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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 1,279 records · Page 71
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Nanomechanical testing of freestanding polymer films: in situ tensile testing and Tg measurement

Abstract A method for small-scale testing and imaging of freestanding, microtomed polymer films using a push-to-pull device is presented. Central to this method was the development of a sample preparation technique which utilized solvents at cryogenic temperatures to transfer and deposit delicate thin films onto the microfabricated push-to-pull devices. The preparation of focused ion beam (FIB)-milled tensile specimens enabled quantitative in situ TEM tensile testing, but artifacts associated with ion and electron beam irradiation motivated the development of a FIB-free specimen preparation method. The FIB-free method was enabled by the design and fabrication of oversized strain-locking push-to-pull devices. An adaptation for push-to-pull devices to be compatible with an instrumented nanoindenter expanded the testing capabilities to include in situ heating. These innovations provided quantitative mechanical testing, postmortem TEM imaging, and the ability to measure the glass transition temperature, via dynamic mechanical analysis, of freestanding polymer films. Results for each of these mentioned characterization methods are presented and discussed in terms of polymer nanomechanics. Graphic Abstract

36 MATERIALS SCIENCE↗
DOE OSTI2019

Scalable Polymer Precursor Based LiPON Type Li-Metal Interface Enabled High Performance Li-Sulfur Battery

The Battery 500 program objective is to research, develop, and demonstrate lithium battery technologies capable of achieving 500 Wh/kg with stable lifetime of 1000 cycles. This Battery 500 seedlings project has demonstrated a new approach and a pathway toward the program’s goals in just one awarded and executed phase. Cells have been assembled, tested, and evaluated. This report details efforts to develop polymer precursor electrolytes that offer properties anticipated to be similar or superior to LiPON glasses. Such precursors offer the potential to be used to process LiPON-like thin glass/ceramic coatings for use in lithium batteries. LiPON glasses provide a design basis for the synthesis of sets of oligomers/polymers by lithiation of OP(NH 2 ) 3-x (NH) x [from OP(NH) 3 ], OP(NH 2 ) 3-x (NHSiMe 3 ) x and [P=N] 3 (NHSiMe 3 ) 6-x (NH) x . Polymer electrolytes impregnated in/on celgard exhibit Li+ conductivities up to ~1×10 -5 S/cm at room temperature and are thermally stable to ≈150 °C. A Li-S battery assembled using a Li 6 SiPON composition polymer electrolyte exhibits an initial reversible capacity of 1500 mAh/g sulfur and excellent cycle performance at 0.25 and 0.5 C rate over 120 cycles, declining to 750 mAh/g at after a 220 h test period. At the same time, computational studies were performed to understand the conduction mechanism of LIPON and its interaction with Li metal. These initial project results provide a foundation for further development of the system to achieve the program goal.

25 ENERGY STORAGE↗
DOE OSTI2020

The Effect of TiDG, DCiTG (Lix ® reg;79), and Other Suppressors on the Compatibility of NGS with SWPF Polymers

This document provides a screening calculation of the potential miscibility of specific polymers proposed for use in the SWPF, notably polyether-etherketone (PEEK), ultra-high molecular weight polyethylene (UHMWPE), polyvinylidene fluoride (PVDF), Viton ® B fluoroelastomer, and Tefzel ® ethylenetetrafluoroethylene (ETFE) copolymer in different suppressors including trisisodecyl guanidine (TiDG), dicyclohexane-isotrisdecyl guanidine (DCiTG), and two other dicyclohexane guanidine related suppressors. The evaluation suggests that Tefzel ® ETFE may mildly interact with the Next Generation Solvent (NGS) regardless of the suppressor used. Based on this approach (calculations), the other listed polymers appear compatible with the NGS containing the four different suppressors. There is evidence of chemical affinity between Tefzel ® ETFE, Viton ® B with aliphatic amines (which are degradation by-products from the TiDG). In addition, the calculation suggests that drawing miscibility conclusions from exposing polymers to a single pure component may give misleading or incorrect results due to the potential for synergistic effects or other interactions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Using Crystallization to Control Filler Dispersion and Vice Versa in Polymer Nanocomposites

