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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 793 records · Page 44
All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Lightweight, Durable, and Multifunctional Electrical Insulation Material Systems for High Voltage Applications

Newly developed multilayer structures of well-known polymer insulation materials significantly improved dielectric breakdown voltage, VB, or dielectric strength, K, if well-bonded, when compared to those of single material insulations or the commercial SOA systems, such as Teflon-Kapton-Teflon (TKT), at the same overall thickness. To date, the greatest improvement of the new structures from a few candidate materials, including various types of Kapton PIs and PFA or PET as bond layer (BL), was about 61% higher than that of the Kapton PI alone films, 40.1 vs. 24.9 kV, which was translated to 86.3% decrease in insulation thickness, thus significant volume and weight reduction of the final system. However, it was of interest to note that most improvements of the multilayer structures occurred at thicker overall thicknesses, above ~ 0.15 mm. Extensive analyses also showed that K of the multilayer structures increased with (i) decreasing individual layer thickness regardless of material type, (ii) increasing total accumulated thickness of PI or overall PI/BL ratio, and (iii) increasing number of interface or total number of layers, but only above the aforementioned overall thickness limit. Increases in VB of the multilayer structures were directly correlated with damage evolution and failure mode. With further material-design-process optimizations of the multilayer structures, it was expected to achieve other multifunctionalities, such as high partial discharge (PD) resistance, improved durability, EMI shielding, and high thermal dissipation in addition to high dielectric strength. These new structures can be used in various high voltage and high temperature applications, such as future hybrid or all electric aircraft wiring and power transmission as well as many other non-aerospace high power cables, electronic parts and components, printed circuit board, and so forth. The multilayer insulation system can be easily processed and manufactured with various conductor types via calendaring, compression-molding, stamping, laminating, vacuum-bagging and autoclaving, or 3D printing, even for complex 3-D components. Based on their unique structural configurations and potential capabilities, the new insulation system was identified as micro-multilayer multifunctional electrical insulation (MMEI). Patent application of the MMEI concept and current design configurations was filed for a 1-year provisional application (OAI-58834, Serial No.: 62/659,234), pending conversion to a U.S. utility application. This paper presents details of the MMEI structures, their dielectric performance analyses, potential mechanisms, and commercial scaleup feasibility assessment.

Multifunctional↗
NASA NTRS2004

Solar Array Panels With Dust-Removal Capability

It has been proposed to incorporate piezoelectric vibrational actuators into the structural supports of solar photovoltaic panels, for the purpose of occasionally inducing vibrations in the panels in order to loosen accumulated dust. Provided that the panels were tilted, the loosened dust would slide off under its own weight. Originally aimed at preventing obscuration of photovoltaic cells by dust accumulating in the Martian environment, the proposal may also offer an option for the design of solar photovoltaic panels for unattended operation at remote locations on Earth. The figure depicts a typical lightweight solar photovoltaic panel comprising a backside grid of structural spars that support a thin face sheet that, in turn, supports an array of photovoltaic cells on the front side. The backside structure includes node points where several spars intersect. According to the proposal, piezoelectric buzzers would be attached to the node points. The process of designing the panel would be an iterative one that would include computational simulation of the vibrations by use of finite- element analysis to guide the selection of the vibrational frequency of the actuators and the cross sections of the spars to maximize the agitation of dust.

Dawson, Stephen↗
NASA NTRS2018

Lightweight, Durable, and Multifunctional Electrical Insulation Material Systems for High Voltage Applications

