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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 1,585 records · Page 88
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Damage Tolerance of Sandwich Plates with Debonded Face Sheets

Axial compression tests were performed on debonded sandwich composites made of graphite/epoxy face-sheets and aramid fiber honeycomb core. The sandwich beams were manufactured using a vacuum baccrin2 process. The face-sheet and the sandwich beam were co-cured. Delamination between one of the face sheets and the core was introduced by using a Teflon layer during the curing process. Axial compression tests were performed to determine the ultimate load carrying capacity of the debonded beams. Flatwise tension tests and Double Cantilever Beam tests were performed to determine. respectively, the strength and fracture toughness of the face-sheet/core interface. From the test results semi-empirical formulas were derived for the fracture toughness and ultimate compressive load carrying capacity in terms of the core density. core thickness. face-sheet thickness and debond length. Four different failure modes and their relation to the structural properties were identified. Linear buckling analysis was found to be inadequate in predicting the compressive load carrying capacity of the debonded sandwich composites.

Avery, John L., III↗
DOE OSTI2019

Effect of Vertical Strut Arrangements on Compression Characteristics of 3D Printed Polymer Lattice Structures: Experimental and Computational Study

This paper discusses the behavior of the three-dimensional (3D) printed polymer lattice core structures during compressive deformation, by both physical testing and computer modeling. Four lattice configurations based on the body-centered cubic (BCC) unit cell were selected to investigate the effect of vertical strut arrangements on stiffness, failure load, and energy absorption per unit mass or the specific energy absorption (SEA). The basic BCC unit cell consists of struts connecting the body center to the corners of the cube. Three variations in the BCC configuration considered in this study are (1) BCCV, with vertical members connecting all nodes of the lattice, (2) BCCA, with vertical members in alternating layers of the lattice, and (3) BCCG, with a gradient in the number of vertical members increasing from none at the top layer to all vertical members at the bottom layer. The unit cell dimensions were 5 mm × 5 mm × 5 mm with strut diameter of 1 mm. The lattice was assembled with 5 cells in the x and y directions and 4 cells in the z direction. Specimens were first made by 3D printing by using a fused deposition modeling printer with acrylonitrile–butadiene–styrene thermoplastic. Specimens were then tested under compression in the z direction under quasi-static conditions. Finite element analysis was used to model the compressive behavior of the different lattice structures. Results from both experiments and finite element models show that the strength of the lattice structures is greater when vertical members are present, and the SEA depends on the lattice geometry and not its mass.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Manufacturing of Ultra-Fine Particle Coal Fly Ash–A380 Aluminum Matrix Composites with Improved Mechanical Properties by Improved Ring Milling and Oscillating Microgrid Mixing

An experimental study is presented of ultra-fine coal fly ash (CFA) aluminum matrix composites produced by successive high-power ring milling of CFA, oscillating microgrid mixing of the CFA–aluminum melt, gravity casting and rapid cooling. Samples corresponding to different CFA concentrations and particle size distributions (1 μm average, or less) are produced and subjected to microstructural and mechanical characterization, including tensile, compressive, impact, hardness and wear testing. While the usual trade-off between increased strength and hardness and reduced ductility and toughness is observed, the obtained ultra-fine particle composites are confirmed to have overall improved mechanical properties compared to composites with larger size particles previously produced by ball milling.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Current activated reactive ultrafast joining (CARUJ) of silicon carbide

In this work we propose and demonstrate a novel approach for rapid fabrication of ceramic-ceramic joint assemblies, using sintered Silicon Carbide (SiC) as an initial example. Current Activated Reactive Ultrafast Joining (CARUJ) utilizes resistive heating of carbon-based materials to apply localized heat at or around the joint zone at heating rates of 101– 103 °C/min. CARUJ is used to fabricate SiC-SiC joints with a Si-SiC interface using minimal pressure (1–2 MPa) at time scales considerably shorter (several minutes opposed to hours) than conventional approaches for similar systems. The reaction of an interfacial precursor based on elemental silicon and carbon leads to in-situ SiC formation to produce a continuous and dense bond in a single step. Measured average joint strengths of roughly 15 MPa are achieved when tested in single lap offset (SLO) compressive shear. Optional additions of refractory metals such as molybdenum can be utilized to introduce secondary inclusions such as MoSi 2 within the joint interface. We further demonstrate SiC-SiC joining using Active Brazing Alloys (ABA) and proof of concept joining of tubular geometries. The localized and rapid heat application realizes a versatile material joining technique that could be extended for joining components at the plant site.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Modeling shockwaves and impact phenomena with Eulerian peridynamics

