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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 1,027 records · Page 57
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Electric Field Activated Shape Memory Polymer Composite

Provided is an electrically activated shape memory polymer composite capable of thermal shape reformation using electric power to heat the composite through its matrix glass transition temperature. The composite includes an adaptable polymer matrix component using a diglycidyl ether resin, at least one substantially well-dispersed conductive or magnetic nano-filler component, and at least one elastic, laminated layer. Also provided are methods of preparing the composite and methods of activating the composite. A shape reformation of the composite is triggered by applying an electric field at DC and/or at a frequency above about 1.mu.Hz for a sufficient time.

Kang, Jin Ho↗
NASA NTRS2018

Modeling-Driven Damage Tolerant Design of Graphene Nanoplatelet/Carbon Fiber/Epoxy Hybrid Composite Panels for Full-Scale Aerospace Structures

The objective of this study is to design a new nano graphenecarbon fiberpolymer hybrid composite that can be used for the NASA SLS Composite Exploration Upper Stage (CEUS) forward skirt structure. The new material will improve the resistance to open-hole compression failure of the structure relative to traditional polymer fiber composites. The material is designed rapidly and with little cost using the Integrated Computational Materials Engineering (ICME) approach. Multiscale modeling and experiments are used to synergistically optimize the material design to yield improved properties and performance by controlling key processing parameters for manufacturing nano-enhanced materials. Specifically, the nanocomposite panel showed a 22 reduction in mass relative to the traditional composite panel, while both designs are equal in terms of ease of manufacture. This potential mass savings corresponds to an estimated 45 savings in materials and manufacturing costs. The multiscale ICME workflow developed for this project can be readily applied to the development of nano-enhanced composite materials and large aerospace structures. In addition, all key aspects of ICME were employed to complete this project including multiscale modeling, experimental characterization and visualization, data management, visualization, error and uncertainty quantification, and education. The results presented herein indicate a dramatic level of success, as well as the power and potential of ICME approach and multiscale modeling for composite materials.

computational mechanics↗
NASA NTRS2018

Composite Technology for Exploration (CTE)

Technology Product Capability: The CTE (Composite Technology for Exploration) project will develop and demonstrate critical composites technologies with a focus on weight-saving, performance-enhancing bonded joint technology for Space Launch System (SLS)-scale composite hardware to support future NASA exploration missions - Improve the analytical capabilities required to predict failure modes in composite structures; - and, Support SLS payload adapters and fittings by maturing composite bonded joint technology and analytical tools to enable risk reduction. Exploration & Science Impact: Lighter weight structures; Improved material predictive capabilities; Improved bonded joint failure load and mode predictions to help reduce knockdown factors; and improve predictability and reliability; Increase confidence of all bonded joint composite structures; Reduce reliance on expensive testing.

CTE↗
NASA NTRS2019

Quasi-Static and Dynamic Analysis of Composite Panels: Characterization and Validation

The predictive capability of a progressive damage model to simulate the quasi-static and dynamic crushing of composite specimens is evaluated in this article. The material model is commercially available within the ABAQUS finite element software package, i.e., “Damage for Fiber reinforced Composites”, and is often utilized to simulate damage progression and failure in static and dynamic failure scenarios such as crushing of a composite plate. The composite specimens used in this study consist of quasi-isotropic C-shaped and corrugated composite panels comprised of carbon fiber/epoxy braided fabric. The C-shaped panel specimen is used to calibrate the model and optimize material/model properties through comparison with experimental results. Then, using the same model parameters, the quasi-static crush response of the corrugated panel is predicted. The predictive capability of the model is further demonstrated by simulating the dynamic crushing response of both C-shaped and corrugated panels using the same material properties as in the quasi-static crush case with only minor adjustments for the dynamic elastic properties (i.e., rate dependent modulus). Results show that the in-built material model available in ABAQUS can successfully reproduce experimental results for both panels (C-shaped and corrugated) subjected to both quasi-static and dynamic loading scenarios. A small-scale parametric study on physical (experimentally measurable) and nonphysical (purely mathematical) model parameters was also conducted. It can be concluded that, achieving successful simulation results requires a more in-depth understanding of the influence of model parameter variation on the mechanical response of the composite together with the strategies and challenges of the utilized modeling methodology (e.g., FEA mesh density, etc.).

