SEARCH · Engineering Papers

Results for “compression rate”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,603 records · Page 89

All sources NASA NTRS DOE OSTI

DOE OSTI2018

Pulse current auxiliary forging of sintered TiAl alloys based on the investigation of dynamic recrystallization and phase transformation

Highlights: • DRX kinetics model of sintered near γ TiAl alloy was established. • DRX process was accompanied by twinning when compressed at 1125 °C/0.1 s{sup − 1}. • Hot deformation has a promotion to the phase transformation of γ → α. - Abstract: Pulse current auxiliary forging is a new and efficient way to fabricate high performance TiAl based alloys. Dynamic recrystallization (DRX) and phase transformation have a pronounced effect on the subsequent deformability of TiAl based alloys. Hence, the dynamic recrystallization kinetics were determined at the temperature range of 1125–1275 °C and strain rate range of 0.1–0.001 s{sup − 1}. In addition, the DRX mechanism and phase transformation of TiAl based alloys were investigated to model the microstructure evolution in order to provide guidance for the pulse current auxiliary forging process. When the specimens were compressed at 1125 °C/0.1 s{sup − 1}, twinning played an important role in the DRX process. With increasing deformation temperature, the microstructure transformed from near gamma into duplex microstructure. In addition, according to the kinetics of dynamic recrystallization and phase transformation, fully DRXed TiAl based alloys were fabricated through pulse current auxiliary forging. The as-forged TiAl-based alloys show good superplastic performance with an elongation over 410%.

36 MATERIALS SCIENCE↗

DOE OSTI2021

LightMAT - Continuous fiber malleable thermoset composites with sub-1-minute dwell times; validation of impact performance and evaluation of the efficacy of the compression forming process (CRADA 409 Final Report)

In spite of carbon fiber composite materials’ significant impact on light-weighting, performance, and efficiency in the aerospace industry, adoption of these materials has been slow in high-volume industries such as automotive. Two major barriers to adoption are cost and cycle-time. Current approaches to thermoset composite part production are dependent on in-mold curing of thermosets which are not optimal for high volume, high throughput production due to limitations and inefficiencies associated with the in-mold cure itself. In addition, ancillary activities, such as transport and storage of shelf-life-limited uncured, or B-staged prepreg materials typically necessitate refrigerated transport and storage which significantly impacts the economic and energy costs associated with manufacturing. Furthermore, limited out-life means that trimmings cannot typically be used as they partially cure during initial production leading to high scrap rates (+20% is common). Finally, the need to cure in-mold drives cycle times to multiple minutes in the best cases, and 10’s of minutes to hours in most cases. Mallinda is developing polyimine malleable thermoset prepreg composite materials which have excellent mechanical properties (100 GPa tensile modulus, 2 GPA tensile strength, 2.4% elongation at break) and high operating temperatures (Tg>200°C). At scale, polyimine resins are commensurate in price with commodity epoxy resins. What distinguishes malleable thermoset prepreg from traditional thermoset prepreg materials, is that they are fully cured during Mallinda’s roll-to-roll production of prepreg laminate. This results in 5 key value-differentiating benefits. First, it simplifies manufacturing logistics by enabling ambient transportation and storage, and by significantly extending out-life and shelf-life almost indefinitely. Second, elimination of autoclave curing reduces the economic and energy costs to the customer. Third, scrap rates can be reduced as malleable thermoset prepreg materials are directly reusable. Fourth, the manufacturing consolidation step can be roughly 10x faster than traditional thermosets, because the resin is already cured. Parts can be made via compression forming by the application of heat and pressure to quickly vitrify and consolidate a multilayer part – easily leading to sub 3-minute cycle times (at lab scale we have demonstrated a 20 second dwell time, with room for further optimization). Finally, the closed-loop cradle-to-cradle solution-based recyclability of malleable thermoset composites can also contribute significantly to the future of sustainable lightweight materials. The focus of this project was the development, optimization and validation of malleable thermoset composite materials which exhibit manufacturing cycle times of 3-minute or less, high speed impact performance on par with incumbent technologies, and defect-free consolidation of 3 dimensional parts. Government funding is required on this project because Mallinda is a start-up company whose focus is the development and scale-up of the described technology for introduction to the transportation segment. Unlike incumbent industry players, Mallinda is bringing a completely new and highly relevant malleable thermoset technology to bear on the problem of high throughput composites. As a small business, Mallinda relies on a combination of government R&D funding and private capital to perform development work.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Phase-field modeling and experiments of dynamic fracture in single crystal quartz

