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NASA NTRSDate not supplied

Towards Quantifying and Correlating RTV Intumescence to Entry-Relevant Conditions

Room Temperature Vulcanizing silicone (RTV) is a high-temperature adhesive used as a gap-filler between Thermal Protection System (TPS) tiles for heatshields on numerous missions. It is also adopted to bond instrumentation plugs of temperature and pressure sensors into heatshield’s tiles. While RTV has been traditionally assumed to be a non-porous and non-ablating material, numerous experiments have shown that RTV pyrolyzes and becomes highly porous as it is heated. Experimental data has also shown heating rate-dependent swelling (or intumescence) and shrinking of RTV, these volume changes may cause roughness-induced boundary layer transition. Outgassing and surface oxide formation of RTV upon decomposition also occur, which can be sources of contamination of heat shield sensors. This combination of detrimental effects motivates a critical need to develop a high-fidelity model for RTV ablation. As a first critical step in RTV modeling, a comprehensive material properties database for RTV was collected that account for the lack of data in properties such as pyrolysis char yield, shape change, virgin and char porosity. The next step is to quantify the volume change of RTV as a function of temperature. While this was done in previous campaigns, limited data was collected which showed a possible heating rate dependent intumescent behavior. To further understand the intumescence phenomenon of RTV, numerous dedicated experiments were performed at Beamline 8.3.2 of the Advanced Light Source, where RTV samples were heated while X-ray scans were taken in situ. Micro-Computed Tomography scans were taken in situ for low heating rates (≤ 60 °C/min), whereas continuous radiography scans were taken for higher heating rates (≤ 1500 ºC/min). Unconstrained samples and samples constrained in different holders (quartz, graphite, FiberForm and PICA) were tested to determine the change in intumescence due to confinement. Using deep learning techniques, the tomographies and radiographies are segmented to obtain volume change, porosity, pore size distributions and connectivity. From the results obtained, modifications to the previous RTV intumescence model are proposed, along with preliminary comparisons to testing RTV at high-enthalpy facilities.

RTV↗

DOE OSTI2025

Quench Analysis of EIC Central Detector (ePIC) Solenoid Magnet (MARCO)

The 2.0 T superconducting solenoid magnet (MARCO) being designed to be built for the EIC central detector (ePIC). Here, the magnet consists of three set of coil in a vacuum impregnated coil pack. Each coil pack consists of a total 554 turns winding wrapped with 6 layers of winding per coil. The coil case assembly is cooled by supercritical helium at 4.6 K. This manuscript presents quench analysis carried out on the magnet system along with the conductor stability. For the normal operation the magnet at 4.6 K and at normal operating current, the quench evaluation is carried out at 4.7 K for design assessment. The quench analysis carried out using commercial multi-physics FEA tool along an equivalent single coil quench model and the requirements for the magnet protection is also presented.

Ghoshal, Probir K. [Thomas Jefferson National Acce↗

NASA NTRS1987

Thermal stress analysis of space shuttle orbiter wing skin panel and thermal protection system

Preflight thermal stress analysis of the space shuttle orbiter wing skin panel and the thermal protection system (TPS) was performed. The heated skin panel analyzed was rectangular in shape and contained a small square cool region at its center. The wing skin immediately outside the cool region was found to be close to the state of elastic instability in the chordwise direction based on the conservative temperature distribution. The wing skin was found to be quite stable in the spanwise direction. The potential wing skin thermal instability was not severe enough to tear apart the strain isolation pad (SIP) layer. Also, the preflight thermal stress analysis was performed on the TPS tile under the most severe temperature gradient during the simulated reentry heating. The tensile thermal stress induced in the TPS tile was found to be much lower than the tensile strength of the TPS material. The thermal bending of the TPS tile was not severe enough to cause tearing of the SIP layer.

Ko, William L.↗

NASA NTRS1987

Development and test of the Shuttle/Centaur cryogenic tankage thermal protection system

The Thermal Protection System (TPS) for the Shuttle/Centaur had to provide fail-safe thermal protection during prelaunch, launch ascent, and on-orbit operations as well as during potential abort where the Shuttle and Centaur would return to earth. The TPS selected used a helium-purged polyimide foam beneath three radiation shields for the liquid hydrogen (LH2) tank and radiation shields only for the liquid oxygen (LO2) tank (three shields on the tank sidewall and four on the aft bulkhead). An evacuated common intermediate bulkhead separated the two tanks. The LH2 tank had one 1.9-cm thick layer of foam on the forward bulkhead and two layers on the larger area side-wall. Full scale tests of the flight vehicle in a simulated Shuttle cargo bay, that was purged with gaseous nitrogen, gave total prelaunch heating rates of 25.9 kW and 12.9 kW for LH2 and LO2 tanks, respectively. Calorimeter tests on a representative LH2 tank sidewall TPS sample indicated that the measured unit heating rate would rapidly decrease from the prelaunch rate of 300 W/sq m to a desired rate of less than 4 W/sq m once on-orbit.

