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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
DOE OSTI2022

Additive Manufacturing Flaw Assessment Methodology

An evolution fatigue data and flaw tolerance of components produced using the Powder Bed Fusion (PBF) Additive Manufacturing (AM) process is documented in this report. Initial differences in fatigue data for AM components compared to smooth bar fatigue data indicated a need for a more detailed analysis of AM data available in technical literature. The investigation was initiated to support the development of a fatigue analysis methodology for AM components to support the of codification of AM technology for pressure equipment. The project was initiated to collect and analyze stainless steel 304L and 316L AM fatigue test data and corresponding process and quality information to develop S-N and E-N based fatigue data representation. Additional AM fatigue test data including Inconel Ti-6-4 and aluminum alloys were also considered for comparison purposes Metallic AM parts tend to contain various forms of defects distributed throughout the part. If an AM part is subjected to fatigue loading in service, a fatigue analysis needs to be performed during the design process to ensure an acceptable service life for the part. Post-process machining and polishing do not to improve fatigue resistance in any significant degree. The low cycle fatigue regime is of particular interest to this project in support of flaw acceptance criteria currently under development by ASME’s BPTCS/BNCS. Internal defects become exposed as external surface defects during machining for the machining of the AM part to final dimensions. This implies that as long as inherent AM defects are within a controlled limit in terms of both size and distribution characteristics, the corresponding fatigue test data in terms of either S-N (stress life) or E-N (strain life) can be investigated and characterized to establish fatigue properties of AM parts for design and fatigue evaluation purposes. The resulting S-N or E-N curves and their scatter bands can be used to derive fatigue design allowable stress values by capturing the effects of distributed discontinuities within an acceptable limit.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Strain–Activated Stimulated Emission from Multilayer MoSe 2 in a Narrow Operation Window

Herein, photoluminescence (PL) and fluorescence lifetime imaging (FLIM) in multilayer MoSe 2 are studied. Strain-activated stimulated emission via defect levels in multilayer MoSe 2 under laser excitation is observed, for the first time in defects of transition metal dichalcogenides. The stimulated emission is indicated by a threshold behavior of PL emission intensity with respect to laser intensity, strong polarization effects, achieved population inversion with a difference in lifetimes of two competing excited states, and localization of the stimulated emission zone as observed in FLIM. Here, the presented results not only demonstrate strain-activated stimulated emission and highlight the necessity of strain engineering in tailoring 2D layered materials for optoelectronic applications, but also shed light on the design of stimulated emission in transition metal dichalcogenide's defects to tailor for potential single-photon emission behavior.

enhanced emission↗
NASA NTRS1991

Effects of floor location on response of composite fuselage frames

Experimental and analytical results are presented which show the effect of floor placement on the structural response and strength of circular fuselage frames constructed of graphite-epoxy composite material. The research was conducted to study the behavior of conventionally designed advanced composite aircraft components. To achieve desired new designs which incorporate improved energy absorption capabilities requires an understanding of how these conventional designs behave under crash type loadings. Data are presented on the static behavior of the composite structure through photographs of the frame specimen, experimental strain distributions, and through analytical data from composite structural models. An understanding of this behavior can aid dynamist in predicting the crash behavior of these structures and may assist the designer achieve improved designs for energy absorption and crash behavior of future structures.

