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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
NASA NTRS1993

An engineering model of woven composites based on micromechanics

Composites with three-dimensional woven architectures exhibit large strains to failure when compared to composites made up of the same materials but not with three-dimensional interlocking tows. The fracture mechanics of such three-dimensional architectures is a subject requiring substantial investigation and experimental testing. Classical fracture mechanics concepts (for instance, an isolated defect in a homogeneous body) will not be applicable to the woven fracture test specimen. The use of an isolated singularity to characterize an entire specimen is inadequate when the density of defects is considerable and the material is heterogeneous. Modelling of such a complex system requires a great deal of insight and consideration as well as prudent choices of model sizes to make numerical schemes feasible. The purpose of this manuscript is to review our recently acquired knowledge of damage accumulation in woven composites and to describe a practicable model of the macroscopic behavior in these and other complex composite architectures based on such knowledge. In this manuscript, discussion will be limited to uniaxial compressive loading; considerations of general loading (monotonic and cyclic) will appear in a subsequent manuscript. Our modelling efforts may be briefly described as follows: the composite is subdivided into microstructural elements (microelements) in which the micromechanical modelling is either understood rigorously or can be represented adequately by statistical parameters. There can be microstructural elements for many different types of composite components, such as the various types of warp and weft and matrix for three-dimensional woven composites. The physical dimensions of microelements are made as large as possible while the response within the element can still be represented by a single micromechatlical calculation. The various elements are linked together(sometimes by associating distinct corners and edges, sometimes by superposition) in a pattern which resembles a particular weave architecture. The model can then be loaded in any manner and the linear and nonlinear elastic responses of representative weaves can be calculated. After the elastic regime, the fracture response is determined by monitoring the damage accumulation.

Carter, W. C.↗
NASA NTRS2018

Alignment and Bonding of Silicon Mirrors for High-Resolution Astronomical X-Ray Optics [10699-141]

Future large x-ray astronomy missions require large area and high resolution. The present consensus is to integrate thin, lightweight, segmented mirrors to form a compact but large telescope with high resolution (better than 1 sec). Key technologies: 1) Accurate mirror substrates: polishing high quality mono-crystalline silicon. 2) Stress-free reflective coating: stress-based distortion cancellation. 3) Precise alignment and integration: kinematic mounting and distortion-free bonding. Four-point alignment for quasi-cylindrically symmetric mirrors (segments) - 4-Point alignment: Pitch and yaw angles, image center (X, Y) are controlled by heights of the 4 mount points; Alignment Precision: better than 1 sec; Bonding error: approx. 0.1 micrometers (approx. 1 sec); Current single mirror pair x-ray tested: 3 sec (Half-Power Diameter). Integration into (meta) shell: Shell structure has rotationally defined axis; Interlocking mirrors means lightweight, mechanically strong telescope.

Chan, Kai-Wing↗
NASA NTRS1991

Regolith-structure modeling

Early lunar missions have provided a basic understanding of the physical and strength properties of lunar regolith, which have been shown to differ from those of dry terrestrial granular soils. Lunar regolith is predominantly a fine sand of which nearly 40 percent can be characterized as silt with a particle size smaller than 100 micrometers. The top 10 to 20 cm of the regolith can be characterized as being in a loose to medium-loose state. The density of the regolith, however, rapidly increases below a depth of 20 cm. The highly irregular and angular shapes of the regolith particles tend to interlock and create relatively strong mechanical bonds that give the particulate mass substantial cohesive properties and smaller amounts of tensile strength properties. In addition, the friction angle of lunar regolith at medium to high densities is quite high and often exceeds 55 degrees. These known properties of lunar regolith have been matched in a terrestrially-manufactured analog known as Minnesota Lunar Simulant. A variety of experiments were conducted using this simulant to both verify existing information and generate new information on the physical and constitutive properties of lunar regolith. These experiments include maximum and minimum density determinations, specific mass of solids, grain-size distribution, conventional triaxial compression and extension, isotropic compression, one-dimensional compression, direct shear, and direct tension. Direct shear experiments were conducted under atmospheric and vacuum conditions. Results of the physical and strength experiments compare closely to results obtained from lunar missions. Results of simulant strength experiments performed in vacuum indicated no observable difference from results obtained in air. A test bed currently under study is one involving a regolith shield covering a first-generation human habitat module. It is understood that regolith in depths ranging from 3 to 5 meters is required for radiation shielding for habitation and workspace. The habitat module is treated as a rigid cylindrical tube with a smooth exterior. By making the cylinder rigid, a complex interaction problem is reduced to a situation where we can consider the support regolith and the shielding regolith as behaving independently of the structural properties of the cylindrical structure. Medium-dense lunar simulant was placed around a scaled model of the habitat module to provide a radiation shield. This embankment-type shield was constructed in relatively thin but fine layers by compacting, by mechanical vibratory means, layer upon layer of simulant placed adjacent to the horizontally-aligned cylinder. The slope angles were constructed at 55 degrees. The model described above was studied in a geotechnical centrifuge, which allows for the scaling of model dimensions to prototype dimensions by increasing the acceleration of gravity on the model. The deformation response can be scaled up to prototype dimensions to provide an assessment of the deformation patterns of the lunar structure. The actual process of local and/or global growth of instabilities or skip planes can also be observed.