Knoll, R. H.↗

NASA NTRS2001

An Assessment of the Scientific Basis Behind Global Environmental Concerns in the 21st Century

The notion that human activities may endanger the earth's environment has emerged as a leading societal concern in the post industrial era. Under the ever increasing pressures of population growth and industrialization, the problems of local air pollution have now become matters of both local and global concern. Smog, toxic chemicals, acid rain, ozone depletion, and climate change have become household words and an intense public policy debate about the cost and benefits of environmental protection continues. There is a growing realization that the consequences of air pollution can be felt in unpredictable ways in near and far away places. Unpopulated regions of the world such as the arctic now suffer from arctic haze and ozone depletions are the largest in the Antarctic stratosphere. In the last4ol three decades many countries have instituted ambient air quality standards designed to mitigate problems of health and welfare associated with the release of chemicals. Global agreements to prevent the depletion of ozone layer and to slow down climatic warming are being actively debated and formulated. In parallel there has been an intense exploration of the science of air pollution all over the world. The scientific basis behind environmental concerns is imperfect and is central to this debate. I will review our current scientific understanding of some of the major environmental concerns. An assessment of the forthcoming efforts to put this science on a more solid footing will be provided.

Singh, Hanwant B.↗

NASA NTRS2004

Characterization of Space Shuttle External Tank Thermal Protection System (TPS) Materials in Support of the Columbia Accident Investigation

NASA suffered the loss of the seven-member crew of the Space Shuttle Columbia on February 1, 2003 when the vehicle broke apart upon re-entry to the Earth's atmosphere. The final report of the Columbia Accident Investigation Board (CAIB) determined that the accident was caused by a launch ascent incident-a suitcase-sized chunk of insulating foam on the Shuttle's External Tank (ET) broke off, and moving at almost 500 mph, struck an area of the leading edge of the Shuttle s left wing. As a result, one or more of the protective Reinforced Carbon-Carbon (RCC) panels on the wing leading edge were damaged. Upon re-entry, superheated air approaching 3,000 F breached the wing damage and caused the vehicle breakup and loss of crew. The large chunk of insulating foam that broke off during the Columbia launch was determined to come from the so-called bipod ramp area where the Shuttle s orbiter (containing crew) is attached to the ET. Underneath the foam in the bipod ramp area is a layer of TPS that is a cork-filled silicone rubber composite. In March 2003, the NASA Marshall Space Flight Center (MSFC) in Huntsville, Alabama received cured samples of the foam and composite for testing from the Michoud Assembly Facility (MAF) in New Orleans, Louisiana. The MAF is where the Shuttle's ET is manufactured. The foam and composite TPS materials for the ET have been well characterized for mechanical property data at the super-cold temperatures of the liquid oxygen and hydrogen fuels used in the ET. However, modulus data on these materials is not as well characterized. The TA Instruments 2980 Dynamic Mechanical Analyzer (DMA) was used to determine the modulus of the two TPS materials over a range of -145 to 95 C in the dual cantilever bending mode. Multi-strain, fixed frequency DMA tests were followed by multi-frequency, fixed strain tests to determine the approximate bounds of linear viscoelastic behavior for the two materials. Additional information is included in the original extended abstract.

