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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 757 records · Page 42
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Advanced Composite Solar Sail System (ACS3) Mission Update

The Advanced Composite Solar Sail System (ACS3) will be the first practical solar sail for the National Aeronautics and Space Administration. [1] ACS3 will also be the first spaceflight demonstration of NASA compact deployable composite boom technology.[2] The primary mission objective of ACS3 will be to deploy and characterize an 80-m2 composite boom structure solar sail technology in low Earth orbit. Extended mission goals will be to demonstrate controlled solar sailing flight via a series of orbit raising and lowering maneuvers. Target mission orbit is a 1000 km x 1000 km midnight-noon sun-synchronous orbit. Launch of ACS3 is scheduled for July 2023 with sail deployment in September 2023. Mission duration is expected to be six to nine months. The ACS3 solar sail vehicle is a 12U Cubesat consisting of a bus module, containing flight and solar sail control avionics, and a solar sail module, containing the composite booms and metallized polymer solar sail membranes of the solar sail structure stowed within a boom deployer mechanism. A four-camera instrument suite for 360-degree imaging of the ACS3 solar sail during and after deployment is also housed within the bus module. The ACS3 80-m2 solar sail design is a sub-scale version of an intermediate-size 500-m2 solar sail using NASA deployable composite boom technology. The sail consists of four metallized 2-m thick polyethylene naphthalate (PEN) 20-m2 triangular quadrants supported by four 7-m long lenticular cross-section composite booms. Booms are flattened and co-coiled for stowage within a tape-spool driven deployer mechanism. Total mass of the ACS3 space vehicle including solar sail is 16 kg. An overview of the ACS3 mission and mission systems will be provided in this presentation. This overview will include descriptions of the solar sail structures and materials technology used with ACS3, and discussion of the scalability and extensibility of the ACS3 solar sail to future larger-scale solar sailing mission requirements. An update on progress towards the launch of ACS3 in July 2023 will also be provided. References [1] https://www.nasa.gov/directorates/spacetech/small_spacecraft/ACS3 [2] https://www.nasa.gov/directorates/spacetech/game_changing_development/projects/dcb

Solar sail↗
NASA NTRSDate not supplied

A Procedure to Quantify Interlaminar Damage in Refractory Composites by In-Situ Micro-X-Ray Computed Tomography

Refractory composites are relevant for hot-structure applications on re-entry vehicles. To develop optimized high-performance hot structures, accurate material property data is required. Material properties that often limit design in two-dimensional (2-D) composites are interlaminar strengths. A better understanding of the failure mechanisms for interlaminar shear (ILS), interlaminar tension (ILT), and curved-beam interlaminar tension (CB-ILT) tests can provide insight on improving the design and fabrication of refractory composites. In-situ tests were performed to capture the progressive failure in American Society for Testing and Materials (ASTM) sized ILS (ASTM D3846), ILT (ASTM D7291), and CB-ILT (ASTM D6415) specimens. Before measuring internal damage of refractory composites specimens, the methodology of the test setup warrants a complete and thorough discussion. Detail on the test procedure, test stand design, micro-x-ray computed tomography (CT) configuration, data processing, and CT system uncertainty is discussed. Through keeping the many parameters of the CT system consistent, the uncertainty of the CT system was minimized, optimizing the quality of measurements. The overall quality of a CT scan can be quantified by three metrics: voxel resolution, minimal voxel resolution feature detection, and directional variability. A better understanding of the progressive failure mechanisms of refractory composites is provided by the results of both the present discussion and the one found in the accompanying paper titled “Analysis of Interlaminar Damage in Refractory Composites by In-Situ Micro-X-Ray Computed Tomography”.

