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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 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Metal-embedded optical fibers for monitoring pressure or corrosion at high temperatures

A fiber optic sensor and a related method of manufacture are provided. The fiber optic sensor includes an embedded optical fiber contained within a metal diaphragm assembly, where the terminal end of the optical fiber is positioned opposite a diaphragm. The method includes forming a metal-embedded optical fiber by ultrasonic additive manufacturing and securing the metal-embedded optical fiber to a housing having a diaphragm that is opposite of the terminal end of the optical fiber. The sensor can provide extremely accurate pressure measurement at high temperatures and in highly corrosive media. An optical fiber-based pressure sensing system is also provided.

Petrie, Christian M.↗
DOE OSTI2023

Imaging crossing fibers in mouse, pig, monkey, and human brain using small-angle X-ray scattering

Myelinated axons (nerve fibers) efficiently transmit signals throughout the brain via action potentials. Multiple methods that are sensitive to axon orientations, from microscopy to magnetic resonance imaging, aim to reconstruct the brain's structural connectome. As billions of nerve fibers traverse the brain with various possible geometries at each point, resolving fiber crossings is necessary to generate accurate structural connectivity maps. However, doing so with specificity is a challenging task because signals originating from oriented fibers can be influenced by brain (micro)structures unrelated to myelinated axons. X-ray scattering can specifically probe myelinated axons due to the periodicity of the myelin sheath, which yields distinct peaks in the scattering pattern. Here, in this work, we show that small-angle X-ray scattering (SAXS) can be used to detect myelinated, axon-specific fiber crossings. We first demonstrate the capability using strips of human corpus callosum to create artificial double- and triple-crossing fiber geometries, and we then apply the method in mouse, pig, vervet monkey, and human brains. We compare results to polarized light imaging (3D-PLI), tracer experiments, and to outputs from diffusion MRI that sometimes fails to detect crossings. Given its specificity, capability of 3-dimensional sampling and high resolution, SAXS could serve as a ground truth for validating fiber orientations derived using diffusion MRI as well as microscopy-based methods.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2019

Additively manufactured carbon fiber-reinforced composites: State of the art and perspective

While polymer additive manufacturing (AM) has advanced significantly over the past few decades, the limitations in material properties, speed of manufacture, and part size have relegated this technology to the space of rapid prototyping rather than the legitimate manufacture of end-use parts. Carbon fiber offers a low density, a low coefficient of thermal expansion, and high thermal conductivity and is an ideal material for bringing polymer-based AM from the realm of form and fit to that of form, fit, and function. The use of carbon fiber in AM can improve material properties, reduce the time required to manufacture functional parts compared with traditional subtractive technologies, and reduce warping, thereby enabling a larger possible build envelope. Therefore, the addition of carbon fiber to various AM technologies is of increasing interest in academic and industrial communities. This paper examines the work performed in this fast-growing area to date. Specifically, the effects of fiber reinforcement on the structure and mechanical properties of 3D printed parts are investigated within the body of literature. Upper bounds for tensile properties of carbon fiber composites are theoretically evaluated and compared with experimentally measured values. Moreover, current and potential applications of additively manufactured carbon fiber composites in the context of desktop 3D printing and big area AM are discussed. Recent innovations and industry breakthroughs in this field are also examined. This review is intended to organize and synthesize the present body of work surrounding AM of carbon fiber reinforced plastics, identify the most promising technologies, and prescribe viable research and development paths forward to advance AM from the application space of rapid prototyping to that of functional, load-bearing, end-use parts.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Multiscale characterization of chemical–mechanical interactions between polymer fibers and cementitious matrix

