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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 721 records · Page 40
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Liquid Letters

Abstract Using the interfacial jamming of cellulose nanocrystal (CNC) surfactants, a new concept, termed all‐liquid molding, is introduced to produce all‐liquid objects that retain the shape and details of the mold with high fidelity, yet remain all liquid and are responsive to external stimuli. This simple process, where the viscosity of the CNC dispersion can range from that of water to a crosslinked gel, opens tremendous opportunities for encapsulation, delivery systems, and unique microfluidic devices. The process described is generally applicable to any functionalized nanoparticles dispersed in one liquid and polymer ligands having complementary functionality dissolved in a second immiscible liquid. Such sculpted liquids retain all the characteristics of the liquids but retain shape indefinitely, very much like a solid, and provide a new platform for next‐generation soft materials.

Shi, Shaowei↗
DOE OSTI2023

Effect of recycled fibers and shredded intermediates variation on the mechanical properties and energy absorption of fiber‐reinforced composite panels

Abstract The global composite industry generates large quantities of waste which mostly ends up in landfills due to a lack of established end‐use applications for multiple waste streams. The scrap from end‐of‐life (EoL) includes manufacturing waste such as dry chopped fiber tows, loose fibers, shredded fibers from fabric textile operations, cured/semi‐cured prepregs, and fully cured composite structure waste from aircraft, automobiles, wind blades, boats, and pressure vessels. In this work, different composite waste streams were reduced to shredded intermediates, followed by simple blending, and subjected to wet compression molding to produce composite panels. The panels/plaques were tested for mechanical properties (flexure and impact), fiber‐matrix wet‐out, and property bounds. It was found that wet‐compression molding was a viable and scale‐able approach to produce recycled panels from EoL composites shredded scrap. Furthermore, full‐scale size panels for use in truck bodies and intermodal shipping container flooring were manufactured and their impact resistance was tested using a drop weight impact test. They were tested both for high‐ and low‐velocity load. In the case of high‐velocity load, the average impact load was 14,673 N; the average absorbed energy was 101.6 J; the average elastic energy was 11.7 J and the impact resistance was 1065 J/m. In the case of the low‐velocity drop weight impact test, it was found that the average impact load was 7877.358 N; the average absorbed energy was 9.718 J; the average elastic energy was 9.14 J, and the impact resistance was 184.1 J/m. The shredded composite was shown to be a candidate material for the manufacture of truck bodies and intermodal containers’ flooring panels. Highlights By using shredded intermediates from different composite waste streams, it is possible to manufacture composite panels. Wet–compression process is an appropriate technique for manufacturing recycled fiber composite panels. Regardless of the source of scrap, the mechanical properties of the produced composite panels were improved. The recycling process technology can be transformed to commercial scale to produce full‐size transportation flooring panels. A product pathway is established in consideration of lower cost and improved recyclability.

Vaidya, Uday↗
DOE OSTI2025

Enhanced Interfacial Strength in Carbon Fiber Composites via Mussel‐Inspired Sizing Polymers

Composite materials possess a high strength-to-weight ratio. A key determinant of their mechanical performance is the interfacial strength between the fibers and the matrix. Sizing agents are commonly used to improve this interface by promoting better adhesion, though optimizing this interaction remains a significant challenge. Here, this study evaluates the use of poly(catechol-styrene) (PCS), a mussel-inspired sizing agent, to enhance fiber–matrix bonding in carbon fiber composites. Woven carbon fiber laminates were dip-coated with varying concentrations of PCS (0.05 and 0.1 wt%) and subsequently fabricated using vacuum-assisted resin transfer molding followed by compression molding. Interlaminar shear strength (ILSS) tests showed improvements of 4% and 8% for the 0.05% and 0.1% PCS treatments, respectively. These results indicate that PCS is effective in reinforcing interfacial adhesion, thereby improving the mechanical integrity of carbon fiber-reinforced composites.

Carbon fiber composites↗
DOE OSTI2019

Manufacturing and Flexural Characterization of Infusion-Reacted Thermoplastic Wind Turbine Blade Subcomponents

Reactive thermoplastics are advantageous for wind turbine blades because they are recyclable at end of life, have reduced manufacturing costs, and enable thermal joining and shaping. However, there are challenges with manufacturing wind components from these new materials. This work outlines the development of manufacturing processes for a thick glass fiber-reinforced acrylic thermoplastic resin wind turbine blade spar cap, with consideration given to effects of the exothermic curing reaction on thick composite parts. Comparative elastic properties of these infusible thermoplastic materials with epoxy thermoset materials, as well as thermoplastic coupon components, are also included. Based on the results of this study it is concluded that the thermoplastic resin system is a viable candidate for the manufacturing of wind turbine blades using vacuum-assisted resin transfer molding. Significant gains in energy savings are realized avoiding heated molds, ability for recycling, and providing an opportunity for utilizing thermal welding.