Carden, Huey D.↗
DOE OSTI2023

Study on the Carbon Nanostructures for Nanosized Si Electrodes

Silicon (Si) has been considered as a next-generation anode material due to natural abundance, low operating potential (<0.5 V vs. Li/Li+), and high theoretical specific capacity of 4200 mAh g-1.[1] However, the electrochemical alloying reaction of Si involves large volume changes of 400% during lithiation and delithiation, causing cracking and pulverization of Si.[1] In addition, solid electrolyte interface (SEI) of Si anode experiences constant changes due to unstable SEI reactivity.[2] Considerable efforts have been made to design nanostructured Si materials to address the issues because nanostructuring can relieve the mechanical strain.[3] However, when compared to micrometer-sized active materials having sufficient electrolyte pathway through interparticle space, the nanoparticle (NP)-based electrodes tend to be densely packed. As mass loading is higher and electrode is thicker, ion transport issue can become more severe in the densely packed electrodes.[4] In this work, we will present studies on engineered porosity impacts performance in Si NP electrodes by altering carbon nanostructures. We explore the extreme limit of effectively non-porous electrodes using quasi-spherical, Si NPs, which result in densely packed electrodes when slurry is prepared with conventional carbon black. We engineer porosity using carbon nanostructures including multi-walled carbon nanotubes and carbon nanorods in place of conventional carbon black to create pore structure in Si NP-based electrodes. These experiments provide a correlation between mass loading, porosity and silicon utilization in Si NP-based electrodes. References: [1] C. K. Chan, H. Peng, G. Liu, K. Mcllwrath, X. F. Zhang, R. A. Huggins, Y. Cui, "High-performance lithium battery anodes using silicon nanowires", Nat. Nanotechnol., 2008, 3, 31, [2] J. D. McBrayer, M.-T. F. Rodrigues, M. C. Schulze, D. P. Abraham, C. A. Apblett, I. Bloom, G. M. Carroll, A. M. Coclasure, C. Fang, K. L. Harrison, G. Liu, S. D. Minteer, N. R. Neale, G. M. Veith, C. S. Johnson, J. T. Vaughey, A. K. Burrel, B. Cunningham, "Calendar aging of silicon-containing batteries", Nat. Energy, 2021, 6, 1164, [3] H. Wu, G. Zheng, N. Liu, T. J. Carney, Y. Yang, Y. Cui, "Engineering Empty space between Si Nanoparticles for Lithium-Ion Battery Anodes", Nano Lett., 2012, 12, 904, [4] X. Zhang, Z. Ju, Y. Zhu, K. J. Takeuchi, E. S. Takeuchi, A. C. Marschilok, G. Yu, "Multiscale Understanding and Architecture Design of High Energy/Power Lithium-Ion Battery Electrodes", Adv. Energy Mater., 2021, 11, 2000808

carbon nanostructure↗
DOE OSTI2021

Investigation of phase-transformation path in TiZrHf(VNbTa)x refractory high-entropy alloys and its effect on mechanical property

Refractory high-entropy alloys (RHEAs) show a great potential as structural materials due to their remarkable properties, such as high strength and thermal stability. Despite these advantages, the RHEAs still suffer from the limited ductility at room temperature. To overcome the strength-ductility trade-off, the new RHEA design strategy, transformation-induced plasticity (TRIP) HEAs, have been developed by applying metastability-engineering approach. With the newly developed RHEAs design strategy, we designed metastable RHEAs, TiZrHfVxNbxTax (x = 1.0, 0.5 and 0.1) with decrease of the β-stabilizing elements (V, Nb, and Ta) to promote the transformation-induced ductility and work-hardening capability. The proper addition of the β-stabilizing elements (V, Nb, and Ta) into the ternary equi-molar TiZrHf alloy (TiZrHfV 0.1 Nb 0.1 Ta 0.1 ) leads to stress/strain-induced phase transformation from the body-centered cubic (BCC) to hexagonal-close-packed (HCP) α' and/or orthorhombic α" phases. Here, detailed studies on the phase transformation sequence during the deformation were carried out using X-ray diffraction (XRD), electron back-scattered diffraction (EBSD), and transmission-electron microscope (TEM), which revealed the stepwise phase transformation that is responsible for the strong strain hardening behavior. Furthermore, we further suggested the new transformation-induced-plasticity (TRIP) HEA design strategy, applying the Bo-Md approach.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effect of Part Size, Displacement Rate, and Aging on Compressive Properties of Elastomeric Parts of Different Unit Cell Topologies Formed by Vat Photopolymerization Additive Manufacturing

