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At least 127 records · Page 7

All sources NASA NTRS DOE OSTI

DOE OSTI2022

Mapping 3D grain and precipitate structure during in situ mechanical testing of open-cell metal foam using micro-computed tomography and high-energy X-ray diffraction microscopy

Open-cell metal foams are ultra-low-density cellular metals with complex hierarchical structures that span bulk, cell, ligament, and sub-ligament scales and give rise to desirable properties such as high strength-to-weight ratio and excellent energy absorption. Although literature suggests that intrinsic material structures at sub-ligament length scales (e.g., grains and precipitates) play an important role in mechanical behavior of open-cell metal foams, there are very few experimental measurements of such structures in three dimensions and for meaningful volumes of foam. This study seeks to map and track the three-dimensional (3D) grain and precipitate structures of an intact volume of open-cell aluminum foam by advancing microstructural characterization techniques that leverage X-ray micro-computed tomography (μCT) and far-field high-energy X-ray diffraction microscopy (FF-HEDM). A 6%-relative-density aluminum foam sample was mechanically tested in compression while μCT and FF-HEDM measurements were collected at interrupted loading states at beamline 1-ID of the Advanced Photon Source. Further, a new scanning strategy and reconstruction algorithm were established to enable characterization of a foam volume with diameter approximately four times wider than the nominal width of the X-ray beam. The result is a set of maps that detail both the 3D grain and precipitate structures throughout the foam volume at successive strain steps. A novel grain tracking procedure was developed to track individual grains within the foam volume by accounting for the large rigid-body motions that individual ligaments can undergo during mechanical loading. The ability to track grains and precipitate structures in three dimensions throughout large bulk deformation of ultra-low-density polycrystalline materials enables new possibilities for validating numerical models and investigating local failure mechanisms. Furthermore, the methods and procedures developed in this study could be applied to other ultra-low-density structures, such as additively manufactured lattices.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Comparison of Single-Phase Convection in Additive Manufactured Versus Traditional Metal Foams

Abstract Metal foams have been often used for thermal management due to their favorable characteristics including high specific surface area (SSA), high thermal conductivity, and low relative density. However, they are accompanied by shortcomings including the significant contact resistances due to attachment method, as well as the need for characterization of foam parameters such as pore diameter and SSA. Additive manufactured (AM) metal foams would eliminate the substrate/foam thermal resistance, decrease the need for pre-usage characterization, and allow for tailoring structures, while also taking advantage of the characteristics of traditionally manufactured foams. A commercial, aluminum foam (nominally 5 pores per inch (PPI), 86.5% porosity) was analyzed using X-ray microcomputed tomography, and a custom-designed metal foam based on the cell diameter and porosity of the commercial sample was subsequently manufactured. Reduced domain computational fluid dynamics/heat transfer (CFD-HT) models were compared against experimental data. Postvalidation, the flow behavior, effect of varying attachment thermal conductivities, and thermal performance were numerically investigated, demonstrating the usefulness of validated pore-scale models, as well as the potential for improved performance using AM metal foams over traditionally manufactured foams.

Engineering↗

DOE OSTI2024

Enhancement of the Physical and Mechanical Properties of Cellulose Nanofibril-Reinforced Lignocellulosic Foams for Packaging and Building Applications

Biobased foams have the potential to serve as eco-friendly alternatives to petroleum-based foams, provided they achieve comparable thermomechanical and physical properties. We propose a facile approach to fabricate eco-friendly cellulose nanofibril (CNF)-reinforced thermomechanical pulp (TMP) fiber-based foams via an oven-drying process with thermal conductivity as low as 0.036 W/(m·K) at a 34.4 kg/m3 density. Acrodur®, iron chloride (FeCl3), and cationic polyacrylamide (CPAM) were used to improve the foam properties. Acrodur® did not have any significant effect on the foamability and density of the foams. Mechanical, thermal, cushioning, and water absorption properties of the foams were dependent on the density and interactions of the additives with the fibers. Due to their high density, foams with CPAM and FeCl3 at a 1% additive dosage had significantly higher compressive properties at the expense of slightly higher thermal conductivity. There was slight increase in compressive properties with the addition of Acrodur®. All additives improved the water stability of the foams, rendering them stable even after 24 h of water absorption.

