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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

Low-Density, Aerogel-Filled Thermal-Insulation Tiles

Aerogel fillings have been investigated in a continuing effort to develop low-density thermal-insulation tiles that, relative to prior such tiles, have greater dimensional stability (especially less shrinkage), equal or lower thermal conductivity, and greater strength and durability. In preparation for laboratory tests of dimensional and thermal stability, prototypes of aerogel-filled versions of recently developed low-density tiles have been fabricated by impregnating such tiles to various depths with aerogel formations ranging in density from 1.5 to 5.6 lb/ft3 (about 53 to 200 kg/cu m). Results available at the time of reporting the information for this article showed that the thermal-insulation properties of the partially or fully aerogel- impregnated tiles were equivalent or superior to those of the corresponding non-impregnated tiles and that the partially impregnated tiles exhibited minimal (<1.5 percent) shrinkage after multiple exposures at a temperature of 2,300 F (1,260 C). Latest developments have shown that tiles containing aerogels at the higher end of the density range are stable after multiple exposures at the said temperature.

Santos, Maryann↗
NASA NTRS2015

Macrosegregation Caused by Convection Associated with Directional Solidification through Cross-Section Change

Al-7 wt% Si and Pb-6 wt% Sb alloy samples were directionally solidified (DS), with liquid above and solid below and gravity pointing down, in cylindrical graphite crucibles through an abrupt cross-section change. Fraction eutectic distribution in the microstructure, primary dendrite spacing and primary dendrite trunk diameters have been measured in the DS samples in the vicinity of section change in order to examine the effect of convection associated with the combined influence of thermosolutal factors and solidification shrinkage. It is observed that convection not only produces extensive radial and axial macrosegregation near cross-section change, it also affects the dendritic array morphology. Primary dendrite spacing and primary dendrite trunk diameter, both, are influenced by this convection. In addition to the experimental results, preliminary results from a numerical model which includes solidification shrinkage and thermosolutal convection in the mushy zone in its analysis will also be presented

Ghods, M.↗
NASA NTRS2017

An Efficient Modelling Approach for Prediction of Porosity Severity in Composite Structures

Porosity, as a manufacturing process-induced defect, highly affects the mechanical properties of cured composites. Multiple phenomena affect the formation of porosity during the cure process. Porosity sources include entrapped air, volatiles and off-gassing as well as bag and tool leaks. Porosity sinks are the mechanisms that contribute to reducing porosity, including gas transport, void shrinkage and collapse as well as resin flow into void space. Despite the significant progress in porosity research, the fundamentals of porosity in composites are not yet fully understood. The highly coupled multi-physics and multi-scale nature of porosity make it a complicated problem to predict. Experimental evidence shows that resin pressure history throughout the cure cycle plays an important role in the porosity of the cured part. Maintaining high resin pressure results in void shrinkage and collapse keeps volatiles in solution thus preventing off-gassing and bubble formation. This study summarizes the latest development of an efficient FE modeling framework to simulate the gas and resin transport mechanisms that are among the major phenomena contributing to porosity.

Bedayat, Houman↗
NASA NTRS2019

A Numerical and Experimental Approach for Modeling Porosity Due to Entrapped Air and Volatiles Off-Gassing During Manufacturing of Composite Structures

High performance composite structures have strict requirements regarding acceptable levels of porosity. The impact can be significant on mechanical performance and mitigating the growth of voids can be a challenge given the complexity of the problem. The evolution of porosity can be summarized as a balance between sources and sinks which determine void growth or shrinkage. The primary sources of void growth include bag leaks, entrapped air in the system, off-gassing of volatiles, and cure shrinkage. Mechanisms which mitigate porosity include removal of air from the system and maintaining sufficient resin pressure during the process to keep volatiles in solution. In this paper, an approach for modeling the evolution of voids due to entrapped air and volatiles is presented. It has been shown in previous experimental studies that decreases in local resin pressure are linked to a higher likelihood of porosity formation. Results of the study are compared to experiments in which the local resin pressure was measured and micrographs of the panels were taken to characterize the porosity.