Most previous development of the peridynamic theory has assumed a Lagrangian formulation, in which the material model refers to an undeformed reference configuration. Here, an Eulerian form of material modeling is developed, in which bond forces depend only on the positions of material points in the deformed configuration. The formulation is consistent with the thermodynamic form of the peridynamic model and is derivable from a suitable expression for the free energy of a material. We show that the resulting formulation of peridynamic material models can be used to simulate strong shock waves and fluid response in which very large deformations make the Lagrangian form unsuitable. The Eulerian capability is demonstrated in numerical simulations of ejecta from a wavy free surface on a metal subjected to strong shock wave loading. The Eulerian and Lagrangian contributions to bond force can be combined in a single material model, allowing strength and fracture under tensile or shear loading to be modeled consistently with high compressive stresses. Furthermore, we demonstrate this capability in numerical simulation of bird strike against an aircraft, in which both tensile fracture and high pressure response are important.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Additively manufactured β-Ti5553 with laser powder bed fusion: Microstructures and mechanical properties of bulk and lattice parts

Ti5553 (Ti-5Al-5Mo-5V-3Cr wt%) is a titanium alloy widely used for its high strength-to-weight ratio and good formability at elevated temperatures. Unlike Ti-6Al-4V, Ti5553 does not undergo martensitic transformation, preventing cracking of brittle martensite upon rapid cooling. This makes it a strong candidate for additive manufacturing (AM), particularly laser powder bed fusion (L-PBF). L-PBF offers the unique opportunity to make fine lattice structures to reduce component weight. Despite the growing field of AM, there have been limited studies on L-PBF Ti5553 lattices and how their properties differ from the bulk. Here the present work addresses this knowledge gap by investigating microstructures and properties of L-PBF bulk and lattice parts and the effect of post L-PBF heat treatments. Electron microscopy and mechanical testing show that the high dislocation density formed during L-PBF increases bulk part’s yield strength by approximately 100 MPa compared to the conventional alloy. Digital image correlation during compression testing of octet truss lattices reveals a layer-by-layer failure mode. Compared to the bulk, the lattice contains copious ω nanoprecipitation, weaker <001> texture, smaller average grain sizes, and larger content of high-angle grain boundaries. These features elicit differences in Taylor factor distributions for the lattice depending on load direction, underlining challenges in predicting lattice mechanical response based on bulk properties. By examining the processing-structure-property relationships in the bulk and lattice, the present results delineate their microstructural and mechanical differences and establish a benchmark for the future design applications of L-PBF Ti5553.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Correlating viscosity and die swell in 3D printing of polyphenylsulfone: A thermo-mechanical optimization modus operandi

Additive manufacturing (AM) of polyphenylsulfone (PPSU), an amorphous high-performance polymer (HPP), has shown promise in exhibiting structural integrity for many applications. With thermoplastic material extrusion 3D printing, parts consisting of layered melts exhibited voids, where the adhesion quality and void size depend on the processing parameters implemented during printing. However, the structure-process-property (SPP) relationships between the thermal properties and rheological and mechanical behavior of AM PPSU are poorly understood. Here, in this study, a comprehensive analysis of the thermal, thermo-mechanical, and layer-by-layer build-up of PPSU is investigated and correlated with viscosity and extrudate die swell behavior with void fraction volume as confirmed by high-resolution x-ray computed tomography (XCT). Gas chromatography–mass spectrometry (GC–MS) pyrolysis confirmed PPSU composition and degradation at 480 °C, consistent with thermo-gravimetric analysis TGA. A 141% difference in viscosity was observed when processing temperatures increased from 350 °C to 400 °C. Likewise, extrudate die swell decreased with increasing temperatures, resulting in a 17% difference. Tensile and compressive properties confirmed that higher extruding temperatures resulted in lower porosity and higher mechanical strength. In general, higher extruding temperatures lower the viscosity to allow for stronger cohesion between layers; however, increasing the temperature too high results in a below unity extrudate die swell, reducing mechanical properties. Therefore, to optimize the mechanical integrity of 3D printed amorphous PPSU parts, an increase in the viscosity, near unity of the extrudate die swell, and tempered extrusion temperature are needed.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Damage to Polystyrene Polymer Film by Shock Wave Induced Bubble Collapse

