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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 901 records · Page 50
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Performance assessment of 3D printed multi-material energy absorber for automotive bumper: pedestrian lower extremity protection

Designing an energy absorber for automotive bumpers involves balancing low-speed and high-speed impacts to ensure safety, reduce repair costs, and meet regulatory standards. Here, this study explores a novel design using multi-material 3D printing and structural optimization to fabricate a lightweight and cost-efficient energy absorber. The design effectively dissipates energy in low-speed collisions and minimizes force transmission in high-speed pedestrain impacts, helping to meet both safety and performance requirements. The energy absorber design combines 20% carbon fiber-reinforced acrylonitrile butadiene styrene (CF-ABS) and thermoplastic polyurethane (TPU) for optimal stiffness and flexibility. It uses 3D-printed lattice structures optimized through finite element simulations to help meet both low-speed and high-speed impact requirements. Full-scale energy absorbers were 3D-printed using optimized CF-ABS/TPU blends and tested under high-speed impact using the Flexible Pedestrian Legform Impactor (Flex-PLI). For fair comparison, a baseline bumper with a traditional triangular lattice structure, also 3D-printed from the same CF-ABS/TPU materials, was similarly tested. Interestingly, both the optimized and baseline 3D-printed energy absorbers showed nearly identical performance, successfully meeting injury limits. Their performances were also benchmarked against an injection-molded energy absorber. While both 3D-printed and injection-molded designs met injury limits, the 3D-printed absorber exhibited a higher tibia bending moment, indicating an opportunity for further optimization. A Techno-Economic Analysis compared the costs of producing energy absorbers using traditional manufacturing and 3D printing. The analysis highlighted that 3D printing offers cost benefits for low to medium production volumes, with the total cost per energy absorber at ∼ $\$$74, compared to traditional methods that become economical beyond 2000 units.

Additive manufacturing↗
DOE OSTI2011

Multigraft Copolymer Superelastomers: Synthesis Morphology, and Properties

The synthesis of well-defined multigraft copolymers having a polydiene backbone with polystyrene side chains is briefly reviewed, with particular focus on controlling branch point spacing and branch point functionality. Use of living anionic polymerization and chlorosilane linking chemistry has led to the synthesis of series of materials having regularly spaced trifunctional (comb), tetrafunctional (centipede), and hexafunctional (barbwire) branch points. The morphologies of these materials were characterized by transmission electron microscopy and small-angle X-ray scattering, and it was found that the morphologies were controlled by the local architectural asymmetry associated with each branch point. Mechanical properties studies revealed that such multigraft copolymers represent a new class of thermoplastic elastomers (TPEs) with superior elongation at break and low residual strains as compared to conventional TPEs.

Uhrig, David↗
DOE OSTI2010

Quality Assessment of Frameless Fractionated Stereotactic Radiotherapy Using Cone Beam Computed Tomography

Purpose: A quality assessment of intracranial stereotactic radiotherapy was performed using cone beam computed tomography (CBCT). Setup errors were analyzed for two groups of patients: (1) those who were positioned using a frameless SonArray (FSA) system and immobilized with a bite plate and thermoplastic (TP) mask (the bFSA group); and (2) those who were positioned by room laser and immobilized using a TP mask (the mLAS group). Methods and Materials: A quality assurance phantom was used to study the system differences between FSA and CBCT. The quality assessment was performed using an Elekta Synergy imager (XVI) (Elekta Oncology Systems, Norcross, GA) and an On-Board Imager (OBI) (Varian Medical Systems, Palo Alto, CA) for 25 patients. For the first three fractions, and weekly thereafter, the FSA system was used for patient positioning, after which CBCT was performed to obtain setup errors. Results: (1) Phantom tests: The mean differences in the isocenter displacements for the two systems was 1.2 {+-} 0.7 mm. No significant variances were seen between the XVI and OBI units (p{approx}0.208). (2)Patient tests: The mean of the displacements between FSA and CBCT were independent of the CBCT system used; mean setup errors for the bFSA group were smaller (1.2 mm) than those of the mLAS group (3.2 mm) (p < 0.005). For the mLAS patients, the 90th percentile and the maximum rotational displacements were 3{sup o} and 5{sup o}, respectively. A 4-mm drift in setup accuracy occurred over the treatment course for 1 bFSA patient. Conclusions: System differences of less than 1 mm between CBCT and FSA were seen. Error regression was observed for the bFSA patients, using CBCT (up to 4 mm) during the treatment course. For the mLAS group, daily CBCT imaging was needed to obtain acceptable setup accuracies.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2022

