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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Multiscale mechanical design of the lightweight, stiff, and damage-tolerant cuttlebone: A computational study

Cuttlebone, the endoskeleton of cuttlefish, offers an intriguing biological structural model for designing low-density cellular ceramics with high stiffness and damage tolerance. Cuttlebone is highly porous (porosity ~93%) and lightweight (density less than 20% of seawater), constructed mainly by brittle aragonite (95 wt%), but capable of sustaining hydrostatic water pressures over 20 atmospheres and exhibits energy absorption capability under compression comparable to many metallic foams (~4.4 kJ/kg). Here, in this work, we computationally investigate how such remarkable mechanical efficiency is enabled by the multiscale structure of cuttlebone. Using the common cuttlefish, Sepia Officinalis, as a model system, we first conducted high-resolution synchrotron micro-computed tomography (µ-CT) and quantified the cuttlebone's multiscale geometry, including the 3D asymmetric shape of individual walls, the wall assembly patterns, and the long-range structural gradient of walls across the entire cuttlebone (ca. 38 chambers). The acquired 3D structural information enables systematic finite-element simulations, which further reveal the multiscale mechanical design of cuttlebone: at the wall level, wall asymmetry provides optimized energy absorption while maintaining high structural stiffness; at the chamber level, variation of walls (number, pattern, and waviness amplitude) contributes to progressive damage; at the entire skeletal level, the gradient of chamber heights tailors the local mechanical anisotropy of the cuttlebone for reduced stress concentration. Our results provide integrated insights into understanding the cuttlebone's multiscale mechanical design and provide useful knowledge for the designs of lightweight cellular ceramics.

36 MATERIALS SCIENCE↗
NASA NTRS1973

The calculation of proportional counter energy-deposition spectra from experimental data.

The experimental approach considered requires the measurement of energy-absorption distributions for a set of pathlengths which define a biological volume. A suitable folding procedure is necessary to produce composite energy-absorption distributions. The investigation is concerned with the quality of the prediction of energy-deposition distributions, taking into account distributions measured with a proportional counter.

Steigerwalt, J. E.↗
DOE OSTI2023

Quasi-Floquet Prethermalization in a Disordered Dipolar Spin Ensemble in Diamond

Floquet (periodic) driving has recently emerged as a powerful technique for engineering quantum systems and realizing nonequilibrium phases of matter. A central challenge to stabilizing quantum phenomena in such systems is the need to prevent energy absorption from the driving field. Fortunately, when the frequency of the drive is significantly larger than the local energy scales of the many-body system, energy absorption is suppressed. The existence of this so-called prethermal regime depends sensitively on the range of interactions and the presence of multiple driving frequencies. Here, we report the observation of Floquet prethermalization in a strongly interacting dipolar spin ensemble in diamond, where the angular dependence of the dipolar coupling helps to mitigate the long-ranged nature of the interaction. Moreover, we extend our experimental observation to quasi-Floquet drives with multiple incommensurate frequencies. In contrast to a single-frequency drive, we find that the existence of prethermalization is extremely sensitive to the smoothness of the applied field. In conclusion, our results open the door to stabilizing and characterizing nonequilibrium phenomena in quasiperiodically driven systems.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Low-velocity repeated impact behaviors of Polymer Fiber Reinforced Plastics (PFRPs)

Modern fiber-reinforced composites have become ubiquitous across multiple industries due to their excellent weight-to-strength ratio. Typically glass or carbon fibers are widely used. While Glass or Carbon Fiber-Reinforced Plastics (GFPRs or CFPRs) have good stiffness, strength, and fatigue life, they are expensive and difficult to recycle. Researchers are exploring Polymer Fiber-Reinforced Plastics (PFRPs) as an alternative solution. PFRPs utilize polymer fibers and a polymer matrix. A wide range of materials options is available, including low-cost thermoplastics such as polyethylene or polypropylene. These thermoplastics are easy to handle and recyclable without special methods. Manufacturing parts using thermoplastics are well-established as well. However, their mechanical performances have not been extensively studied compared to GFRPs or CFRPs. This study examines the low-velocity impact resistance of PFRPs made of different thermoplastics. The low-velocity impacts are applied through a drop-weight tower. The experiment is divided into two cases: a single perforation impact and low-energy repeated impacts. Energy absorption and the number of impacts to failure are measured. The results are compared to traditional CFRPs which have a thermoset matrix. The PFRPs demonstrate energy absorption capabilities comparable to or greater than those of CFRPs with respect to specimen thickness and density. Additionally, the PFRPs show significantly higher impacts-to-failure than the CFRPs in low-energy repeated impact tests. This is particularly noteworthy considering that the PFRPs are much simpler and more economical to manufacture than CFRPs. To further