17 WIND ENERGY↗
DOE OSTI2018

Preparation of Bimetal Objects by Lost Foam Casting

The possibility of obtaining bimetallic steel castings by the lost foam casting method is demonstrated, in which an insert of special steel is placed in an expanded polystyrene mold. Bottom casting is used. With the optimum choice of the casting temperature, fusion of the steels is guaranteed and there is no warping of flat inserts. Stages of bimetallic casting formation are considered and the parameters affecting filling of the mold and ensuring the production of a finished casting are determined. It is shown that the heat treatment of objects with air cooling provides hardness of 20–46 HRC for steel of 20X13 with different tempering conditions. The technology is recommended for parts of the locking assembly of pipeline fittings and other products where a combination of local special properties and workability is required.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A Review on Material and Antimicrobial Properties of Soy Protein Isolate Film

In twenty first century, there is an increasing demand for packed food which requires packaging films. At present, these packaging films are processed from synthetic polymers such as polyethylene, polypropylene and many other synthetic polymers. But we need to start using soy protein as sustainable antimicrobial film that can be used for packaging purposes. There is abundance and high availability of soy protein isolate (SPI) as by-product from industries, such as food processing or biodiesel production. Soy based films from renewable resources can offer a more suitable alternative to films fabricated from synthetic materials. Soy based films in presence of additives such as acidic compounds, nanoparticles and natural compounds have good mechanical properties and are transparent in nature. In addition, soy based film in presence of 2,2-diphenyl-2-hydroxyethanoic acid and copper phosphate can give lotus-like structure as evidenced from morphological studies. Also the manufacturing process (solution casting and compression molding) of SPI film in the presence or absence of additives is very easy and commercially feasible. It is worth noting that SPI films can be produced at laboratory scale by both casting and compression molding methods. In this review paper, we have focused on the material properties as well as antimicrobial properties of SPI based films in the presence of natural and synthetic additives as reported in the last 20 years.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2019

Geometric Form of Gating System Elements and Its Influence on the Initial Filling Phase

Flow of cast steel through twenty-four variants of gating system was examined with the use of numerical modeling conducted in MAGMA. The main goal of the research was to determine the impact of the gating system elements’ geometric form on the kinetics in the initial filling phase, which is crucial in terms of castings quality. The evaluation was based on flow kinetics, maximal height, and the velocity of metal entering the mold. The variables included the geometric form of the sprue and the cross runner, as well as geometric form, length, and expansion of the ingate. Results allow to form valuable conclusions that can lead to improvement in the castings manufacturing technology. Results show that application of proper expansion of the ingate and suitable geometric form of the gating system can significantly reduce the velocity of metal entering the mold cavity, as well as eradicate the jetting, which positively impacts the soundness of the casting.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A novel additive manufacturing compression overmolding process for hybrid metal polymer composite structures

Metal polymer composites combining low density, high strength composites with highly ductile and tough metals have gained traction over the last few decades as lightweight and high-performance materials for industrial applications. However, the mechanical properties are limited by the interfacial bonding strength between metals and polymers achieved through adhesives, welding, and surface treatment processes. In this paper, a novel manufacturing process combining additive manufacturing and compression molding to obtain hybrid metal polymer composites with enhanced mechanical properties is presented. Additive manufacturing enabled deposition of polymeric material with fibers in a predetermined pattern to form tailored charge or preform for compression molding. Here, a grade 300 maraging steel triangular lattice is first fabricated using AddUp FormUp350 laser powder bed system and compression overmolded with additively manufactured long carbon fiber-reinforced polyamide-6,6 (40% wt. CF/PA66) preform. The fabricated hybrid metal polymer composites showed high stiffness and tensile strength. The stiffness and failure characteristics determined from the uniaxial tensile tests were correlated to a finite element model within 20% deviation. Fractographic analyses was performed using microscopy to investigate failure mechanisms of the hybrid structures.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Transmembrane myosin chitin synthase involved in mollusc shell formation produced in Dictyostelium is active