Together with a series of mechanical tests, the interactions and potential bonding between polymeric fibers and cementitious materials were studied using scanning transmission X-ray microscopy (STXM) and microtomography (lCT). Experimental results showed that these techniques have great potential to characterize the polymer fiber-hydrated cement-paste matrix interface, as well as differentiating the chemistry of the two components of a bi-polymer (hybrid) fiber the polypropylene core and the ethylene acrylic acid copolymer sheath. Similarly, chemical interactions between the hybrid fiber and the cement hydration products were observed, indicating the chemical bonding between the sheath and the hardened cement paste matrix. Microtomography allowed visualization of the performance of the samples, and the distribution and orientation of the two types of fiber in mortar. Beam flexure tests confirmed improved tensile strength of mixes containing hybrid fibers, and expansion bar tests showed similar reductions in expansion for the polypropylene and hybrid fiber mortar bars.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Processing and mechanical characterization of short carbon fiber-reinforced epoxy composites for material extrusion additive manufacturing

Fiber-reinforced polymer composites have been extensively utilized in recent years as feedstock materials for material extrusion additive manufacturing (AM) processes to improve strength, stiffness, and functionality of printed parts over unfilled printed polymers. However, the widespread adoption of AM of fiber-reinforced polymer composites requires a deeper understanding of the process-structure-property relationships in printed components, and such relationships are not well understood yet. Fiber length is critically important to the mechanical performance of short fiber composites, but very few studies to-date have focused on how the fiber length distribution (FLD) evolves during processing of composite feedstocks and how this evolution affects printing behavior and mechanical properties in 3D-printed composites. Here, FLD is measured for carbon fiber reinforced epoxy composites over a wide range of ink compositions and shear mixing times, and the distributions are fit with a Weibull-type distribution function. The effects of FLD on the tradeoff between ink processability, ink rheology, printing behavior and mechanical properties are investigated. Furthermore, the effects of printing parameters (nozzle size and print speed) on mechanical anisotropy and fiber orientation distribution (FOD) in printed composites are explored. Mechanical properties of printed composites are characterized via 3 pt-flexural testing, and microstructure is investigated using optical and scanning electron microscopy (SEM), and x-ray computed tomography. Finally, the fitted Weibull parameters are fed into a composite model that incorporates FLD and FOD, and model predictions are found to be in excellent agreement with experimental observations.

3D printing↗
DOE OSTI2024

Life cycle assessment of coir fiber-reinforced composites for automotive applications

Past decades have seen an increasing prevalence of natural fiber-reinforced composites (NFRCs) due to growing conscientiousness around sustainability and a push towards vehicle lightweighting. The environmentally friendly and sustainable claims of NFRCs need to be validated due to their large variability and variety, particularly where material substitutions are concerned, such as in substituting glass fiber with natural fiber. Additionally, the objective of this work is to determine the cumulative energy demand (CED) and greenhouse gas emissions (GHG) associated with an automotive part (of volume 0.001 m3) made from 40 wt% coir fiber-reinforced polypropylene (PP) and compared with a similar part made from 40 wt% glass fiber reinforced PP. SimaPro v. 9.0.0.49 was used for the analysis, whereas inventory data were collected from databases, such as Ecoinvent 3, Transportation Energy Databook, Greet model 2022, and published papers. The results showed that CED and GHG associated with the coir fiber-reinforced composite part were lower than the glass fiber-reinforced composite part for both cradle-to-gate (~34–40%) and cradle-to-grave (excluding end-of-life) (~24%) analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A critical review and meta-analysis of energy demand, carbon footprint, and other environmental impacts from carbon fiber manufacturing

The demand for carbon fibers and carbon fiber-reinforced polymers (CFRPs) is rapidly growing due to their outstanding mechanical properties and potential to enhance sustainability, particularly for lightweighting applications. However, carbon fibers are typically produced from fossil-based feedstocks, involve energy-intensive processes, and have limited options for sustainable end-of-life management or circularity. Despite these challenges, the energy demand and lifecycle environmental implications of their production remain poorly understood. Here, we conduct a critical literature review and meta-analysis of carbon fiber manufacturing, revealing significant variations in reported energy demand, carbon footprint, and lifecycle inventory data. Our analysis makes two novel contributions. First, we identify key underlying factors driving these variations. Second, we highlight that carbon fiber, far from being a homogeneous product, has grades varying substantially in mechanical properties, end-use markets, energy intensity of manufacturing processes, and therefore environmental impacts—an aspect often underrepresented in life cycle assessments. We assert that current data are insufficient for reliably evaluating environmental impacts, posing a risk of misleading decision-making. Addressing this gap requires new lifecycle inventory datasets clearly incorporating carbon fiber heterogeneity and key influencing factors identified in this study. Additionally, we propose actionable recommendations, including a checklist, to advance sustainability in the carbon fiber sector.

