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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Efficient and Robust Dynamic Crosslinking for Compatibilizing Immiscible Mixed Plastics through In Situ Generated Singlet Nitrenes

Abstract Creating a sustainable economy for plastics demands the exploration of new strategies for efficient management of mixed plastic waste. The inherent incompatibility of different plastics poses a major challenge in plastic mechanical recycling, resulting in phase‐separated materials with inferior mechanical properties. Here, this study presents a robust and efficient dynamic crosslinking chemistry that effectively compatibilizes mixed plastics. Composed of aromatic sulfonyl azides, the dynamic crosslinker shows high thermal stability and generates singlet nitrene species in situ during solvent‐free melt‐extrusion, effectively promoting C─H insertion across diverse plastics. This new method demonstrates successful compatibilization of binary polymer blends and model mixed plastics, enhancing mechanical performance and improving phase morphology. It holds promise for managing mixed plastic waste, supporting a more sustainable lifecycle for plastics.

Chemistry↗
DOE OSTI2026

Dynamic Diketoenamine Crosslinking Unlocks Vinyl Polymer Vitrimers From β ‐Triketone Chemistry

Covalent adaptable networks (CANs) offer a compelling strategy to unite the mechanical robustness of thermosets with the reprocessability of thermoplastics, yet achieving simultaneous durability, processability, and true recyclability remains challenging. We introduce diketoenamine (DKE) vitrimers derived from β-triketone methacrylate monomers and demonstrate how rational monomer design dictates network processability, viscoelasticity, and recyclability. By systematically varying the spacer length between the β-triketone (TK) moiety and the polymer backbone, we identify a key structure–property relationship that dictates vitrimer behavior. Networks bearing TK pendants minimally displaced from the backbone suppress creep but exhibit limited stress relaxation, whereas extended spacers yield lower glass transition temperatures, higher effective crosslink densities, and efficient stress dissipation, enabling optical transparency and reprocessability. Extending this platform to ultra-high molecular-weight prepolymers introduces physical entanglements as secondary crosslinks, further enhancing dimensional stability without compromising processability. Both mechanical and chemical recycling validate the closed-loop circularity of these materials. Furthermore, these results establish TK methacrylates as a versatile platform for designing high-performance vitrimers that integrate durability, reprocessability, and true closed-loop recyclability.

closed-loop recyclability↗
DOE OSTI2026

Tuning the Mechanical Properties of Crosslinked Copolymers via Sequence and Solvent‐Selective Swelling for Vat Photopolymerization

Block copolymers (BCPs) offer distinct advantages for vat photopolymerization by enabling mechanically programmable network structures through microphase-separated morphologies that can be kinetically trapped during curing, yielding properties unattainable in homogeneous resins. However, the respective roles of repeat-unit sequence and solvent environment, together with their interplay in directing network formation and mechanical performance, remain unclear. Here, we synthesize a series of CO 2 -based polycarbonate copolymers comprising a crosslinkable glassy poly(vinyl cyclohexene carbonate) (PVCHC, A block) and a non-crosslinkable soft poly(propylene carbonate) (PPC, B block). The polymer sequence is systematically varied (ABA, BAB, and statistical), and solvent choice controls block-selective swelling to jointly control gelation behavior, microphase morphology, and mechanical response through changes in the accessibility and local environment of photocrosslinkable vinyl groups during network formation, as revealed by photorheology and small angle x-ray scattering. By tuning polymer sequence and curing solvent, we transform nominally identical formulations from brittle to highly ductile materials, achieving a three-orders-of-magnitude range in toughness (0.003 to 9.1 MJ m −3 ). These results establish clear structure–processing–property relationships and identify polymer sequence and selective solvation as powerful strategies for programming both printability and performance of block copolymer resins for additive manufacturing.

additive manufacturing↗
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 OSTI2020