Modeling the viscoplastic behavior of a semicrystalline polymer

In this study, a complex constitutive relation is identified using inverse modeling with the nominal mechanical response as sole experimental input. The methodology is illustrated for a semicrystalline thermoplastic in the presence of strain localization at finite deformations. The experimental database includes cylindrical tensile bars, compression pins and round notched bars loaded at strain rates spanning up to five decades and temperatures below and above T g . The data is organized into a calibration set and a validation set. The response of tensile specimens is determined using finite element analyses and a two-phase constitutive relation for semicrystalline polymers that accounts for temperature- and rate-sensitive plastic flow, pressure-sensitivity, small-strain softening and large-strain orientational hardening of the amorphous phase, along with the evolution of crystallinity. The large number of constitutive parameters is identified using an optimization tool coupled with the finite element solver and the calibration set from experiments. The methodology is shown to be successful in predicting the response of round notched bars and replicating the effects of temperature and strain rate on the severity of necking in tensile bars. The proposed model identification strategy is both simple and effective in comparison with other elaborate methods that attempt to access intrinsic behavior directly from high-fidelity experimental measurements.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Simulation-driven design optimization of reaction injection molding (RIM) process for polydicyclopentadiene (pDCPD): Minimizing cycle time, defects, and warpage

Replacing metal components in trucks, trailers, and buses with lightweight polymer composites is challenging due to high temperatures and complex manufacturing. The Reaction Injection Molding (RIM) process using Dicyclopentadiene (DCPD) resin offers a solution by producing robust parts with excellent stiffness, impact strength, and resistance properties. Simulations are essential for optimizing this process, predicting defects, and improving quality. However, most commercial software is tailored for thermoplastics, requiring thermoset users to generate their own datasets. In this study, a material data card for DCPD was developed to perform RIM simulations. Design of Experiments (DOE) was used to identify key factors affecting filling, curing, and warpage, aiming to minimize cycle time and defects. The simulations explored varying injection gate parameters (size, location, number) and process conditions (mold/resin temperature, injection/curing pressure). Results showed that gate design significantly impacts filling behavior and defects. A single central gate provided balanced flow with fewer defects, while two corner gates led to more defects. Additionally, lower injection pressure increased filling time, while higher mold temperature accelerated curing but led to more warpage. In conclusion, this optimization framework aims to enhance DCPD part performance and promote sustainable manufacturing by reducing waste and energy consumption.

42 ENGINEERING↗
DOE OSTI2017

Comparison of Bolus Materials to Highly Absorbent Polypropylene and Rayon Cloth

This study assesses the utility of a highly absorbent polypropylene and rayon cloth (HAPRC) as a bolus material in radiation therapy. A comparison of various bolus materials used clinically at our center to the test bolus material, water-saturated HAPRC, was conducted. The reproducibility of the physical density was assessed by computerized tomography (CT) scanning the water-saturated HAPRC on a uniform density block phantom on multiple occasions, allowing the cloth to dry fully between subsequent CT scans. The cloth was found to have a consistent physical density between 0.8 and 1.0 g/cm{sup 3}. To evaluate the dosimetric impact of the various bolus materials, metal oxide semiconductor field effect transistor dosimetry measurements were performed for a 6 MV treatment beam on the anterior surface of an anthropomorphic thorax phantom. The ability of the bolus material to conform to an irregular surface was assessed by CT scanning the various bolus materials overlaying the nose of an anthropomorphic head phantom and another irregularly shaped test object. The HAPRC conforms well to irregular contours and is relatively inexpensive compared to Superflab and thermoplastic sheets. Before implementing the material into the clinical setting, an appropriate process for laundering the material should be determined, for hygienic reasons.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2015

Structural manipulation approaches towards enhanced sodium ionic conductivity in Na-rich antiperovskites

High-performance solid electrolytes are critical for realizing all-solid-state batteries with enhance safety and cycling efficiency. However, currently available candidates (sulfides and the NASICON-typ ceramics) still suffer from drawbacks such as inflammability, high-cost and unfavorable machinability Here we present the structural manipulation approaches to improve the sodium ionic conductivity in series of affordable Na-rich antiperovskites. Experimentally, the whole solid solutions of Na 3 OX (X ¼ Cl Br, I) are synthesized via a facile and timesaving route from the cheapest raw materials (Na, NaOH an NaX). The materials are nonflammable, suitable for thermoplastic processing due to low melting temperature (<300° C) without decomposing. Notably, owing to the flexibility of perovskite-type structure it's feasible to control the local structure features by means of size-mismatch substitution an unequivalent-doping for a favorable sodium ionic diffusion pathway. Enhancement of sodium ioni conductivity by 2 magnitudes is demonstrated by these chemical tuning methods. The optimized sodiu ionic conductivity in Na 2.9 Sr 0.05 OBr 0.6 I 0.4 bulk samples reaches 1.9 10 - 3 S/cm at 200° C and even highe at elevated temperature. Here, we believe further chemical tuning efforts on Na-rich antiperovskites wil promote their performance greatly for practical all-solid state battery applications.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Property optimized energy absorber for automotive bumpers utilizing multi-material and structural design strategies