In-situ micro-x-ray CT↗
NASA NTRSDate not supplied

Improvements to Stitching Controls for Manufacturing Advanced Stitched Composites

Stitched composites have been extensively studied and have been shown to have benefits over unstitched composites for stiffened structures, including improved damage tolerance, reduced weight, and fewer fasteners. These benefits make stitched composites attractive from a performance perspective, however, the nature of stitching the preforms prior to infusion includes additional manufacturing steps and equipment compared to conventional resin infusion. Stitching of composite material structures at NASA Langley Research Center (LaRC) is performed at the Integrated Structural Assembly of Advanced Composites (ISAAC) facility using control algorithms developed by the lead author. Two deficiencies have been identified in the current control algorithms, and mitigations for these deficiencies were developed within the Hi-Rate Composite Aircraft Manufacturing (HiCAM) project and are presented herein. First, decoupling stitch translation and rotation takes more time for stitching since two robot operation control steps are executed for each stitch. Therefore, a method was developed to determine when to decouple the translation and rotation for stitching, which reduces stitch time by decoupling the operation control steps only when necessary to execute the stitch properly. Second, a correction to the sideslip stitching approach that eliminates a significant portion of the pre- and post-stitching activities was developed. The developed method adjusts the sideslip stitch angle based on the rotations of previous stitches to ensure that the width of the stitching seam remains constant along its length. Constant seam width eliminates observed overlap of the insertion and catcher thread portions for highly curved paths, which maintains the desired uniformity of through-the-thickness architecture along the seam and eliminates the local degradation of properties where the insertion needle is too close to, or crosses, the catcher needle portion of the seam.

stitching↗
DOE OSTI2022

Nanoscale Three-Dimensional Imaging of Degradation in Composite Si-Containing Anodes

The use of silicon (Si) in next-generation lithium-ion battery (LIB) anodes has the potential to dramatically improve electrochemical performance over current LIB graphite (Gr) anodes, due to silicon’s higher specific capacity.1 However, widespread implementation of Si-containing anodes is inhibited by issues such as significant Si volume expansion during lithiation and an unstable solid-electrolyte interphase (SEI), resulting in unreliable performance and poor cycle life. Currently, composite anodes with both Si and graphite active materials are used to increase capacity and mitigate some of the limitations associated with Si. In composite electrodes with a heterogeneous distribution of components with varying electrical properties (including Si, Gr, conductive carbon additive, and binder), it is important to understand the local distribution of each component to correlate with electrochemical processes, particularly localized degradation and heterogeneous aging, and to optimize performance. To investigate Si-containing composite anodes in the nanoscale, we use scanning spreading resistance microscopy (SSRM), a form of scanning probe microscopy (SPM) that probes local electronic resistivity. By examining the intrinsic electronic resistivity contrast between the anode components, separate phases can be distinguished and understood within the composite structure.2 This work studies the effect of electrochemical cycling in two different electrolytes on component distribution and aging by comparing the electrical and structural evolution of composite Si-graphite electrodes and SEI before and after charge-discharge cycling. 1. W. J. Zhang. A review of the electrochemical performance of alloy anodes for lithium-ion batteries J. Power Sources 196 13–24 (2011). 2. C. Stetson, Z. Huey, A. Downard, Z. Li, B. To, A. Zakutayev, C.-S. Jiang, M. Al-Jassim, D. Finegan, S.-D. Han and S. DeCaluwe: Three-Dimensional Mapping of Resistivity and Microstructure of Composite Electrodes for Lithium-Ion Batteries. ACS Nano Letters Accepted (2020).

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Optical Evidence of Compositional Fractioning between Plasma‐Condensed and Melt Pool Matter

Control of multicomponent alloys during welding is challenging because it lacks a real‐time understanding of composition. The optical emissions of plasma formed during laser‐induced metal welding correlate with the composition of particles ejected from the melt pool. Plasma emissions observed in this study contain large iron, manganese, chrome, and copper signatures, which match the composition of emitted particles. Particles recovered closest to the melt pool exhibit a core–shell morphology that is composed of iron‐manganese‐chrome intermetallic cores within copper shells. Particles collected farther from the melt pool, do not share this core–shell morphology, though similar elemental compositions are observed. The correlation between plasma optical emissions and particle composition can be used to predict the composition of the melt pool, allowing for real‐time welding and sintering control.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Hybrid of multi‐dimensional fillers for thermally enhanced polyamide 12 composites fabricated by selective laser sintering