An in-situ crosslinking binder for binder jet additive manufacturing

Additive Manufacturing (AM) of metals is a potentially disruptive technology that could significantly change the industrial supply chain. There are a limited number of AM methods capable of creating metal parts, and one method showing significant potential is Binder Jet AM (Binder Jetting). Binder Jetting utilizes an inkjet print head to deposit a binder fluid onto a powder bed and bind together powder particles into a desired geometry. This study investigates a new binder system consisting of a difunctional monomer, triethylene glycol dimethacrylate (TEG-DMA). TEG-DMA exhibits excellent printability with an Ohnesorge’s number of .258 making the Z number 3.876. During the thermal curing process, the difunctional monomer polymerizes and crosslinks at the onset temperature of 138 °C, becoming a solid dimethacrylate network. When the binder is utilized within the stainless-steel powder bed at 200 °C, it forms a network incorporating the stainless-steel particles, binding the powder into any specified geometry. Crosslinking the monomer within the stainless-steel 420 powder bed imparts a flexural strength of 1.0–3.3 MPa to the green part depending on the volume of monomer in the part. After sintering, the final stainless-steel parts results in a void fraction close to 60 % and carbon content below 0.4 %.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Understanding the impact of SPMAK and PEGPEA in crosslinked PEGDA membranes: Methanol-carboxylate co-transport behavior and correlating structure-physicochemical-transport properties

Investigating multicomponent transport in dense, hydrated polymer membranes is necessary in applications such as fuel cells, electrolyzers, and desalination systems. Of particular interest are photoelectrochemical CO 2 reduction cells (PEC-CRC) which produce liquid products such as alcohols (methanol) and carboxylates (formate, acetate). Flux coupling and competitive sorption behavior of these products (solutes) have been found to affect permselectivity, thereby motivating us to investigate fundamental membrane structure-physicochemical-transport relationships. Past research has shown that systematic tuning of crosslinked cation exchange membranes (CEMs) with charge-neutral monoacrylate monomers containing alkyl and phenyl groups (i.e., poly(ethylene glycol) methacrylate (PEGMA), and poly(ethylene glycol) phenyl ether acrylate (PEGPEA)) can suppress acetate transport (permeability) in co-permeation with methanol. To further investigate this transport behavior and to enhance membrane ionic conductivities, 3-sulfopropyl methacrylate potassium (SPMAK), a sulfonated monoacrylate monomer is incorporated here. SPMAK content is varied with neutral PEGPEA and diacrylate crosslinker, poly (ethylene glycol) diacrylate (PEGDA) of two different chain lengths (n = 10 and 13) to prepare membranes of various compositions. Electrochemical and physicochemical properties including ionic conductivity, ion exchange capacity, and water uptake increase with increasing charged SPMAK content. Different states of water within hydrated membranes are probed using differential scanning calorimetry (DSC), where increasing intermediate (loosely bound) water is observed with increasing hydrophilic SPMAK content. The transport behavior of methanol and carboxylates (formate, acetate, propionate) are investigated, where permeabilities vary as methanol > formate > acetate ≈ propionate. Interestingly, permeabilities decrease with increasing PEGPEA content and are more dependent on solute diffusion than sorption. Permeabilities and diffusivities decrease while permselectivities increase with decreasing PEGDA chain length.

25 ENERGY STORAGE↗
DOE OSTI2023

Simulations of Glass Transition and Mechanical Behavior of Off-Stoichiometric Crosslinked Polymers

Here, this work explores the influence of blend composition, network architecture, and hydrogen bonding on the material properties of crosslinked epoxy networks, focusing on the glass transition temperature (T g ) and Young’s modulus (Y). We used coarse-grained molecular dynamics simulations to simulate varying compositions of stiff and flexible components in epoxy monomer blends with varying excess of curative. We find that, without hydrogen bonding, networks of any composition show a monotonically increasing T g with decreasing excess curative, consistent with theory. In contrast, we find that when hydrogen bonding is introduced, the binary blend networks show significant enhancement in T g for lightly crosslinked systems. This result contributes to an explanation of the anomalous T g behavior observed experimentally in these systems. We further find that Y is generally enhanced by hydrogen bonds, especially below T g , demonstrating that hydrogen bonding has a significant influence on mechanical properties and can allow access to other desirable dynamic behavior, especially self-healing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Surface-Functionalized Cellulose Nanocrystals as Nanofillers for Crosslinking Processes: Implications for Thermosetting Resins