CED↗
DOE OSTI2025

Low spontaneous Brillouin scattering in anti-resonant hollow-core fibers in GHz frequency range

Brillouin light scattering (BLS) is a powerful experimental tool that can be used to gain insights into the fundamental and applied properties of matter, like dispersions of quasiparticles in a solid, as well as their spatiotemporal dynamics. Many applications of light scattering favor the use of optical fibers in place of free-space optics. In this study, we compare the performance of anti-resonant hollow core fibers to that of conventional solid core fused silica fibers for BLS experiments in the GHz frequency range. Conventional fibers are barely suitable for low-noise measurements because of the spontaneous scattering of photons on various phononic modes present in the core and cladding. In the case of the hollow-core fiber, we identify a range of discrete phononic modes and associate them with the various acoustic modes of the structure surrounding the hollow core using finite-element numerical simulations. The measured relative intensity of the spontaneous BLS signal from these modes is orders of magnitude smaller than that of a solid-core fiber, making anti-resonant hollow-core fibers one of the best solutions for the single-mode light guidance for BLS and potentially other low-noise photonic experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Characterization of textile-grade carbon fiber polypropylene composites

In this work, we consider low-cost carbon fiber produced with a textile-grade precursor. The objective of the study is to investigate textile-grade carbon-fiber-reinforced-polypropylene composites (TCF-PP) from compounded pellets for mechanical and thermal characterization. Four sets of pellets with 1%, 5%, 10%, and 15% reinforcement were manufactured using textile-grade carbon fiber (TCF) and polypropylene (PP) by twin-screw compounding. The addition of TCFs through gravimetric feeder directly in the extruder resulted in lower fiber content; however, side feeder has shown good potential. The pellets were further processed in extrusion compression molding to manufacture plaques. An increase in fiber loading has a negligible effect on fiber attrition as fiber length distribution variation between 1% and 15% reinforced pellets was very small. The addition of TCFs in PP showed a significant improvement in mechanical properties. The tensile strength and modulus of the composite were 26% and 161%, respectively, improved by the addition of 10 wt% TCF. Similar results were observed in the flexure test. However, the impact properties were reduced by 25.54% by the addition of 15% TCF.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Investigation of High Temperature Silica Based Fiber Optic Materials (Final Report)

This report summarizes technical progress during the program “Investigation of High Temperature Silica Based Fiber Optic Materials”, performed by the Center for Photonics Technology of the Bradley Department of Electrical and Computer Engineering at Virginia Tech. The objective of this program was to investigate and characterize the performance of commercially available optical fibers at elevated temperatures in replicated fuel gas streams. It also includes performing a comprehensive study of the interactions with the chemical constituents with respect to structural, optical, and mechanical stability and developing design strategies to assure reliable performance of deployed optical fibers and sensors. In the eight quarters of the project, work was done to complete the database of test results and findings for the creation of an optical fiber selection guide for high temperature applications. It is anticipated that this design tool will provide the scientific community with the information necessary to deploy sensing systems with the most robust and reliable fused silica optical fibers. Standard telecommunications grade germanium doped single and multimode fibers have been shown to perform reliably up to temperatures of 1100°C in non-hydrogen environments and/or properly designed sensor applications. Pure silica core single mode and low OH, large core step index multimode fibers, which have also shown to perform reliability up to temperatures of 1000ºC, are recommended for hydrogen and moist environments.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Single Mode Air-Clad Single Crystal Sapphire Optical Fiber