Ko, Hon-Yim↗
NASA NTRS1992

Mechanisms of compressive failure in woven composites and stitched laminates

Stitched laminates and angle interlock woven composites have been studied in uniaxial, in-plane, monotonic compression. Failure mechanisms have been found to depend strongly on both the reinforcement architecture and the degree of constraint imposed by the loading grips. Stitched laminates show higher compressive strength, but are brittle, possessing no load bearing capacity beyond the strain for peak load. Post-mortem inspection shows a localized shear band of buckled and broken fibers, which is evidently the product of an unstably propagating kink band. Similar shear bands are found in the woven composites if the constraint of lateral displacements is weak; but, under strong constraint, damage is not localized but distributed throughout the gauge section. While the woven composites tested are weaker than the stitched laminates, they continue to bear significant loads to compressive strains of approx. 15 percent, even when most damage is confined to a shear band.

Cox, B. N.↗
NASA NTRS1993

Effect of tow alignment on the mechanical performance of 3D woven textile composites

Three-dimensional (3D) woven preforms are currently being considered for use as primary structural components. Lack of technology to properly manufacture, characterize and predict mechanical properties, and predict damage mechanisms leading to failure are problems facing designers of textile composite materials. Two material systems with identical specifications but different manufacturing approaches are investigated. One manufacturing approach resulted in an irregular (nonuniform) preform geometry. The other approach yielded the expected preform geometry (uniform). The objectives are to compare the mechanical properties of the uniform and nonuniform angle interlock 3D weave constructions. The effect of adding layers of laminated tape to the outer surfaces of the textile preform is also examined. Damage mechanisms are investigated and test methods are evaluated.

Norman, Timothy L.↗
DOE OSTI2026

Can classical DEM simultaneously capture compressibility and flowability of milled biomass?

Accurate prediction of the rheological behavior of biomass is essential for the design and operation of hoppers, feeders, and storage systems in biorefineries. This study examines whether the classical, coarse-grained discrete element method (DEM) formulation can simultaneously reproduce the compressibility and flowability of milled herbaceous biomass, using Miscanthus × giganteus as a representative material. The model represents particles as rigid spheres interacting through Hertz-Mindlin elastic-frictional contacts augmented with an area-dependent cohesion term. Laboratory cyclic compression and wedge-shaped hopper discharge experiments were used as calibration benchmarks. Although the model can independently reproduce each behavior by appropriately tuning particle Young's modulus E and cohesion energy density k, an extensive parametric investigation comprising more than 600 simulations reveals that the optimal parameter regions for compression and hopper flow are distinct and non-overlapping in (E, k) space. Surrogate surface analysis further shows that the corresponding objective-function valleys exhibit similar trends but are approximately parallel and spatially offset, precluding a unified calibration within the explored domain. Sensitivity analysis indicates that compressibility is governed predominantly by stiffness and cohesion, whereas the slope of the mass flow rate-opening relation in hopper discharge is primarily controlled by tangential friction. Extensions incorporating particle size distribution and clumped-sphere representations do not eliminate the incompatibility. These results systematically reveal, for the first time, the structural limitation of simplified DEM formulations in representing biomass rheological behavior, underscoring the necessity for models incorporating additional physical mechanisms, such as particle deformability or enhanced interlocking, to achieve unified predictive capability for biomass handling behavior.