Metallic surfaces that are in contact with solutions are commonly used in numerous applications where these surfaces can be damaged by shock wave induced bubble collapse. Use of polymer films that coat such surfaces to prevent them from damage requires a better understanding of how much harm collapsing bubbles produce in the films. In this study, we report the results from coarse-grained molecular dynamics simulations to study the damage to polystyrene (PS) films coating a hard surface. The damage was caused by a collapsing nanobubble located in the proximity of the film and interacting with an impinging shock wave. This collapse produces a high-speed water jet that impacts the PS film with a greater force than the shock front and creates cavities/pits in the PS film. We observed that polymer molecules located in the jet vicinity undergo conformational extension in the direction perpendicular to the jet motion, while chain molecules in the rest of the film undergo compression. Furthermore, we also observed that damage to the film is sensitive to the strength of the shock wave.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Efficiency-optimized relativistic plasma harmonics for extreme fields

Bright harmonic radiation from relativistically oscillating laser plasmas offers a direct route for generating extreme electromagnetic fields. Theory predicts that under optimized conditions, the plasma medium can support strong spatiotemporal compression of laser energy in a coherent harmonic focus (CHF), delivering intensity boosts many orders of magnitude greater than the incident driving laser pulse. Although diffraction-limited performance (spatial compression) and attosecond phase locking (temporal compression) have been demonstrated experimentally, efficient coupling of relativistically intense laser pulse energy into the emitted harmonic cone has not been realized so far. Here we demonstrate that this highly nonlinear interaction can be tailored to deliver the maximum conversion efficiencies predicted from simulations. By fine-tuning the temporal profile of the driving laser on sub-picosecond (<10 −12 s) timescales, energies >9 mJ between the 12th and 47th harmonics are observed. These results are in agreement with the theoretically expected efficiency dependence on harmonic order, verifying that optimal conditions have been achieved in the generation process. This is the important final element required to achieve the expected intensity boosts from a CHF in experiments. Although obtaining spatiotemporal compression and optimal efficiency simultaneously remains challenging, the path to realizing extreme optical field strengths approaching the critical field of quantum electrodynamics (the Schwinger limit at >10 16 V cm −1 or >10 29 W cm −2 ) is now open, permitting all-optical studies of the quantum vacuum and new frontiers for intense attosecond science.

High-harmonic generation↗
DOE OSTI2019

Contaminant Cation Effect on Oxygen Transport through the Ionomers of Polymer Electrolyte Membrane Fuel Cells

We characterized the effects of cobalt (Co 2+ ) and other cation contaminants on the oxygen (O 2 ) transport properties of the PFSA ionomer used in polymer electrolyte membrane fuel cells (PEMFCs) and gained insight into the mechanisms by which contaminant cations inhibit O 2 transport. Such cations can be released by alloy catalysts and environmental conditions and pose a significant challenge to maintaining high current density performance with low platinum (Pt) loadings. We used a test cell capable of isolating the ionomer from the membrane electrode assembly (MEA), allowing for O 2 transport resistance (R O2 ) measurements using a limiting current technique. We contaminated ionomer membranes with Li + , Na + , Ni 2+ , Co 2+ , and Ce 3+ and found a general increase in R O2 for increased contamination levels and decreased water activity. In addition, our Co 2+ results indicated distinct concentration-dependent regimes. The other cation-form ionomers allowed us to separate the impacts of ion pair strength, multivalency, and reduced water uptake. We believe that these factors cause a more compressed hydrophilic domain and tortuous O 2 diffusion path, and a commensurate increase in R O2 . Lastly, we studied the impact of Co 2+ on an operating PEMFC and found an increase in R O2 consistent with the results of our isolated membrane tests.

25 ENERGY STORAGE↗
NASA NTRS1973

Shockwave-boundary layer interference heating analysis.

Interference heating correlations have been developed based on existing wind tunnel test data taken with simple configurations such as wedge/flat plate and compression corner models. For turbulent flow, peak interference heating was first correlated with shock strength (pressure ratio across shock wave) and then as a function of Reynolds number. The peak interference Stanton number was found to exhibit the same Reynolds number and Prandtl number characteristics as the Stanton number variation for undisturbed flow over a flat plate. Similar correlations were developed for laminar flow. Results indicated that for laminar flow at higher Reynolds number, the impinging shockwave may act as a boundary layer trip and cause boundary layer transition resulting in high interference heating. The correlations derived in this study can be used to scale wind tunnel model test data to a full-scale space vehicle at supersonic or hypersonic flight conditions.

Hung, F. T.↗
NASA NTRS1974

Advanced beaded and tubular structural panels. Volume 1: Design and analysis

A study was conducted to exploit the efficiency of curved elements in the design of lightweight structural panels under combined loads of axial compression, inplane shear, and bending. Data cover analytical procedures for optimum panel design, static strength analyses, results of panel design studies, and correlation of theory with test results.