Wingard, Charles D.↗

NASA NTRS2024

A Phenomenological Durability Model for Environmental Barrier Coating Systems Subjected to Steam Oxidation

Environmental barrier coatings (EBC) are used to protect the silicon carbide fiber reinforced silicon carbide matrix (SiC/SiC) ceramic matrix composites (CMC) from rapid surface recession due to volatization by water vapor in a steam oxidation environment. A phenomenological modeling approach is outlined to estimate the durability of a given EBC system when exposed to steam oxidation. The report provides a step-by-step procedure to estimate the life of a given EBC system subjected to thermal loads only. Once calibrated, the methodology can predict the critical thickness of an oxide layer that will cause failure initiation/spallation as well as the remaining strength or stress that the EBC system can take for a given oxide layer thickness

Subodh K Mital↗

NASA NTRSDate not supplied

Preliminary Experimental Investigation of Multi-Shock Shield Performance Against Meteoritic Other Lithic Projectiles

The protection capabilities of micrometeoroid and orbital debris (MMOD) shields are invariably linked to the physical properties of the impactor. Regardless of the shield type, or bumper material employed, the general principles of purposefully designed multi-walled MMOD protection relies on the ability to disrupt, shock, melt, and/or vaporize the projectile before it interacts with a critical spacecraft component. Here, we begin to study the influence of projectile heterogeneity on the performance of multi-shock shields by conducting hypervelocity impact tests using meteorite and a variety of other rock-like (i.e., lithic) materials. Testing was conducted using a .17 caliber two-stage light-gas gun, launching cylindrical lithic projectiles between 5.66 and 7.06 km/s. Shield layups included three layers of Nextel and one layer of graphite composite as a rear wall, with each layer having a 35 mm standoff. After testing a comparison of rear wall and witness plate damage was made to separate tests conducted using spherical Al projectiles of similar mass. It was observed that the more heterogenous meteorite projectile gave rise to notably more damage to the witness plate than an Al projectile of equivalent mass, while the other, more homogeneous lithic projectiles, did not.

meteorite↗

DOE OSTI2024

Updraft Width Implications for Cumulonimbus Growth in a Moist Marine Environment

Abstract An idealized large-eddy simulation of a tropical marine cloud population was performed. At any time, it contained hundreds of clouds, and updraft width in shallow convection emerging from a subcloud layer appeared to be an important indicator of whether specific convective elements deepened. In an environment with 80%–90% relative humidity below the 0°C level, updrafts that penetrated the 0°C level were larger at and above cloud base, which occurred at the lifting condensation level near 600 m. Parcels rising in these updrafts appeared to emerge from boundary layer eddies that averaged ∼200 m wider than those in clouds that only reached 1.5–3 km height. The deeply ascending parcels (growers) possessed statistically similar values of effective buoyancy below the level of free convection (LFC) as parcels that began to ascend in a cloud but stopped before reaching 3000 m (nongrowers). The growers also experienced less dilution above the LFC. Nongrowers were characterized by negative effective buoyancy and rapid deceleration above the LFC, while growers continued to accelerate well above the LFC. Growers occurred in areas with a greater magnitude of background convergence (or weaker divergence) in the subcloud layer, especially between 300 m and cloud base, but whether the convergence actually led to eddy widening is unclear. Significance Statement Cumulonimbus clouds are responsible for many extreme weather phenomena and are important contributors to Earth’s energy balance. However, the processes leading to the growth of individual clouds are not completely understood nor well-represented in weather prediction models. We find that the clouds containing updrafts that start out wider at early stages of their life cycles grow taller, possibly because they are protected more from drier air outside the cloud than narrow clouds. In addition, this work shows how the initial width of clouds might be related to convergence in the lowest part of the atmosphere, at heights where clouds initially develop. However, meteorologists must be careful not to overinterpret these results because numerical simulations inherently include assumptions that may not reflect reality. This reinforces the need to also observe processes occurring at the scales of individual clouds.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1980

Microstructural characterization of the HRSI thermal protection system for space shuttle

Components of the space shuttle high temperature reusable surface insulation (HRSI) system were microscopically characterized, both separately and as a system, to obtain information needed for stress analysis models of the thermal protection system. A tension specimen of the HRSI system was loaded in steps and was microscopically observed at each load condition to demonstrate the tension failure mode associated with strain isolation pad (SIP) behavior. A local failure occurred which should be associated with transfer of load through transverse fibers in the SIP. Stress concentrations attributed to the SIP behavior necessitated strengthening of the HRSI by densification of the RSI at the bondline. An HRSI tile was microscopically characterized after the densification process. The densified surface layer blended into the RSI which caused a gradual change in density. The gradation in density does not appear to represent a sharp discontinuity in elastic modulus between the densified layer and the parent material.