Due to its ability to achieve geometric complexity at high resolution and low length scales, additive manufacturing (AM) has increasingly been used for fabricating cellular structures (e.g., foams and lattices) for a variety of applications. Specifically, elastomeric cellular structures offer tunability of compliance as well as energy absorption and dissipation characteristics. However, there are limited data available on compression properties for printed elastomeric cellular structures of different designs and testing parameters. In this work, the authors evaluate how unit cell topology, part size, the rate of compression, and aging affect the compressive response of polyurethane-based simple cubic, body-centered, and gyroid structures formed by vat photopolymerization AM. Finite element simulations incorporating hyperelastic and viscoelastic models were used to describe the data, and the simulated results compared well with the experimental data. Of the designs tested, only the parts with the body-centered unit cell exhibited differences in stress–strain responses at different part sizes. Of the compression rates tested, the highest displacement rate (1000 mm/min) often caused stiffer compressive behavior, indicating deviation from the quasi-static assumption and approaching the intermediate rate response. The cellular structures did not change in compression properties across five weeks of aging time, which is desirable for cushioning applications. This work advances knowledge on the structure–property relationships of printed elastomeric cellular materials, which will enable more predictable compressive properties that can be traced to specific unit cell designs.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Effects of floor location on response of composite fuselage frames

Experimental and analytical results are presented which show the effect of floor placement on the structural response and strength of circular fuselage frames constructed of graphite-epoxy composite material. The research was conducted to study the behavior of conventionally designed advanced composite aircraft components. To achieve desired new designs which incorporate improved energy absorption capabilities requires an understanding of how these conventional designs behave under crash type loadings. Data are presented on the static behavior of the composite structure through photographs of the frame specimen, experimental strain distributions, and through analytical data from composite structural models. An understanding of this behavior can aid the dynamist in predicting the crash behavior of these structures and may assist the designer in achieving improved designs for energy absorption and crash behavior of future structures.

Carden, Huey D.↗
NASA NTRS2003

Sintering and Interface Strain Tolerance of Plasma-Sprayed Thermal and Environmental Barrier Coatings

Ceramic thermal and environmental barrier coatings will be more aggressively designed to protect gas turbine engine hot section SiC/SiC Ceramic Matrix Composite (CMC) components in order to meet future engine higher fuel efficiency and lower emission goals. A coating system consisting of a zirconia-based oxide topcoat (thermal barrier) and a mullite/BSAS silicate inner coat (environmental barrier) is often considered a model system for the CMC applications. However, the coating sintering, and thermal expansion mismatch between the zirconia oxide layer and the silicate environmental barrier/CMC substrate will be of major concern at high temperature and under thermal cycling conditions. In this study, the sintering behavior of plasma-sprayed freestanding zirconia-yttria-based thermal barrier coatings and mullite (and/or barium-strontium-aluminosilicate, i.e., BSAS) environmental barrier coatings was determined using a dilatometer in the temperature range of 1200-1500 C. The effects of test temperature on the coating sintering kinetics were systematically investigated. The plasma-sprayed zirconia-8wt.%yttria and mullite (BSAS) two-layer composite coating systems were also prepared to quantitatively evaluate the interface strain tolerance of the coating system under thermal cycling conditions based on the dilatomentry. The cyclic response of the coating strain tolerance behavior and interface degradation as a function of cycle number will also be discussed.

Zhu, Dongming↗
NASA NTRS1979

Development of procedures for calculating stiffness and damping of elastomers in engineering applications. Part 5: Elastomer performance limits and the design and test of an elastomer damper

Tests were performed on elastomer specimens of the material polybutadiene to determine the performance limitations imposed by strain, temperature, and frequency. Three specimens were tested: a shear specimen, a compression specimen, and a second compression specimen in which thermocouples were embedded in the elastomer buttons. Stiffness and damping were determined from all tests, and internal temperatures were recorded for the instrumented compression specimen. Measured results are presented together with comparisons between predictions of a thermo-viscoelastic analysis and the measured results. Dampers of polybutadiene and Viton were designed, built, and tested. Vibration measurements were made and sensitivity of vibration to change in unbalance was also determined. Values for log decrement were extracted from the synchronous response curves. Comparisons were made between measured sensitivity to unbalance and log decrement and predicted values for these quantities.

Tecza, J. A.↗
NASA NTRS1981

Current research on shear buckling and thermal loads with PASCO: Panel Analysis and Sizing Code

The PASCO computer program to obtain the detailed dimensions of optimum stiffened composite structural panels is described. Design requirements in terms of inequality constraints can be placed on buckling loads or vibration frequencies, lamina stresses and strains, and overall panel stiffness for each of many load conditions. General panel cross sections can be treated. An analysis procedure involving a smeared orthotropic solution was investigated. The conservatism in the VIPASA solution and the danger in a smeared orthotropic solution is explored. PASCO's capability to design for thermal loadings is also described. It is emphasized that design studies illustrate the importance of the multiple load condition capability when thermal loads are present.