Hickmott, Curtis↗
NASA NTRSDate not supplied

J-OCTA Applications to in Space Manufacturing and Nanofluidic Technologies

We consider examples of J-OCTA software application to physics-based analysis of in-space manufacturing technologies. Firstly, we consider an atomistic model of thermal welding at the polymer-polymer interface for applications to 3D manufacturing by following diffusion of polymer chains. We show that each component of the polymer blend has its own characteristic time of diffusion and that both strain–stress and shear viscosity curves agree with experimental data. Next, nonlinear shrinkage of the metal part during manufacturing by bound metal deposition under microgravity, is considered using a multi-scale physics-based approach that spans from atomistic dynamics to full-part shrinkage. At the smallest scale we use atomistic dynamics to simulated sintering of a few Ti6Al4V nanoparticles, study sintering mechanisms and estimate important parameters including grain boundary width and diffusion rates of the atoms at the surface that are used at the other scales of modelling. Finally, we analyse selective ionic conduction through an artificial nanopore in a graphene sheet motivated by applications to desalination and energy harvesting. We build distributions of the number and orientation of water molecules in the ion’s hydration shells providing novel insight into the ion-water-carbon interaction at the nanopore.

molecular dynamics↗
NASA NTRS2026

Beyond Melting: Amorphous Bonding for Joining and Consolidation

Crystallization may be the hidden constraint in thermoplastic composite manufacturing. It requires tightly controlled cooling, induces residual stresses through shrinkage, and introduces path-dependent behavior that complicates predictive modeling yet remains essential for structural performance. This work asks: can bonding be achieved without relying on melt-driven crystallization? To address this, thin (5–20 μm) polyetherimide (PEI) interlayers are pre-healed to slow-cooled polyaryletherketone (PAEK) in two contexts. The first, Thermabond®, is sub-melt joining of low melt-PAEK laminates. Results show that bond quality is governed primarily by processing (i.e., adequate healing and film handling) rather than modest changes in interlayer thickness. This concept is then extended to laminate-scale manufacturing through an architecture known as OATMEAL (Out-of-autoclave Amorphous/semicrystalline Thermoplastic Material for Energy-efficient Aerospace-grade Laminates). PEI is healed to carbon fiber reinforced polyetheretherketone (PEEK) at the prepreg and excess PEI is then ablated from the surface. Crystallinity is developed off-line during prepreg fabrication, while subsequent consolidation occurs below the melt temperature to preserve it. Cross-ply warpage experiments show that, contrary to intuition, repeated amorphous interfaces reduce global curvature by lowering the effective stress lock-in temperature and eliminating crystallization shrinkage from the lamina response. Correspondingly, laminate behavior is accurately predicted using classical laminate theory (CLT) with a single effective stress-free temperature, whereas conventional CF/PEEK requires accounting for crystallization-driven effects. By decoupling interfacial healing from crystallization, OATMEAL enables sub-melt consolidation, reduces energy consumption by up to 75%, and increases manufacturing throughput by fivefold. These results demonstrate that amorphous bonding is not only a joining strategy, but a pathway to more predictable and scalable thermoplastic composite manufacturing.

solidification↗
NASA NTRSDate not supplied

Thermo-Poro-Mechanical Modeling of RTV Intumescence

Room temperature vulcanizing (RTV) silicone is a high-temperature adhesive used as a gap-filler between heatshield tiles in numerous entry missions. Its propensity to intumesce, or swell upon exposure to heat, is a well-known effect that needs to be carefully quantified during design. At tile interfaces of charring ablators, intumescence, combined with differential recession, could cause the gap filler to protrude past the ablator outer mold line, forming a “fence”. Fencing can in turn cause transition to turbulence of the flow wetting the heat shield, leading to augmented surface heating. Recent experiments conducted at the Plasmatron X facility, the high enthalpy wind tunnel of the Center for Hypersonics and Entry Systems Studies, have shown prominent fencing of RTV gap fillers in PICA, under both nitrogen and air plasmas. Similar observations are well known in the arcjet literature. Further experiments under controlled environment, performed using in situ X-ray micro-computed tomography (micro-CT) at the Advanced Light Source (ALS), have shown heating rate-dependent swelling and shrinkage of RTV during pyrolysis. To simulate RTV intumescence, a novel model was introduced in the Porous Materials Analysis Toolbox based on OpenFOAM, PATO, to account for pore-pressure buildup within both closed- and open-pores. The governing equation for the thermo-poro-mechanical response were developed, assuming linear elasticity for the charring silicone. A new multi-pyrolysis model that tracks non-monotonic advancement of material properties with pyrolysis was proposed. This model addresses the limitations of state-of-the-art ablator models to capture the different stages of thermal degradation and coupled thermomechanics. Swelling of RTV was simulated using the new thermo-poro-mechanical model and compared against in situ micro-CT data. Results showed good agreement in intumescence height and temperature profiles at all heating rates, indicating that the key factor contributing to RTV swelling is the internal pressure build-up within closed- and open-pores. As RTV is cured into a soft (rubbery) compound with low-porosity and permeability, initial temperature increase and pyrolysis gas production cause a significant increase of internal pressure, causing a pronounced volume growth. As thermal degradation progresses, rigidization of the silicone occurs due to char hardening which counteract volume shrinkage after gas pressure relief. Overall, our model shows that accounting for changes in properties such porosity, permeability and key thermomechanical coefficients is crucial for capturing the RTV volume change during ablation and enable a predictive capability for heatshield tile interface response. A plan for future calibration of thermomechanical properties evolution during degradation is discussed, as a key next step to close the new model.