Ransone, P. O.↗

NASA NTRS1999

NASA Lewis Thermal Barrier Feasibility Investigated for Use in Space Shuttle Solid-Rocket Motor Nozzle-to-Case Joints

Assembly joints of modern solid-rocket motor cases are usually sealed with conventional O-ring seals. The 5500 F combustion gases produced by rocket motors are kept a safe distance away from the seals by thick layers of insulation and by special compounds that fill assembly split-lines in the insulation. On limited occasions, NASA has observed charring of the primary O-rings of the space shuttle solid-rocket nozzle-assembly joints due to parasitic leakage paths opening up in the gap-fill compounds during rocket operation. Thus, solid-rocket motor manufacturer Thiokol approached the NASA Lewis Research Center about the possibility of applying Lewis braided-fiber preform seal as a thermal barrier to protect the O-ring seals. This thermal barrier would be placed upstream of the primary O-rings in the nozzle-to-case joints to prevent hot gases from impinging on the O-ring seals (see the following illustration). The illustration also shows joints 1 through 5, which are potential sites where the thermal barrier could be used.

Steinetz, Bruce M.↗

NASA NTRS2010

An Extension of Analysis of Solar-Heated Thermal Wadis to Support Extended-Duration Lunar Exploration

The realization of the renewed exploration of the Moon presents many technical challenges; among them is the survival of lunar surface assets during periods of darkness when the lunar environment is very cold. Thermal wadis are engineered sources of stored solar energy using modified lunar regolith as a thermal storage mass that can supply energy to protect lightweight robotic rovers or other assets during the lunar night. This paper describes an extension of an earlier analysis of performance of thermal wadis based on the known solar illumination of the Moon and estimates of producible thermal properties of modified lunar regolith. The current analysis has been performed for the lunar equatorial region and validates the formerly used 1-D model by comparison of predictions to those obtained from 2-D and 3-D computations. It includes the effects of a thin dust layer covering the surface of the wadi, and incorporating either water as a phase-change material or aluminum stakes as a high thermal conductivity material into the regolith. The calculations indicate that thermal wadis can provide the desired thermal energy and temperature control for the survival of rovers or other equipment during periods of darkness.

Balasubramaniam, R.↗

NASA NTRSDate not supplied

Study the Vertical Structure and Transportation of the Extreme African Dust Storms using MERRA-2 Data

The Modern-Era Retrospective Analysis for Research and Application, Version 2 (MERRA-2) provides the first long-term global reanalysis to assimilate space-based observations of aerosols and represents their interactions with other physical processes in the climate system. In this study, we have examined the variations of atmospheric aerosols for the last 20 years since 2002 using the sub-daily MERRA-2 data and found seven extreme African dust storms that were transported westward across the Atlantic Ocean from the Sahara, crossing 70o-80oW. In particular, the well-known ‘Godzilla’ dust storm occurred in June 2020, and its dust cloud, with the highest-on-record aerosol optical depths, was transported toward the Americas. This storm greatly degraded air quality over large areas of the Caribbean Basin and the United States. The air quality index reached unhealthy levels for sensitive groups in more than ten U.S. states. In our study, the vertical structure and transport characteristics of the dust layers during this extreme dust event are investigated. The geopotential height and temperature were found anomalously low (around 600 hPa) over the Atlantic Ocean off northwest Africa before the June 2020 dust storm. This anomalous circulation pattern was persistent for more than 12 days starting from around May 30, breaking the regular easterly waves that transport dust from the Sahara Desert to the west. To verify the data quality, daily MERRA-2 PM2.5 data were calculated and compared with PM2.5 observations from the U.S. Environmental Protection Agency (EPA) at several selected ground stations in Florida. We provide this case study to illustrate how to effectively use various MERRA-2 data services at Goddard Earth Sciences Data and Information Services Center (GES DISC) where MERRA-2 data are archived, hoping to help data users in exploring their own topics of interest using data services at GES DISC.

data management, reanalysis↗

DOE OSTI2022

Tuning Intermediate Bands of Protective Coatings to Reach the Bulk-Recombination Limit of Stable Water-Oxidation GaP Photoanodes