Abstract Selective laser sintering (SLS) is an additive manufacturing technology that can provide a novel strategy to manufacture complex polymer‐based composites with tailored properties. In this study, polyamide 12 (PA12) composite powders based on Al 2 O 3 , boron nitride (BN), and carbon nanotubes (CNTs) were prepared via a two‐step mixing approach. Morphology characterization techniques indicated that the fillers were uniformly dispersed in the PA12 matrix as expected. Under the optimum 3D‐printing parameters, the fabrication of SLS parts with high filler loading could be obtained. With 40 wt% Al 2 O 3 , 8 wt% BN, and 2 wt% CNT hybrid fillers, the thermal conductivity of PA12 composites could reach 1.09 W/mK. It could be attributed to the synergistic effect of multi‐dimensional fillers to form dense and continuous thermal conduction paths. The factors influencing the performance of PA12 composites such as melting and crystallization behaviors, dielectric properties, and mechanical properties were also discussed. The results show that these composites have favorable dielectric and mechanical properties. Overall, the PA12 composites fabricated by SLS technology in this study exhibit excellent thermal management ability.

Yuan, Yue↗
DOE OSTI2023

Combinatorial Growth of Vertically Aligned Nanocomposite Thin Films for Accelerated Exploration in Composition Variation

Combinatorial growth is capable of creating a compositional gradient for thin film materials and thus has been adopted to explore composition variation mostly for metallic alloy thin films and some dopant concentrations for ceramic thin films. This study uses a combinatorial pulsed laser deposition method to successfully fabricate two‐phase oxide–oxide vertically aligned nanocomposite (VAN) thin films of La 0.7 Sr 0.3 MnO 3 (LSMO)‐NiO with variable composition across the film area. The LSMO‐NiO compositional gradient across the film alters the two‐phase morphology of the VAN through varying nanopillar size and density. Additionally, the magnetic anisotropy and magnetoresistance properties of the nanocomposite thin films increase with increasing NiO composition. This demonstration of a combinatorial method for VAN growth can increase the efficiency of nanocomposite thin film research by allowing all possible compositions of thin film materials to be explored in a single deposition.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Codesigning Alloy Compositions of CdSe y Te 1− y Absorbers and Mg x Zn 1− x O Contacts to Increase Solar Cell Efficiency

Thin‐film solar cells such as CdTe are a major commercial photovoltaic technology, with more than 25 GW installed worldwide and levelized costs of electricity competitive with fossil fuels. Further progress may result from integrating CdSe y Te 1− y absorbers with Mg x Zn 1− x O contacts, but the device efficiency is difficult to maximize due to coupled dependence on chemical composition of both alloys. Herein, a high‐throughput approach is demonstrated to codesign chemical compositions in alloyed Mg x Zn 1− x O/CdSe y Te 1− y thin‐film solar cells, using combinatorial libraries of PV devices with orthogonal composition gradients in CdSe y Te 1− y absorbers and Mg x Zn 1− x O contacts. It is found that the solar cell performance is a strong and coupled function of both elemental compositions, with efficiency up to 17.7% ( V OC = 836 mV, fill factor = 69%, J SC = 30.6 mA cm −2 ) at atomic compositions of Mg/(Mg + Zn) ≈18% and average Se/(Se + Te) ≈4%. These performance trends among >100 devices are explained by >100 ns lifetime of photoexcited charge carriers at the Mg x Zn 1− x O/CdSe y Te 1− y interface where strong Se accumulation is also observed. This study reports the optimal compositions of the commercially relevant Mg x Zn 1− x O/CdSe y Te 1− y solar cells and demonstrates a general approach to codesigning performance of alloyed thin‐film solar cells and other optoelectronic devices.