The observation of single mode propagation in an air-clad single crystal sapphire optical fiber at wavelengths at and above 783 nm is presented for the first time. A high-temperature wet acid etching method was used to reduce the diameter of a 10 cm length of commercially-sourced sapphire fiber from 125 micrometers to 6.5 micrometers, and far-field imaging provided modal information at intervals as the fiber diameter decreased. Modal volume was shown to decrease with decreasing diameter, and single mode behavior was observed at the minimum diameter achieved. While weakly-guiding approximations are generally inaccurate for low modal volume optical fiber with high core-cladding refractive index disparity, consistency between these approximations and experimental results was observed when the effective numerical aperture was measured and substituted for the theoretical numerical aperture in weakly-guiding approximation calculations. With the demonstration of very low modal volume in sapphire at fiber diameters much larger than anticipated by legacy calculations, the resolution of sapphire fiber distributed sensors may be increased and other sensing schemes requiring very low modal volume, such as fiber Bragg gratings, may be realized in extreme environment applications.

36 MATERIALS SCIENCE↗
NASA NTRS2002

Gravitational unloading effects on muscle fiber size, phenotype and myonuclear number

The effects of gravitational unloading with or without intact neural activity and/or tension development on myosin heavy chain (MHC) composition, cross-sectional area (CSA), number of myonuclei, and myonuclear domain (cytoplasmic volume per myonucleus ratio) in single fibers of both slow and fast muscles of rat hindlimbs are reviewed briefly. The atrophic response to unloading is generally graded as follows: slow extensors > fast extensors > fast flexors. Reduction of CSA is usually greater in the most predominant fiber type of that muscle. The percentage of fibers expressing fast MHC isoforms increases in unloaded slow but not fast muscles. Myonuclear number per mm of fiber length and myonuclear domain is decreased in the fibers of the unloaded predominantly slow soleus muscle, but not in the predominantly fast plantaris. Decreases in myonuclear number and domain, however, are observed in plantaris fibers when tenotomy, denervation, or both are combined with hindlimb unloading. All of these results are consistent with the view that a major factor for fiber atrophy is an inhibition or reduction of loading of the hindlimbs. These data also indicate that predominantly slow muscles are more responsive to unloading than predominantly fast muscles. c2002 COSPAR. Published by Elsevier Science Ltd. All rights reserved.

Review, Tutorial↗
DOE OSTI2022

Calibration of Distributed Temperature Sensors Using Commercially Available SMF-28 Optical Fiber From 22 °C to 1000 °C

Optical frequency domain reflectometry (OFDR) is a family of optical techniques which can be used to produce distributed temperature measurements from the spectral shift of an interference pattern based on the Rayleigh backscatter signature of an optical fiber. Adaptive signal processing techniques have recently been used with OFDR to record meaningful spectral shift data from commercially available SMF-28 optical fibers heated beyond 950 °C. Furthermore, a correlation between the measured spectral shift and temperature has not yet been developed at these high temperatures. To extend the measurable temperature range of OFDR in SMF-28, this work describes the development of such a correlation from room temperature (22 °C) to 1000 °C. The relationship between spectral shift and temperature change over this range was found to be best characterized by the fourth-order polynomial ΔT=(-4.241 * 10 -11 )S 4 + (-2.017 * 10 -7 )S 3 + (-3.677 * 10 -4 )S 2 + (-0.8057)S, where ΔT represents the temperature difference compared to the reference temperature, and S represents the spectral shift measured by the fibers. The calibration developed in this work assumes that the fiber has been fully annealed by heating the fiber to 1000 °C for a few hours. This paper is the first to demonstrate the calibration and use of SMF-28 distributed optical fiber sensors up to 1000 °C, enabled using adaptive OFDR-based signal processing.

