Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “FILAMENT WINDING”

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.

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

18 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Sizing comingled CF/PA 6 fibers with cellulose nanofibrils for enhanced performance properties

Compatibility between the reinforcing phase and the polymer matrix is critical to achieving the desired mechanical and thermal performance of composite materials. Several mechanisms can enhance this interfacial interaction, including surface treatments (e.g., oxidation, plasma, or irradiation), in-situ nanoparticle deposition, and fiber sizing. Here, in this study, cellulose nanofibrils (CNF) were employed as a sustainable sizing agent to modify the interface in commingled carbon fiber (CF)/polyamide 6 (PA 6) yarns, in which CF and PA6 filaments are intimately blended to enable simultaneous consolidation. A 0.25 wt% CNF aqueous suspension was applied under bath sonication to ensure uniform dispersion and minimize agglomeration. CNF-sized and unsized yarns were used to fabricate unidirectional composite plates via filament winding on a flat mandrel, followed by compression molding. Scanning electron microscopy confirmed CNF presence on both CF and PA6 filaments. CNF-sized composites exhibited increments in interlaminar shear strength (ILSS) by 50%, flexural strength by 11%, and tensile strength by 2.5% compared to unsized composites. Thermal analysis showed minimal changes in degradation temperature and crystallinity. These findings demonstrate that CNF sizing enhances interfacial bonding and mechanical performance, offering a scalable and environmentally friendly strategy for thermoplastic composite manufacturing along with yarn/tow handleability.

Cellulose nanofibrils (CNF)↗
DOE OSTI2026

JWST Observations of Starbursts: Dust Processing in the M82 Superwind

We present JWST MIRI and NIRCam imaging of the inner ∼5 kpc of the M82 superwind at ~ $0''_{.}05 - 0''_{.}375$(∼0.9–6.5 pc) resolution. Targeted filters probe emission from polycyclic aromatic hydrocarbons (PAHs; F335M, F360M, F770W, F1130W) and continuum (F250M, F360M) The images reveal a network of cool wind filaments traced by PAHs. PAH surface brightness declines with the inverse square of distance to the midplane, suggesting that the incident radiation field from the starburst drives the observed PAH intensity out to ±2.5 kpc. The 3.3/11.3 and 3.3/7.7 μm band ratios show uniformity with distance from the starburst, though comparisons with mid-IR dust emission models indicate a modest shift toward larger PAHs. Outside the disk, 11.3/7.7 μm increases moderately, reflecting that PAHs become more neutral with distance from the starburst as they are exposed to a declining radiation field and ionization parameter. Overall, PAHs in the wind are consistent with standard-to-large sizes and standard-to-high ionization states. Including Spitzer and Herschel data, PAH abundance (q PAH ) is set at ∼1% in the starburst and remains unchanging out to ±5 kpc off the disk. This flat q PAH profile suggests that PAHs are shielded from the hot wind, perhaps residing in the surface layers of cool clouds, with possible replenishment from cloud interiors and enrichment of the halo from previous bursts. In this picture, clouds are not dense enough to promote PAH growth, and they likely undergo radiative cooling and mixing with the hot phase to survive the gauntlet for at least ∼20 Myr.

Cronin, Serena A. [University of Maryland, College↗
DOE OSTI2024

Recent and future developments in pultrusion technology with consideration for curved geometries: A review

Herein this paper examined the current state and future developments in pultrusion with particular emphasis on its application in curved part manufacturing. The relationship between factors such as resin chemistry, fiber characteristics, and die geometry that influences the properties of pultruded product were highlighted. Moreover, the specific challenges associated with pultruding curved parts such as the complexities in achieving uniformity and structural integrity in such geometries were discussed. The review emphasized mold design, process improvement, adaptive control systems for precise resin impregnation and material selection to address these challenges. Additionally, the paper suggests the integration of real-time monitoring and data analytics as ways to enhance quality control during curved parts pultrusion. These advancements will help to overcome challenges specific to curved pultrusion and make the process more efficient. Other manufacturing techniques such as filament winding, thermoforming, pulforming were mentioned as alternatives to curved parts pultrusion. The review also explores pultruded variable curvature processes, highlighting some notable patents and article related to this subject matter. Production of pultruded variable curvature parts was seen as a key driver that can shape the future of pultrusion. Finally, the paper anticipates future trends, with sustainability, customization, integration of advanced materials, and development of techniques for pultrusion of composites parts.