14 SOLAR ENERGY↗
DOE OSTI2024

Aluminum/SmCo 5 composites for structural and magnetic applications

Metal-bonded magnetic composites (MBMCs) present a promising alternative to dense sintered magnets, particularly for intricate components. Compared to polymer-based bonded magnets, MBMCs have wider applicability in harsh environments. In this paper, we demonstrate a solid-state shear-based manufacturing technique to introduce localized magnetization into a paramagnetic aluminum matrix by embedding SmCo5 permanent magnet particles. Our magnetic composites display hard magnetic behavior with a coercivity of 13 kOe and a remanent magnetization of 4.32 emu/g. In addition to magnetization, we also report a 9% improvement in Young’s modulus. Despite the local temperature rise during processing, the magnetic phases didn’t decompose into unwanted phases, preserving the composite's hard magnetic properties. Creation of an interfacial metallurgical bond with the matrix ensured the suitability of the composites for structural applications. Our study investigates the mechanical, and functional properties of composites, paving the way for lightweight structural magnetic composites with a transformative potential in the aerospace, nuclear, and automotive applications. This work underscores the potential for further optimization and development to drive innovations in magnet and equipment design.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Mechanical Characterization of High-Temperature Carbon Fiber-Polyphenylene Sulfide Composites for Large Area Extrusion Deposition Additive Manufacturing

Additive manufacturing (AM) is evolving from rapid prototyping to production of structural components. The widespread application of AM demands a high level of mechanical performance from these components, and it is therefore essential to improve feedstock material in order to meet these mechanical expectations. However, compared to traditional manufacturing techniques, the mechanical properties of AM materials and their resulting components are not well understood. In this study, we investigated the processability, microstructure, and mechanical performance of twin-screw compounded short carbon fiber reinforced polyphenylene sulfide (PPS) pellets as a feedstock material for big area AM (BAAM). The performance of the AM components was compared to that of traditional processing methods, namely injection molding (IM) and extrusion-compression molding (ECM). It was found that the AM composites exhibited 118% lower tensile strength and 55% lower tensile modulus when compared to traditional injection molding composite specimens; however, AM composites exhibited comparable properties to ECM composites. This response was attributed to highly aligned fibers in IM and AM samples. However, the AM composites contained porosity (15.5% volume), which reduced their mechanical properties in comparison to ECM composites. Finally, the IM process showed the maximum amount of fiber attrition with minimum porosity (0.007% volume), while the ECM process exhibited the least fiber attrition with 4.3% volume porosity.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Densification and oxidation behavior of spark plasma sintered Hafnium Diboride-Hafnium Carbide composite

This study reports on the sintering and oxidation behaviors of Hafnium Diboride (HfB 2 ) and Hafnium Carbide (HfC) based ultra-high temperature ceramic (UHTC) composites. Pure Hafnium Diboride, Hafnium Carbide, and HfB 2 -50 vol% HfC composite were consolidated using spark plasma sintering (SPS) without the use of sintering aids. HfB 2 -HfC composite displayed a high sintered density of 98% as compared to 87% density of pure HfB 2 . The increased density of the HfB 2 -HfC composite is attributed to the bimodal powder distribution, which allowed for the smaller HfC particle to occupy the voids between the larger HfB 2 particles resulting in improved packing efficiency. Moreover, the higher planar surface energy, for the (111) and the (200) planes for HfC, contributed to the smaller HfC particle being a significant driving force in the sintering process. Oxidation studies of each material were carried out by exposing them to a high-speed plasma jet in a temperature exceeding 2700 °C. The results of these studies show an improved oxidation resistance of HfB 2 -HfC composite by 54% and 70% over pure HfC and HfB 2 , respectively. The enhanced oxidation behavior is attributed to B 2 O 3 filling in the porosity between the HfO 2 scale and protecting the underlying material. This study provides a new alternative to improve the sinterability of UHTC diborides by introducing another UHTC (i.e., HfC) to form a fully dense composite without sintering aid and superior oxidation resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Enhanced ductility in in-layer glass-carbon fiber/epoxy hybrid composites produced via tailored fiber placement