Naghipour Ghezeljeh, Paria↗
NASA NTRS2019

Test and Analysis Correlation for Sandwich Composite Longitudinal Joint Specimens

The NASA Composite Technology for Exploration (CTE) project is tasked with evaluating methods to analyze and manufacture composite joints for potential use in block upgrades to the Space Launch System (SLS) launch-vehicle structures such as the Payload Attach Fitting (PAF). To perform this task, the CTE project has initiated test and analysis correlation studies for composite joints under various loading conditions. Herein, NASA-developed numerical models are correlated with the experimental results from a series of tension tests. Pretest strain results matched the far-field test data well, but did not capture the nonlinear response in the vicinity of the joint. A refined pretest analytical model was modified to represent progressive failure of the specimens at failure locations observed during the experimental tests. The nonlinear strain response from this progressive failure model predicted the delamination failure load within 15% of the test data, but underpredicted the nonlinearity of the strain response. Further study of composite material models that account for the nonlinear shear response of fabric composites is recommended for the composite joint structures considered in this paper.

Mason, Brian H.↗
NASA NTRS2019

Design of an Automated Ultrasonic Scanning System for In-Situ Composite Cure Monitoring and Defect Detection

The preliminary design and development of an automated ultrasonic scanning system for in-situ composite cure monitoring and defect detection in the high temperature environment of an oven was completed. This preliminary design is a stepping stone to deployment in the high temperature and high pressure environment of an autoclave, the primary cure method of aerospace grade thermoset composites. Cure monitoring with real-time defect detection during the process could determine when defects form and how they move. In addition, real-time defect detection during cure could assist validating physics-based process models for predicting defects at all stages of the cure cycle. A physics-based process model for predicting porosity and fiber waviness originating during cure is currently under development by the NASA Advanced Composites Project (ACP). For the design, an ultrasonic contact scanner is enclosed in an insulating box that is placed inside an oven during cure. Throughout the cure cycle, the box is nitrogen-cooled to approximately room temperature to maintain a standard operating environment for the scanner. The composite part is mounted on the outside of the box in a vacuum bag on the build/tool plate. The build plate is attached to the bottom surface of the box. The scanner inspects the composite panel through the build plate, tracking the movement of defects introduced during layup and searching for new defects that may form during cure. The focus of this paper is the evaluation and selection of the build plate material and thickness. The selection was based on the required operating temperature of the scanner, the cure temperature of the composite material, thermal conductivity models of the candidate build plates, and a series of ultrasonic attenuation tests. This analysis led to the determination that a 63.5 mm thick build plate of borosilicate glass would be utilized for the system. The borosilicate glass plate was selected as the build plate material due to the low ultrasonic attenuation it demonstrated, its ability to efficiently insulate the scanner while supporting an elevated temperature on the part side of the plate, and the availability of a 63.5 mm thick plate without the need for lamination.

Hudson, Tyler B.↗
NASA NTRSDate not supplied

In-Situ Detection of Process-Induced Porosity During Cure of Out-of-Autoclave Composites

Composite materials offer unique benefits in aerospace applications and are becoming increasingly used by industry manufacturers. Current manufacturing and processing methods can lead to defects in the composites, which are identified after fabrication using inspection methods.This study utilized a high-temperature ultrasonic inspection system to detect process-induced porosity in an out-of-autoclave (OOA) composite panel. An ultrasonic scanner was enclosed in a nitrogen-cooled insulating box that prevented thermal damage from the industrial oven to the temperature-sensitive electronics. Inspection of the composite part was performed through the bottom of the enclosure, which served as the tool plate for the part. In this study, a porosity gradient was introduced through a misfit of the part and caul plate. Using the data obtained from B-scans and amplitude C-scans throughout the cure cycle, the high and low porosity regions within the composite laminate were detected and localized. OOA tests aided the transition of this system to an autoclave, which is the primary method of curing aerospace-grade thermoset composites.