Our overall goal was to exploit our ability to control the spatial dispersion of spherical nanoparticles in a semicrystalline polymer matrix to tune the properties of the resulting nanocomposite. In particular, our two tasks were: Hierarchically organize spherical nanoparticles into unique morphologies by varying the ratio of the polymer crystallization rate to the filler diffusion rate during matrix solidification. Organize nanoparticles in the matrix melt into superstructrues as a means to tailor polymer crystallization rates, and potentially the crystal structure and/or morphology of the semicrystalline matrix.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Polymer Additive Manufacturing for Marine Renewable Energy Applications: Best Practices, Research Trends, and Current Challenges

Additive manufacturing (AM) is a rapidly growing technology space, not only for prototyping, but is also becoming more feasible at larger scales and increasing component quantities. There are a large variety of AM processes and materials available to users and effectively applying those processes and materials to a specific use case can be challenging. One specific area where AM could be particularly beneficial is marine renewable energy (MRE). Not only is MRE a relatively nascent industry with a near-term need for rapid deployments and prototype testing, but developers could also see long-term benefits from the broad variety of environmentally resistant materials available and the ability to manufacture complex geometries that AM technologies offer. Over the past 4 years, AM materials have played an increasing role in the Advanced Materials project; a multi-year, multi-laboratory research project funded by the U.S. Department of Energy's Water Power Technologies Office, with the main goal of reducing barriers to the adoption of complex materials in the MRE industry. The primary focus of this project is to develop test methods and generate datasets to understand the long-term performance of advanced materials in marine environmental and address specific material challenges as they arise. This report provides an extensive overview of the research that has been performed specific to AM polymers as part of the Advanced Materials project. The intention of this document is to provide recommendations of best practices with regards to material selection, mechanical test method development, and design practices, lessons learned along the way, current research trends, and ongoing challenges with regards to AM polymers in marine environments. In particular, this report focuses on several key aspects: Material and process selection, Environmental conditioning and subsequent degradation quantification through mechanical characterization, Composite reinforcements on AM polymer substrates, Adhesion of instrumentation for mechanical characterization and loads measurements, Protective coatings for preventing biofouling and water ingress, Other MRE case studies where AM has proved particularly useful. Ultimately, we hope that the test methods that have been developed, data generated, and lessons learned from this research will be valuable to the MRE community (researchers and developers alike), as well as other industries, and can be used as a reference point as the respective MRE and AM industries continue to grow and mature.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

Rational sub-nanometer manipulation of polymer morphology for efficient chemical separations

The ability to control polymer morphology on the sub-nanometer length scale has broad implications for chemical separations. To achieve such control on easily processable systems, this proposal focuses on the synthesis and characterization of polymers containing appended labile moieties that are easily detached by thermolysis or UV irradiation deep within the glassy state. Once liberated, these moieties can diffuse from the polymer matrix as gaseous products, leaving behind templated pathways for selective diffusion and sorption of small molecules. With a specific target of creating polymeric membrane materials with unprecedented diffusion and (ad)sorption characteristics for chemical separations, synthesis of new materials will be complemented with advanced metrologies, simulations, and evaluation of thermodynamic and transport theory.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Predicting Selective Laser Printing Print Quality of Polymer Powders through Melt Flow Index

Selective Laser Sintering (SLS) uses a precisely controlled laser to fuse polymer powder to build complex 3D shapes. While SLS covers a wide application space, the processing knowledge of polymer powder is limited, restricting the number of commercial powders available. This study serves to expand the processing knowledge of polypropylene and polyethylene in parallel with a “mature” SLS feedstock, nylon, through melt flow index (MFI) characterization. Differential Scanning Calorimetry (DSC) was used to explore the sintering window of the polymers. Polyethylene and polypropylene exhibited a relatively narrow sintering window between 4 – 5 °C, whereas the sintering window of nylon was much wider, between 23 – 24 °C. This suggests that the print quality between polyethylene and polypropylene would be similar; however, X-ray computed tomography revealed a higher volume of print defects, voids, and de lamination in polyethylene than in polypropylene. MFI analysis provided additional insight into the difference in print quality, as the MFI of polyethylene was 7.16 g/10 min, 9.95 g/10 min for polypropylene, and 17.23 g/10 min for nylon. MFI is inversely correlated to melt viscosity, and a low melt viscosity is desired for proper coalescing between the layers and particles. These results suggest that MFI is a promising tool, in conjunction with traditional thermal analysis, for screening candidate powder feedstocks for SLS and optimization of print parameters for novel powders.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Stable Diacid Coordinated Quaternary Ammonium Polymers for 80-230 °C Fuel Cells

