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At least 1,207 records · Page 67

All sources NASA NTRS DOE OSTI

DOE OSTI2024

Low-Cost, High-Performance Carbon Fiber for Compressed Natural Gas Storage Tanks (Final Technical Report – Down Select Report)

The aim of this project is to reduce the cost of Type IV, carbon fiber (CF) composite overwrap compressed gas storage tanks by reducing the cost of CF and CF composites. The project team worked to reduce the cost of CF by exploring and testing opportunities for a low-cost alternative precursor material for CF production to supplant market-dominant and costly polyacrylonitrile (PAN). Concurrently, the team aimed to reduce the cost of the tanks at the composite level by improving the interfacial adhesion between the fibers and the matrix resin through the incorporation of low-cost nanoparticles recycled from waste materials, which would reduce the volume of costly CF required to achieve the same tank performance. At the end of the first year, the project team selected mesophase pitch as the primary precursor candidate from a field of materials based on the superior mechanical performance and cost-saving potential. During the second year, the team produced CFs derived from mesophase pitch achieving an average tensile strength of 365.6 ksi and average tensile modulus of 40.74 Msi. Facility availability for spinning and converting these fibers at greater scale has hindered scale-up demonstration, but the team has identified opportunities to conduct this work in the near term. Cost modeling shows that these mesophase pitch-derived CFs can be up to 40% less expensive than PAN-derived CFs due to the lower cost of the feedstock material, higher throughput, greater conversion yield, and lower cost spinning method and compared to PAN. Additionally, the team has demonstrated at lab-scale that nanoparticle coating CFs can significantly increase the interfacial shear strength and load transfer efficiency of CFs in a matrix. Single filament pull-out testing showed a 27% average increase in max interfacial shear strength due to this coating. A continuous method of applying these coatings to a tow of CF has been developed for scale-up. 26 m tows of coated CFs were produced using this system and formed into composite ring samples for ASTM ring burst testing. Issues with the testing protocol have limited assessment of these results. A prototype Type IV tank was designed to meet ANSI HGV2 standards, and the design criteria set out by DOE, using the CF properties developed by the team paired with a proprietary resin matrix, a polyamide liner, and aluminum end bosses. The tank weighs 153.1 kg and with a total capacity of 5.8 kg H2 (5.6 kg usable), which yields a gravimetric capacity of 1.17 kWh/kg. Cost modeling predicts that the tank will have a projected cost of $15.73/kWh. Tank performance modeling does not include considerations for fiber-matrix load transfer efficiency improvements offered by nanoparticle coating method.

08 HYDROGEN↗

DOE OSTI2025

Propylamine Functionalized Porous Fiber Sorbents with High Oxidation Stability for Direct Air Capture

Amine-based sorbents are highly effective for direct air capture (DAC) due to their excellent CO2 capture efficiency under ultra-dilute conditions. However, these sorbents can suffer degradation when exposed to combinations of heat, oxygen, and other atmospheric components, indicating a need for improved sorbent stability. In this study, we developed amidoxime functionalized polymer of intrinsic microporosity (PIM-1-AO) fibers with tethered amines, specifically tris(2-aminoethyl)amine (TAEA) and tris(3-aminopropyl)amine (TAPA), denoted as PIM-1-AO-TAEA and PIM-1-AO-TAPA, respectively. In addition, large scale sorbent fiber spinning has been successfully performed by producing meters of fibers in the lab. We demonstrated that substituting TAEA with TAPA, which has propyl chains instead of ethyl chains, reduces oxidative degradation under regeneration conditions. The findings revealed that PIM-1-AO-TAPA not only significantly outperforms PIM-1-AO-TAEA after accelerated aging process, but also outperforms any other sorbent used in DAC aged under similar conditions. Moreover, PIM-1-AO-TAPA sorbent fibers showed one of the highest amine efficiencies (0.25) considering the low amine loading (21%) coupled with robust CO2 uptake performance (1.12 mmol/g) under DAC conditions.

amine-based sorbent↗

DOE OSTI2022

Mechanical Response and Processability of Wet-Laid Recycled Carbon Fiber PE, PA66 and PET Thermoplastic Composites