In-process, Defect Detection, Cure Monitoring, Por↗
NASA NTRSDate not supplied

Fabrication of Extruded Polyphenylsulfone – Boron Nitride Composite Tapes

Polyphenylsulfone (PPSU) is a high-temperature, chemically resistant thermoplastic with high impact resistance that is often used in interior aircraft cabin components, medical devices, and membranes. The aforementioned properties have led to interest investigating PPSU’s compatibility with hexagonal boron nitride (hBN) platelets as a thermally conductive, electrical composite insulator for high power-density electric machines. Preliminary trials extruding PPSU-hBN composite tapes showed promising dielectric properties and higher thermal conductivity as a function of hBN concentration compared to their neat analog. On the other hand, only few studies have reported on the extrusion process and resulting thermo-mechanical properties for PPSU and its composites made with chopped fiber reinforcement or fillers, none of which contained boron nitride filler. Prospects may exist for this type of material to be incorporated into extrusion-based additive manufacturing techniques to print other composites bearing unique properties useful for aerospace. Loading levels with up to approximately 23 wt% were achieved using micro-size BN platelets without observing any significant affects to PPSU’s glass-transition temperature. This work includes a description of the rheological properties of PPSU, the extrusion parameters for mixing and compounding the PPSU-hBN composite tapes, and the thermal and thermo-mechanical properties of PPSU-hBN composites.

Tiffany Williams↗
NASA NTRS2021

Pluto’s Sputnik Planitia: Composition of geological units from infrared spectroscopy

We have compared spectroscopic data of Sputnik Planitia on Pluto, as acquired by New Horizons’ Linear Etalon Imaging Spectral Array (LEISA) instrument, to the geomorphology as mapped by White et al. (2017) using visible and panchromatic imaging acquired by the LOng-Range Reconnaissance Imager (LORRI) and the Multi-spectral Visible Imaging Camera (MVIC). We have focused on 13 of the geologic units identified by White et al. (2017), which include the plains and mountain units contained within the Sputnik basin. We divided the map of Sputnik Planitia into 15 provinces, each containing one or more geologic units, and we use LEISA to calculate the average spectra of the units inside the 15 provinces. Hapke-based modeling was then applied to the average spectra of the units to infer their surface composition, and to determine if the composition resulting from the modeling of LEISA spectra reflects the geomorphologic analyses of LORRI data, and if areas classified as being the same geologically, but which are geographically separated, share a similar composition. We investigated the spatial distribution of the most abundant ices on Pluto’s surface - CH4, N2, CO, H2O, and a non-ice component presumed to be a macromolecular carbon-rich material, termed a tholin, that imparts a positive spectral slope in the visible spectral region and a negative spectral slope longward of ~1.1 μm. Because the exact nature of the non-ice component is still debated and because the negative spectral slope of the available tholins in the near infrared does not perfectly match the Pluto data, for spectral modeling purposes we reference it generically as the negative spectral slope endmember (NSS endmember). We created maps of variations in the integrated band depth (from LEISA data) and areal mass fraction (from the modeling) of the components. The analysis of correlations between the occurrences of the endmembers in the geologic units led to the observation of an anomalous suppression of the strong CH4 absorption bands in units with compositions that are dominated by H2O ice and the NSS endmember. Exploring the mutual variation of the CH4 and N2 integrated band depths with the abundance of crystalline H2O and NSS endmember revealed that the NSS endmember is primarily responsible for the suppression of CH4 absorptions in mountainous units located along the western edge of Sputnik Planitia. Our spectroscopic analyses have provided additional insight into the geological processes that have shaped Sputnik Planitia. A general increase in volatile abundance from the north to the south of Sputnik Planitia is observed. Such an increase first observed and interpreted by Protopapa et al., 2017 and later confirmed by climate modeling (Bertrand et al., 2018) is expressed geomorphologically in the form of preferential deposition of N2 ice in the upland and mountainous regions bordering the plains of southern Sputnik Planitia. Relatively high amounts of pure CH4 are seen at the southern Tenzing Montes, which are a natural site for CH4 deposition owing to their great elevation and the lower insolation they are presently receiving. The NSS endmember correlates the existence of tholins within certain units, mostly those coating the low-latitude mountain ranges that are co-latitudinal with the tholin-covered Cthulhu Macula. The spectral analysis has also revealed compositional differences between the handful of occurrences of northern non-cellular plains and the surrounding cellular plains, all of which are located within the portion of Sputnik Planitia that is presently experiencing net sublimation of volatiles, and which do not therefore exhibit a surface layer of bright, freshly-deposited N2 ice. The compositional differences between the cellular and non-cellular plains here hint at the effectiveness of convection in entraining and trapping tholins within the body of the cellular plains, while preventing the spread of such tholins to abutting non-cellular plains.