47 OTHER INSTRUMENTATION↗
DOE OSTI2015

Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites (FY 2015 Third Quarterly Report)

During the third quarter of FY 2015, the following technical progress has been made toward project milestones: 1) Magna oversaw the tool build and prepared the molding plan for the complex part of Phase II. 2) PlastiComp hosted a visit by Magna and Toyota on April 23rd to finalize the molding scope and schedule. The plan for molding trials including selection of molding parameters for both LFT and D-LFT for the U-shape complex part was established. 3) Toyota shipped the U-shape complex part tool to Magna on May 28th, 2015. 4) Plasticomp provided 30wt% LCF/PP and 30wt% LCF/PA66 compounded pellets to Magna for molding the complex part. 5) Magna performed preliminary molding trials on June 2nd, 2015 to validate wall thickness, fill profile, tool temperature and shot size requirements for the complex part. 6) Magna performed the first complex part run on June 16th and 17th, 2015 at Magna’s Composite Centre of Excellence in Concord, ON, Canada. Dale Roland of Plasticomp, and Umesh Gandhi of Toyota also attended the molding. 7) Magna discussed and finalized the plan with PNNL and the team for cutting samples from molded parts at selected locations for fiber orientation and length measurements. 8) Magna provided the computer-aided design (CAD) files of the complex parts with and without ribs to PNNL and Autodesk to build the corresponding ASMI models for injection molding simulations. Magna also provided the actual parameters used. 9) Plasticomp’s provided knowledge and experience of molding LCF materials essential to the successful molding of the parts including optimization of fill speed, tool temperatures, and plasticizing conditions for the 30wt% LCF/PP and 30wt% LCF/PA66 materials in both rib and non-rib versions. 10) Magna molded additional parts for evaluation of mechanical property testing including torsional stiffness on June 29th and 30th, 2015 at Magna’s Composite Center of Excellence. 11) Toyota began preparation for the torsion test of the specimens. Preparation of a computer-aided engineering (CAE) model to predict the performance is in progress. 12) Autodesk fixed an error in the implementation of the proper orthogonal decomposition (POD) calculation of fiber length that had caused the ASMI solution to crash and provided an updated build of ASMI containing the fix. 13)Autodesk reviewed and provided feedback for the complex part molding and measurement locations. 14) Autodesk provided support to set up the workflow for ASMI-ABAQUS® analysis, and provided a fix and workaround for a bug in the ASMI-ABAQUS® output command. 15) Autodesk helped build ASMI analysis models for the complex parts with and without ribs. 16) Autodesk worked on improving the orientation prediction accuracy in the shearing layer for 3D meshes based on comparison to measured data of the plaque moldings. 17) PNNL installed a new ASMI version received from Autodesk and performed comparative analyses to assess mid-plane versus 3D fiber length predictions using the full fiber length model and the reduced-order model (ROM) using POD. 18) PNNL presented the project scope, accomplishments, significant results and future plans to DOE and the USCAR Materials Tech Team on June 3rd, 2015. 19) PNNL discussed the cutting of samples from molded parts and finalized a plan with Magna and the team suggesting the sample size, locations and number of samples per location. 20) PNNL and Autodesk built ASMI models for the complex parts with and without ribs, and preliminary analyses of the part with ribs were conducted using the actual molding parameters received from Magna. 21) PNNL worked on a procedure to extract fiber orientation and length results from a 3D ASMI analysis to a 3D ABAQUS model. This procedure is essential to import ASMI fiber orientation and length to a 3D ABAQUS model of the part allowing future part structural analysis for weight reduction study.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Multifunctional Utilization of Pitch-Coated Carbon Fibers in Lithium-Based Rechargeable Batteries

This work reports carbon fibers as an electrode material and current collector for dual-carbon and lithium-ion batteries. Here, fully graphitic and semigraphitic carbon fibers undergo anion intercalation beyond 4.5 V versus Li/Li + . Symmetric dual-carbon full cells using a pitch-coated fully graphitic carbon fiber mat as both cathode and anode delivers an energy-density of 276 and 322 Wh kg -1 at 342 W kg -1 power density in the voltage range of 3.0–5.0 and 3.0–5.2 V, respectively. On the other hand, nongraphitic carbon fibers do not exhibit anion intercalation up to 5.2 V and can be used as a current collector. They also possess a larger number of Li + storage sites in their randomly oriented microstructure when used as an anode. A lithium-ion full cell with double carbon-coated C-LiFePO 4 loaded on nongraphitic carbon fiber as a cathode and pitch-coated nongraphitic carbon fiber as an anode exhibits 202.6 and 75.2 Wh kg -1 energy density at power densities of 46.75 W kg -1 and 11.7 kW kg -1 , respectively in 2.0–3.5 V range. This pitch-coated carbon fiber-based battery configuration eliminates the need for metal foils and costly fluorinated binders, lowers overall weight of the cell, and is capable of sustaining mechanical stress and thermal shock.

