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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 955 records · Page 53
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Changes in Polymeric Tether Properties Due to Atomic Oxygen

The Propulsive Small Expendable Deployer System (ProSEDS) mission is designed to provide an on-orbit demonstration of the electrodynamic propulsion capabilities of tethers in space. The ProSEDS experiment will be a secondary payload on a Delta II unmanned expendable booster. A 5-km conductive tether is attached to the Delta II second stage and collects current fiom the low Earth orbit (LEO) plasma to facilitate de-orbit of the spent stage. The conductive tether is attached to a 10-km non-conductive tether, which is then attached to an endmass containing several scientific instruments. Atomic oxygen (AO) erodes most organic materials. As the orbit of the Delta II second stage decas, the AO flux (atoms/sq cm sec) increases. A nominal AO fluence of 1 x l0(exp 21) atoms/sq cm was agreed upon by the investigators as an adequate level for evaluating the performance of the tether materials. A test series was performed to determine the effect of atomic oxygen (AO) on the mechanical integrity and possible strength loss of ProSEDS tether materials. The tether materials in this study were Dyneema, an ultra-high molecular weight polyethylene material used as the non-conducting portion of the ProSEDS tether, and the Kevlar core strength fiber used in the conductive tether. Samples of Dyneema and Kevlar were exposed to various levels of atomic oxygen up to 1.07 x 10(exp 21) atoms/sq cm in the Marshall Space Flight Center Atomic Oxygen Beam Facility (AOBF). Changes in mass were noted after AO exposure. The tethers were then tensile-tested until failure. AO affected both the Dyneema and Kevlar tether material strength. Dyneema exposed to 1.07 x 10(exp 21) atoms/sq cm of atomic oxygen failed due to normal handling when removed fiom the AOBF and was not tensile-tested. Another test series was performed to determine the effect of AO on the electrical properties of the ProSEDS conductive tether. The conductive tether consists of seven individually coated strands of 28 AWG 1350-0 aluminum wire. The conductive coating, developed by Triton Systems, Inc., is a mix of polyanaline and COR, a clear AO-resistant polymer.

Finckenor, Miria M.↗
NASA NTRS1980

Application of the cubic polynomial strength criterion to the failure analysis of composite materials

A comparative failure analysis is presented based on the application of quadratic and cubic forms of the tensor polynomial lamina strength criterion to various composite structural configurations in a plane stress state. Failure loads have been predicted for off-angle laminates under simple loading conditions and for symmetric-balanced laminates subject to varying degrees of biaxial tension, including configurations subject to multimode failures. Some experimental data are also provided to support these calculations. From these results, the necessity of employing a cubic strength criterion to accurately predict the failure of composite laminae is demonstrated.

Tennyson, R. C.↗
DOE OSTI2016

Preparation of amine-impregnated silica foams using agar as the gelling agent

In this work we successfully prepared amine-impregnated gel-cast silica foams using agar and atmospheric air as the gelling agent and heat treatment atmosphere, respectively. The concentration of 3,6-anhydrogalactose in agar was evaluated by ultraviolet–visible spectroscopy (UV–Vis). The obtained foams were examined by Fourier transform infrared spectroscopy (FTIR), thermogravimetric analysis (TG) coupled to mass spectrometry (TG-MS), scanning electron microscopy (SEM), X-ray microtomography (micro-CT), and Archimedes method. The cold crushing strength of the materials prepared in this work was assessed using a mechanical testing stage available in the micro-CT system. The obtained foams exhibited a highly interconnected pore network, with an expressive presence of open pores. Samples heat-treated at 1300 °C for 2 h showed both an expressive porosity (≈ 77%) and a significant cold crushing strength (≈ 1.4 MPa). It was observed that the calcination of the prepared materials at 1200 °C for times as long as 16 h may lead to the rupture of pore walls. FTIR and TG-MS revealed that amine groups were properly incorporated into the foams structure. - Highlights: •Successful preparation of amine-impregnated gel-cast silica foams •Agar used as the gelling agent •Samples with expressive porosity and cold crushing strength •Sintering times as long as 16 h led to the rupture of the pore network.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Ceramic composites: A review of toughening mechanisms and demonstration of micropillar compression for interface property extraction