RTV↗
NASA NTRSDate not supplied

Thermo-Poro-Mechanical Modeling of RTV Intumescence

Room temperature vulcanizing (RTV) silicone is a high-temperature adhesive used as a gap-filler between heatshield tiles in numerous entry missions. Its propensity to intumesce, or swell upon exposure to heat, is a well-known effect that needs to be carefully quantified during design. At tile interfaces of charring ablators, intumescence, combined with differential recession, could cause the gap filler to protrude past the ablator outer mold line, forming a “fence”. Fencing can in turn cause transition to turbulence of the flow wetting the heat shield, leading to augmented surface heating. Recent experiments conducted at the Plasmatron X facility, the high enthalpy wind tunnel of the Center for Hypersonics and Entry Systems Studies, have shown prominent fencing of RTV gap fillers in PICA, under both nitrogen and air plasmas. Similar observations are well known in the arcjet literature. Further experiments under controlled environment, performed using in situ X-ray micro-computed tomography (micro-CT) at the Advanced Light Source (ALS), have shown heating rate-dependent swelling and shrinkage of RTV during pyrolysis. To simulate RTV intumescence, a novel model was introduced in the Porous Materials Analysis Toolbox based on OpenFOAM, PATO, to account for pore-pressure buildup within both closed- and open-pores. The governing equation for the thermo-poro-mechanical response were developed, assuming linear elasticity for the charring silicone. A new multi-pyrolysis model that tracks non-monotonic advancement of material properties with pyrolysis was proposed. This model addresses the limitations of state-of-the-art ablator models to capture the different stages of thermal degradation and coupled thermomechanics. Swelling of RTV was simulated using the new thermo-poro-mechanical model and compared against in situ micro-CT data. Results showed good agreement in intumescence height and temperature profiles at all heating rates, indicating that the key factor contributing to RTV swelling is the internal pressure build-up within closed- and open-pores. As RTV is cured into a soft (rubbery) compound with low-porosity and permeability, initial temperature increase and pyrolysis gas production cause a significant increase of internal pressure, causing a pronounced volume growth. As thermal degradation progresses, rigidization of the silicone occurs due to char hardening which counteract volume shrinkage after gas pressure relief. Overall, our model shows that accounting for changes in properties such porosity, permeability and key thermomechanical coefficients is crucial for capturing the RTV volume change during ablation and enable a predictive capability for heatshield tile interface response. A plan for future calibration of thermomechanical properties evolution during degradation is discussed, as a key next step to close the new model.

silicone intumescence↗
DOE OSTI2024

PIP-II Linac Cryogenic Distribution System Design Challenges

The PIP-II linac Cryogenic Distribution System (CDS) is characterized by extremely small heat inflows and robust mechanical design. It consists of a Distribution Valve Box (DVB), Intermediate Transfer Line, Tunnel Transfer Line, comprising 25 Bayonet Cans, and ends with a Turnaround Can. Multiple helium streams, each characterized by distinct helium parameters, flow through each of these elements. The CDS geometry allows maintaining an acceptable pressure drop for each helium stream, considering the planned flows and helium parameters in different operation modes. This is particularly crucial for the return line of helium vapors, which return from cryomodules to the cold compressors and thus have very restrictive pressure drop requirements. On both sides of the DVB there are fixed supports for process pipes. One of the DVB design challenges was to route the process pipes in such a way that their shape provided sufficient compensation for thermal shrinkage. This ensures th at the forces resulting from thermal shrinkage acting on the cryogenic valves remain at a level acceptable to the manufacturer. The required thermal budget of the CDS was achieved by thermo-mechanical optimization of its components, like process pipes fixed supports in Bayonet Cans.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Regularized Differentiation for Bioburden Density Estimation in Planetary Protection

