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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 NTRS1980

Predicting the time-temperature dependent axial failure of B/A1 composites

Experimental and theoretical studies were conducted in order to understand and predict the effects of time, temperature, and stress on the axial failure modes of boron fibers and B/A1 composites. Due to the anelastic nature of boron fiber deformation, it was possible to determine simple creep functions which can be employed to accurately describe creep and fracture stress of as-produced fibers. Analysis of damping and strength data for B/6061 A1 composites indicates that fiber creep effects of creep on fiber fracture are measurably reduced by the composite fabrication process. The creep function appropriate for fibers with B/Al composites was also determined. A fracture theory is presented for predicting the time-temperature dependence of the axial tensile strength for metal matrix composites in general and B/A1 composites in particular.

Dicarlo, J. A.↗
NASA NTRS1980

Predicting the time-temperature dependent axial failure of B/Al composites

Theoretical and experimental studies are reviewed whose objective was to gain insight into and predict the effects of time, temperature, and stress on the axial failure modes of boron fibers and B/Al composites. Owing to the inelastic nature of boron fiber deformation, it proved possible to develop simple creep functions which can be used to describe accurately the creep and fracture stress of as-produced fibers. Analysis of damping and stress data for B/6061 Al composites indicates that fiber creep and the effects of creep of fiber fracture are measurably reduced by the composite fabrication process.

Dicarlo, J. A.↗
NASA NTRS1979

Carbon Fibers and Composites

The basic nature of composite materials is considered. Carbon fiber composites and their area of current and planned application in civil aircraft are discussed, specifically within the framework of the various aspects of risk analysis.

Pride, R. A.↗
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 NTRS1992

Fracture resistance development in ceramic composites with nonlinear fiber pullout relationship

This paper addresses the fracture resistance mechanism in fiber reinforced ceramics, and focuses attention on the specific effects associated with nonlinear nature of the fiber pullout mechanism. The model is based on a consideration of the representative boundary value problem typical for the bridging process. The theoretical solution includes an accurate account of the nonlinear fiber matrix friction. The developed approach allows consideration of several types of nonlinear fiber pullout-force dependence. The distinct features of the nonlinear process demonstrate that, contrary to the linear case, the universal fracture resistance curves cannot be developed in cases with significant nonlinear contribution in the fiber friction law. The resulting resistance curves depend strongly on the absolute values of the matrix fracture toughness. On the other hand, these distinct patterns may be used for identification of the particular friction law and determination of the friction parameters.

Rubinstein, Asher A.↗
DOE OSTI2024

Process Optimization of Carbon Electrode Materials Manufacturing by Experimental Study and Machine Learning Techniques

Electrospun carbon fibers from coal have been investigated as electrodes for batteries and supercapacitors. Despite the excellent properties of coal-derived carbon fibers (CCNF) for energy storage devices, there still lacks systematic understanding on how various process parameters affect final electrode performances, which poses challenges to scale from pilot to high volume manufacturing. The goals of this project are twofold. First, we focuse on process optimization for converting a new precursor from powder river basin (PRB) coal, referred to as coal-based polyurethane (CPU) to CCNF using electrospinning. Second, different machine learning techniques will be examined using experimental data from this work and open literature. Specifically, for CPU the following process parameters need to be characterized and optimized in order to produce CCNFs with desirable mechanical integrity and physiochemical properties: precursor composition and viscosity, operating voltage and distance, oxidation and carbonization temperature and duration. Consequently, physiochemical properties of the fibers were characterized to correlate these process parameters with desirable electrochemical performance. Given the complex nature of the fiber production process, ML models are assessed for their ability to capture the nonlinear relationship between process parameters and the electrochemical properties in applications including supercapacitors. As such, we applied various machine learning techniques, to determine which technique produces a model that best predicts device function.