We present that ceramic fiber–matrix composites (CFMCs) are exciting materials for engineering applications in extreme environments. By integrating ceramic fibers within a ceramic matrix, CFMCs allow an intrinsically brittle material to exhibit sufficient structural toughness for use in gas turbines and nuclear reactors. Chemical stability under high temperature and irradiation coupled with high specific strength make these materials unique and increasingly popular in extreme settings. This paper first offers a review of the importance and growing body of research on fiber–matrix interfaces as they relate to composite toughening mechanisms. Second, micropillar compression is explored experimentally as a high-fidelity method for extracting interface properties compared with traditional fiber push-out testing. Three significant interface properties that govern composite toughening were extracted. For a 50-nm-pyrolytic carbon interface, the following were observed: a fracture energy release rate of ~2.5 J/m 2 , an internal friction coefficient of 0.25 ± 0.04, and a debond shear strength of 266 ± 24 MPa. Lastly, this research supports micromechanical evaluations as a unique bridge between theoretical physics models for microcrack propagation and empirically driven finite element models for bulk CFMCs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Dopamine-Mediated Polymer Coating Facilitates Area-Selective Atomic Layer Deposition

Area-selective atomic layer deposition (ALD) has the potential to significantly improve current fabrication approaches by introducing a bottom-up process in which robust and conformal thin films are selectively deposited onto patterned substrates. This bottom-up approach requires selective areas of the substrates to be masked to inhibit deposition. Spontaneous self-assembly and organization of a mask, incorporating adhesion and other functions, are particularly attractive for this role as they do not require a separate patterning step. In this work, we make use of the pH/light tunability of catechol adhesion to develop a catechol-functionalized polymer that exhibits tunable adhesion strengths on different materials based on their specific chemistry. Tunable selective deposition was shown between metal/metal oxide substrates by controlling the local pH. Moreover, by controlling the adhesion strength through UV light, the deposition of hafnium oxide (HfO 2 ) during ALD was successfully inhibited.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Achieving ultrahigh modulus of resilience and enhanced thermal stability in ZnO x /SU-8 interpenetrating network polymer nanocomposite nanopillars

The modulus of resilience, a mechanical property that quantifies the maximum strain energy density a material can store during elastic deformation, is a crucial parameter for materials used in flexible displays, micro/nano-electro-mechanical system (M/NEMS) actuators, and ultra-sensitive pressure sensors. In this study, ZnO x /SU-8 nanocomposite nanopillars with a diameter of 300 nm, fully infiltrated with a uniformly distributed, interpenetrating amorphous ZnO x filler network, were synthesized via vapor-phase infiltration (VPI). In-situ uniaxial nano-compression tests revealed that the modulus of resilience of ZnO x /SU-8 reaches ∼ 12 MJ/m 3 , which is an ultrahigh value among all engineering materials with comparable strength. In addition, the synthesis fidelity, inorganic infiltration depth, and mechanical performance were all significantly improved compared to VPI-synthesized AlO x nanocomposites. Thermal stability, another key requirement for M/NEMS device materials operating under extreme environments, was also notably enhanced. Furthermore, partial crystallization of the amorphous ZnO x fillers during annealing contributed to an additional increase in modulus of resilience, reaching up to ∼ 13.9 MJ/m 3 . This work presents an effective fabrication strategy for producing nanostructured organic–inorganic hybrid nanocomposites with ultrahigh modulus of resilience and superior thermal stability, paving the way for their integration into next-generation flexible displays and high-performance M/NEMS devices working under harsh environments.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Low-Cost Production of Lithium-Ion Separator Membranes w/ Improved Safety

