cement (w/c) ratios, and the surface area, morphology, elemental, and mineralogical composition were characterized. To compensate for the high-water absorption of algal biochar, a small concentration of a superplasticizer was used since higher w/c ratios negatively impact strength. The mechanical performance of algal biochar-cement composites is compared with control composites using commercial silica fume as a typical commercial SCM. The findings suggest that algal biochar is a promising candidate to replace commercial SCM, like silica fume, since algal biochar-cement composites can reach comparable compressive strength and Young’s modulus to commercial pozzolan-cement materials with the same w/c ratio, though at later curing times, 33 days. Although the tensile strength of algal biochar-cement composites is statistically similar at 7 days, it is significantly lower at later curing times, and further investigation is required to improve this property. Algal biochar-based cement binders showed comparable embodied carbon to silica fume-based cement binders based on a cradle-to-gate lifecycle analysis. However, the ability of algal biochar to absorb large volumes of CO 2 over short periods of time, as measured in this study, makes this novel SCM an excellent alternative to reduce the embodied carbon of concrete structures cradle-to-grave at 1/10 of the cost. In conclusion, valorization of algae-derived solid waste provides great potential to reduce embodied carbon and brings credit to biofuel production and concrete-based construction.

algae-derived↗
DOE OSTI2023

The hydration, microstructure, and mechanical properties of vaterite calcined clay cement (VC 3 )

Limestone (calcite) calcined clay cement (LC 3 ) is a promising low-CO 2 binder, but the low activity of calcite cannot compensate the reduction in clinker factor, resulting in low one-day strength and limiting its broad applications. As recent carbon capture and utilization technologies allow scalable production of vaterite, a more reactive CaCO 3 polymorph, we overcome the challenge by introducing vaterite calcined clay cement (VC 3 ), inspired by the vaterite-calcite phase change. In the present study, VC 3 exhibits higher compressive strengths and faster hydration than LC 3 . Compared to hydrated LC 3 , hydrated VC 3 exhibits increased amount of hemi- and mono-carboaluminate formation and decreased amount of strätlingite formation. With gypsum adjustment, the 1-day strength of VC 3 is higher than that of pure cement reference. Finally, VC 3 , a low-CO 2 binder, presents great potential as a host of the metastable CaCO 3 for carbon storage and utilization and as an enabler of carbon capture at gigaton scales.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Mechanical response of composite materials with through-the-thickness reinforcement

An experimental investigation was conducted to identify the key geometrical parameters and quantify their influence on the mechanical response of through-the-thickness (TTT) reinforced composite materials. Composite laminates with TTT reinforcement fibers were fabricated using different TTT reinforcement materials and reinforcement methods and laminates were also fabricated of similar construction but without TTT reinforcement fibers. Coupon specimens were machined from these laminates and were destructively tested. TTT reinforcement yarns enhance damage tolerance and improve interlaminar strength. Thick-layer composites with TTT reinforcement yarns have equal or superior mechanical properties to thin-layer composites without TTT reinforcement yarns. A significant potential exists for fabrication cost reduction by using thick-layer composites with TTT reinforcement yarns. Removal of the surface loop of the TTT reinforcement improves compression strength. Stitching provides somewhat higher mechanical properties than integral weaving.