In this paper, we propose and investigate the performance of two novel shrinkage estimators for bioburden density estimation in planetary protection. The estimators are based on the regularized differentiation of a cumulative count of colony forming units collected throughout the data collecting session or the life cycle of the entire mission. The regularized differentiation recasts the problem of bioburden density estimation as a linear least squares problem. The least squares problem is then solved through regularization techniques, such as truncated singular value decomposition and penalized least squares. The regularization is necessary to avoid noise amplification during the differentiation of noisy data. The two regularization estimators are compared with four other commonly used estimators to simultaneously evaluate the means of multivariable independent Poisson distributions: the maximum likelihood, noninformative Bayes estimator with Jeffreys prior, Empirical Bayes using conjugate gamma-Poisson model with gamma parameters selected by method of moments, and the Clevenson-Zidek estimator. It is shown through computer-simulated data that the regularized differentiation based on ridge regression has the smallest mean-squared error among all estimators. The analysis of shrinkage mechanism implemented by regularized differentiation is performed, and it is shown that the regularized differentiation amounts to performing a weighted averaging of all the samples. The weights are determined by the regularization parameter automatically selected by the L-curve technique. Since the method of least squares makes no distributional assumptions about the data, it presents an attractive technique for bioburden density estimation when there are concerns about the misspecification of the distributional model. The paper concludes with the analysis of the bioburden data collected during InSight mission and directions for future work.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Short-term nodal load forecasting based on machine learning techniques

This paper introduces an advanced Short-term Nodal Load Forecasting (STNLF) method that forecasts nodal load profiles for the next day in power systems, based on the combined use of three machine learning techniques. Least Absolute Shrinkage and Selection Operator (LASSO) is employed to reduce the number of features for a single nodal load forecasting. Principal Component Analysis (PCA) is used to capture the features of historical loads in low-dimensional space compared to the original high-dimensional load space where features are barely possible to depict. Additionally, Bayesian Ridge Regression (BRR) is utilized to decide the parameters of the prediction model from a statistics perspective. Tests based on modified PJM load data demonstrate the effectiveness of the proposed STNLF method compared to the state-of-the-art General Regression Neural Network (GRNN) method. Moreover, the reliability of the day-ahead Unit Commitment (UC) solution is shown to have been improved, based on the forecasted load data using the proposed STNLF method.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Prediction of moisture transfer in cement-based materials: Use of a porous network model to access transfer parameters

Knowing the water transport phenomena is fundamental for understanding the durability of cement-based materials. The moisture content within cementitious materials is of primary importance because it has a direct influence on mechanical (shrinkage, creep) and chemical (penetration of aggressive agents) degradation. Many models based on the determination of the transfer properties of the material under study already exist but require fitting of the parameters to find the experimental kinetics. Transfer parameters are generally estimated from the empirical approaches developed for soils by Van Genuchten and the water vapour diffusion reduction factor is often calculated via Millington's semi-empirical model. In this paper, we make a proposal to improve the prediction of moisture transfer, through mechanisms such as drying, capillary imbibition and water vapour permeability in cement-based materials, by using a porous network model to access the transfer parameters.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Effect of PCEs with different structures on hydration and properties of cementitious materials with low water-to-binder ratio

Polycarboxylate ethers (PCEs) with different structures and densities of anchor groups in the backbone were synthesized and characterized. The surface tension of their solutions, their adsorption on cementitious particles and zeta potential of cement-silica fume pastes with PCEs were measured. Their effects on hydration and properties of cement-silica fume paste with low water-to-binder ratio were examined. Results indicated that the adsorption kinetics of theses PCEs on cementitious particles are fitted the pseudo-second-order model. The introduction of long silane chain on PCE decreased its electrostatic adsorption, while PCE was adsorbed onto the surface of particles via both chemical and electrostatic adsorption, when silicon hydroxyl is directly connected to its backbone. In the presence of PCE with higher adsorbed amount, pastes exhibited lower yield stress and higher flowability, and higher strength at 7 d and 28 d. The low plastic viscosity, autogenous and drying shrinkage were related to the low surface tension of PCE solution.