Ko, Seunghyun↗
DOE OSTI2024

Non-Rare Earth Magnesium Bumper Beams

Magna will team with the Pacific Northwest National Laboratory (PNNL) to develop Shear Assisted Processing and Extrusion (ShAPE™) of rectangular and multi-zoned extrusion profiles using non-RE Mg. It is envisioned that the ShAPE™ process, developed during this project for non-circular profiles, will serve as the foundation for fabrication of full-scale bumper beams of the future where near net-shapes are extruded directly from castings in a single step, without the need for costly rare earth additives. In this project, the ShAPE™ process will be developed for a rectangular profile measuring 1” x 2” with a 0.06” wall thickness. Successful extrusion of rectangular cross sections is a critical step along the path toward profiles with multiple zones. With the process established for a rectangular profile, the project will then make advancements toward multi-zoned cross sections. A magnesium alloy bumper beam offers a 35% weight savings compared to aluminum alloys and 60% compared to high strength steels. The bumper beam was chosen as the first component to target because the geometry can have a fairly simple 0.6-0.12 inch wall/web thickness, generally compatible with PNNL’s knowledge base and equipment capability surrounding ShAPE™. The bumper component offers commercial value by providing mass reduction in the front of the vehicle along with ride and handling benefit. PNNL has demonstrated the ability to ShAPE™ process non-RE Mg tubing with high strength, ductility and energy absorption. It has been shown that ShAPE™ extruded ZK60 and Mg2Si tubing with 0.30 inch diameter and 0.03 inch wall thickness have similar energy absorption to AA6061-T6. This is due to significant grain refinement, breakdown and dispersion of second phases, and the ability to eliminate anisotropy in compressive/tensile strength by aligning texture 45 degrees to the extrusion axis. Scalability of the ShAPE™ process has been demonstrated in ZK60 by fabricating 2.0 inch diameter tubing with 0.06 and 0.12 inch wall thicknesses having concentricity as tight as 1.3%. These tubes exhibit an ultimate tensile strength of 260-300 MPa and room temperature ductility of >20% parallel, perpendicular and 45 degrees to the extrusion axis. Aluminum bumpers represent approximately 54% of the NA light vehicle market. If the research effort is successful, providing a 30% mass reduction at equal cost relative to aluminum bumpers, it is anticipated that 25% market penetration would be realized over the next 5 year and 50% market share by 2030. 100% of the aluminum automotive bumpers are sourced from the tier network, providing resourcing opportunity based on equal performance, reduced mass and cost equivalent lower than aluminum bumpers. Due to the relatively low vehicle content, magnesium components are currently shredded and 100% recycled with aluminum content in the US, presenting a positive life cycle impact.