Farley, Gary L.↗
DOE OSTI2022

5.1.6 Demo #6: NanoStitch (NAWAStitch) Multifunctional Composites Trade Validation

The overall objective of the NanoStitch Multifunctional Composites Trade Validation Demonstration project was to determine the value proposition of adding NanoStitch to rapid-cure composite systems for structures used in the expanding sector of advanced air mobility (AAM) and specifically electric vertical take-off and landing (eVTOL) aircraft. The expected value proposition was stronger composite parts, with new multifunctional attributes, that are lower cost to fabricate and maintain. NanoStitch is a new composite innovation where a contiguous vertically aligned carbon nanotube (VACNT) forest is located between each ply of a laminate composite resulting in improved mechanical properties as well as other multifunctional properties such as enhanced thermal and electrical conductivity. NanoStitch was originally distributed by N12, later acquired by NAWA Technologies, now called NAWAStitch, and henceforth referred to in this document as NAWAStitch. Two significant evaluations were framed to help meet the overall objective. First, was Task 1 to evaluate the effects that adding NAWAStitch to a rapid cure material system would have on the mechanical and processing properties of the material. Second, was Task 2 to evaluate the workability of adding NAWAStitch to practical flight demonstration articles. From previous research, it was already known that the application of NAWAStitch to a composite structure can enhance the mechanical properties of that structure. However, this project will help the engineering community understand those benefits and the basic structural strength values to apply when incorporating NAWAStitch material into composite structure that utilizes a rapid-cure resin system, which is novel. Testing showed that by adding NAWAStitch to the prepreg, most material properties were improved because the VACNTs strengthened the resin to fiber interface, and the interface itself, between plies. For example compression strength improved by more than 20%, and erosion resistance by more than 50%. The UDRI team identified two flight demonstration articles through discussions with Aurora Flight Sciences (Aurora) and reviewing literature on air mobility and the eVTOL market. The demonstration articles were a thin skin honeycomb panel and a section from an eVTOL propeller blade. The manufacturing and testing trials of the demonstration articles were as follows: • NAWAStitch added no manufacturing complexity or detriment to the article physical qualities, while at the same time added multifunctional properties such as enhanced rain erosion and electrothermal de-icing besides enhanced mechanical properties • VACNTs did not increase or hurt the mechanical properties of the interface between honeycomb core materials and the thin skin face sheet • Demonstrated successful de-icing function in an eVTOL propeller meeting real-world specifications in uniformity and endurance • Multifunctional eVTOL propeller cost analysis showed a cost savings of at least 67 % for a single propeller blade with multifunctional de-icing capability and improved mechanical properties which equates to a potential savings of $10,116 per eVTOL aircraft with six three-bladed propellers Overall, the results of this project can provide additional tools for the composite industry to optimize energy efficiency through faster and stronger composite parts that are lower cost to fabricate and maintain. Additionally, the results of this effort can help US industry like NAWA America set the stage for rapid growth and establishment of a manufacturing facility in Ohio. The project has given NAWA America the basic understanding of how the addition of VACNTs to a composite structure can affect the mechanical properties and hence point them to potential commercial applications. The project has also provided Teijin Carbon US with another potential material application for their rapid cure materials that are manufactured at the Renegade facility in Miamisburg, OH.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A eutectic dual-phase design towards superior mechanical properties of heusler-type ferromagnetic shape memory alloys

Heusler-type ferromagnetic shape memory alloys possess attractive multifunctional properties, including magnetic field induced shape memory effect, magnetoresistance and magnetocaloric effect, owing to the unique concurrent magnetic and martensitic transformations. However, these intermetallics generally exhibit intrinsic high brittleness and low strength, which severely impede their workability for processing and applicability in real use. In this study, we demonstrate a new grain refining strategy by means of eutectic solidification to improve the mechanical properties in Ni-Mn-Sn-Fe alloys. In a fully eutectic microstructure, the average γ lamellae thickness was refined to ~170 nm and the composite showed a compressive strength of 1950 MPa, ductility of 19.5%, Young’s Modulus of 38 GPa, pseudoelasticity of 3.2% and high mechanical cyclic stability. The high mechanical performance is attributed to the effect of departmentalization of the brittle Heusler alloy by the densely distributed γ phase fine lamellae in resisting crack propagation. The eutectic Heusler composite exhibited a metamagnetic phase transformation, with a magnetic entropy change of 10.2 J/kg·K and a refrigeration capacity of 168 J/kg in a field change of 5 T.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Effect of Tartaric Acid on Hydration of a Sodium-Metasilicate-Activated Blend of Calcium Aluminate Cement and Fly Ash F

An alkali-activated blend of aluminum cement and class F fly ash is an attractive solution for geothermal wells where cement is exposed to significant thermal shocks and aggressive environments. Set-control additives enable the safe cement placement in a well but may compromise its mechanical properties. Here, this work evaluates the effect of a tartaric-acid set retarder on phase composition, microstructure, and strength development of a sodium-metasilicate-activated calcium aluminate/fly ash class F blend after curing at 85 °C, 200 °C or 300 °C. The hardened materials were characterized with X-ray diffraction, thermogravimetric analysis, X-ray computed tomography, and combined scanning electron microscopy/energy-dispersive X-ray spectroscopy and tested for mechanical strength. With increasing temperature, a higher number of phase transitions in non-retarded specimens was found as a result of fast cement hydration. The differences in the phase compositions were also attributed to tartaric acid interactions with metal ions released by the blend in retarded samples. The retarded samples showed higher total porosity but reduced percentage of large pores (above 500 µm) and greater compressive strength after 300 °C curing. Lastly, mechanical properties of the set cements were not compromised by the retarder.