The interest in recycled carbon fiber (rCF) is growing rapidly and the supply chain for these materials is gradually being established. However, the processing routes, material intermediates and properties of rCF composites are less understood for designers to adopt them into practice. This paper provides a practical pathway for rCFs in conjunction with low cost and, for the most part, commodity thermoplastic resins, namely polyethylene (PE), polyamide 66 (PA66) and polyethylene terephthalate (PET). Industrially relevant wet-laid (WL) process routes have been adopted to produce mats using two variants of WL mats, namely (a) high speed wet-laid inclined wire to produce broad good ‘roll’ forms and (b) 3DEPTM process patented by Materials Innovation Technologies (MIT)-recycled carbon fiber (RCF), now Carbon Conversions, which involves mixing fibers and water and depositing the fibers on a water-immersed mold. These are referred to as ‘sheet’ forms. The produced mats were evaluated for their processing into composites as ‘fully consolidated mats’ and ‘non-consolidated’ as-produced mats. Comprehensive mechanical data in terms of tensile strength, tensile modulus and impact toughness for rCF C/PE, C/PA66 and C/PET are presented. The work is of high value to sustainable composite designers and modelers.

compression molding↗

DOE OSTI2023

Fiber Optic Temperature Sensor System Using Air-Filled Fabry–Pérot Cavity with Variable Pressure

We report a high-resolution fiber optic temperature sensor system based on an air-filled Fabry–Pérot (FP) cavity, whose spectral fringes shift due to a precise pressure variation in the cavity. The absolute temperature can be deduced from the spectral shift and the pressure variation. For fabrication, a fused-silica tube is spliced with a single-mode fiber at one end and a side-hole fiber at the other to form the FP cavity. The pressure in the cavity can be changed by passing air through the side-hole fiber, causing the spectral shift. We analyzed the effect of sensor wavelength resolution and pressure fluctuation on the temperature measurement resolution. A computer-controlled pressure system and sensor interrogation system were developed with miniaturized instruments for the system operation. Experimental results show that the sensor had a high wavelength resolution (<0.2 pm) with minimal pressure fluctuation (~0.015 kPa), resulting in high-resolution (±0.32 ℃) temperature measurement. It shows good stability from the thermal cycle testing with the maximum testing temperature reaching 800 ℃.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Effect of Near-field Distribution on Transmission Characteristics of Fiber-fed Fabry–Perot Etalons

Fiber-fed etalons are widely employed in advanced interferometric instruments such as gravitational-wave detectors, ultrastable lasers and calibration reference for high-precision spectrographs. We demonstrate that variation in near-field distribution of the feeding fiber would deteriorate the spectrum precision of the fiber-fed Fabry–Perot etalon, especially when precision at the order of 3 × 10{sup -10} or higher is required. The octagonal fiber reinforced with double scrambler could greatly improve the steadiness and uniformness of the near-field distribution. When building wavelength calibrators for sub-m s{sup -1} precision radial-velocity instruments, the double scrambler should be considered meticulously.

47 OTHER INSTRUMENTATION↗

NASA NTRS2006

Deep Broad-Band Infrared Nulling Using A Single-Mode Fiber Beam Combiner and Baseline Rotation

The basic advantage of single-mode fibers for deep nulling applications resides in their spatial filtering ability, and has now long been known. However, and as suggested more recently, a single-mode fiber can also be used for direct coherent recombination of spatially separated beams, i.e. in a 'multi-axial' nulling scheme. After the first successful demonstration of deep (<2e-6) visible LASER nulls using this technique (Haguenauer & Serabyn, Applied Optics 2006), we decided to work on an infrared extension for ground based astronomical observations, e.g. using two or more off-axis sub-apertures of a large ground based telescope. In preparation for such a system, we built and tested a laboratory infrared fiber nuller working in a wavelength regime where atmospheric turbulence can be efficiently corrected, over a pass band (approx.1.5 to 1.8 micron) broad enough to provide reasonable sensitivity. In addition, since no snapshot images are readily accessible with a (single) fiber nuller, we also tested baseline rotation as an approach to detect off-axis companions while keeping a central null. This modulation technique is identical to the baseline rotation envisioned for the TPF-I space mission. Within this context, we report here on early laboratory results showing deep stable broad-band dual polarization infrared nulls <5e-4 (currently limited by detector noise), and visible LASER nulls better than 3e-4 over a 360 degree rotation of the baseline. While further work will take place in the laboratory to achieve deeper stable broad-band nulls and test off-axis sources detection through rotation, the emphasis will be put on bringing such a system to a telescope as soon as possible. Detection capability at the 500:1 contrast ratio in the K band (~2.2 microns) seem readily accessible within 50-100 mas of the optical axis, even with a first generation system mounted on a >5m AO equipped telescope such as the Palomar Hale 200 inch, the Keck, Subaru or Gemini telescopes.