Experimental mechanical property results of composite materials with hybrid reinforcements (commingled glass and carbon fibers) are detailed and compared with single-fiber composite properties. In-layer hybrid materials, with carbon and glass fiber tows laid side-by-side, were produced via tailored fiber placement (TFP) technology. Detailed experiments showed a phenomenon of “enhanced ductility” of carbon fiber in the hybrid composites of 12–24% relative to an all-carbon fiber composite and multiple stress–strain peaks were observed. Here, this enhanced ductility was hypothesized to be due to the glass fibers mitigating the shock waves arising from the initial failures of carbon fibers, and preventing the premature failure of the remaining carbon fibers. A novel way to engineer the stress–strain behavior of a hybrid composite to achieve a metal-like ductile response (plateau of stress–strain behavior, often termed “elastic–plastic deformation”) was demonstrated by carefully selecting the type and composition of carbon and glass fiber materials.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Economic competitiveness of pultruded fiber composites for wind turbine applications

Pultrusion manufacturing of fiber reinforced polymers has been shown to yield some of the highest mechanical properties for unidirectional composites, having a high degree of fiber alignment with consistent performance. Pultrusions offer a low-cost manufacturing approach for producing unidirectional composites with a constant cross-section and are used in many applications, including spar caps of wind turbine blades. However, as an intermediate processing step for wind blades, the additional cost of manufacturing pultrusions must be accompanied by sufficient increases in mechanical performance and system benefits. Wind turbine blades are manufactured using vacuum-assisted resin transfer molding with infused unidirectional fiberglass or carbon pultrusions for the spar cap. Infused fiberglass composites are among the most cost-effective structural materials available and replacing this material in the cost-driven wind industry has proven challenging, where infused fiberglass spar caps are still the predominant material system in use. To evaluate alternative material systems in a pultruded composite form, it is necessary to understand the costs for this additional manufacturing step which are shown to add 33%–55% on top of the material costs. A pultrusion cost model has been developed and used to quantify cost sensitivities to various processing parameters. The mechanical performance for pultruded composites is improved versus resin-infusion manufacturing with a 17% increase in design strength at a constant fiber volume fraction, but also enables higher achievable fiber volume fractions. The cost-specific mechanical performance is compared as a function of processing parameters for pultruded composites to identify the opportunities for alternative material and manufacturing approaches for wind turbine spar caps. Finally, four materials are compared in a representative wind turbine blade model to assess the performance of pultruded carbon fiber systems and pultruded fiberglass relative to infused fiberglass, where the pultruded systems produce lower weight blades with various cost distinctions.

42 ENGINEERING↗
DOE OSTI2023

Crashworthiness of recycled carbon fiber composite sinusoidal structures at dynamic rates

Fiber reinforced polymer composites are finding applications in the automotive space for structurally critical applications including crash management. The use of recycled carbon fiber reinforcement can greatly reduce carbon emissions. In this study, recycled carbon fiber composites were manufactured into a self-supporting geometry using three matrices: polyphenylene sulfide (PPS), acrylonitrile butadiene styrene (ABS), and a structural epoxy, and subsequently crushed between flat platens at dynamic rates ranging from 4.6 to 9.1 ms -1 at temperatures in a range of -40°C to 80°C. Load-displacement data was used to evaluate their specific energy absorption, crush efficiency, and steady-state crush stress. Further, the energy absorption of the ABS composites was strongly sensitive to temperature, while the PPS composites exhibited strong crush efficiency dependence with both rate and temperature. The epoxy composites exhibited stable crush behavior at dynamic crush rates but exhibited a dramatic reduction in crush efficiency relative to quasi-static tests. The results of this study indicate that recycled fiber composites can achieve very high energy absorption levels (50–80kJkg -1 at room temperature) that make them an excellent alternative to more expensive and less environmentally friendly continuous virgin fiber laminates.

42 ENGINEERING↗
DOE OSTI2024

Reassessing the proposed “CY chondrites”: Evidence for multiple meteorite types and parent bodies from Cr-Ti-H-C-N isotopes and bulk elemental compositions