Pluto's Sputnik Planitia↗
NASA NTRSDate not supplied

Material Variability Effects on Damage Development Within Composite Adhesively Bonded Joints

Use of composite adhesively bonded joints (ABJ) is of critical importance to the adoption of composite materials in the automotive industry, as ABJ enable lower stress concentrations as compared to conventional mechanically fastened joints. ABJ are better suited for joining composite materials as compared to fastened joints because fastened joints require drilling of holes which locally affect composite material structure. Composite materials and adhesives are subject to unavoidable stochastic local material variations which make different failure scenarios possible. An experimentally tested ABJ configuration is simulated using finite element analysis (FEA). Experimentally, under tension, the joints failed by three major failure modes, with peak loads ranging from 13.0-16.1 kips. Progressive failure analysis tools are used to simulate damage development within each material within the joint. The simulation agreed well with the average experimental peak load. Stochastically occurring adhesive porosity and matrix-fiber micro-disbonding were numerically simulated. The simulations revealed a similar trend as observed experimentally: joints which failed at higher peak loads had lower levels of damage within the face-sheets of the composite panels which were adhesively bonded; these joints which failed at higher peak loads also had greater damage in the doubler of the experimentally tested double lap joint configuration.

Richard Larson↗
NASA NTRS2021

Modular Composite Damage Detection System (MCDDS)

The 2020 CIF funded Modular Composite Damage Detection System (MCDDS) aims to advance the technology of damage detection in composites in the areas of thin, flexible damage detection panel construction, encapsulation techniques in composite matrixes, innovative integration and interfacing techniques with flexible embedded sensory panels, repair methods of composite materials, and improved packaging of the MCDDS. Custom thin, flexible polyimide printed circuit boards (PCBs) were designed and procured for fabrication of test specimens. A custom interface PCB was designed and fabricated to monitor the newly developed damage detection test specimens. Test specimens were fabricated using the novel flexible circuitry that were either fully or partially encapsulated. The fully encapsulated specimens were used to demonstrate embedded damage detection concepts and the partially encapsulated specimens were used to demonstrate surface-mounted (laminate) damage detection concepts. The new composite damage detection test specimens were tested and evaluated to determine if the novel damage detection sensory panels could withstand low-cycle threshold fatigue loading per a modified version of American Society for Testing and Materials (ASTM) D 7264 for up to 50 cycles without void formation. The data for multiple sensory panels indicates that the newly fabricated sensory panels are robust and do indeed withstand three-point bend flexural loading for more than 50 cycles. Additionally, testing was performed to determine if damage could be detected in damage detection test specimens subjected to failure using a 3-point bend test per a modified version of ASTM D 7264. Again, multiple sensory panels (both fully and partially encapsulated) showed the ability to detect damage to specimens subjected to failure per a modified version of ASTM D 7264. Additionally, a novel concept for tracking and monitoring of cracking (and potentially delamination) in composites was designed and developed that utilizes painted-on conductors.