The purpose of this Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and Porous Power Technologies, LLC (PPT) was to validate the performance, durability, and safety of a new type of reinforced, composite lithium ion battery separator produced as either a free-standing product or by a method of direct coating after electrode fabrication. ORNL’s primary roles were to develop novel separator thermophysical and mechanical property characterization methods and assist with fundamental understanding of SYMMETRIX® HPX and HPX-F product line chemical makeup and microstructure. PPT’s primary roles were to implement the understanding gained from the ORNL developed characterization methods into a refined product line featuring nonwoven-reinforced, ceramic-filled composite HPX-F separators for the lithium ion battery industry and quantify long-term cell performance improvements associated with HPX-F separators. Over the course of this CRADA, the product line of PPT was expanded from a pure polyvinylidene fluoride (PVDF) HP and polyester nonwoven-reinforced HPX separator platform to one that includes a variety of ceramic-filled HPX-F separators. In addition, the laminating and direct coating technologies for HPX and HPX-F separators are now more developed and moving towards commercial licensing. PPT’s SYMMETRIX® production process will revolutionize the production of lithium ion batteries by eliminating one of the most expensive components (the free-standing separator membrane) while improving performance and safety. The performance and safety improvements are due primarily to replacement of the conventional polyethylene/polypropylene (PE/PP) separator material with polyvinylidene fluoride (PVDF), and to ceramic materials added to the PVDF to form a short-resistant, thermally-stable composite structure. Ultimately, lithium ion battery manufacturers will be able to produce PPT separators in-house through the laminating or direct coating methods such as those based on the SYMMETRIX® product line, giving them higher performance cells at a fraction of the cost required to purchase separators from existing vendors. Direct coating of separators onto electrodes eliminates the cost of a downstream thermal lamination step and requires little or no change to existing equipment. It is a clear path for lithium ion battery manufacturers to reach the <$1/m2 separator price target set by the U.S. Advanced Battery Consortium (USABC). The technology enabled by this project will have a substantial impact on energy efficiency required to produce cells and is anticipated to save up to $1B annually by 2014 in reduced manufacturing costs. In addition, it will contribute significantly to production energy savings associated with transporting free-standing polyolefin (PE/PP) separators from the vendor to the cell manufacturer locations. SYMMETRIX® separators have shown increased cell capacity, improved thermal stability, and longer cycle life over their PE/PP counterparts and have been repeatedly demonstrated to improve nearly all aspects of lithium ion battery performance Prior to the start of this CRADA, widespread adoption has been limited by three factors: 1) difficulty in handling the material on high-speed processing equipment due to lower tensile strength than oriented PE/PP materials; 2) cost concerns associated with the higher expense of PVDF as a raw material; and 3) questions regarding short resistance and durability. The first factor was addressed through thorough mechanical (ultimate tensile strength and dynamic mechanical analysis, etc.) property characterization of HPX and HPX-F materials against the commercial polyolefin baselines. The second factor was address by shifting the focus of PPT’s product line towards the HPX-F materials with low-PVDF (high ceramic filler) content to reduce overall separator cost. Concerns associated with the third factor were alleviated by evaluating the internal shorting resistance of the separators using a custom developed ORNL measurement method and obtaining long-term cycling data of the new HPX-F separator formulations. A materials emphasis was placed on polyester fiber mats for the nonwoven reinforcement (to boost overall separator tensile strength) and proprietary metal oxides for the HPX-F fillers (to improve thermomechanical properties of the separator and make it more resistant to overcharge and internal shorting).

batteries↗
NASA NTRS2024

Seismic Velocities of the Tagish Lake Meteorite: Exploring Sample Size Limits for Elastic Property Determination

Understanding the mechanical and elastic properties of rocks comprising asteroids is be-coming of greater practical importance as more spacecraft interact with them (e.g. OSIRIS-REx, Hayabusa2, DART). However, knowledge of asteroid lithologies’ physical properties is limited due to sample paucity and the resulting challenges that come with working with small samples. Measuring seismic velocities is one way to directly and indirectly (through relation-ships established with analog materials) explore elastic and strength properties, respectively, while minimizing use of available material. While sample preparation requires cutting, the seismic measurements are non-destructive.