Here, we report a coordinated bulk Cr-Ti-H-C-N isotopic and compositional study of six carbonaceous chondrites from Antarctica that are often considered to be related and termed Yamato-like carbonaceous (CY) chondrites. These meteorites are known to have undergone extensive aqueous alteration followed by different degrees of thermal alteration, to be similar to one another in regard to mineralogy, and share affinities with both the Ivuna-like carbonaceous (CI) and Mighei-like carbonaceous (CM) chondrites. While mineralogically similar, a key difference among these samples is that chondrules have been found in some of these samples, but not in others. The aim of this study is to evaluate the relationship of these meteorites to one another, and investigate how they relate to the CI and CM chondrite groups. We find that with the addition of the isotopic compositions of these ‘CY’ chondrites, there is now a continuum of isotopic compositions among the carbonaceous chondrites. The CI chondrites are no longer separate in O isotopic compositions from the other carbonaceous chondrite groups in plots of Cr-O and Ti-O. We also find that the ‘CY’ chondrites represent two distinct populations, which correlate with their heating stage. However, the peak temperatures experienced by each population can only explain the differences in H and C isotopes and abundances and N abundances between samples, and cannot have caused the differences in N, Cr, and Ti isotopes, or all the volatile element depletions of the sample’s bulk compositions. Instead, we conclude that the compositional and isotopic data of these two populations correlate with their known chondrule abundances, indicating distinct precursors for each population. We find it most likely that these samples originate from two distinct asteroids, implying that among the six samples studied here, there are not five related samples to constitute a new meteorite group. The chondrule-free heating Stage III samples are most likely heated CI chondrites, while the chondrule-bearing heating Stage IV samples could be heated CM chondrites.

58 GEOSCIENCES↗
DOE OSTI2022

Quasi-static and dynamic response of a Cu/Nb composite following equal channel angular extrusion

The article presents a study of the plastic properties of a Cu–18%Nb composite following equal channel angular extrusion under both low- and high-strain rate loadings. The microstructures are characterized by optical and scanning electron microscopy as well as electron backscatter diffraction. Comparisons are also made with a Cu–50%Nb laminate made by accumulative roll bonding. Textures obtained within the respective phases in the extruded composite closely mimic those previously reported for the pure components alone (Cu, Nb). Grain sizes of the major phase (Cu) exhibit broad distributions, due largely to partial recrystallization during the extrusion process. Further re-crystallization is obtained within localized deformation bands produced at high strain rates (3 × 10 3 s –1 ). While the degree of anisotropy and the strain rate sensitivity of the composite response are similar to those of pure Cu after extrusion, the strength levels of the composite are somewhat greater, falling broadly between those obtained in the pure components after extrusion to comparable plastic strains. Furthermore, the implications for selection of composite composition and processing for achieving higher strengths are briefly discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Thermal mechanical assessment of a SiC-SiC-composite clad fuel pin concept in a light water reactor environment

Accident Tolerant Fuels (ATFs) are designed to increase coping time following an accident scenario while preserving or improving current steady state reactor operational performance. A potential ATF concept is SiC-SiC composite claddings. Fuel performance simulations were conducted on a SiC-SiC based cladding concept utilizing a multilayered approach for improved performance. This cladding concept referred to as the Duplex concept is a duplex structure composed of a monolithic SiC layer placed on the outside of a SiC-SiC composite. A liquid metal is added to fuel-cladding gap for improved heat dissipation from the fuel. The monolithic SiC layer is used to improve the coolant corrosion characteristics and protect the SiC-SiC composite layer from exposure to the coolant. The fuel performance code BISON was used to conduct fuel performance simulations on the cladding concepts. Comparisons are made with a current prototypic fuel rod design (UO 2 fuel enclosed in Zircaloy-4 cladding). Representative steady-state cases were considered for normal power and two cycle power histories. Additionally, a PCI ramp case was simulated to analyze potential anticipated operational occurrences. Transient response during a Loss of Coolant Accident and a Reactivity Initiated Accident were also simulated. This computational study demonstrated that for normal operating conditions, the SiC concept cladding performed as well as the baseline for the standard power cases evaluated. The ramping evaluations indicate potential fracturing of the SiC-SiC composite of the composite cladding compared to the Zircaloy-4 cladding due to the temperature gradient and the subsequent differential thermal conductivity degradation and swelling across the composite thickness. In conclusion, the rod fails early at low enthalpy for RIA but survives a LOCA with minimal material loss due to high temperature steam corrosion.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