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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Quantum Composites with Charge-Density-Wave Fillers

Here, a unique class of advanced materials—quantum composites based on polymers with fillers composed of a van der Waals quantum material that reveals multiple charge-density-wave quantum condensate phases—is demonstrated. Materials that exhibit quantum phenomena are typically crystalline, pure, and have few defects because disorder destroys the coherence of the electrons and phonons, leading to collapse of the quantum states. The macroscopic charge-density-wave phases of filler particles after multiple composite processing steps are successfully preserved in this work. The prepared composites display strong charge-density-wave phenomena even above room temperature. The dielectric constant experiences more than two orders of magnitude enhancement while the material maintains its electrically insulating properties, opening a venue for advanced applications in energy storage and electronics. The results present a conceptually different approach for engineering the properties of materials, extending the application domain for van der Waals materials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

In Situ Alloying Enabled by Active Liquid Metal Filler for Self‐Healing Composite Polymer Electrolytes

Abstract Solid inorganics, known for kinetically inhibiting polymer crystallization and enhancing ionic conductivity, have attracted significant attention in solid polymer electrolytes. However, current composite polymer electrolytes (CPEs) are still facing challenges in Li metal batteries, falling short of inhibiting severe dendritic growth and resulting in very limited cycling life. This study introduces Ga 62.5 In 21.5 Sn 16 (Galinstan) liquid metal (LM) as an active liquid alternative to conventional passive solid fillers, aiming at realizing self‐healing protection against dendrite problems. Compared to solid inorganics, for example silica, LM droplets could more significantly reduce polymer crystallinity and enhance Li‐ion conductivity due to their liquid nature, especially at temperatures below the polymer melting point. More importantly, LMs are unraveled as dynamic chemical traps, which are capable of blocking and consuming lithium dendrites upon contact via in situ alloying during battery operation and further inhibiting dendritic growth due to the lower deposition energy barrier of the formed Li‐LM alloy. As a proof of concept, by strategically designing an asymmetric CPE with the active LM filling, a solid‐state Li/LiFePO 4 battery achieves promising full‐cell functionality with notable rate performance and stable cycle life. This active filler‐mediated self‐healing approach could bring new insights into the battery design in versatile solid‐state systems.

Wu, Kai↗
DOE OSTI2021

Thermal stability of filler‐based ethylene/vinyl acetate/vinyl alcohol terpolymer in nitroplasticizer oxidative environment

Abstract To study the thermal stability of ethylene/vinyl acetate/vinyl alcohol (EVA‐OH) composite with filler particles, systematic thermogravimetric analysis (TGA) investigation was conducted in both nonisothermal and isothermal modes. The effect of polymer concentration on the aging behavior of EVA‐OH was investigated in the nitroplasticizer (NP) environment. Fourier transform infrared spectroscopy was used to probe chemical structural changes in the EVA‐OH polymer before and after thermal aging. The results suggest that filler addition accelerates the rate of NP exudation out of the EVA‐OH composites and deteriorates the thermal stability of NP at moderate temperatures (up to 70°C). The degradation of NP, in turn, accelerates the degradation of EVA‐OH polymer in its composite form through oxidation and hydrolysis indicating the importance of antioxidants in such phase blends.

36 MATERIALS SCIENCE↗
DOE OSTI2022

On the mechanism of performance improvement of electroactive polyvinyl chloride (PVC) gel actuators via conductive fillers

Abstract The electromechanical actuation of transparent plasticized polyvinyl chloride (PVC) gels with conductive fillers were studied. The effects of functionalized carbon nanotubes (CNTs) and 1-butyl-3-methylimidazolium tetrafluoroborate ([Bmim]BF 4 ) ionic liquid (IL) on both the electrical conduction and dielectric processes within PVC gels were investigated, and the differences between the two were clarified. Both CNTs and IL were shown to increase the conductivity of the gels and produce larger electromechanical transduction of a contraction actuator, but only CNTs were shown to increase the electrostatic adhesion force of the PVC gels. The addition of charge carriers to the gel via the inclusion of ILs was shown to significantly reduce the conductivity relaxation time, and the transient current upon voltage polarity reversal indicated multiple peaks corresponding to the introduction of carriers with different polarities and mobilities into the gel. This is believed to cause a screening effect, reducing the charge accumulation at the anode that is the foundational basis for PVC gels’ actuation mechanism. A recommendation for preferable conductive fillers for various applications is made.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Influence of functional additives, fillers, and pigments on thermal and catalytic pyrolysis of polyethylene for waste plastic upcycling