Cincotta, Robert E.F.↗
NASA NTRS2010

Software Development to Assist in the Processing and Analysis of Data Obtained Using Fiber Bragg Grating Interrogation Systems

A fiber Bragg grating is a portion of a core of a fiber optic stand that has been treated to affect the way light travels through the strand. Light within a certain narrow range of wavelengths will be reflected along the fiber by the grating, while light outside that range will pass through the grating mostly undisturbed. Since the range of wavelengths that can penetrate the grating depends on the grating itself as well as temperature and mechanical strain, fiber Bragg gratings can be used as temperature and strain sensors. This capability, along with the light-weight nature of the fiber optic strands in which the gratings reside, make fiber optic sensors an ideal candidate for flight testing and monitoring in which temperature and wing strain are factors. A team of NASA Dryden engineers has been working to advance the fiber optic sensor technology since the mid 1990 s. The team has been able to improve the dependability and sample rate of fiber optic sensor systems, making them more suitable for real-time wing shape and strain monitoring and capable of rivaling traditional strain gauge sensors in accuracy. The sensor system was recently tested on the Ikhana unmanned aircraft and will be used on the Global Observer unmanned aircraft. Since a fiber Bragg grating sensor can be placed every halfinch on each optic fiber, and since fibers of approximately 40 feet in length each are to be used on the Global Observer, each of these fibers will have approximately 1,000 sensors. A total of 32 fibers are to be placed on the Global Observer aircraft, to be sampled at a rate of about 50 Hz, meaning about 1.6 million data points will be taken every second. The fiber optic sensors system is capable of producing massive amounts of potentially useful data; however, methods to capture, record, and analyze all of this data in a way that makes the information useful to flight test engineers are currently limited. The purpose of this project is to research the availability of software capable of processing massive amounts of data in both real-time and post-flight settings, and to produce software segments that can be integrated to assist in the task as well. The selected software must be able to: (1) process massive amounts of data (up to 4GB) at a speed useful in a real-time settings (small fractions of a second); (2) process data in post-flight settings to allow test reproduction or further data analysis, inclusive; (3) produce, or make easier to produce, three-dimensional plots/graphs to make the data accessible to flight test engineers; and (4) be customized to allow users to use their own processing formulas or functions and display the data in formats they prefer. Several software programs were evaluated to determine their utility in completing the research objectives. These programs include: OriginLab, Graphis, 3D Grapher, Visualization Sciences Group (VSG) Avizo Wind, Interactive Analysis and Display System (IADS), SigmaPlot, and MATLAB.

Hicks, Rebecca↗
NASA NTRS2009

Software Development to Assist in the Processing and Analysis of Data Obtained Using Fiber Bragg Grating Interrogation Systems

A fiber Bragg grating is a portion of a core of a fiber optic strand that has been treated to affect the way light travels through the strand. Light within a certain narrow range of wavelengths will be reflected along the fiber by the grating, while light outside that range will pass through the grating mostly undisturbed. Since the range of wavelengths that can penetrate the grating depends on the grating itself as well as temperature and mechanical strain, fiber Bragg gratings can be used as temperature and strain sensors. This capability, along with the light-weight nature of the fiber optic strands in which the gratings reside, make fiber optic sensors an ideal candidate for flight testing and monitoring in which temperature and wing strain are factors. The purpose of this project is to research the availability of software capable of processing massive amounts of data in both real-time and post-flight settings, and to produce software segments that can be integrated to assist in the task as well.

Hicks, Rebecca↗
DOE OSTI2024

Magnetic Field Sensing via Multi-Material Acoustic Sensing Optical Fibers with Magnetostrictive Cladding Inclusions

In this conducted research, optical fiber sensors are used to measure low strength alternating magnetic fields. Various fiber sensor configurations are tested and investigated to demonstrate sensing capabilities at different field magnitudes and frequencies. Distributed acoustic sensing fibers (DAS) have been largely studied and documented across a variety of applications and sensing systems. This research uses the DAS technology in tandem with magnetostrictive materials to create a distributed multi-material optical fiber magnetic sensor. Magnetic sensing has high demand across different fields and often runs into challenges of extreme environments including high temperature, corrosion, and areas with poor accessibility. The robust and distributed nature of optical fiber sensors which can be cheaply produced for long lengths is an attractive option over other single point magnetic sensors. In down hole applications specifically, having a distributed sensor able to be deployed easily and over long distances for magnetic sensing would be a large improvement to bulkier traditional magnetometers. In the conducted study, different magnetostrictive materials are implemented in distributed optical fiber sensors to analyze and compare the effective sensitivity and potential commercial viability. Nickel, galfenol alloy, and MetGlas alloy inclusions are drawn into fused silica optical fibers with Bragg gratings inscribed later on for DAS capability. Each was investigated for its response to varying AC magnetic fields to determine relative sensitivity and resolution for distributed magnetic field sensing.