15 GEOTHERMAL ENERGY↗
DOE OSTI2015

Fracture propagation in Indiana Limestone interpreted via linear softening cohesive fracture model

In this study, we examine the use of a linear softening cohesive fracture model (LCFM) to predict single-trace fracture growth in short-rod (SR) and notched 3-point-bend (N3PB) test configurations in Indiana Limestone. The broad goal of this work is to (a) understand the underlying assumptions of LCFM and (b) use experimental similarities and deviations from the LCFM to understand the role of loading paths of tensile fracture propagation. Cohesive fracture models are being applied in prediction of structural and subsurface fracture propagation in geomaterials. They lump the inelastic processes occurring during fracture propagation into a thin zone between elastic subdomains. LCFM assumes that the cohesive zone initially deforms elastically to a maximum tensile stress ( σ max ) and then softens linearly from the crack opening width at σ max to zero stress at a critical crack opening width w 1 . Using commercial finite element software, we developed LCFMs for the SR and N3PB configurations. After fixing σ max with results from cylinder splitting tests and finding an initial Young's modulus ( E ) with unconfined compressive strength tests, we manually calibrate E and w 1 in the SR model against an envelope of experimental data. We apply the calibrated LCFM parameters in the N3PB geometry and compare the model against an envelope of N3PB experiments. For accurate simulation of fracture propagation, simulated off-crack stresses are high enough to require inclusion of damage. Different elastic moduli are needed in tension and compression. We hypothesize that the timing and location of shear versus extensional micromechanical failures control the qualitative macroscopic force-versus-displacement response in different tests. For accurate prediction, the LCFM requires a constant style of failure, which the SR configuration maintains until very late in deformation. The N3PB configuration does not maintain this constancy. To be broadly applicable between geometries and failure styles, the LCFM would require additional physics, possibly including elastoplastic damage in the bulk material and more complicated cohesive softening models.

58 GEOSCIENCES↗
NASA NTRS2000

Directionally Solidified NiAl-Based Alloys Studied for Improved Elevated-Temperature Strength and Room-Temperature Fracture Toughness

Efforts are underway to replace superalloys used in the hot sections of gas turbine engines with materials possessing better mechanical and physical properties. Alloys based on the intermetallic NiAl have demonstrated potential; however, they generally suffer from low fracture resistance (toughness) at room temperature and from poor strength at elevated temperatures. Directional solidification of NiAl alloyed with both Cr and Mo has yielded materials with useful toughness and elevated-temperature strength values. The intermetallic alloy NiAl has been proposed as an advanced material to extend the maximum operational temperature of gas turbine engines by several hundred degrees centigrade. This intermetallic alloy displays a lower density (approximately 30-percent less) and a higher thermal conductivity (4 to 8 times greater) than conventional superalloys as well as good high-temperature oxidation resistance. Unfortunately, unalloyed NiAl has poor elevated temperature strength (approximately 50 MPa at 1027 C) and low room-temperature fracture toughness (about 5 MPa). Directionally solidified NiAl eutectic alloys are known to possess a combination of high elevated-temperature strength and good room-temperature fracture toughness. Research has demonstrated that a NiAl matrix containing a uniform distribution of very thin Cr plates alloyed with Mo possessed both increased fracture toughness and elevated-temperature creep strength. Although attractive properties were obtained, these alloys were formed at low growth rates (greater than 19 mm/hr), which are considered to be economically unviable. Hence, an investigation was warranted of the strength and toughness behavior of NiAl-(Cr,Mo) directionally solidified at faster growth rates. If the mechanical properties did not deteriorate with increased growth rates, directional solidification could offer an economical means to produce NiAl-based alloys commercially for gas turbine engines. An investigation at the NASA Glenn Research Center at Lewis Field was undertaken to study the effect of the directional solidification growth rate on the microstructure, room temperature fracture toughness, and strength at 1027 C of a Ni-33Al-31Cr-3Mo eutectic alloy. The directionally solidified rates varied between 7.6 and 508 millimeters per hour Essentially fault-free, alternating (Cr, Mo)/NiAl lamellar plate microstructures (left photograph) were formed during growth at and below 12.7 mm/hr, whereas cellular microstructures (right photograph) with the (Cr, Mo) phase in a radial spokelike pattern were developed at faster growth rates. The compressive strength at 1027 C continuously increased with increasing growth rate and did not indicate a maxima as was reported for directionally solidified Ni-33Al-34Cr. Surprisingly, samples with the lamellar plate microstructure (left photograph) possessed a room-temperature fracture toughness of approximately 12 MPa(sup square root of m), whereas all the alloys with a cellular microstructure had a toughness of about 17 MPa(sup square root of m). These results are significant since they clearly demonstrate that Ni-33Al-31Cr-3Mo can be directionally solidified at much faster growth rates without any observable deterioration in its mechanical properties. Thus, the potential to produce strong, tough NiAl-based eutectics at commercially acceptable growth rates exists. Additional testing and alloy optimization studies are underway.