Christopher Forney↗
NASA NTRS2023

Distributions of Mesoscale Periodic Structures in the Elemental and Ionic Composition of the Solar Wind

Multiple statistical and event studies based on in situ observations have shown that the solar wind contains mesoscale (∼ 100 – 10,000 Mm) periodic structures in the proton number density. Remote observations of such structures and event studies of concurrent variations in composition have demonstrated that they can form in the solar atmosphere and be preserved while advecting outwards through the heliosphere. Viall, Kepko, and Spence (J. Geophys. Res. (Space Phys.) 113, A07101, 2008; J. Geophys. Res. (Space Phys.) 114, A01201, 2009) and Kepko, Viall, and Wolfinger (J. Geophys. Res. (Space Phys.) 125(8), e28037, 2020) have reported that periodic proton density structures preferentially occur at specific radial length scales and have published their distributions from Wind measurements near L1. Here, we conduct a statistical study of 14 years (1998 – 2011) of 12-minute composition data measured by the Solar Wind Ion Composition Spectrometer instrument aboard the Advanced Composition Explorer spacecraft. We found that the elemental and ionic composition also contain statistically significant mesoscale periodic structures and, for the first time, present occurrence distributions for elemental abundance ratios with low, intermediate, and high first ionization potentials as well as for key solar wind charge states. These distributions set important constraints on solar wind formation in general and the formation of periodic mesoscale solar wind structures specifically, as the elemental and ionic composition are known to be determined at the Sun and to not evolve during advection.

Solar wind↗
NASA NTRSDate not supplied

Evaluation Marcelling in Composites using Ultrasonic Guided Wave

Thermoplastic composite (TPC) material seldom manifests in-plane fiber waviness during manufacturing. In-plane fiber waviness is called marcelling. Marcelling com-promises the composite strength and performance. When present in a structure, marcelling is not only a surface defect but can extend partially along the thickness of the composite. There is no established nondestructive evaluation (NDE) method to detect and quantify marcelling in composite. Ultrasonic guided waves can saturate the complete thickness of a composite structure. Thus, physics of guided wave creates an opportunity to detect and quantify the marcelling in composites. Before guided waves could be used to detect marcelling, it is necessary to quantify the marcelling in the structure and identify the marcelling affected zones (MAZE). In this research first, high frequency scanning acoustic microscopy (SAM) was performed to quantify the marcelling and statistical distribution of the defects at different MAZE was obtained. Next the MAZE with known statistical distribution of quantified marcelling (marcelling wavelength and marcelling amplitude) was inspected using ultrasonic guided wave setup. The method quantified the guided wave feature as a function of quantitative degree of marcelling. The overarching objective of this research is to implement post process NDE inspection of TPC large structures where in plane fiber waviness or marcelling can be detected and MAZEs could be identified. Primary fining is that the reduction of wave velocity and amplitude of ultrasonic guided wave could be good indicators of MAZE. However, more rigorous calibration is necessary where inspection direction is carefully devised with respect to the marcelling.

HiCAM↗
DOE OSTI2020

Durable polymer-aerogel based superhydrophobic coatings: a composite material

Provided are polymer-aerogel composite coatings, devices and articles including polymer-aerogel composite coatings, and methods for preparing the polymer-aerogel composite. The exemplary article can include a surface, wherein the surface includes at least one region and a polymer-aerogel composite coating disposed over the at least one region, wherein the polymer-aerogel composite coating has a water contact angle of at least about 140° and a contact angle hysteresis of less than about 1°. The polymer-aerogel composite coating can include a polymer and an ultra high water content catalyzed polysilicate aerogel, the polysilicate aerogel including a three dimensional network of silica particles having surface functional groups derivatized with a silylating agent and a plurality of pores.

Kissel, David J.↗
DOE OSTI2022

Characterization of anisotropic mechanical properties of polymer composites from a hybrid additive manufacturing-compression molding process using x-ray computer tomography

In this study, anisotropic stiffness tensors were reconstructed based on fiber orientation distributions obtained from X-ray computer tomography (xCT). A preform was manufactured via a big area additive manufacturing (BAAM) system with carbon fiber (CF) filled acrylonitrile butadiene styrene (ABS). The tailored preform from additive manufacturing (AM) was used in the compression molding (CM) process to produce a low-void high-performance thermoplastic composite panel. An xCT technique was employed to detect the fiber orientations in CF/ABS composites manufactured via three different methods: AM from BAAM, extrusion compression molding (ECM), and AM-CM. The anisotropic stiffness tensor was obtained from the composite panel manufactured via the three manufacturing methods (AM, ECM, and AMCM). A micromechanics theory was used to obtain the orthotropic stiffness tensors of the composite panels and compared with the experimental values. The predicted stiffness tensors of AM and AM-CM composite panels were used to study the deformation characteristics of a steering wheel during airbag deployment by performing finite element analysis (FEA). The approach developed in this study can be utilized for evaluating high-performance composites.