Chemistry↗

NASA NTRS1996

Final Report: Research Study on Development of Environmental Friendly Spray-on Foam Insulation (SOFI) for the External Tank (ET)

The selection and quantification of four foams using a more environmentally friendly HCFC-141b blowing agent replacing foams that used the CFC-11 blowing agent for the external tank (ET) LWT has been addressed along with problems and solutions that were encountered during verification. The effort on two lower density spray foams for the ET SLWT are presented, but predicted weight savings were not encouraging. Suggestions for possible problem solving are included along with a new approach for selecting foams for qualification as back-up foams for the foams used on the ET LWT. We investigated three resins for use as thermally sprayed coatings for corrosion prevention on metal. The best coating was obtained with a thermoplastic polyimide resin. This coating has a good chance of meeting ET requirements. Possible third generation blowing agents have been shown usable in polyurethane spray and pour foams, and solubility in isocyannate foam components are acceptable. We considered aerogels as insulation materials on space vehicles, and suggested a liner for a liquid oxygen (LOX) composite tank.

Stuckey, James M.↗

NASA NTRS1999

Rheology of Foam Near the Order-Disorder Phase Transition

Foams are extremely important in a variety of industrial applications. Foams are widely used in fire-fighting applications, and are especially effective in fighting flammable liquid fires. In fact the Fire Suppression System aboard the Space Shuttle utilizes cylinders of Halon foam, which, when fired, force a rapidly expanding foam into the convoluted spaces behind instrument panels. Foams are critical in the process of enhanced oil recovery, due to their surface-active and highly viscous nature. They are also used as drilling fluids in underpressurized geologic formations. They are used as transport agents, and as trapping agents. They are also used as separation agents, where ore refinement is accomplished by froth flotation of the typically lighter and hydrophobic contaminants. The goal of the proposed investigation is the determination of the mechanical and rheological properties of foams, utilizing the microgravity environment to explore foam rheology for foams which cannot exist, or only exist for a short time, in 1g.

Holt, R. Glynn↗

NASA NTRS2004

Vibration Characteristics Determined for Stainless Steel Sandwich Panels With a Metal Foam Core for Lightweight Fan Blade Design

The goal of this project at the NASA Glenn Research Center is to provide fan materials that are safer, weigh less, and cost less than the currently used titanium alloy or polymer matrix composite fans. The proposed material system is a sandwich fan construction made up of thin solid face sheets and a lightweight metal foam core. The stiffness of the sandwich structure is increased by separating the two face sheets by the foam layer. The resulting structure has a high stiffness and lighter weight in comparison to the solid facesheet material alone. The face sheets carry the applied in-plane and bending loads (ref. 1). The metal foam core must resist the transverse shear and transverse normal loads, as well as keep the facings supported and working as a single unit. Metal foams have ranges of mechanical properties, such as light weight, impact resistance, and vibration suppression (ref. 2), which makes them more suitable for use in lightweight fan structures. Metal foams have been available for decades (refs. 3 and 4), but the difficulties in the original processes and high costs have prevented their widespread use. However, advances in production techniques and cost reduction have created a new interest in this class of materials (ref. 5). The material chosen for the face sheet and the metal foam for this study was the aerospace-grade stainless steel 17-4PH. This steel was chosen because of its attractive mechanical properties and the ease with which it can be made through the powder metallurgy process (ref. 6). The advantages of a metal foam core, in comparison to a typical honeycomb core, are material isotropy and the ease of forming complex geometries, such as fan blades. A section of a 17-4PH sandwich structure is shown in the following photograph. Part of process of designing any blade is to determine the natural frequencies of the particular blade shape. A designer needs to predict the resonance frequencies of a new blade design to properly identify a useful operating range. Operating a blade at or near the resonance frequencies leads to high-cycle fatigue, which ultimately limits the blade's durability and life. So the aim of this study is to determine the variation of the resonance frequencies for an idealized sandwich blade as a function of its face-sheet thickness, core thickness, and foam density. The finite element method is used to determine the natural frequencies for an idealized rectangular sandwich blade. The proven Lanczos method (ref. 7) is used in the study to extract the natural frequency.