Highlights: Black-Right-Pointing-Pointer Dictyostelium produces the 264 kDa myosin chitin synthase of bivalve mollusc Atrina. Black-Right-Pointing-Pointer Chitin synthase activity releases chitin, partly associated with the cell surface. Black-Right-Pointing-Pointer Membrane extracts of transgenic slime molds produce radiolabeled chitin in vitro. Black-Right-Pointing-Pointer Chitin producing Dictyostelium cells can be characterized by atomic force microscopy. Black-Right-Pointing-Pointer This model system enables us to study initial processes of chitin biomineralization. -- Abstract: Several mollusc shells contain chitin, which is formed by a transmembrane myosin motor enzyme. This protein could be involved in sensing mechanical and structural changes of the forming, mineralizing extracellular matrix. Here we report the heterologous expression of the transmembrane myosin chitin synthase Ar-CS1 of the bivalve mollusc Atrina rigida (2286 amino acid residues, M.W. 264 kDa/monomer) in Dictyostelium discoideum, a model organism for myosin motor proteins. Confocal laser scanning immunofluorescence microscopy (CLSM), chitin binding GFP detection of chitin on cells and released to the cell culture medium, and a radiochemical activity assay of membrane extracts revealed expression and enzymatic activity of the mollusc chitin synthase in transgenic slime mold cells. First high-resolution atomic force microscopy (AFM) images of Ar-CS1 transformed cellulose synthase deficient D. discoideumdcsA{sup -} cell lines are shown.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2021

Fiber orientation effects on ultra-high performance concrete formed by 3D printing

Despite the growing interest in 3D concrete printing, its current progress is limited by reinforcing methods. Inclusion of steel fibers is a potential reinforcing solution; however, the effect of printing process on orientation of the fibers is still unknown. This study aims to quantitatively investigate the orientation distribution of steel fibers in 3D printed ultra-high performance concrete. The effects of extrusion nozzle size, Cartesian print speed, and fiber volume fraction on the orientation of fibers were evaluated using digital image analysis. The consequent effects of the fiber orientation on the mechanical properties of the 3D-printed specimens were also determined. The results were compared with those of the conventionally mold-cast specimens. The results revealed that the smaller nozzle size and higher fiber volume fraction significantly enhanced the fiber alignment parallel to the printing direction. This preferential fiber alignment led to superior mechanical performance of the printed specimens to the mold-cast specimens.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Stochastic reconstruction and microstructure modeling of SMC chopped fiber composites

Here, to establish an integrated Processing-Microstructure-Property workflow for the prediction of material behaviors, this paper presents a new stochastic pseudo-3D microstructure reconstruction method for Sheet Molding Compounds (SMC) chopped fiber composites. The proposed method captures the bi-level microstructural features of SMC composites. At the higher level, a Voronoi diagram-based algorithm is developed to reconstruct the unique substructure features of SMC fiber tows. The geometry of Voronoi cells is adjusted by a Simulated Annealing (SA) algorithm to match the geometrical statistics of the real fiber tows. At the lower level, the algorithm assigns fiber orientation to each Voronoi cell (which represents a fiber tow). The fiber orientation angles are recovered from a statistical fiber orientation tensor. The proposed method is employed to establish a multi-layer pseudo-3D SMC Representative Volume Element (RVE) model for Finite Element Analysis (FEA) of SMC microstructure. This model enables the prediction of mechanical properties based on the material processing information (e.g. fiber orientation tensor obtained from compression molding simulation), and the microstructure information obtained from microscopic imaging for an SMC composite. Lastly, the predicted properties are successfully validated by experimental tensile tests.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Performance assessment of 3D printed multi-material energy absorber for automotive bumper: pedestrian lower extremity protection