This study proposes a novel design for automotive bumper using optimized lattice structures and multi-materials to balance low-speed collision and high-speed pedestrian impact performance. Different blends of 20 % carbon fiber-reinforced acrylonitrile butadiene styrene with thermoplastic polyurethane were used to tailor material properties. The energy absorber features lattice structures with customized mechanical responses, created by varying the incline angle θ from 0 to 180°. We conducted 576 finite element simulations on a half-scale model to optimize energy absorption and stiffness, leading to 66 optimized designs that met both low-speed and high-speed impact criteria. Two sub-scale optimized energy absorbers with different peak forces—both meeting low-speed impact requirements—were 3D printed and validated through drop-weight testing. The one with lower peak stress demonstrated a more compliant response, exhibiting approximately 90 % lower initial peak force and an increase in energy absorption of around 33 % (from 24 J to 32 J). Compared to the baseline triangular lattice, the optimized absorber increased energy absorption by 68 % from (19 J to 32 J) and reduced peak stress by 70 %. It also showed near-complete recovery with minimal fractures, making it suitable for repeated use. This design improves safety while offering a lightweight, durable, and cost-effective bumper system.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Feasibility of an online adaptive replanning method for cranial frameless intensity-modulated radiosurgery

To introduce an approach for online adaptive replanning (i.e., dose-guided radiosurgery) in frameless stereotactic radiosurgery, when a 6-dimensional (6D) robotic couch is not available in the linear accelerator (linac). Cranial radiosurgical treatments are planned in our department using intensity-modulated technique. Patients are immobilized using thermoplastic mask. A cone-beam computed tomography (CBCT) scan is acquired after the initial laser-based patient setup (CBCT{sub setup}). The online adaptive replanning procedure we propose consists of a 6D registration-based mapping of the reference plan onto actual CBCT{sub setup}, followed by a reoptimization of the beam fluences (“6D plan”) to achieve similar dosage as originally was intended, while the patient is lying in the linac couch and the original beam arrangement is kept. The goodness of the online adaptive method proposed was retrospectively analyzed for 16 patients with 35 targets treated with CBCT-based frameless intensity modulated technique. Simulation of reference plan onto actual CBCT{sub setup}, according to the 4 degrees of freedom, supported by linac couch was also generated for each case (4D plan). Target coverage (D99%) and conformity index values of 6D and 4D plans were compared with the corresponding values of the reference plans. Although the 4D-based approach does not always assure the target coverage (D99% between 72% and 103%), the proposed online adaptive method gave a perfect coverage in all cases analyzed as well as a similar conformity index value as was planned. Dose-guided radiosurgery approach is effective to assure the dose coverage and conformity of an intracranial target volume, avoiding resetting the patient inside the mask in a “trial and error” way so as to remove the pitch and roll errors when a robotic table is not available.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2024

Deep reinforcement learning for optimal control of induction welding process

Optimizing induction welding (IW) process parameters for the application of joining thermoplastic composites is challenging as it requires achieving complex spatiotemporal thermal characteristics along the weld-line to obtain desired weld quality. We formulate an optimal control problem which captures these requirements and seeks to optimize the IW coil speed using a fast-acting dynamic IW process model. We develop a novel Deep Reinforcement Learning (DRL) framework to solve this computationally challenging control problem and demonstrate via simulation study that the learned DRL feedback control policy results in better spatiotemporal thermal characteristics as compared to the current state-of-the-art.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Friction surface layer deposition of triple-phase Al 10 Cr 12 Fe 35 Mn 23 Ni 20 high entropy alloy: Process optimization and microstructural evolution