Dejneka, Zach↗
DOE OSTI2024

Tailoring Nanoporous Silica and Natural Straw Structural Insulation Composites

Nanoporous silica exhibits ultralow thermal conductivity as a result of its nanoscale pore size, high pore volume, and specific surface area. In this study, we report the self-assembled surfactant-templated synthesis of nanoporous silica, which is integrated with cellulose fibers derived from natural straw to manufacture high thermal insulation and mechanically robust nanocomposites. The nanocomposite shows a low thermal conductivity of 22.5 mW/(m·K), a compressive modulus of 0.93 MPa, and a hydrophobicity with a water contact angle of 125°. Moreover, we observed a marked reduction in water absorption capacity and a carbon footprint of 0.21 kg CO 2 equiv/kg. Here, this study provides a pathway toward the development of nanoporous structural insulation materials for energy-efficient building applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Embedded 3D printing of isotropically enhanced lattice structure with programmable elasticity via three-dimensional fiber alignment

Engineered composites with fiber orientation in a complete three-dimensional (3D) context are highly desired for maximizing structural performance as they mimic the well-organized fiber arrangement in natural composites. However, most fabrication techniques lack the capability for through-plane (z-axis) alignment, limiting the possibility for structural design and performance optimization. In this study, we present an embedded 3D printing approach that enables complete 3D fiber alignment, including region-specific alignment control along the through-plane direction. Our method utilizes the extrusion and suspension of composite inks within a supporting matrix. By regionally adjusting the ink extrusion rate and nozzle translation rate, we locally manipulated the fiber arrangement within the composite 3D architecture. Here, we demonstrate that the 3D alignment of carbon fibers in a structural composite significantly enhances both mechanical properties and thermal conductivity in the in-plane and through-plane directions. Furthermore, by strategically arranging regional fiber orientations within micro-architected materials, we fabricated metamaterial engineered composites with programmable anisotropy ratio and directional moduli.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Application of advanced material systems to composite frame elements

A three phase program has been conducted to investigate DuPont's Long Discontinuous Fiber (LDF) composites. Additional tests were conducted to compare LDF composites against toughened thermosets and a baseline thermoset system. Results have shown that the LDF AS4/PEKK offers improved interlaminar (flange bending) strength with little reduction in mechanical properties due to the discontinuous nature of the fibers. In the third phase, a series of AS4/PEKK LDF C-section curved frames (representing a typical rotorcraft light frame) were designed, manufactured and tested. Specimen reconsolidation after 'stretch forming' and frame thickness were found to be key factors in this light frame's performance. A finite element model was constructed to correlate frame test results with expected strain levels determined from material property tests. Adequately reconsolidated frames performed well and failed at strain levels at or above baseline thermoset material test strains. Finally a cost study was conducted which has shown that the use of LDF for this frame would result in a significant cost savings, for moderate to large lot sizes compared with the hand lay-up of a thermoset frame.