42 ENGINEERING↗
DOE OSTI2024

Attosecond Probing of Coherent Vibrational Dynamics in CBr 4

A coherent vibrational wavepacket is launched and manipulated in the symmetric stretch (a1) mode of CBr 4 , by impulsive stimulated Raman scattering (ISRS) from nonresonant 400 nm laser pump pulses with various peak intensities on the order of tens of 10 12 W/cm 2 . Extreme ultraviolet (XUV) attosecond transient absorption spectroscopy (ATAS) records the wavepacket dynamics as temporal oscillations in XUV absorption energy at the bromine M 4,5 3d 3/2,5/2 edges around 70 eV. The results are augmented by nuclear timedependent Schrödinger equation simulations. Slopes of the (Br 3d 3/2,5/2 ) –1 10a 1 * core-excited state potential energy surface (PES) along the a 1 mode are calculated to be –9.4 eV/Å from restricted open-shell Kohn–Sham calculations. Using analytical relations derived for the small-displacement limit and the calculated slopes of the core-excited state PES, a deeper insight into the vibrational dynamics is obtained by retrieving the experimental excursion amplitude of the vibrational wavepacket and the amount of population transferred to the vibrational first-excited state as a function of pump-pulse peak intensity. Experimentally, the results show that XUV ATAS is capable of resolving oscillations in the XUV absorption energy on the order of a few to tens of meV with tens of femtosecond time precision. This corresponds to change in C–Br bond length on the order of 10 –4 to 10 –3 Å. The results and the analytic relationships offer a clear physical picture, on multiple levels of understanding, of how the pump-pulse peak intensity controls the vibrational dynamics launched by nonresonant ISRS in the small-displacement limit.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Deep learning approaches for instantaneous laser absorptance prediction in additive manufacturing

Abstract The quantification of absorbed light is essential for understanding laser-material interactions and melt pool dynamics in order to minimize defects in additively manufactured metal components. The geometry of a vapor depression formed during laser melting is closely related to laser energy absorption. This relationship has been observed by the state-of-the-art in situ high-speed synchrotron X-ray visualization and integrating sphere radiometry. These two techniques create a temporally resolved dataset consisting of vapor depression images and corresponding laser absorptance. In this work, we propose two different approaches to predict instantaneous laser absorptance. The end-to-end approach uses deep convolutional neural networks to learn implicit features of X-ray images automatically and predict the laser energy absorptance. The two-stage approach uses a semantic segmentation model to engineer geometric features and predict absorptance using classical regression models. While having distinct advantages, both approaches achieved a consistently low mean absolute error of less than 3.3%.

Chemistry↗
NASA NTRS1977

Thermal environment effects on strength and impact properties of boron-aluminum composites

Thermal effects on fracture strength and impact energy were studied in 50 volume percent unidirectional composites of 143 and 203 micron boron fibers in 6061 and 1100 aluminum matrices. For 6061 matrix composites, strength was maintained to approximately 400 C in the cyclic tests and higher than 400 C in the static tests. For the 1100 matrix composites, strength degradation appeared near 260 C after cycling and higher than 260 C in static heating. This composite strength degradation is explained by a fiber degradation mechanism resulting from a boron-aluminum interface reaction. The impact energy absorption degraded significantly only above 400 C for both matrix alloys. Thus, while impact loss for the 6061 composite correlates with the fiber strength loss, other energy absorption processes appear to extend the impact resistance of the 1100 matrix composites to temperatures beyond where its strength is degraded. Interrupted impact tests on as-received and thermally cycled composites define the range of load over which the fibers break in the impact event.

Grimes, H. H.↗
NASA NTRS1976

General aviation crash safety program at Langley Research Center

The purpose of the crash safety program is to support development of the technology to define and demonstrate new structural concepts for improved crash safety and occupant survivability in general aviation aircraft. The program involves three basic areas of research: full-scale crash simulation testing, nonlinear structural analyses necessary to predict failure modes and collapse mechanisms of the vehicle, and evaluation of energy absorption concepts for specific component design. Both analytical and experimental methods are being used to develop expertise in these areas. Analyses include both simplified procedures for estimating energy absorption capabilities and more complex computer programs for analysis of general airframe response. Full-scale tests of typical structures as well as tests on structural components are being used to verify the analyses and to demonstrate improved design concepts.

Thomson, R. G.↗
NASA NTRS2024

Improved Mechanical Performance in FDM Cellular Frame Structures through Partial Incorporation of Faces