Pyrolysis offers a relatively green and economical method to convert waste plastics into valuable chemicals and fuels without the need for harmful solvents, toxic chemicals, or costly high-pressure reactors. Despite its popularity among chemical upcycling technologies, industrial adoption suffers from feedstock heterogeneity, low-quality products, and catalyst deactivation. Most plastics in our daily lives are formulated with functional additives, fillers, and colorants. These additives remaining in end-of-life waste streams increase feedstock heterogeneity, creating a challenging issue in recycling plastics. Still, the potential impacts of additives on the chemical upcycling of plastics have been poorly understood. In this study, polyethylene compounded with a range of widely used additives (antioxidants, stabilizers, pigments, fillers, slip agents, and flame retardants) was subjected to both thermal pyrolysis and catalytic pyrolysis in different catalyst-to-feedstock contact modes. It showed that many inorganic additives, such as talc, kaolin, CaCO 3 , TiO 2 , carbon black, and zinc stearate, facilitated polymer decomposition during pyrolysis, increasing light hydrocarbons while also promoting aromatic and carbon residue formation. Conversely, antioxidants and stabilizers inhibited depolymerization, favoring heavier hydrocarbons. During catalytic pyrolysis with HZSM-5 zeolite, additives strongly enhanced aromatic and catalytic coke formation, especially when there was direct contact between plastics and catalysts. Although certain additives seem beneficial in the short term by promoting polymer cracking and improving the selectivity of aromatics, the transport of the additives and their degradation products and increased carbon coking can contaminate products, deactivate or modify catalysts, and foul reactors. These findings address a critical knowledge gap in effectively converting waste plastics via a greener route.

42 ENGINEERING↗
DOE OSTI2020

Polymer Composites Reinforced by Carbon-Allotrope Fillers for Selective Laser Sintering (SLS) - A Review

The limited commercial availability of applicable polymer powders has hindered the widespread implementation of SLS as a legitimate manufacturing method. This is partly due to the mechanism of SLS, which requires powders to meet rigid specifications if processing is to be successful. Furthermore, powders that do meet requirements are often incapable of producing quality, high-performance parts. Academic and industrial research has focused on composite development to overcome this problem. The incorporation of fillers including calcium carbonate, molybdenum disulfide, and aluminum have all been found to influence the processing behavior of PA12 powder and ultimately, the properties of the final part.3-5 Here, the thermal and mechanical properties of sintered composite parts produced using polymer powders reinforced by various carbon-based fillers is discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Joint Work Plan for DPC Filler Testing

The US generates approximately 2,000 Metric Tons of Heavy Metal (MTHM) of commercial spent fuel (SNF) each year and currently stores ~ 85,000 MTHM of commercial SNF at 70+ reactor sites, the disposal of which is the responsibility of the US Department of Energy (DOE). SNF is initially stored in spent nuclear fueld pools (SFPs). SFPs were initially constructed by US utilities for temporary fuel storage, but with no final disposal pathway available, SFPs are reaching capacity. To allow continued operation of the nation's commercial nuclear reactor fleet, utilities started transferring SNF from SFPs (wet storage) to dry cask storage systems, typically using dual-purpose (storage and transportation) canisters (DPCs). And while DPCs were designed, licensed and loaded to meet Nuclear Regulatory Commission (NRC) requirements that preclude the possibility of a critical event during SNF storage and transport, they were not designed or loaded to preclude the possibility of a criticality event during the regulated post-closure period following disposal, which could be up to 1,000,000 years (Price, 2019). DPC filler option criteria are detailed and materials that exhibit these attributes are explored. This document is an update of the SNL Joint Workplan on Filler Investigations for DPCs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Effects of Structure and Filler on Mechanical Properties of Direct Ink Write Pads