PF6− intercalation↗
DOE OSTI2022

Directly Spun Epoxy-Crosslinked Polyethylenimine Fiber Sorbents for Direct Air Capture and Postcombustion Capture of CO 2

A novel, directly injected solid fiber sorbent is synthesized from a solvent-stable, epoxy-crosslinked basic immobilized amine sorbent (BIAS) for CO 2 capture. Leach resistance of the BIAS organics toward 1-methyl-2-pyrrolidone/H 2 O (90/10, fiber solvent) reaches near 100% at the expense of CO 2 capture and is achieved by increasing the extent of crosslinking. The optimized fiber sorbent, prepared with an N,N-diglycidyl-4-glycidyloxyaniline/polyethylenimine (PEI)-0.35/1 wt. ratio, retains 79.2% of PEI and captures 0.37 (direct air capture [DAC]) and 0.67 (postcombustion) mmol CO 2 g-fiber -1 . A nonoptimized prototype hollow fiber exhibits a stable 0.2 mmol CO 2 g-fiber -1 during DAC cycling and is assembled into a ten-fiber module. In conclusion, these results demonstrate a large step toward practical application of this material.

42 ENGINEERING↗
DOE OSTI2018

Enhancement of Mechanical Properties of Bio-Resin Epoxy/Flax Fiber Composites using Acetic Anhydride

Chemically treated acetic anhydride (AA) flax fiber mats were investigated. Bio-based epoxy resin and conventional epoxy resin unidirectional fiber composites were manufactured using a vacuum bagging technique. Flax fibers in the bio-resin composites were chemically treated with 1, 2, 3 and 4% (AA), while the fibers used with the conventional resin were not treated. The composites with the conventional resin were compared with the bio-resin in an untreated condition. A 2% AA treatment improved the bio-resin composite tensile strength, stiffness and bond shear strength by 55%, 58% and 7%, respectively. These three properties were evaluated and the results statistically analyzed using ANOVA. The AA reduced moisture absorption intake and improved adhesion of the fiber/matrix interface. The composites treated with 1–2% AA were most successful with a 65% moisture resistance. The scanning electron microscope was used to observe the fiber surface and fractured surfaces of the untreated and treated flax fibers. A chemical pre-treatment has improved the composite mechanical and moisture resistance over the non-treated fiber composites.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Thermal and Mechanical Properties of Eco-friendly Poly(Vinyl Alcohol) Films with Surface Treated Bagasse Fibers

Bagasse fibers reinforced poly(vinyl alcohol) (PVA) composite films were successfully prepared by solution casting method. To enhance the dispersing effect of the fillers, alkali treatment of the plant fibers was adopted before the fabrication of composites. The structure and properties of the resulting composites were characterized by scanning electron microscopy (SEM), X-ray diffraction, differential scanning calorimetry, mechanical tests, water uptake and thermal stability in detail. The results showed that bagasse fibers after surface modification exhibited good compatibility with PVA matrix. The increased polarity as well as the roughness would be beneficial to the interaction and mechanical interlocking between the fiber and matrix. Acting as the heterogeneous nucleation agents, the fibers could enhance the degree of crystallization and decrease the supercooling degrees of PVA matrix. The fibers exhibited dramatically reinforcing effect in the matrix, and with the increase of fiber, the Young’s modulus and tensile yield stress increased. The Young’s modulus and tensile yield stress of composites with 8% filler would be 3 and 2 times compared with neat PVA films. The thermal stability decreased a little and the water uptake increased with the increase of filler content. These composite films would find wide applications in green packaging areas for their fine mechanical and thermal properties.

36 MATERIALS SCIENCE↗