Whittenberger, J. Daniel↗
NASA NTRS1956

Study of Size Effect in Sheet-stringer Panels

An investigation was conducted to determine whether there are significant size effects in compressive strength of large Z-stiffened sheet-stringer panels as compared with geometrically similar smaller models and thus to ascertain whether the prediction of the strength of large panels by model tests is reliable. The specimens studied were manufactured from 7075-T6 aluminum alloy and included four representative types of panel designs, with full- and one-quarter-scale panels of each type.

LOADS AND STRESSES, STRUCTURAL - COMPRESSION↗
DOE OSTI2018

Freeze-drying method as a new approach to the synthesis of polyurea aerogels from isocyanate and water

Polyurea (PUA) aerogels were prepared as the polycondensation product of triisocyanate and water. PUA aerogels were formed through supercritical drying (SC) and, for comparison, by freeze-drying (FD). The effect of isocyanate concentration, catalyst concentration, and drying method on properties like density, specific surface area, pore volume, compressive strength, and morphology was investigated. The properties of aerogels strongly depend on the concentration of the isocyanate in the parent solution and, to a lesser extent, on catalyst concentration. For example, aerogels with higher isocyanate concentration exhibited a higher surface area and modulus. Depending on the formulation, the materials had a density between 0.128 and 0.220 g/cm 3 , surface area between 140 and 210 m 2 /g, pore volume between 0.593 and 1.500 cm 3 / g, compressive modulus between 6.5 and 25 MPa, and thermal conductivity between about 0.028 and 0.033 W/m K. Most importantly, the drying method did not strongly affect the properties of the materials. These were within ~15% for SC and FD. Furthermore the results indicate that freeze-drying can be successfully used to fabricate aerogels in a cost-effective way.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Design of refractory multi-principal-element alloys for high-temperature applications

Abstract Refractory multi-principal-element alloys (RMPEAs) exhibit high specific strength at elevated temperatures ( T ). However, current RMPEAs lack a balance of room-temperature (RT) ductility, high- T strength, and high- T creep resistance. Using density-functional theory methods, we scanned composition space using four criteria: (1) formation energies for operational stability: $$-150\le {E}_{{\rm {f}}}$$ − 150 ≤ E f ≤ +70 meV per atom; (2) higher strength found via interstitial electron density with Young’s moduli E > 250 GPa; (3) inverse Pugh ratio for ductility: G / B < 0.57; and (4) high melting points: T m > 2500 °C. Using rapid bulk alloy synthesis and characterization, we validated theory and down-selected promising alloy compositions and discovered Mo 72.3 W 12.8 Ta 10.0 Ti 2.5 Zr 2.5 having well-balanced RT and high- T mechanical properties. This alloy has comparable high- T compressive strength to well-known MoNbTaW but is more ductile and more creep resistant. It is also superior to a commercial Mo-based refractory alloy and a nickel-based superalloy (Haynes-282) with improved high- T tensile strength and creep resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Heat-treated glassy carbon under pressure exhibiting superior hardness, strength and elasticity

Glassy carbon (GC) is a type of non-graphitizing disordered carbon material at ambient pressure and high temperatures, which has been widely used due to its excellent mechanical properties. Here we report the changes in the microstructure and mechanical properties of GC treated at high pressures (up to 5 GPa) and high temperatures. The formation of intermediate sp 2 –sp 3 phases is identified at moderate treatment temperatures before the complete graphitization of GC, by analyzing synchrotron X-ray diffraction, Raman spectra, and transmission electron microscopy images. The intermediate metastable carbon materials exhibit superior mechanical properties with hardness reaching up to 10 GPa and compressive strength reaching as high as 2.5 GPa, nearly doubling those of raw GC, and improving elasticity and thermal stability. The synthesis pressure used in this study can be achieved in the industry on a commercial scale, enabling the scalable synthesis of this type of strong, hard, and elastic carbon materials.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Advanced Numerical Model for Irradiated Concrete