physical properties↗
NASA NTRS1984

Status of Understanding for Gear Materials

Today's gear designer has a large selection of possible gear materials to choose from. The choice of which material to use should be based on the requirements of the application and will include the operating conditions of load, speed, and temperature in addition to reliability, weight, noise limitation, accuracy, and cost. The plastic materials are generally low in cost with low strength capabilities and are suitable for many light-duty applications. Die-cast alloy and sintered powder-metal gears are also fairly inexpensive and will operate at higher loads and temperatures than plastic gears. The three types of cast iron offer a medium-strength gear at a cost that varies with the accuracy of machining requirements. Gears can be manufactured from several aluminum alloys for lightweight and medium cost and may be anodized for improved load capacity. The copper alloys, bronze and brass, are more costly but have good sliding and wear properties that are useful for worm gear applications. The hot-forged powder-metal gears have the advantage of medium cost with good accuracy and high strength. Several low- to medium alloy steels are available for gear design and most can be heat treated for added strength. The medium-alloy gear materials offer high strength when case hardened and will satisfy most high-load medium-temperature applications. For more severe load, speed, and temperature requirements the advanced high temperature alloys must be used. These include EX-53, CBS 600, Vasco X-2, Super Nitralloy (5Ni-2Al), and forged AISI M-50. As the requirements become more stringent, the cost will also increase. It is necessary that the gear designer have a working knowledge of the various gear materials in order to match the most economical material with the design requirements.

Dennis P Townsend↗
DOE OSTI2022

Transport and mechanical behavior in PEO-LLZO composite electrolytes

Abstract Composite solid electrolytes (CEs), wherein ion-conducting polymer and ceramic/glass is mixed, are promising candidates for all-solid-state batteries due to their promise of acceptable ionic conductivity and mechanical properties compared to their individual constituents. While numerous studies have focused on improving the performance of CEs, it is still unclear what the material targets are that can result in improved macroscopic performance especially in light of the coupled needs for high transport and high mechanical strength in these materials. In this study, a two-dimensional (2D) mathematical model is developed to investigate electrochemical and mechanical characteristics of CEs. The model is compared to CEs consisting of poly-ethylene-oxide (PEO) polymer and lithium lanthanum zirconium oxide (LLZO) ceramic material with examination of the impact of varying LLZO volume fractions. The potential drop at the PEO-LLZO interface is evaluated using the junction potential theory. Using experimental data from the literature, the model estimates the ionic conductivity, effective transference number, and mechanical stiffness of the CEs. While the mechanical stiffness improves with increasing volume fraction of LLZO, the impact on conductivity and transference number depends on interfacial resistance at the interface. Finally, the study reports CE’s potential to enhance Li-ion transport and mechanical properties to inhibit lithium (Li) dendrite growth.

25 ENERGY STORAGE↗
DOE OSTI2017

Impact of Protostellar Outflows on Turbulence and Star Formation Efficiency in Magnetized Dense Cores

The star-forming efficiency of dense gas is thought to be set within cores by outflow and radiative feedback. We use magnetohydrodynamic simulations to investigate the relation between protostellar outflow evolution, turbulence, and star formation efficiency. We model the collapse and evolution of isolated dense cores for ≳0.5 Myr including the effects of turbulence, radiation transfer, and both radiation and outflow feedback from forming protostars. We show that outflows drive and maintain turbulence in the core environment even with strong initial fields. The star formation efficiency decreases with increasing field strength, and the final efficiencies are 15%–40%. The Stage 0 lifetime, during which the protostellar mass is lower than that of the dense envelope, increases proportionally with the initial magnetic field strength and ranges from ∼0.1 to 0.4 Myr. The average accretion rate is well represented by a tapered turbulent core model, which is a function of the final protostellar mass and is independent of the magnetic field strength. By tagging material launched in the outflow, we demonstrate that the outflow entrains about three times the actual launched gas mass, a ratio that remains roughly constant in time regardless of the initial magnetic field strength. However, turbulent driving increases for stronger fields since momentum is more efficiently imparted to non-outflow material. The protostellar outflow momentum is highest during the first 0.1 Myr and declines thereafter by a factor of ≳10 as the accretion rate diminishes.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS1985