Current automotive fuel cells that use sulfonated polymer-based proton exchange membranes are challenging to operate at > 100 °C without humidification. In this project, we developed polymer electrolyte fuel cells that run at > 100 °C without humidification using a novel class of proton exchange membranes made from thermos-oxidatively stable acid-coordinated quaternary ammonium polymers. These fuel cells remove the external humidifiers/demisters and reduce the size of radiators, thus vastly simplifying fuel cell integration, which increases tolerance to impurities and improves electrode kinetics of catalysts. Operating fuel cells without hydration has a significant benefit on fuel cell cost and economic feasibility was investigated by comparing existing fuel cell systems. This project bridges the scale-up process to manufacture the fuel cell component through the U.S. DOE L’Innovator project sponsored by the U.S. DOE Hydrogen and Fuel Cell Technologies Office (HFTO).

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

ASU’s DAC polymer-enhanced cyanobacterial bioproductivity (AUDACity)

ASU’s DAC polymer-enhanced cyanobacterial bioproductivity (AUDACity) project aims to demonstrate a novel, scalable method for removing carbon dioxide (CO 2 ) directly from ambient air and delivering it to cyanobacterial cultures to produce commodity biofuel, mid-value protein for supplements, and high value phycocyanin (PC), a natural blue colorant (Figure A). This approach uses low-cost, reusable anion exchange polymers embedded in modular mesh packets, which capture CO 2 during drying cycles when exposed to ambient air, and release concentrated CO 2 into aqueous cultivation systems. The project addresses a critical challenge in energy research needed for developing sustainable, economically viable methods of Direct Air Capture (DAC) that can be integrated with bio-based systems for fuel and chemical production. AUDACity contributes to scientific understanding by integrating materials chemistry, cyanobacterial biology, and system engineering to create a distributed CO 2 delivery platform. Key insights have emerged around the design of biocompatible sorbents, optimization of CO 2 capture-release cycles, and durability of packet-based delivery systems under outdoor conditions. Notably, the team has synthesized and tested a range of polymer sorbents, identified mechanisms of material degradation and fouling, and advanced both lab- and pilot-scale cultivation systems to evaluate performance. From a technical and economic standpoint, AUDACity shows promise for achieving cost-effective CO 2 capture and delivery into aqueous media and biofuel production. Preliminary techno-economic analysis (TEA) indicates that the DAC system based on current performance can reach $\$$680/tonne CO 2 delivered into aqueous solution; with reasonable improvements to sorbent lifetime, sorbent capacity, reducing water uptake the approach could reach $\$$66/tonne by avoiding the need for energy-intensive sorbent regeneration and CO 2 compression, making it more feasible for decentralized deployment. With these costs for CO 2 and by extracting and selling high-value PC ($\$$50/kg) and mid-value protein supplement ($\$$6/kg), the remaining biomass can be hydrothermally treated into biofuel for $\$$2.50/gallon, and would support a small first-of-a-kind biorefinery capable of producing 500 barrels per day of biofuel. The project offers meaningful public benefits by advancing carbon removal technologies that are low-energy, modular, and adaptable to non-arable land and brackish water use. It aligns with national goals to develop advanced biotechnology and supports future pathways for bio-based fuels and products. By enabling direct coupling of CO 2 transfer into aqueous medium and biological carbon utilization, AUDACity lays the groundwork for effective algae cultivation without wasteful CO 2 delivery and is a promising and innovative solution for low-carbon fuel and bioproduct generation contributing to a vigorous bioeconomy.

09 BIOMASS FUELS↗
DOE OSTI2026

Gold Catalyzed Polymerization Reactions of Unsaturated Substrates: Towards New Functional, Recyclable, and Upcycled Aromatic Polymers (Final Report)