Predicting the onset and characteristics of brittle fracture is important for a wide range of engineering and geological material applications. In this paper, we study important aspects of brittle fracture in α-quartz by phase-field modeling and experiments using a top-down approach. In the modeling framework, the work term in the Griffith energy balance is replaced with internal energy contributions that represent surface energy, thermal energy, and elastic strain energy stored in defects. This allows parametrization of individual energy contributions in terms of internal state variables and keeps track of energy partitioning after the onset of fracture. The path and history dependence of fracture is included in evolution laws for internal state variables, e.g., entropy evolution, while the energy remains a true potential. In the experimental part, dynamic compression experiments coupled with X-ray phase contrast imaging are performed on cube-like samples with a hole. In the top-down analysis, dynamic compression and three point bending experiments from the literature are simulated with the developed phase-field damage model. In conclusion, the fitted model highlights the strain rate, size, and stress state dependence of damage nucleation and evolution in single crystal α-quartz.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Scaling Up metal additive manufacturing process to fabricate molds for composite manufacturing

Direct Energy Deposition (DED) systems are currently used to repair and maintain existing parts in the aerospace and automotive industries. This paper discusses an effort to scale up the DED technique in order to Additively Manufacture (AM) molds and dies used in the composite manufacturing industry. The US molds and dies market has been in a rapid decline over the last decade due to outsourcing to non-US entities. Oak Ridge National Laboratory (ORNL), Wolf Robotics and Lincoln Electric have developed a Metal Big Area Additive Manufacturing (MBAAM) system that uses a high deposition rate and a low-cost wire feedstock material. In this work we used the MBAAM system with a mild steel wire, ER70S-6, to fabricate a compression molding mold for composite structures used in automotive and mass-transit applications. In addition, the mechanical properties of the AM structure were investigated, and it was found that the MBAAM process delivers parts with high planar isotropic behavior. The paper investigates the microstructure and grain of the printed articles to confirm the roots of the observed planar isotropic properties. Here, the manufactured AM mold was used to fabricate 50 composite parts with no observed mold deformations.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Diffusive tunneling in an isobaric but non-isothermal fuel-pusher mixture

The hydrodynamic mix of fusion fuel and inert pusher can simultaneously generate smaller fuel pockets and finer pusher layers that separate them. Smaller fuel pockets have greater local Knudsen numbers, which tend to exacerbate the Knudsen layer reactivity reduction. A thinner pusher layer separating the neighboring fuel pockets, on the other hand, can enable the diffusive tunneling of Gamow fuel ions through the pusher layer and hence alleviate the Knudsen layer reactivity degradation. Here in this paper, the diffusive tunneling phenomenon describes a random walk process by which the Gamow fuel ions from one fuel pocket can traverse the inert pusher layer to join a neighboring fuel pocket without losing much of their energy. This is made possible by the much slower collisional slowing down rate compared with the pitch angle scattering rate of light fuel ions with heavier pusher ions. In an isobaric target mixture where fuel and pusher segments can have distinct temperatures, due to their different compressibilities, the temperature effect on the critical pusher layer areal density below which diffusive tunneling can occur, which is a property of the hydrodynamic mix, is understood by computing the ion charge state distribution using a collisional radiative model. This information is fed into the collisionality evaluation, enabling a parametric scan of the diffusive tunneling physics in terms of the target pressure, fuel, and pusher temperatures. It is found that when the gold pusher layer has a temperature above 1 keV, the variation of the pusher temperature has little effect on the critical areal mass density below which diffusive tunneling can occur. If the pusher layer is 1 keV or below, the critical areal mass density rises sharply, indicating that for a stronger fuel-pusher temperature disparity, the onset of diffusive tunneling will be at an earlier stage of the hydrodynamic mix when the fuel-pusher mixing structures are of less reduced size.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