A high-strength Co-free triple-phase Al 10 Cr 12 Fe 35 Mn 23 Ni 20 high-entropy alloy (HEA) was successfully fabricated using Friction Surface Layer Deposition (FSLD), a bulk manufacturing method. Multiple single-layer deposits were produced by varying forging force (F) and traverse speeds (T r ) to optimize the process parameters. The optimized conditions (F = 40 kN & T r = 200 mm/min) were then applied to manufacture a scaled-up multi-layer specimen. The initial microstructure of the HEA consisted of coarse grains of the soft FCC-phase, long columnar dendrites of the hard BCC-phase, and small precipitates of the harder B2-phase within the BCC-dendrites. During FSLD, the FCC-matrix underwent continuous dynamic recrystallization due to high-temperature severe plastic deformation, forming finer equiaxed grains. Simultaneously, the BCC-dendrites fractured into smaller fragments, some of which experienced partial growth and coarsening under applied stress, resulting in an hourglass morphology. In contrast, the small B2-precipitates within the BCC-fragments dissolved during the elevated temperatures of FSLD and reprecipitated as substantially finer precipitates during continuous cooling post-FSLD. Additionally, the orientation relationships between the FCC and BCC/B2 phases were completely destroyed by the severe thermoplastic deformation inherent to FSLD. The microstructural refinements led to a substantial improvement in hardness from 177 HV to 283 HV, driven by Hall-Petch strengthening. The increased number of interfaces, including coherent BCC-B2 interfaces, potentially enhances the sink strength and radiation tolerance of the HEA, making it a promising candidate for nuclear applications. In conclusion, this study also highlights FSLD as a versatile technique for achieving tunable properties in HEAs, with detailed schematics illustrating the complex mechanisms of phase transformations during processing.

Additive Manufacturing↗
DOE OSTI2018

3D printing via ambient reactive extrusion

Here, Additive Manufacturing (AM) has the potential to offer many benefits over traditional manufacturing methods in the fabrication of complex parts with advantages such as low weight, complex geometry, and embedded functionality. In practice, today’s AM technologies are limited by their slow speed and highly directional properties. To address both issues, we have developed a reactive mixture deposition approach that can enable 3D printing of polymer materials at over 100X the volumetric deposition rate, enabled by a greater than 10X reduction in print head mass compared to existing large-scale thermoplastic deposition methods, with material chemistries that can be tuned for specific properties. Additionally, the reaction kinetics and transient rheological properties are specifically designed for the target deposition rates, enabling the synchronized development of increasing shear modulus and extensive cross linking across the printed layers. This ambient cure eliminates the internal stresses and bulk distortions that typically hamper AM of large parts, and yields a printed part with inter-layer covalent bonds that significantly improve the strength of the part along the build direction. The fast cure kinetics combined with the fine-tuned viscoelastic properties of the mixture enable rapid vertical builds that are not possible using other approaches. Through rheological characterization of mixtures that were capable of printing in this process as well as materials that have sufficient structural integrity for layer-on-layer printing, a “printability” rheological phase diagram has been developed, and is presented here. We envision this approach implemented as a deployable manufacturing system, where manufacturing is done on-site using the efficiently-shipped polymer, locally-sourced fillers, and a small, deployable print system. Unlike existing additive manufacturing approaches which require larger and slower print systems and complex thermal management strategies as scale increases, liquid reactive polymers decouple performance and print speed from the scale of the part, enabling a new class of cost-effective, fuel-efficient additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Creep suppression and fatigue in bio-based composites manufactured via conventional and large format additive manufacturing processes

The emergence of novel extrusion-based additive manufacturing (AM) processes has prompted the development of new thermoplastic composite feedstocks, and broadening sustainability initiatives have driven the development of bio-based and recyclable material for AM feedstocks. Poly(lactic acid) (PLA) with wood flour (WF) is one composite system that has been demonstrated in numerous AM applications, as well as traditional processing methods (i.e., compression and injection molding); however, there has been a need to understand how the variation in processing methodology impacts the material performance of these bio-based feedstocks from a fundamental perspective, with particular emphasis on creep for an extended application use-life. Herein, PLA/WF is explored as a feedstock material for large format additive manufacturing (LFAM) and the performance of additively manufactured materials is compared to those produced via more traditional processing methods. It is also demonstrated that the addition of WF decreases the material’s coefficient of thermal expansion (CTE) while increasing its Young’s modulus, susceptibility to water uptake, and creep fatigue resistance. Essentially, the addition of 20 wt% WF results in a 92 % decrease in rubbery regime CTE while simultaneously resulting in a 14 % increase in modulus, 190 % increase in water uptake, and a 31 % decrease in residual strain after cyclic creep tests. The processing method was also found to play a large role in the final part performance, with the printed material increasing the crystallinity by 183 % and 214 % compared to its compression and injection molded counterparts. Furthermore, the porosity of printed samples increased by two orders of magnitude compared to samples prepared via traditional processing methods.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Power performance and loads characterization of laboratory-scale cross-flow rotors fabricated using additive manufacturing