The overarching goal of this project lied in the translation of gold (Au) catalyzed small molecule synthetic transformations to the field of polymer science, the generation of new macromolecular structures, and the application of the materials and methodologies produced toward sustainable polymer development and chemical upcycling. Specifically, this project aimed to polymerize monomers based on unsaturated precursors and access novel polymeric materials through the extension of Au catalyzed intermolecular processes. The specific objectives of this project comprised: (1) the extension of Au-catalyzed intermolecular reactions to bifunctional monomers and the polycondensation of diverse nucleophiles; (2) to gain fundamental mechanistic insight into Au-catalyzed polymerizations; (3) the application of these reactions to the synthesis of new classes of aromatic polymers that can be readily and/or selectively deconstructed; and (4) to apply these chemistries to post-polymerization modification (PPM) of commercially relevant polyaromatic substrates, including post-industrial plastics and post-consumer waste.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Finite Element Modeling of the Fiber-Matrix Interface in Polymer Composites

Polymer composites are used in numerous industries due to their high specific strength and high specific stiffness. Composites have markedly different properties than both the reinforcement and the matrix. Of the several factors that govern the final properties of the composite, the interface is an important factor that influences the stress transfer between the fiber and matrix. The present study is an effort to characterize and model the fiber-matrix interface in polymer matrix composites. Finite element models were developed to study the interfacial behavior during pull-out of a single fiber in continuous fiber-reinforced polymer composites. A three-dimensional (3D) unit-cell cohesive damage model (CDM) for the fiber/matrix interface debonding was employed to investigate the effect of interface/sizing coverage on the fiber. Furthermore, a two-dimensional (2D) axisymmetric model was used to (a) analyze the sensitivity of interface stiffness, interface strength, friction coefficient, and fiber length via a parametric study; and (b) study the shear stress distribution across the fiber-interface-matrix zone. It was determined that the force required to debond a single fiber from the matrix is three times higher if there is adequate distribution of the sizing on the fiber. The parametric study indicated that cohesive strength was the most influential factor in debonding. Moreover, the stress distribution model showed the debonding mechanism of the interface. It was observed that the interface debonded first from the matrix and remained in contact with the fiber even when the fiber was completely pulled out.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Polyferrocenylsilane Semicrystalline Polymer Additive for Solution-Processed p-Channel Organic Thin Film Transistors

In this study, we demonstrated for the first time that a metal-containing semicrystalline polymer was used as an additive to mediate the thin film morphology of solution-grown, small-molecule organic semiconductors. By mixing polyferrocenylsilane (PFS) with an extensively-studied organic semiconductor 6,13-bis(triisopropylsilylethynyl) pentacene (TIPS pentacene), PFS as a semicrystalline polymer independently forms nucleation and crystallization while simultaneously ameliorating diffusivity of the blend system and tuning the surface energies as a result of its partially amorphous property. We discovered that the resultant blend film exhibited a 6-fold reduction in crystal misorientation angle and a 3-fold enlargement in average grain width. Enhanced crystal orientation considerably reduces mobility variation, while minimized defects and trap centers located at grain boundaries lessen the adverse impact on the charge transport. Consequently, bottom-gate, top-contact organic thin film transistors (OTFTs) based on the TIPS pentacene/PFS mixture yielded a 40% increase in performance consistency (represented by the ratio of average mobility to the standard deviation of mobility). The PFS semicrystalline polymer-controlled crystallization can be used to regulate the thin film morphology of other high-performance organic semiconductors and shed light on applications in organic electronic devices.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Data-Driven Tailoring Optimization of Thermoset Polymers Using Ultrasonics and Machine Learning

Thermoset polymers are highly demanded for their structural robustness, thermal stability, and chemical resistance. Tailoring the properties of these polymers for high-performance applications is often preferred to designing brand-new polymers. However, the traditional destructive techniques used to characterize their properties as a function of manufacturing parameters are expensive and time-consuming. A novel non-destructive, data-driven method leveraging ultrasonics and machine learning techniques to tailor the properties of thermosets as a function of the manufacturing parameters is demonstrated. Thermoset epoxy samples with varying curing temperatures (15–40 °C) and curing agent amounts (±40%) were manufactured and tested. Their curing kinetics were monitored by determining the sound speed in the material in real time, while the longitudinal modulus of the samples was determined post-cure. Machine learning models were developed using a k-nearest neighbors algorithm. These models were implemented to predict the curing and final elastic properties using the manufacturing parameters, i.e., stoichiometry and curing temperature, and vice versa. Understanding and modeling how these parameters affect the cure kinetics and final properties will allow for efficient and reliable optimization of thermoset tailoring and manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Fast Neutron Scintillator Screens for Neutron Imaging Using a Layered Polymer-Phosphor Architecture