Understanding the response of fillers in the epoxy resin crosslinking process and characterizing polymer–filler dynamics are the key features that guide the engineering of new thermosetting resin composites. Here, in this work, X-ray photon correlation spectroscopy (XPCS) is used as a thermal analysis tool to track the microscopic changes occurring during the cure of a functionalized cellulose nanocrystal (mCNC)–epoxy composite. In contrast, traditional methods such as differential scanning calorimetry (DSC) and curing rheology are used to understand the kinetics and properties on macroscopic length scales. Of interest is the influence of the mCNC on the curing kinetics and properties of the thermosetting resin. Two levels of modification (increasing hydrophobicity) were chosen to observe the effect of functionalization. Before cure, the highly functionalized CNC (mCNC3) shows a 44% increase in complex viscosity (η*), while the less functionalized CNC (mCNC2) shows a η* value similar to that of the neat resin. As the cure cycle progresses, results from DSC, rheology, and XPCS further show the enhancement in dispersion for mCNC3. The results show a clear difference in the maximum drift velocity, maximum heat flow, and complex viscosity during the ramp to the isothermal cure temperature (T cure ). Such results suggest that mCNC3 contains a well-dispersed network of particles due to the higher level of functionalization. During T cure , a transition in elastic modulus (G') occurs only for the highly functionalized CNC particle system. We believe that heat-induced aggregation occurs, and the crosslinked resin ultimately dominates the macroscopic properties of the final cured system for all samples. The results from the three techniques are in good agreement and showcase XPCS as a beneficial experimental tool for characterizing the microscopic dynamics of particulate-filled thermosetting resins. Hence, we envision this to be a fundamental curing study for the design of thermosetting resin composites.

36 MATERIALS SCIENCE↗
DOE OSTI2021

In situ mechanical reinforcement of polymer hydrogels via metal-coordinated crosslink mineralization

Biological organic-inorganic materials remain a popular source of inspiration for bioinspired materials design and engineering. Inspired by the self-assembling metal-reinforced mussel holdfast threads, we tested if metal-coordinate polymer networks can be utilized as simple composite scaffolds for direct in situ crosslink mineralization. Starting with aqueous solutions of polymers end-functionalized with metal-coordinating ligands of catechol or histidine, here we show that inter-molecular metal-ion coordination complexes can serve as mineral nucleation sites, whereby significant mechanical reinforcement is achieved upon nanoscale particle growth directly at the metal-coordinate network crosslink sites.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Crosslinked metallo-polyelectrolytes with enhanced flexibility and dimensional stability for anion-exchange membranes

High-performing anion-exchange membranes (AEMs) have attracted tremendous interest for applications in emerging energy storage and conversion devices. In this work, we present a strategy for the synthesis of crosslinked metallo-polyelectrolytes as mechanically flexible, dimensionally stable and ionically conductive AEMs. The water uptake and swelling ratio are suppressed remarkably by introducing a crosslinked polymeric network. The as-prepared membranes also exhibit excellent thermal stability. The phase-separated morphology allows rapid ion-transport with low water uptake at various temperatures. Specifically, a conductivity of 53.3 mS cm -1 at 80 °C was achieved with an ion exchange capacity of 1.07 mmol g -1 and a low swelling ratio of 13%.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Increased CO 2 /N 2 selectivity of PTMSP by surface crosslinking

The surface crosslinking of poly[1-(trimethylsilyl)-1-propyne] (PTMSP) membranes by dithiothreitol under thiol–ene click reaction conditions has yielded membranes having CO 2 /N 2 selectivities in excess of 30 with CO 2 permeances in excess of 300 GPU (gas permeation units). Here, the simplicity of this surface crosslinking strategy together with these permeation results suggests that PTMSP that is modified in such ways could lead to useful materials for the separation of CO 2 /N 2 from flue gas and for certain other gaseous mixtures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Highly stretchable ionically crosslinked acrylate elastomers inspired by polyelectrolyte complexes

Dynamic bonds are a powerful approach to tailor the mechanical properties of elastomers and introduce shape-memory, self-healing, and recyclability. Among the library of dynamic crosslinks, electrostatic interactions among oppositely charged ions have been shown to enable tough and resilient elastomers and hydrogels. In this work, we investigate the mechanical properties of ionically crosslinked ethyl acrylate-based elastomers assembled from oppositely charged copolymers. Using both infrared and Raman spectroscopy, we confirm that ionic interactions are established among polymer chains. We find that the glass transition temperature of the complex is in between the two individual copolymers, while the complex demonstrates higher stiffness and more recovery, indicating that ionic bonds can strengthen and enhance recovery of these elastomers. We compare cycles to increasing strain levels at different strain rates, and hypothesize that at fast strain rates ionic bonds dynamically break and reform while entanglements do not have time to slip, and at slow strain rates ionic interactions are disrupted and these entanglements slip significantly. Further, we show that a higher ionic to neutral monomer ratio can increase the stiffness, but its effect on recovery is minimal. Lastly, taking advantage of the versatility of acrylates, ethyl acrylate is replaced with the more hydrophilic 2-hydroxyethyl acrylate, and the latter is shown to exhibit better recovery and self-healing at a cost of stiffness and strength. The design principles uncovered for these easy-to-manufacture polyelectrolyte complex-inspired bulk materials can be broadly applied to tailor elastomer stiffness, strength, inelastic recovery, and self-healing for various applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