Llorente, Steven↗
NASA NTRS2002

Structural Health Monitoring of Composite Wound Pressure Vessels

The increasing use of advanced composite materials in the wide range of applications including Space Structures is a great impetus to the development of smart materials. Incorporating these FBG sensors for monitoring the integrity of structures during their life cycle will provide valuable information about viability of the usage of such material. The use of these sensors by surface bonding or embedding in this composite will measure internal strain and temperature, and hence the integrity of the assembled engineering structures. This paper focuses on such a structure, called a composite wound pressure vessel. This vessel was fabricated from the composite material: TRH50 (a Mitsubishi carbon fiber with a 710-ksi tensile strength and a 37 Msi modulus) impregnated with an epoxy resin from NEWPORT composites (WDE-3D-1). This epoxy resin in water dispersed system without any solvents and it cures in the 240-310 degrees F range. This is a toughened resin system specifically designed for pressure applications. These materials are a natural fit for fiber sensors since the polyimide outer buffer coating of fiber can be integrated into the polymer matrix of the composite material with negligible residual stress. The tank was wound with two helical patterns and 4 hoop wraps. The order of winding is: two hoops, two helical and two hoops. The wall thickness of the composite should be about 80 mil or less. The tank should burst near 3,000 psi or less. We can measure the actual wall thickness by ultrasonic or we can burst the tank and measure the pieces. Figure 1 shows a cylinder fabricated out of carbon-epoxy composite material. The strain in different directions is measured with a surface bonded fiber Bragg gratings and with embedded fiber Bragg gratings as the cylinder is pressurized to burst pressures. Figure 2 shows the strain as a function of pressure of carbon-epoxy cylinder as it is pressurized with water. Strain is measured in different directions by multiple gratings oriented in both axial and hoops directions.

Joseph Grant↗
DOE OSTI2025

Contaminant Investigation and Pre‐Processing Opportunities for Textile‐To‐Textile Recycling

Millions of metric tons of textiles are landfilled or incinerated each year in the United States, with less than 1% of textiles recycled into new clothing or fabrics. To counter this trend, a growing number of companies and researchers are exploring how a circular economy can be applied to support textile‐to‐textile recycling. A significant barrier they face comes down to quickly and efficiently extracting pure feedstock material from post‐consumer garments that feature a mix of natural and synthetic fibers. Textile recyclers prefer pure feedstocks, as working with mixed sources typically means lower throughput, higher risk of equipment failure, and diminished business margins. To facilitate a circular economy for textiles, methods, and technologies are needed that can efficiently separate out materials and contaminants from end‐of‐life textiles to increase the flow of pure feedstocks to recyclers. This paper summarizes findings from interviews with a cross section of textile recyclers and from a review of literature to define basic feedstock requirements. In addition to our qualitative research, we deconstruct a bale of post‐consumer textiles and analyze them using computer‐vision imaging, Fourier transform infrared spectroscopy (FTIR), and machine learning. The resulting data are used to set system‐level design inputs for an automated contaminant removal system to process post‐consumer clothing into appropriate feedstocks for recycling. To set the system's levels for automated real‐time near‐infrared analysis, we identify the minimum percentage of primary material that any single garment in a load of used clothing must contain for the average of the full output stream to meet the target purity levels of recyclers. Here, the envisioned automated system can also address undesirable trace materials that might contaminate the processed stream by using imaging cameras coupled with artificial intelligence to identify sections of clothing for de‐trimming. Proof‐of‐concept machine learning algorithms are evaluated to locate and identify trims or garment areas with hidden contaminant materials. Integrating these methods into automated textile cutting systems can provide a cost‐effective means for increasing feedstock purity from used clothing, which can advance circularity for textiles by helping recyclers to reach production volumes and quality targets that were not possible solely with manual dismantling operations.

Parsons, Ryan [Rochester Institute of Technology, ↗
NASA NTRS2014

Challenges in Modelling of Lightning-Induced Delamination; Effect of Temperature-Dependent Interfacial Properties

Lightning is a major cause of damage in laminated composite aerospace structures during flight. Due to the dielectric nature of Carbon fiber reinforced polymers (CFRPs), the high energy induced by lightning strike transforms into extreme, localized surface temperature accompanied with a high-pressure shockwave resulting in extensive damage. It is crucial to develop a numerical tool capable of predicting the damage induced from a lightning strike to supplement extremely expensive lightning experiments. Delamination is one of the most significant failure modes resulting from a lightning strike. It can be extended well beyond the visible damage zone, and requires sophisticated techniques and equipment to detect. A popular technique used to model delamination is the cohesive zone approach. Since the loading induced from a lightning strike event is assumed to consist of extreme localized heating, the cohesive zone formulation should additionally account for temperature effects. However, the sensitivity to this dependency remains unknown. Therefore, the major focus point of this work is to investigate the importance of this dependency via defining various temperature dependency profiles for the cohesive zone properties, and analyzing the corresponding delamination area. Thus, a detailed numerical model consisting of multidirectional composite plies with temperature-dependent cohesive elements in between is subjected to lightning (excessive amount of heat and pressure) and delamination/damage expansion is studied under specified conditions.