Stable photoelectrochemical solar fuel production requires protective coatings to achieve effective charge separation, transport, and injection at the semiconductor–liquid interfaces, implying that the coating should energetically align its intermediate band (IB) with both the photoabsorber's band edge and co-catalyst's potentials. Yet approaches to adjust coating IB positions to accommodate various semiconductor light absorbers for constructing efficient and stable photoelectrodes have not been developed. In this report, three types of transition metal (M = Mn 2+ , Mn 3+ , and Cr 3+ ions) alloyed TiO2 coatings are discovered using atomic layer deposition (ALD). The IB energetics of these coatings are characterized by X-ray photoelectron spectroscopy and are found to be tunable inside the TiO 2 bandgap, through varying ALD growth conditions. By applying these coatings to n-type GaP and integrating with IrO x co-catalysts, the water-oxidation J–E performance is comparable to an uncoated corroding GaP photoanode. It reaches the bulk recombination limit of the GaP and achieves ≈28% absorbed photon to current efficiency under 475-nm light excitation (6.48 mW cm -2 ) and 100-h stable water oxidation. The outstanding performance and stability are attributed to the efficient charge separation and hole transport, as allowed by the energy alignment of the coating IB and the GaP valence band edge.

36 MATERIALS SCIENCE↗

DOE OSTI2025

First-Principles study of interface capture of Ni during high-temperature oxidation of NiCr alloys

The formation of precipitated phases of less reactive metals within an oxide scale during alloy oxidation can disrupt its structural integrity, significantly compromising the protective function of the oxide. To better understand this phenomenon, it is crucial to investigate the atomic-level diffusion mechanisms that drive precipitate formation. In this study, we employ first-principles calculations to examine the diffusion and aggregation of Ni atoms across the NiCr/Cr 2 O 3 interface during the high-temperature oxidation of NiCr alloys. Our results reveal that, in the absence of Cr vacancies, Ni atoms predominantly remain within the NiCr substrate, with minimal migration toward the Cr 2 O 3 layer. However, when Cr vacancies are present at both the NiCr/Cr 2 O 3 interface and within the Cr 2 O 3 bulk, Ni atoms exhibit a strong propensity to migrate from the NiCr substrate into the Cr 2 O 3 bulk, where they aggregate into Ni-rich regions with a corundum structure. This study provides valuable atomic-level insights into the diffusion and aggregation of less-reactive metals at the alloy/oxide interface, enhancing our understanding of solute capture and its contribution to the degradation of oxidation resistance in alloys.

Chen, Jianmin [Xiangtan University (China)] (ORCID↗

DOE OSTI2025

Preventing native oxide formation in niobium thin films through platinum encapsulation

Superconducting transmon qubits are a key technology in quantum computing, with niobium (Nb) widely used due to its favorable superconducting properties and compatibility with scalable fabrication. However, the performance of Nb-based qubits is hindered by two-level systems (TLS), which arise predominantly from native oxide layers at surfaces and interfaces. These oxides and suboxides form rapidly in air and contribute significantly to decoherence by introducing dielectric losses. While various mitigation strategies, including thermal-annealing, chemical-etching, and nitrogen plasma treatment, have been explored, many are challenging to integrate into large-scale manufacturing due to complexity and instability in ambient conditions. In this study, we investigate the structural, chemical, and superconducting properties of room-temperature sputtered Nb thin films grown on sapphire substrates. We focus on a surface protection strategy using noble metal encapsulation with platinum (Pt) to suppress oxides and reduce TLS-related losses. Structural and chemical characterization were performed using X-ray diffraction, X-ray photoelectron spectroscopy, and transmission electron microscopy. Superconducting properties were measured using a physical property measurement system. Results demonstrate that Pt encapsulation effectively suppresses surface oxidation and mitigates its detrimental impact on superconducting performance. In conclusion, this approach offers a promising path toward enhancing the coherence of Nb-based qubits while remaining compatible with scalable-fabrication processes.

36 MATERIALS SCIENCE↗

NASA NTRS1996

Evaluation of an Anthropometric Human Body Model for Simulated EVA Task Assessment