In this report, we establish a numerical model for concrete exposed to irradiation to address these three critical points. The model accounts for creep in the cement paste and its coupling with damage, temperature and relative humidity. The shift in failure mode with the loading rate is also properly represented. The numerical model for creep has been validated and calibrated against different experiments in the literature [Wittmann, 1970, Le Roy, 1995]. Results from a simplified model are shown to showcase the ability of numerical homogenization to simulate irradiation effects in concrete. In future works, the complete model will be applied to the analysis of the irradiation experiments of Elleuch et al. [1972] and Kelly et al. [1969]. This requires a careful examination of the experimental environmental conditions as in both cases certain critical information are missing, including the relative humidity history. A sensitivity analysis will be conducted to provide lower and upper bounds of the concrete expansion under irradiation, and check if the scatter in the simulated results matches the one found in experiments. The numerical and experimental results will be compared in terms of expansion and loss of mechanical stiffness and strength. Both effects should be captured accordingly by the model to validate it. Once the model has been validated on these two experiments, it can be applied to simulate concrete from nuclear power plants. To do so, the materials used in these concrete must be as well characterized as possible. The main parameters required are the mechanical properties of each constituent in the concrete (aggregates, cement paste), namely the elastic modulus, the creep properties, the tensile and compressive strength, the thermal expansion coefficient, and the drying shrinkage. These can be either measured experimentally, estimated from the initial composition in the case of cement paste, or back-calculated from mechanical tests on concrete. If some are unknown, a sensitivity analysis must be carried out to provide lower and upper bounds of the material behaviour. Finally, the model can be used as a basis to formulate a macroscopic material model for concrete subject to irradiation, which later can be used in structural analyses to estimate the structural impact of irradiation on nuclear power plants.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Quality Investigation of Pultruded Carbon Fiber Panels Subjected to Four-Point Flexure via Fiber Optic Sensing

Pultruded carbon fiber-reinforced composites are attractive to the wind energy industry due to the rapid production of highly aligned unidirectional composites with enhanced fiber volume fractions and increased specific strength and stiffness. However, high volume carbon fiber manufacturing remains cost-prohibitive. This study investigates the feasibility of a pultruded low-cost textile carbon fiber-reinforced epoxy composite as a promising material in spar cap production was undertaken based on mechanical response to four-point flexure loading. As spar caps are primarily subjected to flexural loading, large-span four-point flexure was considered, and coupon testing was restricted to tensile modulus and compression strength assessment. High-resolution spatial fiber optic strain sensing was utilized to determine spatial strain distribution during four-point flexure, revealing consistent strain along the length of the part and proved to be an excellent option for process manufacturing quality examination. Additionally, holes with diameters of 2.49 mm, 5.08 mm, and 1.93 mm were drilled through the thickness of full-width parts to determine the feasibility of structural health monitoring of pultruding parts internal to wind blades via fiber optic strain sensing.

Chemistry↗
NASA NTRS1991

Damage development under compression-compression fatigue loading in a stitched uniwoven graphite/epoxy composite material

Damage initiation and growth under compression-compression fatigue loading were investigated for a stitched uniweave material system with an underlying AS4/3501-6 quasi-isotropic layup. Performance of unnotched specimens having stitch rows at either 0 degree or 90 degrees to the loading direction was compared. Special attention was given to the effects of stitching related manufacturing defects. Damage evaluation techniques included edge replication, stiffness monitoring, x-ray radiography, residual compressive strength, and laminate sectioning. It was found that the manufacturing defect of inclined stitches had the greatest adverse effect on material performance. Zero degree and 90 degree specimen performances were generally the same. While the stitches were the source of damage initiation, they also slowed damage propagation both along the length and across the width and affected through-the-thickness damage growth. A pinched layer zone formed by the stitches particularly affected damage initiation and growth. The compressive failure mode was transverse shear for all specimens, both in static compression and fatigue cycling effects.

Vandermey, Nancy E.↗
DOE OSTI2026

Peridynamic modeling of cementitious materials for nuclear waste management

Radioactive and hazardous waste generated from fuel processing plants, nuclear reactors, and hospitals, requires effective management strategies. Cementitious materials are widely applied for these needs, serving as structural materials, reactive barriers, or waste forms. In these applications cracking poses a significant risk to performance, driven by inconsistent shrinkage of the components and the varying strength and permeability of their interfaces. Traditional modeling approaches face challenges in representing the complex fracture behavior of cementitious materials due to the reliance on spatial derivatives and difficulties with mesh generation. Here, to overcome these limitations, we employ peridynamics, a novel continuum mechanics formulation that uses integrals to describe mechanical equilibrium, avoiding discontinuities associated with traditional methods. Through incorporation of a bi-linear softening model and quasistatics, an experimentally validated model for Portland cement concrete samples was created. Mechanical parameters, including compressive strength and elastic modulus were validated and variation due to aggregate packing was evaluated. Additionally, sensitivity analysis of the peridynamic parameters to the bulk material properties was established. The results lay the groundwork for evaluating the impact of unique conditions of cementitious waste forms that can be assessed to improve the reliability of waste management strategies.

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