Designing an energy absorber for automotive bumpers involves balancing low-speed and high-speed impacts to ensure safety, reduce repair costs, and meet regulatory standards. Here, this study explores a novel design using multi-material 3D printing and structural optimization to fabricate a lightweight and cost-efficient energy absorber. The design effectively dissipates energy in low-speed collisions and minimizes force transmission in high-speed pedestrain impacts, helping to meet both safety and performance requirements. The energy absorber design combines 20% carbon fiber-reinforced acrylonitrile butadiene styrene (CF-ABS) and thermoplastic polyurethane (TPU) for optimal stiffness and flexibility. It uses 3D-printed lattice structures optimized through finite element simulations to help meet both low-speed and high-speed impact requirements. Full-scale energy absorbers were 3D-printed using optimized CF-ABS/TPU blends and tested under high-speed impact using the Flexible Pedestrian Legform Impactor (Flex-PLI). For fair comparison, a baseline bumper with a traditional triangular lattice structure, also 3D-printed from the same CF-ABS/TPU materials, was similarly tested. Interestingly, both the optimized and baseline 3D-printed energy absorbers showed nearly identical performance, successfully meeting injury limits. Their performances were also benchmarked against an injection-molded energy absorber. While both 3D-printed and injection-molded designs met injury limits, the 3D-printed absorber exhibited a higher tibia bending moment, indicating an opportunity for further optimization. A Techno-Economic Analysis compared the costs of producing energy absorbers using traditional manufacturing and 3D printing. The analysis highlighted that 3D printing offers cost benefits for low to medium production volumes, with the total cost per energy absorber at ∼ $\$$74, compared to traditional methods that become economical beyond 2000 units.

Additive manufacturing↗
DOE OSTI2020

Characterization of paste microstructure for durability properties of concrete

In this study, paste samples from different cementitious systems were characterized by using X-Ray Micro Computed Tomography (µ-CT) and Fluorescence Microscopy techniques. Quantitative and qualitative aspects of defects from paste samples were investigated to develop indicators of durability related properties of corresponding concrete samples. In the first phase of this study, hour glass shaped 3D printed molds were used to investigate five cementitious combinations consisting of three cement types (Coarse Ground portland cement, Type IL Portland Limestone Cement and Type I/II ordinary portland cement) and fly ash as a supplementary cementitious material. In the second phase, metal molds were used to compare the results of Coarse Ground portland cement with Type I ordinary portland cement, 5% of which was replaced with colloidal nanosilica. Potential correlations between paste and concrete have been presented. This work was supported by US Department of Energy and North Dakota Department of Commerce.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Identification of mycotoxins by UHPLC–QTOF MS in airborne fungi and fungi isolated from industrial paper and antique documents from the Archive of Bogotá

Mold deterioration of historical documents in archives and libraries is a frequent and complex phenomenon that may have important economic and cultural consequences. In addition, exposure to toxic fungal metabolites might produce health problems. In this work, samples of broths of fungal species isolated from the documentary material and from indoor environmental samples of the Archive of Bogotá have been analyzed to investigate the presence of mycotoxins. High resolution mass spectrometry made possible to search for a large number of mycotoxins, even without reference standards available at the laboratory. For this purpose, a screening strategy based on ultra-high pressure liquid chromatography coupled to quadrupole-time of flight mass spectrometry (UHPLC–QTOF MS) under MS{sup E} mode was applied. A customized home-made database containing elemental composition for around 600 mycotoxins was compiled. The presence of the (de)protonated molecule measured at its accurate mass was evaluated in the samples. When a peak was detected, collision induced dissociation fragments and characteristic isotopic ions were also evaluated and used for tentative identification, based on structure compatibility and comparison with literature data (if existing). Up to 44 mycotoxins were tentatively identified by UHPLC–QTOF MS. 34 of these tentative compounds were confirmed by subsequent analysis using a targeted LC–MS/MS method, supporting the strong potential of QTOF MS for identification/elucidation purposes. The presence of mycotoxins in these samples might help to reinforce safety measures for researchers and staff who work on reception, restoration and conservation of archival material, not only at the Archive of Bogotá but worldwide. - Highlights: • Mold deterioration of historical documents is a frequent and complex phenomenon. • Samples of broths of fungal species isolated from Archive of Bogotá analyzed. • UHPLC–QTOF MS (MS{sup E}) applied for mycotoxins screening, without reference standards. • Customized home-made database for around 600 mycotoxins compiled. • 44 mycotoxins tentatively identified, 34 of which confirmed by LC–MS/MS.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2013

Does UV disinfection compromise sutures? An evaluation of tissue response and suture retention in salmon surgically implanted with transmitters