09 BIOMASS FUELS↗
DOE OSTI2020

Joining of Thermoset Carbon Fiber Reinforced Polymer and AZ31 Magnesium Alloy Sheet Via Friction Stir Interlocking

A new technique called friction stir interlocking (FSI) was applied for lap-joining of AZ31 magnesium sheet and thermoset carbon fiber reinforced polymer (TS-CFRP) sheet. Instead of directly joining AZ31 and TS-CFRP, a series of magnesium interlocks were used to friction stir weld with AZ31 sheet to enable joining with TS-CFRP. Microstructural characterization of joint cross sections showed that a tool rotation rate of 800 rpm produced incomplete mixing of magnesium interlocks and the top AZ31 sheet, while 1200 rpm achieved sufficient material mixing to avoid unwelded regions. Mechanical property characterization showed that AZ31/TS-CFRP dissimilar joints failed through the magnesium interlock shanks during lap shear tensile testing, with a maximum normalized joint strength reaching ~100 MPa.

Wang, Tianhao↗
NASA NTRS1992

Mechanisms of compressive failure in 3D composites

The present study of angle-interlock woven polymer matrix composite behavior under uniaxial monotonic compression notes these materials to be macroscopically ductile, with compressive strains in failure that can exceed 15 percent. Some of the tests conducted on stitched laminates indicated brittle behavior. Woven composite failure mechanisms have been studied by a combination of optical microscopy, moire interferometry, stereoscopy, and digital image comparisons; the critical failure event was in all cases a kink band formation in the primary load-bearing axial rows.

Cox, B. N.↗
DOE OSTI2020

Laser powder bed fusion of Inconel 718 on 316 stainless steel

The joining of Inconel 718 and 316 stainless steel has notable industrial importance. However, traditional arc-welding has many issues. In particular, the formation of the detrimental Nb-rich Laves phase in the heat affected zone can promote crack initiation and propagation, which leads to poor mechanical properties. The small heat input and the rapid solidification of laser powder bed fusion (PBF) has the potential to suppress this problem. Despite the infancy of the multi-material PBF, it is of interest to investigate the relationship among the process parameter, the microstructure at the materials joining point, and the mechanical performance. In this study, we used high-speed x-ray imaging to in-situ monitor the printing of Inconel 718 tracks on a 316H SS substrate via laser powder bed fusion, followed by post-build characterization and testing with SEM, XRD and nanoindentation. We observed that a higher linear energy density resulted in a more diffused interface and a smaller compositional gradient, but as a trade-off, generated more keyhole pores and thermal cracks. Furthermore, we also showed that the built layer exhibited chemical inhomogeneity at two length scales: a tens-of-mu m-scale compositional vortex due to the melt flow, and a sub-mu m-scale Nb-rich dendritic structure due to the non-equilibrium solidification that led to the formation of the Laves phase. It was inferred that the chemical inhomogeneity may benefit the mechanical properties at the interface by providing more interlocking between the two materials and also by limiting the effect of the brittle Laves phase to potentially short range.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Vibration mitigation in interlocking metasurfaces

Interlocking metasurfaces (ILMs) are a new class of mechanical metamaterials with patterned surface features that enable joining of two adjacent bodies, serving as an alternative to welds, fasteners, or adhesives. While the strength of ILMs has been explored previously, it is also possible to envision ILMs that possess the ability to dampen vibration or tailor energy transmission across the interface. In this study, we explore the vibration transmission under frequency sweep and random excitation of three ILM designs. This is the first study to characterize the response of ILMs under vibration. We find that ILMs which are tightly coupled (e.g., small interference fit) behave as a linear system and depart only marginally from the behavior of a solid body. However, through strategic manipulation of the ILM topology, and in particular the fit clearances, we show that vibrations can be damped by over an order of magnitude. Design strategies to employ ILMs for vibration mitigation are developed using a first-order model.