Newly developed multilayer structures of well-known polymer insulation materials significantly improved dielectric breakdown voltage, VB, or dielectric strength, K, if well-bonded, when compared to those of single material insulations or the commercial SOA systems, such as Teflon-Kapton-Teflon (TKT), at the same overall thickness. To date, the greatest improvement of the new structures from a few candidate materials, including various types of Kapton PIs and PFA or PET as bond layer (BL), was about 61% higher than that of the Kapton PI alone films, 40.1 vs. 24.9 kV, which was translated to 86.3% decrease in insulation thickness, thus significant volume and weight reduction of the final system. However, it was of interest to note that most improvements of the multilayer structures occurred at thicker overall thicknesses, above ~ 0.15 mm. Extensive analyses also showed that K of the multilayer structures increased with (i) decreasing individual layer thickness regardless of material type, (ii) increasing total accumulated thickness of PI or overall PI/BL ratio, and (iii) increasing number of interface or total number of layers, but only above the aforementioned overall thickness limit. Increases in VB of the multilayer structures were directly correlated with damage evolution and failure mode. With further material-design-process optimizations of the multilayer structures, it was expected to achieve other multifunctionalities, such as high partial discharge (PD) resistance, improved durability, EMI shielding, and high thermal dissipation in addition to high dielectric strength. These new structures can be used in various high voltage and high temperature applications, such as future hybrid or all electric aircraft wiring and power transmission as well as many other non-aerospace high power cables, electronic parts and components, printed circuit board, and so forth. The multilayer insulation system can be easily processed and manufactured with various conductor types via calendaring, compression-molding, stamping, laminating, vacuum-bagging and autoclaving, or 3D printing, even for complex 3-D components. Based on their unique structural configurations and potential capabilities, the new insulation system was identified as micro-multilayer multifunctional electrical insulation (MMEI). Patent application of the MMEI concept and current design configurations was filed for a 1-year provisional application (OAI-58834, Serial No.: 62/659,234), pending conversion to a U.S. utility application. This paper presents details of the MMEI structures, their dielectric performance analyses, potential mechanisms, and commercial scaleup feasibility assessment.

Electric aircrafts↗
DOE OSTI2015

SURFACE MORPHOLOGY OF CARBON FIBER POLYMER COMPOSITES AFTER LASER STRUCTURING

The increasing use of Carbon Fiber Polymer Composite (CFPC) as a lightweight material in automotive and aerospace industries requires the control of surface morphology. In this study, the composites surface was prepared by ablating the resin in the top fiber layer of the composite using an Nd:YAG laser. The CFPC specimens with T700S carbon fiber and Prepreg - T83 resin (epoxy) were supplied by Plasan Carbon Composites, Inc. as 4 ply thick, 0/90o plaques. The effect of laser fluence, scanning speed, and wavelength was investigated to remove resin without an excessive damage of the fibers. In addition, resin ablation due to the power variation created by a laser interference technique is presented. Optical property measurements, optical micrographs, 3D imaging, and high-resolution optical profiler images were used to study the effect of the laser processing on the surface morphology.

Sabau, Adrian S↗
NASA NTRS2002

Advanced Metallic Thermal Protection System Development

A new Adaptable, Robust, Metallic, Operable, Reusable (ARMOR) thermal protection system (TPS) concept has been designed, analyzed, and fabricated. In addition to the inherent tailorable robustness of metallic TPS, ARMOR TPS offers improved features based on lessons learned from previous metallic TPS development efforts. A specific location on a single-stage-to-orbit reusable launch vehicle was selected to develop loads and requirements needed to design prototype ARMOR TPS panels. The design loads include ascent and entry heating rate histories, pressures, acoustics, and accelerations. Additional TPS design issues were identified and discussed. An iterative sizing procedure was used to size the ARMOR TPS panels for thermal and structural loads as part of an integrated TPS/cryogenic tank structural wall. The TPS panels were sized to maintain acceptable temperatures on the underlying structure and to operate under the design structural loading. Detailed creep analyses were also performed on critical components of the ARMOR TPS panels. A lightweight, thermally compliant TPS support system (TPSS) was designed to connect the TPS to the cryogenic tank structure. Four 18-inch-square ARMOR TPS panels were fabricated. Details of the fabrication process are presented. Details of the TPSS for connecting the ARMOR TPS panels to the externally stiffened cryogenic tank structure are also described. Test plans for the fabricated hardware are presented.

Blosser, M. L.↗
NASA NTRS1992

Active control of sound transmission through stiff lightweight composite fuselage constructions

Work was performed on the active control of sound transmission in composite structures. First, a model was outlined of a vibrating plate with arbitrary boundary conditions. Second, the far field was minimized to radiate acoustic power using secondary force inputs. Third, a model of a simple case of freely mounted stiff lightweight panels was used. Fourth, experimental results for aluminum honeycomb composite panels is presented. Fifth, experimental results are presented for the combination of a clamped steel plate and an aluminum honeycomb panel with secondary forces acting between the partitions. Finally, experimental results for the combination of a clamped steel plate with four secondary aluminum honeycomb panels is presented. All materials are shown in viewgraph format.