High Efficacy Validation of Hydride Mega Tanks at the ARIES Lab (HEVHY METAL)

The High Efficacy Validation of Hydride Mega Tanks at ARIES Lab (HEVHY METAL) project will advance materials-based hydrogen storage technologies by large-scale demonstration and identification of deployment pathways. This includes demonstrating how two metal hydride HY2MEGA subsystems are installed with megawatt-scale green hydrogen infrastructure; validating its performance via rates, capacities, and efficiencies; and investigating supply and demand side techno-economics.

ARIES↗

DOE OSTI2026

Development and Application of High-Fidelity Models for Heterogeneous CO2 Frost Formation

Carbon America has developed a cryogenic carbon capture technology ("FrostCC") that separates CO2 from point source emissions by solidifying it at cold temperatures through preferential desublimation. Cooling is achieved through a series of interlinked compression, heat exchange, and expansion operations. In the current system, frosting of CO2 happens in heat exchangers, followed by CO2 recovery in a separate extraction step. In this work, multiphysics computational fluid dynamics (CFD) models are developed and validated for compressible and low Mach flows to simulate the formation of solid CO2 in flue gas flowing in a heat exchanger geometry. The models track the mass transfer rate of CO2 from gas phase to solid phase, heat released from desublimation, and the evolution of the solid CO2 layer. Simulations are used to answer scientific questions related to the angle of heat exchanger pipes, where buoyancy effects from flow velocity and pipe orientation influence CO2 frosting. Results show that upwardly angled pipes produce notably different flow structures compared to horizontal or vertical configurations, and that carbon capture efficiency correlates with buoyancy effects for pipe angles within plus or minus 23 degrees of horizontal.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1984

Mission science value-cost savings from the Advanced Imaging Communication System (AICS)

An Advanced Imaging Communication System (AICS) was proposed in the mid-1970s as an alternative to the Voyager data/communication system architecture. The AICS achieved virtually error free communication with little loss in the downlink data rate by concatenating a powerful Reed-Solomon block code with the Voyager convolutionally coded, Viterbi decoded downlink channel. The clean channel allowed AICS sophisticated adaptive data compression techniques. Both Voyager and the Galileo mission have implemented AICS components, and the concatenated channel itself is heading for international standardization. An analysis that assigns a dollar value/cost savings to AICS mission performance gains is presented. A conservative value or savings of $3 million for Voyager, $4.5 million for Galileo, and as much as $7 to 9.5 million per mission for future projects such as the proposed Mariner Mar 2 series is shown.

Rice, R. F.↗

NASA NTRS1990

Shock interference heating in scramjet engines

Experimental and analytical research sponsored by the NASA Langley Research center and the NASP Structures Technology Maturation Program to define critical aerothermal loads for the NASP engine is summarized. Presented is a review of (1) shock-shock interaction on the engine cowl leading edge that results in a supersonic jet impinging on the leading edge surface and causes the heat transfer rate to be amplified by a factor of 30 or more over the undisturbed (no shock interaction) flow stagnation point heat transfer rate, (2) the effectiveness of supersonic film cooling with and without the effects of an impinging oblique shock wave, and (3) oblique shock impingement in an axial compression corner.

Wieting, Allan R.↗

NASA NTRS1993

Computation of selected eigenvalues of generalized eigenvalue problems

The Arnoldi (1951) and Lanczos (1950) iterative algorithms are used to obtain a few selected eigenvalues of the generalized eigenvalue problem A(x) = lambdaB(x), where A and B are n x n nonsymmetric banded complex matrices. A shift-and-invert strategy is used to increase the rate of convergence toward the desired eigenvalues, and the two approaches are evaluated in view of their performance in a model problem concerning the linear stability of compressible boundary layers. A general scheme for computing the eigenvalues that lie within a 'box' in the complex plane is presented.