42 ENGINEERING↗
DOE OSTI2025

Resin Testing and Modeling for Optimal Composite Processing

Polymer composites have properties such as high strength and stiffness, low weight, good thermal and chemical stability, as well as impact and abrasion resistance that make them ideal for high-performance applications. The chemistries of these materials are continuously improving, so determining their properties is vital for successfully producing them and achieving the desired results. Multiple methods can be employed to monitor characteristics such as heat flow, weight, dimension, and modulus as a function of time and temperature. By analyzing this information, models can be developed to predict outcomes of parameters not tested for. In one application, materials proposed for wet filament winding and the production of high pressure vessels can be analyzed to verify they will have the necessary low viscosity for good fiber wetting and long pot life for the extended handling inherent to this process. Such data about a prospective system provides valuable information on how that material could ultimately be processed to yield the desired part.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Predicting Thermoset Resin Cure Kinetics for Composite Processing

Predicting a material’s thermal properties is not only useful for designing parts but also for defining processing parameters. This is especially applicable to wet-filament winding operations and the production of composite parts using thermoset res ins. For these, the formation of cross-linking bonds is affected by time and temperature, but the degree of cross-linking can be modeled using phenomenological methods. In the current study, the Kissinger and Flynn/Wall/Ozawa methods were both used to calculate kinetic parameters and produced values that were in agreement with each other. The kinetic parameters activation energy ( E a ) and pre-exponential factor (𝐴) calculated from exothermic peak data increased between an epoxy and resole phenol resin system, with a cyanate ester having the highest. The successful application of both methods suggests applicability to future studies for developing cure recipes.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Fully Recyclable CFRP Particles (CRADA 519)

The proposed resin-enhanced materials, which utilize fully recycled CFRP (carbon-fiber-reinforced polymer) particles, are enabled by PARC's proprietary Chemically Linked Particles Networks (13 granted patents and patent applications). PNNL and PARC have collaborated to develop manufacturing methods, such as vacuum-assisted wet compression molding and filament winding, for fabricating fiber-reinforced composites with the PARC matrix. PNNL has conducted various mechanical, physical, and thermal characterizations to compare their differences between the composites with baseline and PARC matrices. Those characterizations include density, void volume fraction, optical micrography, uniaxial tension, four-point bending/flexure, interlaminar shear, coefficient of thermal expansion, glass transition temperature, and curing kinetics.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Innovative Joining Method for Hybrid Composites with Tailored Performance

In various industries, such as renewables and aerospace, the demand for carbon fiber is rapidly growing to meet the requirements of high-performance applications with optimized designs. Traditionally, these optimized designs have been limited to single-material composites due to process constraints. However, this study aims to explore the feasibility of transitioning between two different fiber types for pultrusion and filament winding processes, thereby enhancing design flexibility, and optimizing performance. This research introduces a novel method of hybrid reinforcement through splicing techniques. By employing a splicing method, fibers are merged prior to infusion, resulting in a transition of higher strength compared to traditional joints. Moreover, this technique enables the creation of composites with variable compositions, allowing for the selective placement of properties in a process previously characterized by static properties. The objective of this paper is to evaluate the mechanical properties of dry fiber splicing and its impact on the resulting composite material. Through comprehensive analysis, we aim to provide insights into the feasibility and advantages of employing this innovative splicing technique in composite manufacturing processes.