Thomas, D. R.↗
DOE OSTI2017

PRESAGE: Protecting Structured Address Generation against Soft Errors

Modern computer scaling trends in pursuit of larger component counts and power efficiency have, unfortunately, lead to less reliable hardware and consequently soft errors escaping into application data ("silent data corruptions"). Techniques to enhance system resilience hinge on the availability of efficient error detectors that have high detection rates, low false positive rates, and lower computational overhead. Unfortunately, efficient detectors to detect faults during address generation (to index large arrays) have not been widely researched. We present a novel lightweight compiler-driven technique called PRESAGE for detecting bit-flips affecting structured address computations. A key insight underlying PRESAGE is that any address computation scheme that flows an already incurred error is better than a scheme that corrupts one particular array access but otherwise (falsely) appears to compute perfectly. Enabling the flow of errors allows one to situate detectors at loop exit points, and helps turn silent corruptions into easily detectable error situations. Our experiments using PolyBench benchmark suite indicate that PRESAGE-based error detectors have a high error-detection rate while incurring low overheads.

Sharma, Vishal C.↗
NASA NTRS1989

Adaptive structures for precision segmented optical systems

An adaptive structures approach for a large segmented optical system with a 20-meter primary reflector made of lightweight hexagonal composite panels is considered. This approach makes it possible to vary the static and dynamic characteristics of a structural system through actuators and sensors integrated within the structure. Topics discussed include quasi-static shape adjustment and active damping augmentation of the primary backup truss structure, deformable panels for long spatial wavelength quasi-static figure correction, and an on-orbit identification system for large segmented optical systems.

Chen, G.-S.↗
DOE OSTI2019

Buckling of Two-Dimensional Covalent Organic Frameworks under Thermal Stress

Two-dimensional covalent organic frameworks (2D COFs) are periodic, permanently porous, and lightweight solids that are polymerized from topologically designed monomers. The predictable design and structural modularity of these materials make them promising candidates for applications including catalysis, environmental remediation, chemical separations, and organic electronics, many of which will require stability to mechanical and thermal stress. Based on their reinforced structures and high degradation temperatures, as determined by thermal gravimetric analysis (TGA), many reports have claimed that COFs have excellent thermal stability. However, their stability to heat and pressure has not been probed using methods that report on structural changes rather than the loss of volatile compounds. Here, we explore two structurally analogous 2D COFs with different polymerization chemistries using in operando X-ray diffraction (XRD), which demonstrates the loss of crystallinity at lower temperatures than the degradation temperatures measured by TGA. Density functional theory calculations suggest that an asymmetric buckling of the COF lattice is responsible for the observed loss of crystallinity. In addition to their thermal stability, XRD of the 2D COFs under gas pressures up to 100 bar showed no loss in crystallinity or structural changes, indicating that these materials are robust to mechanical stress by applied pressure. We expect that these results will encourage further exploration of COF stability as a function of framework design and isolated form, which will guide the design of frameworks that withstand demanding application-relevant conditions.

Evans, Austin↗
DOE OSTI2025

Bioinspired Dry‐Steam Superinsulation Straw Foam

Abstract Cellulosic materials offer sustainable advantages for building energy conservation. However, their development has been hindered by reduced thermal performance, often caused by structural collapse during the transition from solution to solid. Inspired by natural goose down, a bio‐based, lightweight insulation foam derived from agricultural waste straw is presented. Through in situ synthesis, bio‐silica fibers with branched structures capable of supporting hollow silica microspheres are fabricated. After steam‐mediated processing, the resulting foam exhibit low density (95 mg cm − 3 ), high porosity (95.5%), low thermal conductivity (0.03 ± 0.003 W mK −1 ), and a cyclic compressive strength of 90 kPa at 50% strain. Owing to the synergistic microstructure formed by branched bio‐fibers and hollow silica spheres, the bio‐silica foam exhibit outstanding thermal insulation performance relative to other bio‐based foams prepared by ambient drying. A passivated insulation panel is further developed by incorporating this material as the core component, achieving a thermal conductivity of 0.0275 W mk −1 and flexural strength of 6.85 MPa. The panel demonstrated durability with stable thermal performance throughout a 60‐day outdoor test. Moreover, the bio‐silica foam shows a carbon footprint of 7.50 kgCO₂ kg −1 at 70.2 wt.% silica, highlighting its promise as a sustainable insulation solution for green buildings.