Pokkalla, Deepak↗
DOE OSTI2022

Ce:YAG/A12O3 composites for laser-excited solid-state white lighting

A method for fabricating a composite useful in a white light emitting device, includes mixing a phosphor and a filler to form a mixture; sintering the mixture (e.g., using spark plasma sintering) to form a composite; and annealing the composite to reduce oxygen vacancies and improve optical properties of the composite. Also disclosed is a white light emitting device including a laser diode or light emitting diode optically pumping the phosphor in the composite to produce white light. The composite fabricated using the method (and having. e.g., at most 50% phosphor by weight) can (1) reduce an operating temperature of the phosphor by 55 degrees, (2) increase an external quantum efficiency (e.g., by at least 15%) of the white light emitting device, and (3) result in color points and quality of the white light that is equal to or improved, as compared to without the filler.

Cozzan, Clayton J.↗
DOE OSTI2023

Enhanced through-thickness electrical conductivity and lightning strike damage response of interleaved vertically aligned short carbon fiber composites

Through-thickness electrical conductivity of carbon fiber reinforced polymers (CFRPs) is a key characteristic that determines the severity of lighting strike-induced damage. Carbon Fibers (CFs) are inherently electrically conductive and therefore provide high conductivity in the direction of the fiber orientation. However, electrical conductivities through the thickness and orthogonal to the CF orientation in CFRPs are governed by the insulating polymer matrix present between CFs. Here, in this work, through the thickness alignment of short CFs in between layers of CFRP laminates is demonstrated to improve the through-thickness electrical conductivity. Composites with interleaved vertically aligned short CF fibers (<150 μm) will be referred as V-fiber composites hereafter. The effect of the V-fiber on the lightning strike damage is evaluated against an artificial lightning strike of 100 kA (modified waveform A of SAE ARP-5412B standard). The improved through-thickness electrical conductivity of CFRP laminates (1.15 S/cm) through vertical alignment of short CFs was compared to reference CFRP laminates (0.13 S/cm) and was found to dissipate the artificial lightning strike current more efficiently. The surface damage after the artificial lightning strike in the V-fiber composites was reduced to 12.69 cm 2 compared to the reference CFRP surface damage of 57.67 cm 2 , a 78% reduction. It was also demonstrated that Joule heat generated due to lightning strike on the composites was significantly less than the reference sample using infrared (IR) thermography. A high retention (up to 78%) of flexural properties (modulus and strength) was observed in V-fiber composites post lightning strike impact as compared to only 47% retention in the reference panel.

42 ENGINEERING↗
DOE OSTI2025

A deep learning and finite element approach for exploration of inverse structure–property designs of lightweight hybrid composites

Hybrid composites have important applications, such as high-performance and lightweight materials in aerospace and automotive industries. Hybrid composites utilize the synergy of diverse fillers to achieve desired material properties, but usually have more complicated microstructures. While topology optimization can optimize a particular property, designing hybrid composites for customized mechanical performances, e.g. full-range stress–strain curve, remains challenging. Here, a computational framework that integrated finite element analysis (FEA) and artificial intelligence (AI) methods of Conditional Generative Adversarial Networks (cGAN) deep learning and transfer learning was developed to establish inverse structure–property relationships and design tailor-made hybrid composites. Based on FEA-generated datasets of hybrid fiber-particle–matrix microstructures and their corresponding full-range stress–strain curves, a cGAN architecture was trained to generate tailored microstructures and establish structure–property relationships. Similarity in microstructural features and well-matched stress–strain curves based on the AI-generated composites were achieved. In conclusion, transfer learning was used to expand the pre-trained model for designing different materials systems.

Hybrid composites↗