interlaminar damage↗
NASA NTRSDate not supplied

Composite Technologies for Science Missions

ASTROLAB, Lunar Geophysical Network, Mars Icebreaker and Mars PLACER Net missions propose use of various types of vehicles – such as rovers, landers and flying probes - to accomplish their scientific objectives. Although designs for such vehicles are myriad, many structural components can be made using composite manufacturing technologies. Composite materials are also myriad, by nature, but carbon fiber reinforced polymers (CFRP) in particular are sought after for their high specific strength and specific stiffness. CFRP components could be especially beneficial in vehicle designs for Moon or Mars missions due to their nearly negligible coefficient of thermal expansion (CTE). CTE is a critical design characteristics in environments where significant thermal swings are prevalent, such as those of atmosphere-less Moon and Mars.MSFC/EM42 houses several relevant composites technologies. Strong and rigid struts can be filament-wound. Shells and platforms can be laid-up using automated fiber placement (for repeatability) or by hand (for small features). Monolithic structures can even be designed to reduce part count and therefore reduce the risk of joint failures. Composites are also tailorable, allowing the incorporation of different material types or formats through the thickness of a part. This includes materials which shield from radiation or electrostatic discharge. Finally, the rigidity of composite parts minimizes overall vibration and compliance within a design.Additionally, missions such as Triton Ocean World Surveyor anticipate use of traditional, metallic fuel tanks. Composite overwrapped pressure vessels (COPVs) are suitable for use in this application as well. The Triton mission even cites a concern for heat retention, for which CFRP also offers improved characteristics over traditional metallic tanks.

Lightweight↗
NASA NTRS2022

Design of synthetic collagens that assemble into supramolecular banded fibers as a functional biomaterial testbed

Collagens are the most abundant proteins of the extracellular matrix, and the hierarchical folding and supramolecular assembly of collagens into banded fibers is essential for mediating cell-matrix interactions and tissue mechanics. Collagen extracted from animal tissues is a valuable commodity, but suffers from safety and purity issues, limiting its biomaterials applications. Synthetic collagen biomaterials could address these issues, but their construction requires molecular-level control of folding and supramolecular assembly into ordered banded fibers, comparable to those of natural collagens. Here, we show an innovative class of banded fiber-forming synthetic collagens that recapitulate the morphology and some biological properties of natural collagens. The synthetic collagens comprise a functional-driver module that is flanked by adhesive modules that effectively promote their supramolecular assembly. Multiscale simulations support a plausible molecular-level mechanism of supramolecular assembly, allowing precise design of banded fiber morphology. We also experimentally demonstrate that synthetic fibers stimulate osteoblast differentiation at levels comparable to natural collagen. This work thus deepens understanding of collagen biology and disease by providing a ready source of safe, functional biomaterials that bridge the current gap between the simplicity of peptide biophysical models and the complexity of in vivo animal systems.

Jinyuan Hu↗
NASA NTRS1997

Fungal degradation of fiber-reinforced composite materials

As described in a previous report, a fungal consortium isolated from degraded polymeric materials was capable of growth on presterilized coupons of five composites, resulting in deep penetration into the interior of all materials within five weeks. Data describing the utilization of composite constituents as nutrients for the microflora are described in this article. Increased microbial growth was observed when composite extract was incubated with the fungal inoculum at ambient temperatures. Scanning electron microscopic observation of carbon fibers incubated with a naturally developed population of microorganisms showed the formation of bacterial biofilms on the fiber surfaces, suggesting possible utilization of the fiber chemical sizing as carbon and energy sources. Electrochemical impedance spectroscopy was used to monitor the phenomena occurring at the fiber-matrix interfaces. Significant differences were observed between inoculated and sterile panels of the composite materials. A progressive decline in impedance was detected in the inoculated panels. Several reaction steps may be involved in the degradation process. Initial ingress of water into the resin matrix appeared to be followed by degradation of fiber surfaces, and separation of fibers from the resin matrix. This investigation suggested that composite materials are susceptible to microbial attack by providing nutrients for growth.

Environmental Microbiology↗