One of the more mission-critical tasks performed in space is extravehicular activity (EVA) which requires the astronaut to be external to the station or spacecraft, and subsequently at risk from the many threats posed by space. These threats include, but are not limited to: no significant atmosphere, harmful electromagnetic radiation, micrometeoroids, and space debris. To protect the astronaut from this environment, a special EVA suit is worn which is designed to maintain a sustainable atmosphere (at 1/3 atmosphere) and provide protection against the hazards of space. While the EVA suit serves these functions well, it does impose limitations on the astronaut as a consequence of the safety it provides. Since the astronaut is in a virtual vacuum, any atmospheric pressure inside the suit serves to pressurize the suit and restricts mobility of flexible joints (such as fabric). Although some of the EVA suit joints are fixed, rotary-style joints, most of the mobility is achieved by the simple flexibility of the fabric. There are multiple layers of fabric, each of which serves a special purpose in the safety of the astronaut. These multiple layers add to the restriction of motion the astronaut experiences in the space environment. Ground-based testing is implemented to evaluate the capability of EVA-suited astronauts to perform the various tasks in space. In addition to the restriction of motion imposed by the EVA suit, most EVA activity is performed in a micro-gravity (weight less) environment. To simulate weightlessness EVA-suited testing is performed in a neutral buoyancy simulator (NBS). The NBS is composed of a large container of water (pool) in which a weightless environment can be simulated. A subject is normally buoyant in the pressurized suit; however he/she can be made neutrally buoyant with the addition of weights. In addition, most objects the astronaut must interface with in the NBS sink in water and flotation must be added to render them "weightless". The implementation of NBS testing has proven to invaluable in the assessment of EVA activities performed with the Orbiter and is considered to be a key step in the construction of the International Space Station (ISS). While the NBS testing is extremely valuable, it does require considerable overhead to maintain and operate. It has been estimated that the cost of utilizing the facility is approximately $10,000 per day. Therefore it is important to maximize the utility of NBS testing for optimal results. One important aspect to consider in any human/worksite interface is the considerable wealth of anthropometric and ergonomic data available. A subset of this information specific to EVA activity is available in NASA standard 3000. The difficulty in implementing this data is that most of the anthropometric information is represented in a two-dimensional format. This poses some limitations in complete evaluation of the astronaut's capabilities in a three-dimensional environment. Advances in computer hardware and software have provided for three-dimensional design and implementation of hardware with the advance of computer aided design (CAD) software. There are a number of CAD products available and most companies and agencies have adopted CAD as a fundamental aspect of the design process. Another factor which supports the use of CAD is the implementation of computer aided manufacturing (CAM) software and hardware which provides for rapid prototyping and decreases the time to product in the design process. It is probable that most hardware to be accessed by astronauts in EVA or IVA (intravehicular activity) has been designed by a CAD system, and is therefore represented in three-dimensional space for evaluation. Because of the implementation of CAD systems and the movement towards early prototyping, a need has arisen in industry and government for tools which facilitate the evaluation of ergonomic consideration in a three-dimensional environment where the hardware has been designed by the CAD tools. One such product is Jack which was developed by the University of Pennsylvania with funding from several government agencies, including NASA. While the primary purpose of Jack is to model human figures in a ground-based (gravity) environment, it can be utilized to evaluate EVA-suited activities as well. The effects of simulated gravity must be turned off by turning off "behaviors". Although Jack provides human figures for manipulation, the primary instrument to be evaluated for EVA mobility is the work envelope provided by the EVA suit. An EVA Jack suit model has been developed by NASA-JSC and was utilized in this study. This suit model provided a more restrictive motion environment as expected for an EVA suited subject. As part of this study, the anthropometric dimensions for a 50th percentile male were compared with basic anthropometric data and were found to be representative for the population group expected in the NASA flight program. The joints for the suit were created in a manner which provided consistent performance with EVA reach envelopes published in NASA standard #3000.

Etter, Brad↗

DOE OSTI2026

HYBRID COMPOSITES VIA CO-EXTRUSION ADDITIVE MANUFACTURING-COMPRESSION MOLDING FOR PERFORMANCE OPTIMIZATION

The growing demand for hybrid polymer composites with multifunctional properties has led to the development of various hybridization techniques, such as multi-material compounding and controlled laminate stacking sequence. In this study, a novel hybrid manufacturing approach was used by integrating a multiplexing extrusion system (MExS) based on additive manufacturing with subsequent compression molding process. This technique enabled the co-extrusion of different materials during the additive manufacturing process to fabricate composites with tailored performance. The developed hybrid composite featured a skin layer of glass fiberreinforced polycarbonate (PC/GF) encapsulating a carbon fiber-reinforced acrylonitrile butadiene styrene (CF/ABS) core. The structure was engineered to promote improved thermal and impact resistance at the surface, supported by a stiff core for enhanced overall mechanical integrity. Mechanical, thermal and morphological properties of the hybrid composites were investigated to understand trade-offs in performance compared to a single-material system. The results demonstrate that this approach enables the production of multifunctional composites suitable for applications such as automotive body panels and protective housings, where a balance of weight, mechanical strength, and thermal performance is essential.

Wasti, Sanjita [ORNL]↗