single mode fibers↗

NASA NTRS2006

Measurement of Spatial Filtering Capabilities of Single Mode Infrared Fibers

Spatial filtering is necessary to achieve deep nulls in optical interferometer and single mode infrared fibers can serve as spatial filters. The filtering function is based on the ability of these devices to perform the mode-cleaning function: only the component of the input field that is coupled to the single bound (fundamental) mode of the device propagates to the output without substantial loss. In practical fiber devices, there are leakage channels that cause light not coupled into the fundamental mode to propagate to the output. These include propagation through the fiber cladding and by means of a leaky mode. We propose a technique for measuring the magnitude of this leakage and apply it to infrared fibers made at the Naval Research Laboratory and at Tel Aviv University.

infrared↗

NASA NTRS2017

Fiber Optic Temperature Sensors in TPS: Arc Jet Model Design & Testing

Techniques for using fiber optics with Fiber Bragg Gratings (FBGs) have been developed by IFOS Corp. for use in thermal protection systems (TPS) on spacecraft heat shield materials through NASA Phase 1 and 2 SBIR efforts and have been further improved in a recent collaboration between IFOS and NASA that will be described here. Fiber optic temperature sensors offer several potential advantages over traditional thermocouple sensors including a) multiplexing many sensors in a single fiber to increase sensor density in a given array or to provide spatial resolution, b) improved thermal property match between sensor and TPS to reduce heat flow disruption, c) lack of electrical conductivity.

sensors↗

NASA NTRS2017

SiC Fibers and SiCf/SiC Ceramic Matrix Minicomposites Damage Behavior

Silicon Carbide based Ceramic Matrix Composites (CMCs) are attractive materials for use in high-temperature applications in the aerospace industry. Performance and durability of CMCs depend on the properties of its constituents such as fibers and matrix. Therefore, CMCs constituents limitations and damage mechanisms are discussed and characterized in representative simulated application conditions and dominant damage mechanisms are identified at elevated temperatures. In this work, the initiation and evolution of damage in Hi-Nicalon type S fiber-reinforced minicomposites with different interphases thicknesses from different manufacturers were investigated employing several nondestructive evaluation techniques such as acoustic emission, electrical resistance and microscopy. Moreover, the tensile creep behavior of single Hi-Nicalon Type S SiC fibers were tested and characterized and creep parameters were extracted. Fibers creep tests were performed in air or vacuum at 1200-1482 C under high stresses. Creep parameters was then used in understanding load sharing and lifing of ceramic matrix minicomposites. Future work plans will be reviewed.

SiC fibers↗

NASA NTRS2018

Bit Error Rate Performance on Passive Alignment in Free Space Optical Links Using Large Core Fibers

A 20-meter free-space optical link (FSOL) is proposed for data transmission between external ISS payload sites and the main cabin at a target rate of 10 Gbps (gigabits per second). Motion between a payload site and the main cabin is predicted to cause up to 5 cm in lateral misalignment and 0.2 degrees of angular misalignment. Due to the harsh environment of space it is advantageous to locate the optical transceivers inside the spacecraft or in a controlled environment. With the optical components and transceivers in separate locations, a fiber optic cable will be required to carry light between the two. In our past work we found that the use of large-core fibers provide an increased misalignment tolerance for such systems and could eliminate the need for active control of the optics. In that work, it was shown that a 105 ïm core diameter fiber optic cable offered a viable low SWaP (size, weight, and power) solution for the ISS application; however, the effects of modal dispersion were not investigated. This paper will present bit error rate performance of the FSOL using these large-core fibers.

Free Space Optical Link↗

NASA NTRS2018

Bit Error Rate Performance on Passive Alignment in Free Space Optical Links Using Large Core Fibers

Optical Bit Error Rate Testing↗

NASA NTRS2023

Leveraging Automated Fiber Placement Computer Aided Process Planning Framework for Defect Validation and Dynamic Layup Strategies