Nayar, Narinder↗

NASA NTRS1992

Analysis of composite structures with delaminations under combined bending and compression

A methodology had been developed for strength prediction of composite structures with delaminations under combined bending and compression loads. The methodology is an extension of the delamination analysis method developed under the USAF/Boeing/Northrop 'Damage Tolerance of Composites' program. Delamination buckling and strain energy release rate analyses are used as basic tools in the strength prediction. In addition, failure mode interaction and structural configuration effects are considered. The influence of fasteners on the strength of a delaminated structure is incorporated to evaluate assembly-caused delaminations. The capabilities and limitations of the analysis method are shown by correlating the analytical results with the existing experimental data. The failure load, failure mode and failure sequence of a structure containing delaminations are predicted and the analytical results are compared with test data.

Kan, Han-Pin↗

NASA NTRS1995

High Modulus and High T(sub g) Thermally Stable Polymers from p-Ethynyl-Terminated Rigid-Rod Monomers

Novel p-ethynyl-substituted rigid rod monomers were studied by pressure Differential Scanning Calorimetry (DSC), ThermoGravimetric Analysis (TGA), IsothermoGravimetric Analysis (IGA), and TGA-IR. These monomers, 4,4'-bis(((4-ethynylphenyl)carbonyl)oxy)biphenyl, designated 1, 1,5-bis-(((4-ethynylphenyl)carbonyl)oxy)naphthalene, designated 2, and bis(4-ethynylphenyl)pyromellitimide, designated 3, were polymerized in the solid state. Thermal polymerization in N2 or air produced highly cross-linked resins with polymerization exotherms centered between 212 and 276 C. The (delta)H's of polymerization of these resins in air were found to be double those in N2. When monomers 1 and 2 were heated in air from 23 to 750 C at 10 C/min, the main decomposition product was carbon dioxide, evolving at a maximum rate between 500 and 600 C; water was also detected as a decomposition product. Void-free neat resin moldings, designated lp to 3p, were made by compression molding the monomers and then heating them. The resulting polymers were highly cross-linked, and their glass transition temperatures (T(sub g)) were much higher than their polymerization temperatures. Using ThermoMechanical Analysis (TMA), we found that polymers lp to 3p had T(sub g)'s of 422, 329, and 380 C, respectively. The thermal and thermooxidative stabilities improved when lp to 3p were postcured in N2 (the postcured polymers were designated 1pp to 3pp). The Linear Thermal Expansions (LTE) for lp and 3p were 1% between 23 and 420 C. Using rheological analysis, we could not clearly detect the T(sub g)'s of lp to 3p because their moduli dropped only slightly between 23 and 490 C and the changes in tan beta were very low. Because of high cross-link density, their moduli changed little as the resins went from a glassy to a rubbery state. Their shear storage moduli in air ranged from 0.82 (3p, 3pp) to 1.6 GPa (lpp) at 23 C, from 0.16 (2p) to 0.7GPa(lpp) at 380 C, and from 0.18(lpp)to 0.6GPa(2p) at 490 C. Finally, these novel-p-ethynyl polymers exhibited an excellent combination of high T(sub g), low LTE, and high thermooxidative stability. Most notably, 3pp lost only 3% of its initial weight when it was aged for 500 h at 288 C in air.

Melissaris, Anastasios P.↗

DOE OSTI2023

High Efficacy Validation of Hydride Mega Tanks at ARIES Lab (HEVHY METAL)