Ultraviolet radiation (UVR) can be used as a tool to disinfect surgery tools used for implanting transmitters into fish. However, the use of UVR could possibly degrade monofilament suture material used to close surgical incisions. This research examined the effect of UVR on monofilament sutures to determine if they were compromised and negatively influenced tag and suture retention, incision openness, or tissue reaction. Eighty juvenile Chinook salmon Oncorhynchus tshawytscha were surgically implanted with an acoustic transmitter and a passive integrated transponder. The incision was closed with a single stitch of either a suture exposed to 20 doses of UV radiation (5 minute duration per dose) or a new, sterile suture. Fish were then held for 28 d and examined under a microscope at day 7, 14, 21 and 28 for incision openness, ulceration, redness, and the presence of water mold. There was no significant difference between treatments for incision openness, redness, ulceration or the presence of water mold on any examination day. On day 28 post-surgery, there were no lost sutures; however, 2 fish lost their transmitters (one from each treatment). The results of this study do not show any differences in negative influences such as tissue response, suture retention or tag retention between a new sterile suture and a suture disinfected with UVR.

disinfection↗
DOE OSTI2016

Processing of alnico permanent magnets by advanced directional solidification methods

Advanced directional solidification methods have been used to produce large (>15 cm length) castings of Alnico permanent magnets with highly oriented columnar microstructures. In combination with subsequent thermomagnetic and draw thermal treatment, this method was used to enable the high coercivity, high-Titanium Alnico composition of 39% Co, 29.5% Fe, 14% Ni, 7.5% Ti, 7% Al, 3% Cu (wt%) to have an intrinsic coercivity (H ci ) of 2.0 kOe, a remanence (B r ) of 10.2 kG, and an energy product (BH) max of 10.9 MGOe. These properties compare favorably to typical properties for the commercial Alnico 9. Directional solidification of higher Ti compositions yielded anisotropic columnar grained microstructures if high heat extraction rates through the mold surface of at least 200 kW/m 2 were attained. This was achieved through the use of a thin walled (5 mm thick) high thermal conductivity SiC shell mold extracted from a molten Sn bath at a withdrawal rate of at least 200 mm/h. However, higher Ti compositions did not result in further increases in magnet performance. Images of the microstructures collected by scanning electron microscopy (SEM) reveal a majority α phase with inclusions of secondary αγ phase. Transmission electron microscopy (TEM) reveals that the α phase has a spinodally decomposed microstructure of FeCo-rich needles in a NiAl-rich matrix. In the 7.5% Ti composition the diameter distribution of the FeCo needles was bimodal with the majority having diameters of approximately 50 nm with a small fraction having diameters of approximately 10 nm. The needles formed a mosaic pattern and were elongated along one <001> crystal direction (parallel to the field used during magnetic annealing). Cu precipitates were observed between the needles. Regions of abnormal spinodal morphology appeared to correlate with secondary phase precipitates. The presence of these abnormalities did not prevent the material from displaying superior magnetic properties in the 7.5% Ti composition. As a result, higher Ti compositions did not display the preferred spinodal microstructure, explaining their inferior magnetic properties.

36 MATERIALS SCIENCE↗
DOE OSTI2018

EBSD characterization of the eutectic microstructure in hypoeutectic Fe-C and Fe-C-Si alloys

Highlights: • EBSD investigation of eutectic cementite and austenite in as-solidified low-alloy cast iron • Crystallographically independent growth of rapidly solidified cementite/austenite eutectic • Epitaxial growth of eutectic austenite from primary dendrites • Eutectic cementite and eutectoid ferrite frequently obey Bagaryatsky or Pitsch-Petch orientation relationship. - Abstract: Hypoeutectic Fe-C and Fe-C-Si model alloys were produced at different solidification conditions. Copper mold casting yields low cooling rates promoting the formation of a eutectic microstructure, which is characterized by two morphologies: elongated cementite plates and a rod structure growing perpendicular to the plates, i.e. austenite rods in a cementite matrix. Electron beam surface remelting generates a mainly plate-like eutectic due to rapid solidification. The microstructures were characterized by light-optical microscopy and electron backscatter diffraction (EBSD). The latter allows for a spatially resolved investigation of the growth crystallography of the eutectic phases. Thereby, a possible existence of crystallographic orientations relationships between cementite and austenite within the plate-like eutectic was assessed experimentally. The eutectic phases were found to grow largely crystallographically independently. Moreover, ferrite and eutectic cementite within the decomposed eutectic microstructure frequently comply with the Bagaryatsky or the Pitsch-Petch orientation relationship. Complementary X-ray diffraction (XRD) analysis reveals a pronounced cementite {002} texture in the microstructure produced by mold casting. Characteristic changes in the lattice parameters indicate that as-cast cementite is non-stoichiometric.

36 MATERIALS SCIENCE↗