Chemistry↗
DOE OSTI2023

Achieving superior mechanical properties: Tailoring multicomponent microstructure in AISI 9254 spring steel through a two-stage Q&P process and nanoscale carbide integration

In the pursuit of lightweight, durable steel, we have successfully developed a multicomponent structure in AISI 9254 spring steel using a two-stage quenching and partitioning (Q&P) process. The primary objective of this process was to engineer an optimized microstructure consisting of nanobainite, martensite, and nano-carbides. Utilizing the insights gained from the results of advanced techniques such as X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and atom probe tomography (APT) performed on the as-received AISI 9254 spring steel, we refined the quenching and partitioning (Q&P) path, leading to the successful establishment of a bainitic transformation for superior mechanical properties. Our tensile tests revealed a high yield strength (≈ 1600 ± 25 MPa) and ultimate tensile strength (≈ 1850 ± 50 MPa), along with considerable elongation (≈ 11.15 ± 0.25%). We also identified that pre-formed martensite lath defects and high silicon content play crucial roles during the Q&P process, preventing carbide coalescence and increasing strain-hardening capacity. Finally, this study demonstrates the potential of a Q&P process to generate high-strength, ductile steel for automotive and aerospace applications.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Lightweighting Automotive Materials for Increased Fuel Efficiency and Delivering Advanced Modeling and Simulation Capabilities to U.S. Manufacturers

The National Center for Manufacturing Sciences (NCMS) worked with the U.S. Department of Energy (DOE), National Energy Technology Laboratory (NETL), to bring together research and development (R&D) collaborations to develop and accelerate the knowledgebase and infrastructure for lightweighting materials and manufacturing processes for their use in structural and applications in the automotive sector.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1980

On the dynamics of large orbiting flexible beams and platforms oriented along the local horizontal

The dynamics and stability of large orbiting flexible beams and platforms oriented along the local horizontal are treated both analytically and numerically. It is assumed that such structures could be gravitationally stabilized by attaching a rigid lightweight dumbbell at the center of mass by a spring loaded hinge which also could provide viscous damping. For the beam it is seen that the small amplitude inplane pitch motion, dumbbell librational motion, and the anti-symmetric elastic modes are all coupled. The three dimensional equations of motion for a circular flat plate in orbit with a two-degree-of-freedom gimballed dumbbell are also developed and show that only those elastic modes described by a single nodal diameter line are influenced by the dumbbell motion. Stability criteria are developed for both examples and a parametric study of the least damped mode characteristics together with numerically simulated transient responses are carried out.

Bainum, P. M.↗
NASA NTRS1982

Preliminary design of the thermal protection system for solar probe

A preliminary design of the thermal protection system for the NASA Solar Probe spacecraft is presented. As presently conceived, the spacecraft will be launched by the Space Shuttle on a Jovian swing-by trajectory and at perihelion approach to three solar radii of the surface of the Earth's sun. The system design satisfies maximum envelope, structural integrity, equipotential, and mass loss/contamination requirements by employing lightweight carbon-carbon emissive shields. The primary shield is a thin shell, 15.5-deg half-angle cone which absorbs direct solar flux at up to 10-deg off-nadir spacecraft pointing angles. Secondary shields of sandwich construction and low thickness-direction thermal conductivity are used to reduce the primary shield infrared radiation to the spacecraft payload.

Dirling, R. B., Jr.↗
NASA NTRS1982

Plans for a large deployable reflector for submillimeter and infrared astronomy from space

Continuing plans for a large deployable reflector (LDR), conceived as a 10- to 30-m-diameter clear-aperture telescope, operating at wavelengths from 1000 microns to a diffraction-limited 30 microns, and to be placed in orbit for a life of 10 years by the Space Shuttle, are discussed. The primary reflector will be composed of a number of closely packed hexagonal segments of glass or lightweight composite material and attached to a truss integrating structure through position actuators providing three degrees of freedom for each segment. Technical aspects of optical design, surface measurement systems, deployment, and detectors are discussed, as are practical and fiscal limitations.

Swanson, P. N.↗
NASA NTRS1983

New techniques for fusion bonding and replication for large glass reflectors

Lightweight, space-deployable glass honeycomb telescope primary mirror structures are produced by a novel method which involves the heating to softening temperature of many borosilicate or silica glass tube sections that are packed to form a honeycomb matrix and filled with a high expansion coefficient refractory sand. The close packed tubes yield a hexagonal-cell honeycomb. Attention is given to the results of an experiment in which a highly refractory master was used to shape a honeycomb of less refractory glass, employing a 1-micron thick, vacuum-deposited gold coating as a parting layer between the two.

Angel, J. R. P.↗