ARIES↗

DOE OSTI2025

Novel Preprocessing Techniques for Enhancing Flowability of Miscanthus

Purpose-grown energy crops possess significant potential as promising feedstocks for biofuel and biochemical production. However, similar to other biomass feedstocks, their utilization has been hindered by handling and feeding challenges such as clogging and segregation, which prevent biorefineries from operating at full capacity. These challenges arise primarily due to particle attributes including irregular shape, high flexibility, and high compressibility, leading to interlocking, high compaction, and significant friction under stress consolidation. To enhance operational reliability, it is crucial to focus on preprocessing techniques to address these issues, alongside accurately characterizing the mechanical and physical properties and flow performance of these feedstocks. This study investigates novel preprocessing techniques, including pelletization and torrefaction, to fundamentally alter these particle attributes and improve flowability. Miscanthus, an herbaceous energy crop, was the primary focus of this study. Samples were processed using a Forest Concepts Crumbler rotary shear system and an oscillating multi-stack screen bed to achieve two nominal (baseline) particle sizes: 6mm and 2mm. The study evaluated the efficiency and energy consumption of size reduction, revealing that while 2mm particles required more energy, they exhibited better flowability and higher yield strength compared to 6mm particles. Shear and compression tests assessed the material's shear strength, internal friction, and elastic modulus, while wedge-shaped hopper tests measured the critical arching distance and mass flow rate. The results provide valuable insights into the mechanical properties and processing efficiency of Miscanthus, contributing to the development of a preprocessing framework that enhances energy efficiency and material flowability in bioenergy production. However, further preprocessing and development are required to optimize this framework fully.

09 - BIOMASS FUELS↗

DOE OSTI2016

High-precision measurements of the compressibility of chalcogenide glasses at a hydrostatic pressure up to 9 GPa

The volumes of glassy germanium chalcogenides GeSe{sub 2}, GeS{sub 2}, Ge{sub 17}Se{sub 83}, and Ge{sub 8}Se{sub 92} are precisely measured at a hydrostatic pressure up to 8.5 GPa. The stoichiometric GeSe{sub 2} and GeS{sub 2} glasses exhibit elastic behavior in the pressure range up to 3 GPa, and their bulk modulus decreases at pressures higher than 2–2.5 GPa. At higher pressures, inelastic relaxation processes begin and their intensity is proportional to the logarithm of time. The relaxation rate for the GeSe{sub 2} glasses has a pronounced maximum at 3.5–4.5 GPa, which indicates the existence of several parallel structural transformation mechanisms. The nonstoichiometric glasses exhibit a diffuse transformation and inelastic behavior at pressures above 1–2 GPa. The maximum relaxation rate in these glasses is significantly lower than that in the stoichiometric GeSe{sub 2} glasses. All glasses are characterized by the “loss of memory” of history: after relaxation at a fixed pressure, the further increase in the pressure returns the volume to the compression curve obtained without a stop for relaxation. After pressure release, the residual densification in the stoichiometric glasses is about 7% and that in the Ge{sub 17}Se{sub 83} glasses is 1.5%. The volume of the Ge{sub 8}Se{sub 92} glass returns to its initial value within the limits of experimental error. As the pressure decreases, the effective bulk moduli of the Ge{sub 17}Se{sub 83} and Ge{sub 8}Se{sub 92} glasses coincide with the moduli after isobaric relaxation at the stage of increasing pressure, and the bulk modulus of the stoichiometric GeSe{sub 2} glass upon decreasing pressure noticeably exceeds the bulk modulus after isobaric relaxation at the stage of increasing pressure. Along with the reported data, our results can be used to draw conclusions regarding the diffuse transformations in glassy germanium chalcogenides during compression.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1993

Towards a generalized computational fluid dynamics technique for all Mach numbers