Tidal energy conversion is a relatively new application for additive manufacturing (AM), where the focus has been on fabricating axial-flow turbine blades. AM techniques add material precisely where it is needed, creating more complex shapes with less waste. Cross-flow rotor geometry presents an opportunity for AM to improve rotor performance by fabricating features that cannot be created economically via conventional manufacturing. The challenges associated with using AM in cross-flow design include water resistance and degradation over time while retaining a level of quality equivalent to conventionally machined parts. In this work, AM materials were tested by environmentally conditioning samples in a seawater tank for 5 months, followed by performance and phase-resolved load testing of laboratory-scale rotors in a hydraulic flume. We found that while metals like titanium and Inconel have excellent performance in marine environments, achieving the desired geometry and performance is difficult. Thermoplastics degraded in seawater but were easier to form into desired geometries and could exceed the performance of an aluminum control rotor. Warping and surface finish were significant detractors from AM rotor performance. These results suggest that the primary benefits of using AM for cross-flow rotors is to quickly fabricate and test unconventional rotor geometries.

16 TIDAL AND WAVE POWER↗
DOE OSTI2013

Phase structure in segmented polyurethanes having fatty acid-based soft segments

Abstract: Structural studies on two segmented polyurethanes prepared form the modified oleic acid soft segments and butane diol/diphenylmethane diisocyanate hard segments, were carried out. Polyurethanes were thermoplastic elastomers with soft segment concentration (SSC) of 50% (TPU-50) and 70% (TPU-70). Dynamic mechanical analysis revealed the co-continuous morphology in TPU-50 and dispersed hard domains in the soft matrix in TPU-70. AFM revealed the micron size globules in TPU-70 ascribed to hard segment-rich spherulites and alternating small soft and hard domains in TPU- 50, with lateral dimensions of about 15 nm with local modulus deviations from 40 to 50 MPa, consistent with co-continuous morphology. The dispersed hard domains in the soft matrix for TPU-70, and co-continuous phases in TPU-50 morphology was confirmed. USAXS showed the domain spacing for TPU-50 was about 13.3 nm and about 11.3 nm for TPU-70. USAXS revealed that the interface between phase-separated domains exhibit a surface-fractal-like behavior.

fatty acid↗
DOE OSTI2021

Effect of Microstructure on Chain Flexibility and Glass Transition Temperature of Polybenzofulvene

Polybenzofulvene (PBF) is a polydiene with a very high glass transition temperature (T g ), which makes it a potential candidate for use as the hard block for high-temperature thermoplastic elastomer applications. The T g s of polydienes are known to be related to chain flexibility. However, no studies have been reported that correlate the chain flexibility to the microstructure of PBF. Herein, we present a study of solution properties of linear PBFs with narrow molecular weight dispersity and having 1,2-addition ranging from 23% to 99%. The materials were prepared by living anionic polymerization under different conditions. Specifically, the chain flexibility as defined by the Flory's characteristic ratio, , and dependence of chain flexibility on microstructure by combined measurements of intrinsic viscosity and molecular weight using triple-detector size exclusion chromatography (SEC) is studied. The persistence lengths (l p ) and chain diameters (d B ) were also estimated using the touched-bead wormlike chain model. To the best of our knowledge, the characteristic ratio of PBF is found to be the highest of all polydienes that have been reported so far.

36 MATERIALS SCIENCE↗
DOE OSTI2025

3D printed polymer gaskets for custom-form batteries

Additive manufacturing (AM) processes, like 3D printing, help to facilitate complex and customizable battery geometries which can provide design freedom and enhance volumetric energy density within electronic devices. AM materials must have the thermal and mechanical properties that enable printability, and when used in batteries, AM materials must also be chemically and electrochemically compatible with the battery chemistry. The compatibility between AM materials and the battery is of particular importance for the cell packaging materials which must be inert and are often overlooked. This study systematically studies AM-compatible polymeric materials for use as gaskets in lithium-ion cells. The materials investigated include three thermoplastics suitable for material extrusion printing: polylactic acid (PLA), polycarbonate, and polypropylene/polyethylene copolymer (PPPEC); and two photoresins suitable for vat photopolymerization (VPP) printing: an acrylate-based photoresin and a polyethylene glycol diacrylate photoresin. The AM gasket materials were tested in comparison to a conventional commercial polypropylene gasket. Mechanical testing (swell measurements and material stiffness) and electrochemical testing (linear sweep voltammetry and galvanostatic cycling of full cells) demonstrated that PLA and the VPP polymers were the least compatible with the lithium-ion battery chemistry, despite their prevalent use in studies of AM batteries, and that PPPEC was the most compatible.

3D printing↗