Ghosn, Louis J.↗

NASA NTRS2006

Atomic Oxygen Exposure of Polyimide Foam for International Space Station Solar Array Wing Blanket Box

Onorbit photos of the International Space Station (ISS) solar array blanket box foam pad assembly indicate degradation of the Kapton film covering the foam, leading to atomic oxygen (AO) exposure of the foam. The purpose of this test was to determine the magnitude of particulate generation caused by low-Earth orbital environment exposure of the foam and also by compression of the foam during solar array wing retraction. The polyimide foam used in the ISS solar array wing blanket box assembly is susceptible to significant AO erosion. The foam sample in this test lost one-third of its mass after exposure to the equivalent of 22 mo onorbit. Some particulate was generated by exposure to simulated orbital conditions and the simulated solar array retraction (compression test). However, onorbit, these particles would also be eroded by AO. The captured particles were generally <1 mm, and the particles shaken free of the sample had a maximum size of 4 mm. The foam sample maintained integrity after a compression load of 2.5 psi.

Finckenor, M. M.↗

NASA NTRS2006

Crack Initiation and Growth in Rigid Polymeric Closed-Cell Foam Cryogenic Applications

Cryogenic vessels, such as the Space Shuttle External Tank, are often insulated with closed-cell foam because of its low thermal conductivity. The coefficient of thermal expansion mismatch between the foam and metallic substrate places the foam under a biaxial tension gradient through the foam thickness. The total foam thickness affects the slope of the stress gradient and is considered a significant contributor to the initiation of subsurface cracks. Rigid polymeric foams are brittle in nature and any subsurface cracks tend to propagate a finite distance toward the surface. This presentation investigates the relationship between foam thickness and crack initiation and subsequent crack growth, using linear elastic fracture mechanics, in a rigid polymeric closed-cell foam through analysis and comparison with experimental results.

Sayyah, Tarek↗

NASA NTRS2006

Thermal Expansion of Polyurethane Foam

Closed cell foams are often used for thermal insulation. In the case of the Space Shuttle, the External Tank uses several thermal protection systems to maintain the temperature of the cryogenic fuels. A few of these systems are polyurethane, closed cell foams. In an attempt to better understand the foam behavior on the tank, we are in the process of developing and improving thermal-mechanical models for the foams. These models will start at the microstructural level and progress to the overall structural behavior of the foams on the tank. One of the key properties for model characterization and verification is thermal expansion. Since the foam is not a material, but a structure, the modeling of the expansion is complex. It is also exacerbated by the anisoptropy of the material. During the spraying and foaming process, the cells become elongated in the rise direction and this imparts different properties in the rise direction than in the transverse directions. Our approach is to treat the foam as a two part structure consisting of the polymeric cell structure and the gas inside the cells. The polymeric skeleton has a thermal expansion of its own which is derived from the basic polymer chemistry. However, a major contributor to the thermal expansion is the volume change associated with the gas inside of the closed cells. As this gas expands it exerts pressure on the cell walls and changes the shape and size of the cells. The amount that this occurs depends on the elastic and viscoplastic properties of the polymer skeleton. The more compliant the polymeric skeleton, the more influence the gas pressure has on the expansion. An additional influence on the expansion process is that the polymeric skeleton begins to breakdown at elevated temperatures and releases additional gas species into the cell interiors, adding to the gas pressure. The fact that this is such a complex process makes thermal expansion ideal for testing the models. This report focuses on the thermal expansion tests and the response of the microstructure. A novel optical method is described which is appropriate for measuring thermal expansion at high temperatures without influencing the thermal expansion measurement. Detailed microstructural investigations will also be described which show cell expansion as a function of temperature. Finally, a phenomenological model on thermal expansion will be described.

Lerch, Bradley A.↗

DOE OSTI2020

Solvent depression of transition temperature to selectively stimulate actuation of shape memory polymer foams

An embodiment of the invention is a shape memory polymer (SMP) foam designed to recover its original shape through exposure to a solvent. Thermo-responsive SMPs are polymers designed to maintain a programmed secondary shape until heated above their transition temperature, upon which the polymer recovers its original, or primary, shape. The thermo-responsive SMP foam is programmed to its secondary shape prior to use, typically compression of the foam to a small volume, and remains in this programmed shape until exposed to a selected solvent such as dimethyl sulfoxide or ethyl alcohol. Upon exposure to the solvent, the transition temperature of the SMP foam decreases below the temperature of the environment and the SMP foam actuates to its primary shape. The SMP foam is tailored to actuate upon exposure to specific solvents while minimizing or preventing actuation when exposed to water or other solvents. This selective solvent actuation can be used to increase working time of a SMP foam device, that is, the time allowed for use of a device without undesired actuation, while maintaining functional SMP actuation. Solvent actuated SMP foams can be used in various applications including, but not limited to, treatment of aneurysms and arterio-venous malformations, tissue engineering, and wound healing.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Study on Foam Fracturing of Granite for the Development of Enhanced Geothermal Systems