Stroud, W. J.↗
NASA NTRS2022

Optimization Approach for Wind Tunnel Fan Blade Strain Gage Correlation with Test Fixture Unknowns

NASA has a significant maintenance challenge with the aging wind tunnel infrastructure across the Agency. Some wind tunnel fan blades, such as those in the National Transonic Facility at NASA Langley Research Center, have been in use for far longer than their planned 10-year lifetime. No detailed analytical models of the fan blades from their initial fabrication were created. To support the fabrication of either new, nominally identical fan blades or newly designed fan blades, accurate analytical models of the existing fan blades are necessary to demonstrate an understanding of the capabilities of the existing fan blades. Additionally, the existing documentation of the testing of the existing fan blades has gaps. In this report, a process for improving test-analysis correlation for these wind tunnel fan blades is discussed. This process involved a detailed study of unknown parameters in test fixture parameters from the old and incomplete test documentation. To improve correlation, these unknown parameters were used as design variables in an optimization study to minimize the error between test data and computed structural responses. Legacy strain gage data from tests conducted in 1981 were compared with results from a finite element model created in 2019. The use of test data from 1981 was necessary because none of the existing fan blades could be spared for use in destructive structural testing. While this process was demonstrated for wind tunnel fan blades, this process could be utilized for evaluating unknowns in test fixtures for other structural test configurations.

wind tunnel↗
NASA NTRS1987

Strain measurements in composites subjected to compressive loading using moire interferometry

Experimental apparatus to apply a uniaxial compressive load to composite laminates and measure the resulting in-plane displacement fields using moireinterferometry were designed and built. Quasi-isotropic graphite/epoxy and graphite/PEEK laminates were subjected to near-ultimate compressive creep loadings at room temperatures. Creep loads were applied for times up to 28 hrs. Strains were calculated from the measured displacements, and compared with theoretical results.

Klein, R. J.↗
DOE OSTI2023

A materials data framework and dataset for elastomeric foam impact mitigating materials

The availability of materials data for impact-mitigating materials has lagged behind applications-based data. For example, data describing on-field helmeted impacts are available, whereas material behaviors for the constituent impact-mitigating materials used in helmet designs lack open datasets. Here, we describe a new FAIR (findable, accessible, interoperable, reusable) data framework with structural and mechanical response data for one example elastic impact protection foam. The continuum-scale behavior of foams emerges from the interplay of polymer properties, internal gas, and geometric structure. This behavior is rate and temperature sensitive, therefore, describing structure-property characteristics requires data collected across several types of instruments. Data included are from structure imaging via micro-computed tomography, finite deformation mechanical measurements from universal test systems with full-field displacement and strain, and visco-thermo-elastic properties from dynamic mechanical analysis. These data facilitate modeling and design efforts in foam mechanics, e.g., homogenization, direct numerical simulation, or phenomenological fitting. The data framework is implemented using data services and software from the Materials Data Facility of the Center for Hierarchical Materials Design.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Spin test of turbine rotor

Experimental data are presented for the tangential and radial stresses in the disks of the 36,000 horsepower, 4000 rpm turbine for the M-1 engine oxidizer turbopump. The two-stage Curtis turbine is a special light-weight design utilizing thin conical disks with hollow sheet metal blades attached by electron-beam welding techniques. The turbine was fabricated from Inconel 718, a nickel-chromium alloy. The stresses were obtained by strain-gage measurements using a slip-ring assembly to transmit the electrical signals. Measurements were made at different rotative speeds and different thermal loads. In addition to presenting test data, the report describes test equipment, design of associated hardware, test procedures, instrumentation, and tests for the selection and calibration of strain gages.