Comparison of Bond in Roll-bonded and Adhesively Bonded Aluminums

Lap-shear and peel test measurements of bond strength have been carried out as part of an investigation of roll bonding of 2024 and 7075 aluminum alloys. Shear strengths of the bonded material in the F temper are in the range of 14 to 16 ksi. Corresponding peel strengths are 120 to 130 lb/inch. These values, which are three to five times those reported in the literature for adhesively bonded 2024 and 7075, are a result of the true metallurgical bond achieved. The effects of heat-treating the bonded material are described and the improvements in bond strength discussed relative to the shear strength of the parent material. The significance of the findings for aerospace applications is discussed.

Schwensfeir, R. J., Jr.↗
NASA NTRS2011

The Effect of Dose Rate on Composite Durability When Exposed to a Simulated Long-Term Lunar Radiation Environment

Human exploration of space beyond low Earth orbit (LEO) requires a safe living and working environment for crew. Composite materials are one type of material being investigated by NASA as a multi-functional structural approach to habitats for long-term use in space or on planetary surfaces with limited magnetic fields and atmosphere. These materials provide high strength with the potential for decreased weight and increased radiation protection of crew and electronics when compared with conventional aluminum structures. However, these materials have not been evaluated in a harsh radiation environment, as would be experienced outside of LEO or on a planetary surface. Thus, NASA has been investigating the durability of select composite materials in a long-term radiation environment. Previously, NASA exposed composite samples to a simulated, accelerated 30-year radiation treatment and tensile stresses similar to those of a habitat pressure vessel. The results showed evidence of potential surface oxidation and enhanced cross-linking of the matrix. As a follow-on study, we performed the same accelerated exposure alongside an exposure with a decreased dose rate. The slower dose ]rate is comparable to a realistic scenario, although still accelerated. Strain measurements were collected during exposure and showed that with a fastdose rate, the strain decreased with time, but with a slow ]dose rate, the strain increased with time. After the radiation exposures, samples were characterized via tensile tests, flexure tests, Fourier Transform Infrared Spectroscopy (FTIR), and Differential Scanning Calorimetry (DSC). The results of these tests will be discussed.

Rojdev, Kristina↗
DOE OSTI2017

Corrosion and Fatigue Behavior of High-Strength Steel Treated with a Zn-Alloy Thermo-diffusion Coating

High and low cycle fatigue tests were conducted on high-strength steel using four-point bending. The materials tested were ASTM A723 steel in the as-machined condition, grit-blasted condition, MIL-DTL-16232 heavy manganese phosphate-coated condition, and ASTM A1059 Zn-alloy thermo-diffusion coated (Zn-TDC). The ASTM A723 steel base material exhibits a yield strength of ~1000 MPa. The effects of the surface treatments versus uncoated steel were examined. The fatigue life of the Zn-TDC specimens was generally reduced on as-coated specimens versus uncoated or phosphate-coated specimens. Several mechanisms are examined including the role of compressive residual stress relief with the Zn-TDC process as well as fatigue crack initiation from the hardened Zn-Fe alloy surface layer produced in the gas-metal reaction. Additionally, the effects of corrosion pitting on the fatigue life of coated specimens are explored as the Zn-TDC specimens exhibit significantly improved corrosion resistance over phosphate-coated and oiled specimens.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Hydrogen Embrittlement