Currently there exists no single unified approach for efficiently and accurately solving computational fluid dynamics (CFD) problems across the Mach number regime, from truly low speed incompressible flows to hypersonic speeds. There are several CFD codes that have evolved into sophisticated prediction tools with a wide variety of features including multiblock capabilities, generalized chemistry and thermodynamics models among other features. However, as these codes evolve, the demand placed on the end user also increases simply because of the myriad of features that are incorporated into these codes. In order for a user to be able to solve a wide range of problems, several codes may be needed requiring the user to be familiar with the intricacies of each code and their rather complicated input files. Moreover, the cost of training users and maintaining several codes becomes prohibitive. The objective of the current work is to extend the compressible, characteristic-based, thermochemical nonequilibrium Navier-Stokes code GASP to very low speed flows and simultaneously improve convergence at all speeds. Before this work began, the practical speed range of GASP was Mach numbers on the order of 0.1 and higher. In addition, a number of new techniques have been developed for more accurate physical and numerical modeling. The primary focus has been on the development of optimal preconditioning techniques for the Euler and the Navier-Stokes equations with general finite-rate chemistry models and both equilibrium and nonequilibrium thermodynamics models. We began with the work of Van Leer, Lee, and Roe for inviscid, one-dimensional perfect gases and extended their approach to include three-dimensional reacting flows. The basic steps required to accomplish this task were a transformation to stream-aligned coordinates, the formulation of the preconditioning matrix, incorporation into both explicit and implicit temporal integration schemes, and modification of the numerical flux formulae. In addition, we improved the convergence rate of the implicit time integration schemes in GASP through the use of inner iteration strategies and the use of the GMRES (General Minimized Resisual) which belongs to the class of algorithms referred to as Krylov subspace iteration. Finally, we significantly improved the practical utility of GASP through the addition of mesh sequencing, a technique in which computations begin on a coarse grid and get interpolated onto successively finer grids. The fluid dynamic problems of interest to the propulsion community involve complex flow physics spanning different velocity regimes and possibly involving chemical reactions. This class of problems results in widely disparate time scales causing numerical stiffness. Even in the absence of chemical reactions, eigenvalue stiffness manifests itself at transonic and very low speed flows which can be quantified by the large condition number of the system and evidenced by slow convergence rates. This results in the need for thorough numerical analysis and subsequent implementation of sophisticated numerical techniques for these difficult yet practical problems. As a result of this work, we have been able to extend the range of applicability of compressible codes to very low speed inviscid flows (M = .001) and reacting flows.

Walters, R. W.↗

DOE OSTI2023

Polyimide dynamically compressed to decomposition pressures: Two-wave structures captured by velocimetry and modeling

We performed a series of six plate impact experiments on polyimide and modeled them using new reactant and products equations of state combined with an Arrhenius rate model. The first experiment was diagnosed with embedded electromagnetic velocity gauges through which we directly observed attenuation of the lead shock to an approximately constant state over a propagation distance of roughly 4 mm. Simulated gauge profiles were in excellent qualitative agreement with experiment and suggested a sluggish chemical reaction that did not proceed to completion. The remaining five experiments were conducted in a transmission geometry and diagnosed velocimetrically at the sample/window interface. All five of these yielded profiles with a sharp shock followed by a more gradual approach to maximum interface velocity that was “rounded” to varying degree. These profiles proved difficult to interpret unambiguously due to the convolution of the reactive wave upon first shock with reflection of the lead wave and reshock or release by the window. Comparison with thermochemical calculations strongly suggests that the point of maximum interface velocity corresponds to the equilibrium reshock or release locus. We discuss the implications of this point for the practice of impedance matching based on the reflected Hugoniot of reactive materials such as polymers. The reactant and thermochemical products equations of state are developmental SESAME tables 97710 and 97720, respectively.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2017

Kinetic simulations of laser parametric amplification in magnetized plasmas

Laser pulse compression using magnetized resonance near the upper-hybrid frequency is promising for achieving higher output intensity in regimes previously thought impossible using unmagnetized plasmas. Using one dimensional particle-in-cell simulations, we verify that, by partially replacing plasma with an external transverse magnetic field of megagauss scale, the output pulse can be intensified by a factor of a few, due to the increased allowable amplification time despite a decreased growth rate. Further improvement is impeded by the generation of an electromagnetic wakefield, to which the amplified pulse loses more energy than it does in the unmagnetized case. This limitation can however be circumvented by the use of a stronger pump. In contrast to unmagnetized compression, the magnetized amplification remains efficient when the pump intensity is well above the wavebreaking threshold, until a higher phase-mixing threshold is exceeded. Here, this surprising resilience to wavebreaking in magnetized plasma is of great benefit for magnetized compression.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