The utilization of lattice-type cellular architectures has seen a significant increase, owing to their predictable shape and the ability to fabricate templated porous materials through low-cost 3D-printing methods. Frames based on atomic lattice structures such as face-centered cubic (FCC), body-centered cubic (BCC), or simple cubic (SC) have been utilized. In FDM, the mechanical performance has been impeded by stress concentration at the nodes and melt-solidification interfaces arising from layer-by-layer deposition. Adding plates to the frames has resulted in improvements with a concurrent increase in weight and hot-pocket-induced dimensional impact in the closed cells formed. In this paper, we explore compressive performance from the partial addition of plates to the frames of a SC-BCC lattice. Compression testing of both single unit cells and 4 × 4 × 4 lattices in all three axial directions is conducted to examine stress transfer to the nearest neighbor and assess scale-up stress transfer. Our findings reveal that hybrid lattice structure unit cells exhibit significantly improved modulus in the range of 125% to 393%, specific modulus in the range of 13% to 120%, and energy absorption in the range of 17% to 395% over the open lattice. The scaled-up lattice modulus increased by 8% to 400%, specific modulus by 2% to 107%, and energy absorption by 37% to 553% over the lattice frame. Parameters that emerged as key to improved lightweighting.

FDM↗
DOE OSTI2023

Experimental and Numerical Investigations on Dynamic Mechanical Properties of TPMS Structures

Triply Periodic Minimal Surface (TPMS) lattice structures have been of increasing interest due to their light weighting, enhanced mechanical properties, and energy absorption characteristics for automotive and biomedical applications. With the advent of additive manufacturing and geometric modeling software, TPMS lattices with complex geometries can be realized. In this work, TPMS lattice structures were fabricated with PLA using fused filament fabrication (FFF) and their dynamic properties are characterized through drop tower experiments. Although lightweight TPMS lattices are beneficial for their impact absorption capability, most of the existing works are limited to quasi-static compression and dynamic impact tests are rarely performed. The current study investigates the stress-strain and energy absorption characteristics of TPMS lattices through drop tower testing and numerical modeling. Finite element modeling for TPMS lattices is carried out to validate the experimental responses. The mechanical properties, deformation, and failure mechanisms of TPMS lattices under dynamic impact are summarized for potential future applications.

Pokkalla, Deepak↗
DOE OSTI2020

Mechanical design of the highly porous cuttlebone: A bioceramic hard buoyancy tank for cuttlefish

Cuttlefish, a unique group of marine mollusks, produces an internal biomineralized shell, known as cuttlebone, which is an ultra-lightweight cellular structure (porosity, ~93 vol%) used as the animal’s hard buoyancy tank. Although cuttlebone is primarily composed of a brittle mineral, aragonite, the structure is highly damage tolerant and can withstand water pressure of about 20 atmospheres (atm) for the species Sepia officinalis . Currently, our knowledge on the structural origins for cuttlebone’s remarkable mechanical performance is limited. Combining quantitative three-dimensional (3D) structural characterization, four-dimensional (4D) mechanical analysis, digital image correlation, and parametric simulations, here we reveal that the characteristic chambered “wall–septa” microstructure of cuttlebone, drastically distinct from other natural or engineering cellular solids, allows for simultaneous high specific stiffness (8.4 MN∙m/kg) and energy absorption (4.4 kJ/kg) upon loading. We demonstrate that the vertical walls in the chambered cuttlebone microstructure have evolved an optimal waviness gradient, which leads to compression-dominant deformation and asymmetric wall fracture, accomplishing both high stiffness and high energy absorption. Moreover, the distribution of walls is found to reduce stress concentrations within the horizontal septa, facilitating a larger chamber crushing stress and a more significant densification. Overall, the design strategies revealed here can provide important lessons for the development of low-density, stiff, and damage-tolerant cellular ceramics.

42 ENGINEERING↗
NASA NTRSDate not supplied

Lunar Lander Landing Modeling and Simulation in Simscape

The landing gear is a critical subsystem of a lander for a successful landing on the moon or a planet. During a landing event, structural loading, energy absorption and toppling stability are important factors for the landing gear development. These aspects can be studied using simulations. The landing gear comprising the primary struct, secondary structs, footpad, and joints, is easily modeled using Simscape Multibody toolbox. The energy absorption mechanisms in the structs is readily modeled using Simulink and Multibody blocks based on the relative motions of the inner and outer cylinder of the structures. During touchdown, the footpads strike the lunar surface, and the contact forces can be modeled including the soil mechanical properties. Slosh dynamics are included using a mechanical pendulum model. Tip-over controllers are developed using Simulink blocks and toolboxes. This model was intensively tested manually then additionally with Monte Carlo simulation. It offers the opportunity for landing stability study, i.e. the max slope a lander can land without tipping over in 3D realistic landing situations.