Guzorek, Steven↗
DOE OSTI2025

A Wind-driven Origin for the Firework Morphology of the Supernova Remnant Pa 30

Pa 30—the likely remnant of the Galactic Type Iax supernova of 1181 AD—displays an unusual, firework-like morphology, consisting of radial filaments extending from a common center, where a white dwarf (WD) currently drives a very fast wind (speed ≳10 4 km s −1 ). We propose the filaments arose from the Rayleigh–Taylor-unstable nature of the interface between the circumstellar medium (CSM) and the shocked wind launched by the natal WD; the filaments then elongated intact due to the Kelvin–Helmholtz-stable nature of the large initial density contrast between the wind and CSM, supplemented by the slowly declining wind density profile (relative to homologously expanding ejecta). To support this interpretation, we present two-dimensional hydrodynamical simulations and derive the filament properties, including their speed, density, and temperature, all of which are consistent with observations. We suggest the filaments elongate until the wind and CSM densities become comparable at the contact discontinuity, which occurs within 1–10 yr, and then truncate because the Rayleigh–Taylor instability (RTI) halts. The subsequent Kelvin–Helmholtz instability growth timescale across the current width of the filaments is longer than the age of Pa 30, so they remain intact. The filament-less central region in Pa 30 is therefore more likely a consequence of the finite timescale over which the RTI operates, rather than a wind termination shock. In general, firework-like filaments may form in other systems, provided there is a sufficiently large density contrast between the ejecta and its surroundings.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

Mechanical characterization of Bi-2212 composite winding pack samples for high-field superconducting magnet design

Bi₂Sr₂CaCu₂O8−x (Bi-2212) multi-filament round wire is a high-temperature superconductor (HTS) capable of carrying high transport currents, which makes it suitable for high-field magnet applications. However, its weak Ag–Mg sheath leaves it vulnerable to mechanical stress, posing challenges for high-field magnet design. To better understand and improve mechanical stress management in Bi-2212 winding packs, we conducted an experimental study evaluating the axial stress–strain behavior of five winding pack configurations with varying insulation materials, reinforcement strategies, and construction quality. Using uniaxial tensile testing at 77 K, we measured Young’s modulus and Poisson’s ratio for each composition. Our results show that pure alumina braid insulation and co-wind reinforcements significantly enhance stiffness compared to aluminosilicate braids, with more than 2.5 times increased winding pack Young’s modulus. Rule of mixtures analysis further quantified the contribution of non-wire composite components to overall stiffness. These findings highlight the critical role of insulation material selection and reinforcement design in optimizing Bi-2212 coil performance under stress, providing a foundation for improved mechanical models and more reliable high-field HTS magnet designs.

Bi-2212 magnet↗
DOE OSTI2024

Vapor kinetic energy for the detection and understanding of atmospheric rivers

Poleward water vapor transport in the midlatitudes mainly occurs in meandering filaments of intense water vapor transport, spanning thousands of kilometers long and hundreds of kilometers wide and moving eastward. The water vapor filaments are known as atmospheric rivers (ARs). They can cause extreme wind gusts, intense precipitation, and flooding along densely populated coastal regions. Many recent studies about ARs focused on the statistical analyses of ARs, but a process-level understanding of ARs remains elusive. Here we show that ARs are streams of air with enhanced vapor kinetic energy (VKE) and derive a governing equation for Integrated VKE to understand what contributes to the evolution of ARs. We find that ARs grow mainly because of potential energy conversion to kinetic energy, decay largely owing to condensation and turbulence, and the eastward movement is primarily due to horizontal advection of VKE. Our VKE framework complements the integrated vapor transport framework, which is popular for identifying ARs but lacks a prognostic equation for understanding the physical processes.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Advanced silver sheathed 2212/Ag wire for high field magnets

Commercial High Temperature Superconductors (HTS) are all tape shaped (widths > 10 times thickness), because achieving useful current densities required them to be processed into this form, even though this also makes it more problematic to use them in some important coil types. Our product is based on 2212 (Bi2Sr2CaCu2O8) and it is the only HTS that can be processed into high current density wire forms that are similar to proven low temperature superconductors (LTS), while surpassing them in field generating and operating temperature capability. Required now are higher current density, lower cost and longer length 2212 wires to enable broad utilization where HTS tape usage is problematic. In Phase II we developed vital cost-lowering process technology elements and we test-processed longer wires with the standard commercial design as baseline and benchmark for our lower cost, higher quality and longer piece length wire advances. By initial application of Jc-boosting wire features, these wires exhibited significant performance increases. This Phase IIA program has now developed and qualified these technologies for lower cost, higher quality and longer piece length manufacturing in combination with current density-boosting wire features, paving the way to manufacturing capability that is essential for cost-effective commercial utilization of 2212 wire. Technical areas included automated, high uniformity powder packing, advanced drawing, annealing, lubricant cleaning and filament bundling, followed by integration of higher current density wire features and process variations.