Greene, B. E.↗
NASA NTRS1980

Composite materials research and education program: The NASA-Virginia Tech composites program

Major areas of study include: (1) edge effects in finite width laminated composites subjected to mechanical, thermal and hygroscopic loading with temperature dependent material properties and the influence of edge effects on the initiation of failure; (2) shear and compression testing of composite materials at room and elevated temperatures; (3) optical techniques for precise measurement of coefficients of thermal expansion of composites; (4) models for the nonlinear behavior of composites including material nonlinearity and damage accumulation and verification of the models under biaxial loading; (5) compressive failure of graphite/epoxy plates with circular holes and the buckling of composite cylinders under combined compression and torsion; (6) nonlinear mechanical properties of borsic/aluminum, graphite/polyimide and boron/aluminum; (7) the strength characteristics of spliced sandwich panels; and (8) curved graphite/epoxy panels subjected to internal pressure.

Herakovich, C. T.↗
NASA NTRS1980

Buckling and postbuckling research on flat and curved composite panels

Progress in the development of verified design technology for generic advanced-composite structural components loaded in compression is reported. Generic structural configurations material systems and load ranges of interest for a given application were investigated using structural procedures, structural analysis procedures, and laboratory testing of structural specimens. Both flat and curved composite compression panels that are designed either to be buckling resistant or to have postbuckling strength depending on the expected application of the panels were considered.

Starnes, J. H., Jr.↗
NASA NTRS1990

Development and mechanical properties of construction materials from lunar simulants

The development of construction materials such as concrete from lunar soils without the use of water requires a different methodology than that used for conventional terrestrial concrete. Currently, this research involves two aspects: (1) liquefaction of lunar simulants with various additives in a furnace so as to produce a construction material like an intermediate ceramic; and (2) cyclic loading of simulant with different initial vacuums and densities with respect to the theoretical maximum densities (TMD). In both cases, bending, triaxial compression, extension, and hydrostatic tests will be performed to define the stress-strain strength response of the resulting materials. In the case of the intermediate ceramic, bending and available multiaxial test devices will be used, while for the compacted case, tests will be performed directly in the new device. The tests will be performed by simulating in situ confining conditions. A preliminary review of high-purity metal is also conducted.

Desai, Chandra S.↗
NASA NTRS1992

Transient events in the outer magnetosphere - Boundary waves of flux transfer events?

Simultaneous solar wind and magnetospheric observations are presented for a series of flux transfer events (FTEs) observed by the UKS and IRM spacecraft in the outer prenoon magnetosphere on October 28, 1984. The CCE satellite, located near local noon, observed an enhancement in the magnetospheric magnetic field strength 4 min prior to each IRM/UKS event, suggesting the antisunward propagation of a compression in the magnetopause surface. It is suggested that these compressions resulted from wavy magnetopause motion driven by variations in the solar wind dynamic pressure applied to the magnetosphere, rather than the motion of FTEs formed by magnetic merging. This hypothesis is confirmed by the fact that the events previously identified as FTEs occurred during a sequence of quasi-periodic (5-6 min) oscillations in the magnetospheric plasma velocity and magnetic field.

Sibeck, D. G.↗
NASA NTRS1994

TEXCAD: Textile Composite Analysis for Design. Version 1.0: User's manual

The Textile Composite Analysis for Design (TEXCAD) code provides the materials/design engineer with a user-friendly desktop computer (IBM PC compatible or Apple Macintosh) tool for the analysis of a wide variety of fabric reinforced woven and braided composites. It can be used to calculate overall thermal and mechanical properties along with engineering estimates of damage progression and strength. TEXCAD also calculates laminate properties for stacked, oriented fabric constructions. It discretely models the yarn centerline paths within the textile repeating unit cell (RUC) by assuming sinusoidal undulations at yarn cross-over points and uses a yarn discretization scheme (which subdivides each yarn not smaller, piecewise straight yarn slices) together with a 3-D stress averaging procedure to compute overall stiffness properties. In the calculations for strength, it uses a curved beam-on-elastic foundation model for yarn undulating regions together with an incremental approach in which stiffness properties for the failed yarn slices are reduced based on the predicted yarn slice failure mode. Nonlinear shear effects and nonlinear geometric effects can be simulated. Input to TEXCAD consists of: (1) materials parameters like impregnated yarn and resin properties such moduli, Poisson's ratios, coefficients of thermal expansion, nonlinear parameters, axial failure strains and in-plane failure stresses; and (2) fabric parameters like yarn sizes, braid angle, yarn packing density, filament diameter and overall fiber volume fraction. Output consists of overall thermoelastic constants, yarn slice strains/stresses, yarn slice failure history, in-plane stress-strain response and ultimate failure strength. Strength can be computed under the combined action of thermal and mechanical loading (tension, compression and shear).

Naik, Rajiv A.↗