Fast neutrons enable a nondestructive examination of dense, large, and highly attenuating samples due to their lower interaction probability compared to thermal neutrons. However, this also creates a challenge in fast neutron imaging, as the thicker sensors necessary to detect fast neutrons degrade an image’s spatial resolution due to scattering within the sensor and the indeterminate depth of interaction in the sensor. This work explores the advantages of a fast neutron imaging screen with a layered polymer-phosphor screen approach as opposed to a mixed polymer-phosphor screen typically used in fast neutron imaging. Proton recoil is the primary conversion mechanism for fast neutron imaging. Simulations showed that the recoil proton range of typical fast neutrons is approximately 200 µm, however, tests at Idaho National Laboratory revealed that the light output of these screens increased at much greater polymer thicknesses. The NECTAR fast neutron beamline at FRM II was used to test the imaging performance of layered fast neutron imaging screens. Distinguishing between the fast-neutron and γ-ray signals is a major challenge in fast neutron imaging because all fast neutron sources also produce γ-rays. A relative comparison between a control plate and the fast neutron screen was made to distinguish between a γ-ray and fast neutron signals. MCNP modeling quantified the γ-ray and fast neutron contributions to the images measured at NECTAR, which were approximately a 75% γ-ray image.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Challenge Solutions for a Significant Water Cut Reduction History Match on Heavy Oil Polymer EOR

Milne Point Field is conducting the first-ever active polymer flood pilot program designed to enhance oil recovery (EOR) of heavy oils on the Alaska North Slope (ANS). The experimental field program consists of two pairs of horizontal injection and production wells deployed in an isolated fault block in the Schrader Bluff reservoir. The EOR method combines polymer flooding and low salinity water flooding to improve recovery. Prior average water cut reduction in polymer EOR fields ordinarily ranges between 10% to 15% for most light oil and heavy oil reservoirs. When comparing other field applications, the long-lasting (24 months) and much lower water cut poses a challenge for numerical history matching when applying typical simulation methods. This abstract discusses two practical new approaches used for history matching of the long-lasting ultralow water cut. These new applications include 1) multiple relative permeability curves with J-function incorporation with low endpoints of relative permeability of water (Krw). This approach integrated the permeability differential adjustment in the geometries of horizontal and vertical directions based on geological review. 2) A specific permeability channel strips along with the horizontal or vertical planar assumption. The current history matching results indicate success in achieving an excellent agreement with the field observed low water-cut.

Namie, S.↗
DOE OSTI2022

Epoxy as Filler or Matrix for Polymer Composites

Epoxy is a widely used polymer because of its ease of processing, high adhesiveness, and high chemical resistance. Epoxy-based composites are commonly used in aerospace, automotive, and marine applications. The epoxy type, function, curing agent, and curing process are discussed in this chapter. Epoxy is used as either a filler or polymer matrix in composite applications. As a filler, the epoxy modification on the fiber is discussed. As a polymer matrix, the epoxy is reinforced by natural and synthetic fibers. The manufacturing process and the fabricated epoxy-based composites’ performance (e.g., mechanical and thermal properties) are investigated. The advantages and disadvantages of epoxy’s function are discussed and summarized. Epoxy modification is an effective approach to improve the composites’ performance.

Zhao, Xianhui↗
NASA NTRS1970

Polymer degradation rate control of hybrid rocket combustion

Polymer degradation to small fragments is treated as a rate controlling step in hybrid rocket combustion. Both numerical and approximate analytical solutions of the complete energy and polymer chain bond conservation equations for the condensed phase are obtained. Comparison with inert atmosphere data is very good. It is found that the intersect of curves of pyrolysis rate versus interface temperature for hybrid combustors, with the thermal degradation theory, falls at a pyrolysis rate very close to that for which a pressure dependence begins to be observable. Since simple thermal degradation cannot give sufficient depolymerization at higher pyrolysis rates, it is suggested that oxidative catalysis of the process occurs at the surface, giving a first order dependence on reactive species concentration at the wall. Estimates of the ratio of this activation energy and interface temperature are in agreement with best fit procedures for hybrid combustion data. Requisite active species concentrations and flux are shown to be compatible with turbulent transport. Pressure dependence of hybrid rocket fuel regression rate is thus shown to be describable in a consistent manner in terms of reactive species catalysis of polymer degradation.

Stickler, D. B.↗