Direct ink write (DIW) is an extrusion-based additive manufacturing (AM) technique that enables superior repeatability, property tuning, and material customization compared to conventional manufacturing techniques. In this research, DIW is used to print silicone foams that must accommodate the thermal expansion of other parts. This expansion requires the material to compress and subsequently recover. Thus, a key performance metric is reducing “compression set” or deformation retained after the material is compressed. For this study, a silicone resin was compounded with a getter material, 1,4 bis(phenylethynyl)benzene (DEB) mixed with carbon-supported palladium (Pd) and printed in a variety of lattice structures. The effects of the filler and print structure on compression set were evaluated. In these experiments, 0.5-inch diameter coupons were compressed to 75% their original height for 22 hours at 70 °C, and the change in height calculated at intervals between 30 minutes and 24 hours post-decompression. The unfilled pad with skin layers had the best compression set at 0.7% ± 0.1%, followed by the unfilled pad with no skins at 1.5% ± 0.1%. As the number of filled layers increased, compression set performance degraded. The pad with filled skin layers and all filled layers had a compression set of 7.0% ± 0.3%. Additionally, the reaction extent of DEB was found to increase compression set, possibly due to the diffusion of DEB to the surface at elevated temperatures. Imaging reveals extensive crystallization at the surface. These investigations show that a non-reinforcing filler will increase compression set but that print structure can mitigate this effect.

36 MATERIALS SCIENCE↗
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↗
NASA NTRS1967

Composite weld rod corrects individual filler weaknesses

Composite filler wire welds together an assembly made from components of Rene 41 nickel base alloy. Using equal parts of Rene 41 and Hastelloy W weld wire in the filler reduces the cracking and weaknesses of the individual parent metals.

Grimaldo, S.↗
NASA NTRS1970

Filler-wire positioner for electron beam welding

Miniaturized positioner is installed in any electron beam vacuum chamber for use with wire feed applications requiring filler wire. Horizontal and vertical control of the positioner is maintained from a console while chamber is under vacuum. Device permits more positive positioning of welding filler wire.

Beaupre, W. M.↗
NASA NTRS1973

Some possible filler alloys with low vapor pressures for refractory-metal brazing

A compilation of eutectics and melting-point minima for binary combinations of metals having vapor pressures below 10 to the minus 10th power torr at 1500 degrees K and .00005 torr at 2000 degree K is presented. These compositions and others near them on their phase diagrams are potential special brazing fillers for refractory metals. Some possible problems and advantages for fusion bonds of such mixtures are indicated. Evaluations of brazing fillers containing refractory metals are reported.

Morris, J. F.↗
NASA NTRS1978

Intumescent-ablator coatings using endothermic fillers

An intumescent-ablator coating composition which contains the ammonium salt of 1,4-nitroaniline-2-sulfonic acid or 4,4 dinitrosul fanilide, a polymeric binder system and about 5 to 30% weight of an endothermic filler is reported. The filler has a decomposition temperature about or within the exothermic region of the intumescent agent.

Sawko, P. M.↗
NASA NTRS1979

Study of austenitic stainless steel welded with low alloy steel filler metal

The tensile and impact strength properties of 316L stainless steel plate welded with low alloy steel filler metal were determined. Tests were conducted at room temperature and -100 F on standard test specimens machined from as-welded panels of various chemical compositions. No significant differences were found as the result of variations in percentage chemical composition on the impact and tensile test results. The weldments containing lower chromium and nickel as the result of dilution of parent metal from the use of the low alloy steel filler metal corroded more severely in a marine environment. The use of a protective finish, i.e., a nitrile-based paint containing aluminum powder, prevented the corrosive attack.

Burns, F. A.↗
NASA NTRS1982

Prolonging the Life of Refractory Fillers

Useful life of a refractory glass cloth gap filler is increased by coating it with a suspension of silicon carbide in butanol and polyethylene. Coating is applied to the refractory filler that seals gaps between insulating tiles on the Space Shuttle orbiter. Silicon carbide coating prevents embrittlement at high temperatures such as those encountered on reentry into Earth's atmosphere.

Schomburg, C.↗
NASA NTRS1982

Wind-Resistant Filler for Tile Gaps

Filler developed for gaps between insulating tiles on Space Shuttle finds application in industries that use tiles for thermal or environmental protection. Filler consists of tight-fitting ceramic tubes and fibrous alumina. Combination resists high wind loads while providing requisite heat protection. Quartz-thread stitching holds envelope together.

Bellavia, J.↗