3D-printed ketoenamine crosslinked polyrotaxane hydrogels and their mechanochromic responsiveness

A ketoenamine-based dynamic covalent crosslinker was introduced here to α-cyclodextrin-based polypseudorotaxanes, forming viscoelastic hydrogels for direct-ink-write 3D printing. The irreversible enol–keto tautomerization imparts high chemical stability to the extensively crosslinked polyrotaxane hydrogels, which showed mechanochromic responsiveness in the presence of the integrated fluorophores.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Plasticizer-Free Gradient-Crosslinked Polyurethane Electrolyte for Room-Temperature Solid-State Lithium Batteries

Polymer-based solid-state electrolytes are promising for next-generation lithium metal batteries, yet their limited ionic conductivity and mechanical stability at ambient conditions remain key challenges. Herein, we report a novel gradient crosslinked polymer electrolyte (PU/PUA/PU) synthesized via a sequential in situ UV-curing process that integrates a mechanically robust polyurethane acrylate (PUA) core with soft linear polyurethane (PU) interfaces. This all-solid membrane operates without any liquid plasticizer and the interfacial PU layers ensure low interfacial resistance and intimate electrode contact, while the PUA core provides enhanced dimensional stability and dendrite suppression. As a result, the gradient electrolyte delivers an impressive ∼2.6 × 10 −4 S cm −1 ionic conductivity at 25 °C (two orders of magnitude higher than conventional PEO) and remains electrochemically stable >5 V (vs Li + /Li). Structural analysis confirms the formation of a well-defined crosslinked network with suppressed crystallinity and expanded interchain spacing. Electrochemical impedance spectroscopy (EIS) and linear sweep voltammetry (LSV) further validate these properties. When applied in a Li||NMC811 cell, the PU/PUA/PU electrolyte delivers stable cycling with high capacity at both 60 °C and 25 °C, demonstrating its potential for room-temperature solid-state battery applications without reliance on plasticizers or heating. In conclusion, this gradient design offers a practical path toward ambient-condition operation of solid-state lithium batteries, providing a paradigm for overcoming the traditional trade-off between ionic conductivity and mechanical robustness.

25 ENERGY STORAGE↗
DOE OSTI2023

CrossLink: Meshing a 3D part from a STEP file [Slides]

This example shows how to use CrossLink to create a mesh for a 3D geometry part read in from a STEP file. A STEP file (Standard for the Exchange of Product data) is a common file format used for 3D modelling that can be written out from a CAD program (e.g., Creo Parametric). Being able to read and mesh STEP file geometries is essential for meshing parts from engineering models. Creating the mesh typically involves: (1) Importing the geometry; (2) Creating geometry groups; (3) Assigning curves and surfaces to the geometry groups; (4) Building a topology; (5) Applying geometric and mesh constraints; and (6) Generating the final mesh. Current issues with this process in CrossLink include: (1) The GUI does not display trimmed surfaces; (2) The user must manually create and assign geometry groups; and (3) The user must be aware of duplicate curves and surfaces from the CAD model.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1975

Effects of multifunctional crosslinking agents on the thermomechanical properties of polyimide films

Three polyfunctional amines were synthesized. Polyimide films containing varying amounts of the amine crosslinking agents were prepared. Their thermomechanical properties were compared with those of control film samples prepared from difunctional amines. The effect of crosslink density on isothermal weight loss, polymer softening, and glass transition temperature is discussed.

Delvigs, P.↗
NASA NTRS1980

Process for the preparation of fluorine containing crosslinked elastomeric polytriazine and product so produced

Crosslinking elastomeric polytriazines are prepared by a 4 step procedure which consists of (1) forming a poly(imidoylamidine) by the reaction, under reflux conditions, of anhydrous ammonia with certain perfluorinated alkyl or alkylether dinitriles; (2) forming a linear polytriazine by cyclizing the imidoylamidine linkages by reaction with certain perfluorinated alkyl or alkylether acid anhydrides or halides; (3) extending the linear polytriazine chain by further refluxing in anhydrous ammonia; and (4) heating to cyclize the new imidoylamidine and thereby crosslink the polymer.

Rosser, R. W.↗