Bolmin, O. [Carnegie Mellon Univ., Pittsburgh, PA ↗
DOE OSTI2025

Topotaxially grown composite cathodes for cobalt-free high-energy long-life Li-ion batteries

The vehicle industry’s increasing demand for electrification necessitates the removal of expensive and rare cobalt from current high-energy batteries. However, eliminating cobalt poses challenges due to its vital role in maintaining the layered structural ordering and cycling stability of commonly used Li(NiMnCo)O 2 cathodes. As an alternative to conventional layered oxide designs, we report a lithium nickelate cathode with a composite structure comprising major stoichiometric layered and minor rocksalt phases within the same oxygen lattice. This material outperforms conventional designs by maintaining stable battery operation at voltages up to 4.8 V vs. Li|Li + , with 88% capacity retention after 1000 cycles at 2C. The topotaxial-growth-enabled interlock between the two components mitigates chemo-mechanical degradation, offering a promising pathway to cobalt-free cathodes. Additionally, we reveal a miscibility gap in the Li-Ni-O system that enables kinetic adjustment of composition and structure during sintering, thereby tuning the functionality of high-energy cathodes.

25 ENERGY STORAGE↗
DOE OSTI2024

Designing a Dynamic Material via Interlocking Kraft Lignin with Ultrahigh Molecular Weight Poly(ethylene oxide)

The environmental issues stemming from plastic waste and the excessive use of petroleum-based chemicals are both concerning and urgent. To effectively address this problem, we need to adopt a comprehensive approach involving developing more sustainable and renewable materials. These materials should be capable of demonstrating similar or even better performance than functional polymers synthesized from petroleum-based chemicals. Our research aims to develop more sustainable materials by leveraging the intrinsic characteristics of a natural polymer, lignin, a byproduct of the biorefinery industries. We utilized the three-dimensional branching structure of lignin as a material framework. We employed an approach to co-reactive melt processing of kraft lignin with aliphatic flexible chains of soft cross-linkers through the reaction of the cross-linker epoxy chain ends with lignin functional groups. Our study demonstrates that the interlocked structure formed from the co-blending of kraft lignin with ultrahigh molecular weight poly(ethylene oxide) and the cross-linking of lignin chains through a solvent-free process can manipulate the macromolecular interactions and relaxation. This manipulation results in materials that exhibit a wide range of thermomechanical properties and self-healing and shape memory effects, with drastically improved stiffness in a single material. We have explored the fundamental understanding of the macromolecular chain relaxation dynamics originating from the interlocking structure formation. In conclusion, this investigation utilized various techniques, including thermal, mechanical, rheology, and quasi-elastic neutron scattering.

36 MATERIALS SCIENCE↗
NASA NTRS1989

Fracture toughness of polycrystalline ceramics in combined mode I and mode II loading

The present investigation of the fracture of alumina and zirconia polycrystalline ceramic specimens of precracked-disk type, in diametral compression, evaluated fracture toughness in pure mode I, combined mode I/mode II, and pure mode II, depending on the alignment of the center crack relative to the loading diameter. The mixed-mode fracture-toughness envelope thus obtained exhibits significant deviation to higher fracture toughness in mode II, relative to the predictions of linear elastic fracture mechanics theory. Crack-surface resistance due to grain-interlocking and abrasion are identified as the primary sources of increased fracture resistance in mode II loading of the polycrystalline ceramics.