Foam fracturing has been considered as a potential technical approach to address water concerns with hydraulic stimulation in the development of enhanced geothermal systems (EGS). This paper reports the recent progress of a project sponsored by the U.S. DOE GTO Waterless Stimulation Initiative. The project investigates the foam fracturing as an alternative approach to the hydraulic fracturing. The paper describes the development of foam fracturing testing system at Oak Ridge National Laboratory (ORNL). The system can be used to perform the hydraulic fracturing of rock-like materials with both water and foamed fluids under pressure to 6,000 psi (41.4 MPa). The system features the sections of foam generation and foam injection and has the capability of testing materials in both monotonic and cyclic injection modes.Experimental results of foam fracturing on Charcoal Black granite will be reported. Cylindrical granite specimens with a blind hole were studied along with water and nitrogen-gas-in-water foam as the fracturing fluids. The effects of fracturing fluids and injection modes on the breakdown pressure and failure responses of the material were examined. The observations from the experimental work and the implications to the EGS application will be presented and discussed.

Wang, Hong↗

DOE OSTI2021

Solvent depression of transition temperature to selectively stimulate actuation of shape memory polymer foams

Boyle, Anthony↗

DOE OSTI2025

Use of Captured CO2 for Production of Sustainable Polyurethane Foams in Automotive Applications

Captured CO2 has been investigated as a feedstock for the production of polyurethane (PU) foams for automotive applications. Previous work has shown successful incorporation of CO2 into polyols via three distinct reaction pathways. These CO2-derived polyols, as well as several commercially available polyols with varying CO2 content, were used to produce PU foams for automotive seating and NVH (noise, vibration, and harshness) applications. Foam formulations were optimized to maximize sustainable content while maintaining manufacturability constraints and performance requirements for each end use application. PU foams were first formulated at lab scale to confirm free rise and molded foam properties, then scaled up to pilot and industrial scales to evaluate production manufacturing feasibility. Finally, CO2-derived foams were used to produce molded components for end use product validation. Life cycle assessment (LCA) was used to quantify the environmental impact of using captured CO2 and bio-renewable content into polyols and PU foams through the metrics of global warming potential and embodied energy. Tradeoffs among environmental impacts, energy usage, manufacturability, and PU foam performance from the incorporation of CO2 and bio-renewable content will be discussed.

Lee, Ellen [Ford Motor Company]↗

DOE OSTI2021

Anisotropy evolution of elastomeric foams during uniaxial compression measured via in-situ X-ray computed tomography

We have characterized the three-dimensional evolution of microstructural anisotropy of a family of elastomeric foams during uniaxial compression via in-situ X-ray computed tomography. Flexible polyurethane foam specimens with densities of 136, 160 and 240 kg/m 3 were compressed in uniaxial stress tests both parallel and perpendicular to the foam rise direction, to engineering strains exceeding 70%. The uncompressed microstructures show slightly elongated ellipsoidal pores, with elongation aligned parallel to the foam rise direction. The evolution of this microstructural anisotropy during deformation is quantified based on the autocorrelation of the image intensity, and verified via the mean intercept length as well as the shape of individual pores. Trends are consistent across all three methods. In the rise direction, the material remains transversely anisotropic throughout compression. Anisotropy initially decreases with compression, reaches a minimum, then increases up to large strains, followed by a small decrease in anisotropy at the largest strains as pores collapse. Compression perpendicular to the foam rise direction induces secondary anisotropy with respect to the compression axis, in addition to primary anisotropy associated with the foam rise direction. In contrast to compression in the rise direction, primary anisotropy initially increases with compression, and shows a slight decrease at large strains. These surprising non-monotonic trends and qualitative differences in rise and transverse loading are explained based on the compression of initially ellipsoidal pores. Microstructural anisotropy trends reflect macroscopic stress-strain and lateral strain response. These findings provide novel quantitative connections between three-dimensional microstructure and anisotropy in moderate density polymer foams up to large deformation, with important implications for understanding complex three-dimensional states of deformation.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Tailorable thermoplastic insulation foam composites enabled by porous-shell hollow glass spheres and expandable thermoplastic microspheres