Wei Wu↗
DOE OSTI2024

Elastic wave suppression through additively manufactured petal lattice metamaterials

Lattice-core sandwich structure metamaterials are lightweight alternatives to monolithic materials that can present better mechanical, thermal, and energy dampening performance. Manufacturing lattice metamaterials to follow curved surfaces can pose a challenge, as the lattices rely on their geometric orientation to the substrate for their mechanical properties. This work rationally designed a lattice structure where the surface is broken up into “petals” connected to the underlying lattice, which localizes the petals’ impact response. This design opens a pathway for implementation of lattice-core sandwich structures onto complex surface geometries. These petal structures were evaluated for their energy absorption efficiency experimentally by utilizing pressure waves generated with nanosecond lasers and computationally via finite element modeling. The lattice structures exhibited a two-orders-of-magnitude decrease in transmitted pressure compared to their constituent steel at equivalent mass. Furthermore, localizing energy absorption into petal structures provided a 44% reduction in peak load compared to a continuous “single-petal” design.

Sarracino, Alex↗
NASA NTRSDate not supplied

Modeling and Characterization of Crushable Composite Structures

The crushing response and the energy absorption capacity of a quasi-isotropic C-shaped composite panel is presented to simulate the progressive damage and failure mechanisms involved in the component testing. Crushable composite structures are widely used for impact applications, as because of their great high-energy absorption capability and lower weight. Simulating the crush characteristics of composite structures is challenging, as the conventional tools fail to accurately represent the failure mechanisms at the component level. Here, a cost-effective predictive tool ‘CZone’ is applied for simulating the crushing response of composite materials. CZone for Abaqus (CZA) is an add-on capability for Abaqus/Explicit and combines with the commercially available impact modeling capabilities included within the Abaqus finite element software package.

crush zone↗
DOE OSTI2020

Crushing behaviors of unidirectional carbon fiber reinforced plastic composites under dynamic bending and axial crushing loading

The dynamic crushing characteristics of unidirectional carbon fiber reinforced plastic composites under two loading types, dynamic three-point bending and axial crushing, are investigated by experiment and finite element simulation. Hat section samples with two different layup orientations are tested at various impact velocities to investigate its effects. The experiment results show that delamination plays a critical role in dynamic bending deformation. Different layup orientations lead to similar crushing bending behaviors, but remarkable variations in delamination pattern evolutions. In contrast, layup orientation exerts more significant effects on failure modes and energy absorption in axial crushing. A finite element model with multiple layers of thick shell element and cohesive element is established, and simulations are performed for both dynamic three-point bending and axial crushing. The model can capture the crushing behaviors in the two loading types reasonably well. The damage evolution and energy absorption through various mechanisms at different loading conditions are discussed.

42 ENGINEERING↗
NASA NTRS1980

Impact penetration studies of graphite/epoxy laminates

A study was conducted to provide an initial insight into the role of the matrix in impact energy absorption of graphite/epoxy laminates. A single epoxy system, NARMCO 5208, in both composite and cured neat-resin form was studied with a constant velocity impact test apparatus. The parameters investigated include resin cure temperature, fiber type, ply thickness and orientation, and impact velocity. The results from the study show that matrix chemistry, as obtained by cure temperature changes, has a significant effect upon the failure mode and energy absorption during impact.

Sykes, G. F.↗
NASA NTRS1991

Effects of floor location on response of composite fuselage frames

Experimental and analytical results are presented which show the effect of floor placement on the structural response and strength of circular fuselage frames constructed of graphite-epoxy composite material. The research was conducted to study the behavior of conventionally designed advanced composite aircraft components. To achieve desired new designs which incorporate improved energy absorption capabilities requires an understanding of how these conventional designs behave under crash type loadings. Data are presented on the static behavior of the composite structure through photographs of the frame specimen, experimental strain distributions, and through analytical data from composite structural models. An understanding of this behavior can aid dynamist in predicting the crash behavior of these structures and may assist the designer achieve improved designs for energy absorption and crash behavior of future structures.

Carden, Huey D.↗