Vavra, M. H.↗
NASA NTRS2010

A Two-Axis Direct Fluid Shear Stress Sensor

This innovation is a miniature or micro sized semiconductor sensor design that provides two axis direct non-intrusive measurement of skin friction or wall shear stress in fluid flow. The sensor is fabricated by micro-electro-mechanical system (MEMS) technology, enabling small size and low cost reproductions. The sensors have been fabricated by utilizing MEMS fabrication processes to bond a sensing element wafer to a fluid coupling wafer. This layering technique provides for an out of plane dimension that is on the same order of length as the inplane dimensions. The sensor design has the following characteristics: a shear force collecting plate with dimensions that can be tailored to various application specific requirements such as spatial resolution, temporal resolution and shear force range and resolution. This plate is located coplanar to both the sensor body and flow boundary, and is connected to a dual axis gimbal structure by a connecting column or lever arm. The dual axis gimbal structure has torsional hinges with embedded piezoresistive torsional strain gauges which provide a voltage output that is correlated to the applied shear stress (and excitation current) on force collection plate that is located on the flow boundary surface (hence the transduction method). This combination of design elements create a force concentration and resolution structure that enables the generation of a large stress on the strain gauge from the small shear stress on the flow boundary wall. This design as well as the use of back side electrical contacts establishes a non-intrusive method to quantitatively measure the shear force vector on aerodynamic bodies.

Adcock, Edward E.↗
DOE OSTI2024

Developing multi-gene CRISPRa/i programs to accelerate DBTL cycles in ABF hosts engineered for chemical production

This project developed and implemented a modular CRISPR activation and interference (CRISPRa/i) platform to accelerate strain optimization and pathway development for industrially relevant microbial hosts. By integrating multiplexed transcriptional perturbation tools with data-driven Design–Build–Test–Learn (DBTL) workflows, the team achieved reductions in cycle time and enhanced production of industrial aromatics, particularly 4-aminocinnamic acid (4-ACA), in Pseudomonas putida. Key accomplishments included: ● Development of a robust, tunable CRISPRa/i system in P. putida that enabled efficient multi-target gene regulation via guide RNA (gRNA) programs ● Completion of two full DBTL cycles, guided by machine learning (ML) models trained on transcriptomic and performance data, reducing engineering time by over 30% ● Optimization of multi-gene regulatory programs to balance expression of host and pathway modules, improve 4-ACA titers, and resolve metabolic bottlenecks ● Demonstration of system portability through a limited proof-of-concept extension in Acinetobacter baylyi, underscoring the generalizability of the approach ● Evaluation of strain performance on lignocellulosic biomass-derived substrates, demonstrating the feasibility of converting renewable carbon into aromatic building blocks These results illustrate the feasibility of applying ML-guided CRISPRa/i perturbation strategies to accelerate strain development in complex microbial systems. The resulting tools and datasets contribute to DOE objectives by improving platform predictability, reducing development costs, and enabling broader access to sustainable, economically viable bioproduction technologies.

09 BIOMASS FUELS↗
DOE OSTI2024

Effect of sintering temperature on feature resolution and flexural strength of ceramics fabricated through vat photopolymerization additive manufacturing

Although ceramic additive manufacturing (AM) could be used to fabricate complex, high-resolution parts for diverse, functional applications, one ongoing challenge is optimizing the post-process, particularly sintering, conditions to consistently produce geometrically accurate and mechanically robust parts. This study aims to investigate how sintering temperature affects feature resolution and flexural properties of silica-based parts formed by vat photopolymerization (VPP) AM. Test artifacts were designed to evaluate features of different sizes, shapes and orientations, and three-point bend specimens printed in multiple orientations were used to evaluate mechanical properties. Sintering temperatures were varied between 1000°C and 1300°C. Deviations from designed dimensions often increased with higher sintering temperatures and/or larger features. Higher sintering temperatures yielded parts with higher strength and lower strain at break. Many features exhibited defects, often dependent on geometry and sintering temperature, highlighting the need for further analysis of debinding and sintering parameters. To the best of the authors’ knowledge, this is the first time test artifacts have been designed for ceramic VPP. This work also offers insights into the effect of sintering temperature and print orientation on flexural properties. These results provide design guidelines for a particular material, while the methodology outlined for assessing feature resolution and flexural strength is broadly applicable to other ceramics, enabling more predictable part performance when considering the future design and manufacture of complex ceramic parts.

36 MATERIALS SCIENCE↗