Here we report a simple and commercially viable strategy to produce thermoplastic composite foams using synergistic foaming approaches – incorporating porous-shell hollow-interior glass spheres (PHGS) as a filler and utilizing expandable thermoplastic microspheres (EMS) as a physical blowing agent – for thermal insulation applications. The EMS in these composites ensure formation of highly porous, low-density foam while the PHGSs provide low thermal conductivity and lightweight mechanical reinforcement. Through systematic optimization of the PHGS and EMS loadings, a lightweight, and robust insulation with thermal resistivity greater than 27.7 m·K/W (R/in. > 4) is achieved. Notably, the fabricated foams also demonstrated comparable compressive strength than some commercial thermoplastic insulating materials. Through optimization of PHGS and EMS concentrations, results indicated similar thermal performance characteristics at varying foam densities, while higher loadings of both components lead to reduced insulation performance and weak mechanical stability of the foams. The results obtained, when coupled with the potential scalability and tailor ability of the overall process towards targeted insulation performance, not only endows competitiveness with current commercial thermoplastic insulating materials but also offers great promise for the development of unique thermoplastic composite foams for a variety of insulation systems.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Augmentation of pool boiling heat transfer on tube bundles using metal foam

Pool boiling on a tube bundle is one of the most important heat transfer modes in several industrial applications, including steam generators, shell and tube heat exchangers for waste heat recovery, and desalination. Although several enhanced tubes (e.g., external micro-finned tubes) have been extensively studied and commercialized, the studies that pertain to the metal foam enhanced tube bundles are limited in the open literature. The objective of the present study is to perform an experimental study to analyze the pool boiling heat transfer characteristics of a metal foam tube bundle and compare its performance with that of a tube bundle with no enhancement. The performance of the metal foam tube bundles with different porosities (81%, 75%, and 62%) is compared against the conventional bare tube bundle. The results showed that the heat transfer coefficients of the metal foam tube bundles are 100–212% higher than those of the bare tube bundle. Among the different porosities, metal foam with 75% porosity showed a higher heat transfer coefficient. Furthermore, the wall temperature of the metal foam tubes is nearly 5–14⁰C lower than that of the bare tubes. In conclusion, when compared with a tube pitch of 25.4 mm, a tube pitch of 19.05 mm showed a maximum of 9% and 14% enhancement in bare and metal foam tube bundles, respectively.

42 ENGINEERING↗

DOE OSTI2023

Evaluation and selection of eutectic salts combined with metal foams for applications in high-temperature latent heat thermal energy storage

This study presents a systematic process for selecting eutectic salts for use in latent heat thermal energy storage (LHTES), and provides experimental evidence regarding their performance. One primary goal was to identify the most suitable eutectic salt for use with metallic foams over a temperature range of 450 °C–500 °C. Twenty-one eutectic salts were preselected for comparison. Here, the performance and cost-effectiveness of each were evaluated based on the Ragone relation, enabling a fair comparison of each salt's heat storage capacity and power density relative to cost. As a result, MgCl-NaCl, CaCl 2 -NaCl, and FLiNaK were selected as the most promising candidates. Subsequently, experiments were performed to demonstrate the compatibility of the selected salts with metal foams while the copper and aluminum foams were immersed in the salts at 550 °C for 120 h. Combining C10100 (copper alloy) foam with CaCl 2 -NaCl was observed to generate the least surface corrosion due to oxidation. The charge/discharge performance and thermal stability of CaCl 2 -NaCl, both with and without the copper foam, were also tested to confirm the feasibility of this combination. The capsule with the copper foam showed enhanced performance (a 13 % reduced discharge rate) in comparison to the capsule without copper foam. The melting point of the CaCl 2 -NaCl remained unchanged for 300-h duration of the cyclic melting/solidification experiments, and no thermal stability issues were observed.

25 ENERGY STORAGE↗

NASA NTRS2015

Space Shuttle Stiffener Ring Foam Failure Analysis, a Non-Conventional Approach

The Space Shuttle Program made use of the excellent properties of rigid polyurethane foam for cryogenic tank insulation and as structural protection on the solid rocket boosters. When foam applications de-bond, classical methods of failure analysis did not provide root cause of the failure of the foam. Realizing that foam is the ideal media to document and preserve its own mode of failure, thin sectioning was seen as a logical approach for foam failure analysis to observe the three dimensional morphology of the foam cells. The cell foam morphology provided a much greater understanding of the failure modes than previously achieved.

cryogenic tank insulation↗