Singh, Dileep↗
DOE OSTI2026

Multi-Objective design of interlocking metasurfaces using conditional diffusion models

Unit cell design remains a major challenge for interlocking metasurfaces, a promising joining technology for dissimilar materials, due to the complex, competing, multivariate design space and the need for rapid adaptation to varying performance requirements. This study explores Conditional Diffusion Models as a design optimization tool for interlocking metasurfaces. Given the complex, competing, multivariate design space for interlocking metasurfaces, unit cell design remains a major challenge for this joining technology. We trained a conditional diffusion model on 25,000 finite element analysis-simulated interlocking metasurface unit cells to generate designs with tailored thermo-mechanical properties (tensile strength, shear strength, and thermal conductivity) based on specified performance criteria. The model demonstrated a success rate of approximately 72 % in producing designs that met specified property bounds. The conditional diffusion model generated both thermally resistive and conductive designs, revealing clear trends in design characteristics: taller, dendritic structures were advantageous for tensile loads, while shorter, robust designs excelled in shear applications. Our findings indicate that the model's performance is more influenced by the breadth of the design space than by the quantity of training data, highlighting the importance of expansive design domains for generating innovative solutions. This work establishes conditional diffusion models as a highly efficient and adaptable tool for rapid interlocking metasurface unit cell design, paving the way for advancements in multi-material joining technologies, as well as highlighting the justification to leverage conditional diffusion models as design tools across complex design domains.

Conditional diffusion models↗
NASA NTRS1989

Analysis of particulates of comet nucleus samples: Possible use of olivine as indicator phase

The electron microprobe is a proven instrument for particulate analysis and modifications are possible for in situ analysis of particulates in ice at temperatures near that of liquid nitrogen. Present sample requirements allow for polished samples with 0.25 x 0.25 dimensions to be maintained in the sample chamber of a modern electron probe (CAMECA SX-50) at a temperature of -150 C; larger samples are possible but at higher temperatures as determined by thermal conductivity. The major problem is transport and insertion of samples into the instrument through vacuum interlocks. The manufacturer of the above microprobe has designed an exchange mechanism to allow storage and transport of samples previously prepared for their sample holder which attaches to their instrument allowing extraction and insertion of samples while maintaining -150 C temperature. An important test will be the capability of preparing polished surfaces of an ice-particulate sample without loss of particles and at low temperatures. While thin sections of water ice are routine, these are not examined for particulate material and are prepared at temperatures easily obtained in room-size volumes. Anticipated problems include rounding of small grains in the relatively soft ice matrix and the technical problem of dry polishing.

Steele, I. M.↗
DOE OSTI2021

A review of technologies for welding magnesium alloys to steels

Here we review various state-of-the-art methods for welding magnesium alloys and steels using different joint configurations. Microstructural characterizations indicate that four microstructures may form at the Mg/steel interface after welding: unwelded gap, metal oxides, solid solutions, or intermetallic compounds. Reaction products at the Mg/steel interface vary with different welding methods, alloying elements in base materials, interlayers or coatings applied, and preparations of base material before welding. Regarding mechanical property characterization, (a) lap tensile shear testing for lap-welded and spot-welded joints, (b) tensile testing for butt-welded joints and (c) fatigue properties of lap-welded and spot-welded joints are summarized and compared, separately. Reaction products at the Mg/steel interface are correlated with mechanical properties. Finally, ways to enhance Mg/steel joint strength, such as introducing interlocking features during friction stir lap and butt welding, are discussed.

Wang, Tianhao↗
DOE OSTI2023

Final Technical Report

The project goal is to demonstrate low-cost, interlocking, and carbon-storing insulation materials with thermal insulation of R5/inch, flexural modulus > 10 MPa, low material price < $ 0.5/ft2 wall area (materials cost for ½” thick panel), and net embodied carbon of 0.8t net CO2e/t (60% reduction compared to gypsum), respectively, which can meet the cost and performance targets of department of energy (DOE)’s 2050 climate target. To achieve this goal, the project plans three tasks, and each has a specific objective: 1) Modular design and engineering analysis of interlocking insulation panel blocks using biogenic materials (cellulose, straw, etc.): with the consideration of potential assembling and recycling. 2) Scalable manufacturing of biogenic-based interlocking insulation panels: scale up the modular panel production using ambient pressure drying and surface superhydrophobic modification at 1ft*1ft with the potential for further scalable mass production of 4ft*4ft. 3) Code-compliant testing, recycling and carbon footprint analysis of manufactured interlocking insulation panels examined using ASTM standards of thermal insulation (ASTM C518), mechanical properties (ASTM C1161), and water vapor transmission (ASTM E96).

Ren, Shenqiang↗