Hydrogen embrittlement (HE) is a process resulting in a decrease in the fracture toughness or ductility of a metal due to the presence of atomic hydrogen. In addition to pure hydrogen gas as a direct source for the absorption of atomic hydrogen, the damaging effect can manifest itself from other hydrogen-containing gas species such as hydrogen sulfide (H2S), hydrogen chloride (HCl), and hydrogen bromide (HBr) environments. It has been known that H2S environment may result in a much more severe condition of embrittlement than pure hydrogen gas (H2) for certain types of alloys at similar conditions of stress and gas pressure. The reduction of fracture loads can occur at levels well below the yield strength of the material. Hydrogen embrittlement is usually manifest in terms of singular sharp cracks, in contrast to the extensive branching observed for stress corrosion cracking. The initial crack openings and the local deformation associated with crack propagation may be so small that they are difficult to detect except in special nondestructive examinations. Cracks due to HE can grow rapidly with little macroscopic evidence of mechanical deformation in materials that are normally quite ductile. This Technical Memorandum presents a comprehensive review of experimental data for the effects of gaseous Hydrogen Environment Embrittlement (HEE) for several types of metallic materials. Common material screening methods are used to rate the hydrogen degradation of mechanical properties that occur while the material is under an applied stress and exposed to gaseous hydrogen as compared to air or helium, under slow strain rates (SSR) testing. Due to the simplicity and accelerated nature of these tests, the results expressed in terms of HEE index are not intended to necessarily represent true hydrogen service environment for long-term exposure, but rather to provide a practical approach for material screening, which is a useful concept to qualitatively evaluate the severity of hydrogen embrittlement. The effects of hydrogen gas on mechanical properties such as tensile strength, ductility, fracture, low and high cycle fatigue, crack growth rate, and creep rupture are analyzed with respect to the general trends established from the HEE index values. It is observed that the severity of HE effects is also influenced by environmental factors such as pressure, temperature, and hydrogen gas purity. The severity of HE effects is also influenced by material factors such as surface finish, heat treatment, and product forms, compositions, grain direction, and crystal orientations.

Jonathan A. Lee↗
NASA NTRS2003

Development of Probabilistic Life Prediction Methodologies and Testing Strategies for MEMS

This effort is to investigate probabilistic life prediction methodologies for MicroElectroMechanical Systems (MEMS) and to analyze designs that determine stochastic properties of MEMS. This includes completion of a literature survey regarding Weibull size effect in MEMS and strength testing techniques. Also of interest is the design of a proper test for the Weibull size effect in tensile specimens. The Weibull size effect is a consequence of a stochastic strength response predicted from the Weibull distribution. Confirming that MEMS strength is controlled by the Weibull distribution will enable the development of a probabilistic design methodology for MEMS - similar to the GRC developed CARES/Life program for bulk ceramics. Another potential item of interest is analysis and modeling of material interfaces for strength as well as developing a strategy to handle stress singularities at sharp corners, filets, and material interfaces. The ultimate objective of this effort is to further develop and verify the ability of the Ceramics Analysis and Reliability Evaluation of Structuredlife (CARES/Life) code to predict the time-dependent reliability of MEMS structures subjected to multiple transient loads. Along these lines work may also be performed on transient fatigue life prediction methodologies.

Jadaan, Osama M.↗
DOE OSTI2021

National and regional waste stream in the United States: conformance and disparity

Accurate estimation of municipal solid waste (MSW) composition is critical for efficient waste management. In the United States, site-specific and material flow approaches determine the MSW composition at regional and national levels. The material flow-based national estimates are determined by the US EPA; the US EPA’s estimates are known to differ substantially from the aggregated tonnage of MSW managed by waste handling facilities in the United States. However, the material class-specific discrepancies of the US EPA’s material flow approach resulting in these differences are unknown. To find the basis of these discrepancies, we analyze the discarded MSW stream of 27 US states, which roughly accounts for 73 percent of the US population. Our analysis indicates that the material flow-based national estimates are accurate for the food, plastic, and glass material classes. In contrast, we find that the US EPA’s material flow-based predictions underestimate paper waste disposal by at least 15 million tons annually. These differences likely stem from incorrect assumptions of residence time. These results highlight the material class-specific strengths and drawbacks of the US EPA’s material flow-based MSW estimates.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