36 MATERIALS SCIENCE↗
DOE OSTI2021

On the use of limestone calcined clay cement (LC3) in high-strength strain-hardening cement-based composites (HS-SHCC)

Highlights: • Use of LC{sup 3} slightly reduces flowability and shortens the setting time of fresh matrices. • Highly polymerized C-A-S-H gel and abundant ettringite benefit flexural strength of LC{sup 3}-matrices. • Use of LC{sup 3} enhances the bond strength between fiber and high-strength matrix. • LC{sup 3}-based HS-SHCC yields similar flexural performance as the composite with Portland cement. High-strength strain-hardening cement-based composites (HS-SHCC) demonstrate excellent mechanical and durability properties. However, high cement content typical to HS-SHCC results not only in high carbon footprint, but also in excessive hydration heat and severe autogenous shrinkage. In this investigation, Limestone Calcined Clay Cement (LC{sup 3}) was used to produce sustainable HS-SHCC. The LC{sup 3} substitution resulted in higher energy consumption during mixing and in shorter setting times of the fresh, plain matrices. Although the LC{sup 3} substitution slightly reduced the compressive strength, the formation of highly polymerized C-A-S-H gel and abundant ettringite benefited the flexural strength of the plain matrices. Additionally, single-fiber pullout experiments showed that the use of LC{sup 3} led to increased fiber-matrix bond strength and pullout energy. Finally, the replacement of Portland cement by LC{sup 3} resulted in HS-SHCC with similar mechanical performance to the reference composite, indicating a high potential for using LC{sup 3} in high-performance cement-based composites.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Mechanisms of internal curing water release from retentive and non-retentive superabsorbent polymers in cement paste

This paper examines the mechanisms of desorption within cement pastes for superabsorbent polymers (SAP) with different sorption kinetics: retentive and non-retentive (self-releasing). Despite the different behavior in solution, both SAP types mitigated the autogenous shrinkage of cement pastes. {sup 1}H NMR and X-ray tomography showed that the cavities formed by both SAP types were saturated until 9–11 h after mixing, while the entrained water in the cavities redistributed to the cement matrix afterwards. In particular, the non-retentive SAP might have rapidly released the absorbed water, but the released water stayed in the original cavities. Therefore, the behavior of the SAP in the pore solution may not completely determine their internal curing performance in cement pastes. In particular, the initial absorption that forms the solution-filled cavities might be more important than whether the SAP are able to retain the solution for extended periods of time or not.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Ettringite hysteresis under sorption from molecular simulations

Highlights: • Hybrid Grand Canonical Monte Carlo (GCMC) and Molecular Dynamics (MD) simulations are performed. • Anisotropic large strain coefficient of crystal shrinkage of ettringite is provided. • Entropy increases when ettringite converts into metaettringite. • Sorption-induced stress may lead to columns collapse upon drying. • H-bonds involving OH groups in columns play a role in hysteresis. The response of ettringite under sorption is critical for the utilization of this mineral as an energy storage material and to understand the concrete durability problems associated with ettringite formation. We report molecular simulations directly sampling the osmotic ensemble to understand the sorption processes and structural changes in ettringite-metaettringite transition. Desorption branch and sorption-induced volume changes from simulations agree with the experiments. The structural changes at low relative humidity are analyzed, revealing for the first time details of metaettringite structure. The reversibility under sorption observed experimentally is captured by simulation in the ettringite domain. The reversibility in the conversion of metaettringite into ettringite is not captured by the direct simulations in the osmotic ensemble due to the large volume changes associated with ettringite desorption. Finally, we discuss the role of hydrogen bonds on the hysteresis in ettringite.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Macroscale Fabrication of Lightweight and Strong Porous Carbon Foams through Template-Coating Pair Design

Manufacturing of low-density-high-strength carbon foams can benefit the construction, transportation, and packaging industries. One successful route to lightweight and mechanically strong carbon foams involves pyrolysis of polymeric architectures, which is inevitably accompanied by drastic volumetric shrinkage (usually >98%). As such, a challenge of these materials lies in maintaining bulk dimensions of building struts that span orders of magnitude difference in length scale from centimeters to nanometers. Here, this work demonstrates fabrication of macroscale low-density-high-strength carbon foams that feature exceptional dimensional stability through pyrolysis of robust template-coating pairs. The template serves as the architectural blueprint and contains strength-imparting properties (e.g., high node density and small strut dimensions); it is composed of a low char-yielding porous polystyrene backbone with a high carbonization-onset temperature. The coating serves to imprint and transcribe the template architecture into pyrolytic carbon; it is composed of a high char-yielding conjugated polymer with a relatively low carbonization-onset temperature. The designed carbonization mismatch enables structural inheritance, while the decomposition mismatch affords hollow struts, minimizing density. The carbons synthesized through this new framework exhibit remarkable dimensional stability (≈80% dimension retention; ≈50% volume retention) and some of the highest specific strengths (≈0.13 GPa g -1 cm 3 ) among reported carbon foams derived from porous polymer templates.

36 MATERIALS SCIENCE↗