Process planning represents an essential stage of the Automated Fiber Placement (AFP) workflow. It develops useful and efficient machine processes based upon the working material, composite design, and manufacturing resources. The current state of process planning requires a high degree of interaction from the process planner and could greatly benefit from increased automation. Therefore, a list of key steps and functions are created to identify the more difficult and time-consuming phases of process planning. Additionally, a set of metrics must exist by which to evaluate the effectiveness of the manufactured laminate from the machine code created during the Process Planning stage. Layup strategies, in addition to dog ears, stagger shifts, steering constraints, and starting points, represented the group of functions labeled as process optimization and ranked the highest in terms of priority for automation. The laminates resulting from the selected parameters are evaluated through the occurrences of principal defect metrics such as fiber gaps, overlaps, angle deviation and steering violations. This document presents an automated software solution to the layup strategy and starting point selection phase of process planning. A series of ply scenarios are generated with variations of these ply parameters and evaluated according to a set of metrics entered by the Process Planner. These metrics are generated through use of the Analytical Hierarchy Process (AHP), where relative importance between each of the fiber features are defined. The ply scenarios are selected which reduce the overall fiber feature scores based on the defects the Process Planner wishes to minimize.

HiCAM↗

DOE OSTI2025

Pilot-Scale Validation of Distributed Optical Fiber Sensors for Underground Pipeline Monitoring

Distributed fiber optic sensing is a cutting-edge technology that has found extensive applications in the monitoring of Ensuring the safety, integrity, and operational efficiency of underground product pipelines is vital for maintaining the nation’s critical infrastructure. Monitoring parameters such as hoop strain, pressure, and acoustic vibrations is key to detecting potential leaks, intrusions, or structural issues. Distributed optical fiber sensor (DOFS) systems provide a compelling solution for continuous, real-time monitoring over long distances. This paper details the development and pilot-scale implementation of DOFS systems for underground pipeline monitoring, evolving from a proof-of-concept stage. Multiple custom-designed DOFS interrogator units—such as optical frequency-domain reflectometry (OFDR), Brillouin optical time-domain analysis (BOTDA), and multimodal interferometer-based fiber acoustic sensors—were employed to measure key parameters like hoop strain, pressure, and acoustic vibrations. The underground product pipeline's outer diameter is 30 inches, the wall thickness is 1.28 inches, and the 3-foot depth. The fiber deployment strategies, and sensing data acquisition methods for these systems are discussed. The results demonstrate the effectiveness of DOFS in detecting hoop strain, temperature changes, and acoustic vibrations, showcasing their potential for real-time monitoring and enhancing pipeline safety.

distributed fiber sensing↗

DOE OSTI2024

Manufacturing of Continuous Core–Shell Hydrated Salt Fibers for Room Temperature Thermal Energy Storage

The encapsulation of salt hydrate phase change materials (PCMs) in uniform microscale bodies has yet been reported in research due in part to the delicate relationship between thermal performance and water-to-salt ratios which are easily altered during manufacturing. Herein, core–shell composite fibers comprised of a salt hydrate PCM core and a poly(acrylonitrile) (PAN) shell are wet spun in a continuous process using a syringe pump and coaxial die. The PCM phase comprises calcium chloride hexahydrate (CaCl 2 ·6H 2 O) with strontium chloride hexahydrate(SrCl 2 ·6H 2 O) (3 wt%) and fumed silica(SiO 2 ) (2 wt%) as additive, a composition that is prepared from homogenous melt at 40 °C. 15 wt% PAN in dimethylsulfoxide solvent is used to prepare the shell-forming polymer gel. PCM and polymer gel injection rates of 10–40 mL h –1 are used to spin coaxial fibers through a coagulation bath, yielding continuous microtubules with diameters in the range of 850–1500 μm. Cyclic testing shows that after 1000 cycles, melting enthalpies incurred only a 3.5% decline from 131.46 to 126.9 J g –1 . In conclusion, success here overcomes several coincidental drawbacks of PCM fiber performance and manufacturing and delivers the first example of scalable roll-to-roll PCM fiber produced by wet spinning for building material applications.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Effect of dietary fiber fermentation on short‐chain fatty acid production and microbial composition in vitro

Abstract BACKGROUND The efficient utilization of fiber‐rich co‐products is important for optimizing feed resource utilization and animal health. This study was conducted to evaluate the fermentation characteristics of fiber‐rich co‐products, which had equal quantities of total dietary fiber (TDF), at different time points using batch in vitro methods. It considered their gas production, short‐chain fatty acid (SCFA) production, and microbial composition. RESULTS The fermentation of wheat bran (WB) and oat bran (OB) showed higher and faster ( P < 0.05) gas and SCFA production than corn bran (CB), sugar beet pulp (SBP), and soybean hulls (SH). The α ‐diversity was higher in the CB, SBP, and SH groups than in the WB and OB groups ( P < 0.05). At the phylum level, OB and WB fermentation showed lower ( P < 0.05) relative abundance of Actinobacteria than the CB, SBP, and SH groups. At the genus level, OB and WB fermentation increased the Enterococcus population in comparison with the CB, SBP, and SH groups, whereas CB and SBP fermentation improved the relative abundance of the Christensenellaceae R‐7 group more than the WB, OB, and SH groups ( P < 0.05). CONCLUSION Overall, WB and OB were rapidly fermented by fecal microbiota, in contrast with SBP, SH, and CB. Fermentation of different fiber‐rich co‐products with an equal TDF content gives different responses in terms of microbial composition and SCFA production due to variations in their physicochemical properties and molecular structure. © 2020 Society of Chemical Industry

Bai, Yu↗

DOE OSTI2020

Structure, properties, and applications of polyacrylonitrile/carbon nanotube ( CNT ) fibers at low CNT loading

Abstract Bi‐component, polyacrylonitrile (PAN)/carbon nanotube (CNT) fibers were processed, at different core‐sheath area ratios, by gel spinning. A percolated CNT network at 10 wt% CNT in the sheath enhanced electrical conductivity as compared to the neat PAN fiber, while PAN polymer in the core contributed to the good mechanical properties. Fibers with relatively thin sheath allowed overall CNT loading as low as 3.7 wt% to be made with good electrical conductivity, and PAN stabilization by Joule heating was demonstrated. Such fibers with combined good mechanical properties and electrical conductivity can also potentially be used for electrical heating of fabrics, for making smart textiles, and for electromagnetic interference shielding.

Lu, Mingxuan↗

DOE OSTI2020

Mechanical Characterization of High-Temperature Carbon Fiber-Polyphenylene Sulfide Composites for Large Area Extrusion Deposition Additive Manufacturing

Additive manufacturing (AM) is evolving from rapid prototyping to production of structural components. The widespread application of AM demands a high level of mechanical performance from these components, and it is therefore essential to improve feedstock material in order to meet these mechanical expectations. However, compared to traditional manufacturing techniques, the mechanical properties of AM materials and their resulting components are not well understood. In this study, we investigated the processability, microstructure, and mechanical performance of twin-screw compounded short carbon fiber reinforced polyphenylene sulfide (PPS) pellets as a feedstock material for big area AM (BAAM). The performance of the AM components was compared to that of traditional processing methods, namely injection molding (IM) and extrusion-compression molding (ECM). It was found that the AM composites exhibited 118% lower tensile strength and 55% lower tensile modulus when compared to traditional injection molding composite specimens; however, AM composites exhibited comparable properties to ECM composites. This response was attributed to highly aligned fibers in IM and AM samples. However, the AM composites contained porosity (15.5% volume), which reduced their mechanical properties in comparison to ECM composites. Finally, the IM process showed the maximum amount of fiber attrition with minimum porosity (0.007% volume), while the ECM process exhibited the least fiber attrition with 4.3% volume porosity.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Functional fiber-optic sensors embedded in stainless steel components using ultrasonic additive manufacturing for distributed temperature and strain measurements

The nuclear industry is progressing toward microreactors that can be factory assembled and deployed to remote regions for reliable, scalable power generation. However, the reduced power output requires enhanced monitoring capabilities to reduce staffing and eventually move toward autonomous control to improve the economics of microreactors. The ability to embed sensors such as fiber-optics, which can provide spatially distributed temperature and strain measurements, within microreactor components for real-time health monitoring would be particularly advantageous. Recent advances in ultrasonic additive manufacturing (UAM) have demonstrated the successful embedding of fiber-optics in soft materials such as Al and Cu by placing the sensors in machined cavities and ultrasonically welding over the top with thin foils. This article reports the first successful embedment of fiber-optic sensors and thermocouples within a common nuclear reactor material, SS304, via UAM. UAM parameters were first explored with simple plate geometries before moving to more complex geometries, such as pipes and other test articles for heat pipe–based microreactors. Select samples were sectioned for microscopy to evaluate the sensor/foil and foil/foil interfaces from samples fabricated by using 100% SS304 foils vs. foils plated with a Ni coating to improve UAM bonding. Furthermore, embedding metal-coated, low-bend loss fibers resulted in greatly reduced signal attenuation and adequate compressive residual strain in the embedded region to ensure successful strain coupling. Pipe specimen functional testing was performed by monitoring temperature and strain during transient and steady-state thermal testing.

36 MATERIALS SCIENCE↗