17 WIND ENERGY↗
DOE OSTI2025

Electron-scale Magnetic Holes Generation Driven by Whistler-to-Bernstein Mode Conversion in Fully Kinetic Plasma Turbulence

Magnetic holes (MHs) are coherent structures characterized by a strong and localized magnetic field amplitude dip, commonly observed in the heliosphere. These structures come in different sizes, from magnetohydrodynamic to kinetic scales. Subion-scale MHs are usually sustained by an electron current vortex and exhibit a strong electron temperature anisotropy, with higher temperatures perpendicular to the background magnetic field. Magnetospheric multiscale observations (MMSs) have revealed electron-scale MHs to be ubiquitous in the turbulent Earth’s magnetosheath and the solar wind, potentially playing an important role in the energy cascade and dissipation. Despite abundant observations, the origin of electron-scale MHs is still unclear and debated. In this work, we use fully kinetic simulations to investigate the role of plasma turbulence in generating electron-scale MHs. We find that the turbulence spontaneously produces electron-scale MHs via the following mechanism: first, large-scale turbulent velocity shears produce regions with high electron temperature anisotropy; these localized regions become unstable, generating oblique electron-scale whistler waves; as they propagate over the inhomogeneous turbulent background, whistler fluctuations develop an electrostatic component, turning into Bernstein-like modes; the strong electrostatic fluctuations produce current filaments that merge into an electron-scale current vortex; the resulting electron vortex locally reduces the magnetic field amplitude, finally evolving into an electron-scale MH. We show that MHs generated by this mechanism have properties consistent with MMSs and nontrivial kinetic features with a “mushroom”-shaped electron velocity distribution function. Our results have potential implications for understanding the formation and occurrence of electron-scale MHs in astrophysical turbulent and space environments, such as the Earth’s magnetosheath and the solar wind.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Experiments in 3D Printing Electric Motors

This paper catalogues a series of experiments we conducted to explore how to 3D print a DC electric motor. The individual parts of the electric motor were 3D printed but assembled by hand. First, we focused on a rotor with soft magnetic properties, for which we adopted ProtoPasta TM , which is a commercial off-the-shelf PLA filament incorporating iron particles. Second, we focused on the stator permanent magnets, which were 3D printed through binder jetting. Third, we focused on the wire coils, for which we adopted a form of laminated object manufacture of copper wire. The chief challenge was in 3D printing the coils, because the winding density is crucial to the performance of the motor. We have demonstrated that DC electric motors can be 3D printed and assembled into a functional system. Although the performance was poor due to the wiring problem, we showed that the other 3D printing processes were consistent with high performance. Nevertheless, we demonstrated the principle of 3D printing electric motors.

3D printed motor↗
DOE OSTI2025

Global stellarator coil optimization with quadratic constraints and objectives

Most present stellarator designs are produced by costly two-stage optimization: the first for an optimized equilibrium, and the second for a coil design reproducing its magnetic configuration. Few proxies for coil complexity and forces exist at the equilibrium stage. Rapid initial state finding for both stages is a topic of active research. Most present convex coil optimization codes use the least square winding surface method by Merkel (NESCOIL), with recent improvements in conditioning, regularization, sparsity, and physics objectives. While elegant, the method is limited to modeling the norms of linear functions in coil current. We present QUADCOIL, a global coil optimization method that targets combinations of linear and quadratic functions of the current. It can directly constrain and/or minimize a wide range of physics objectives unavailable in NESCOIL and REGCOIL, including the Lorentz force, magnetic energy, curvature, field-current alignment, and the maximum density of a dipole array. QUADCOIL requires no initial guess and runs nearly $10$ 2 x faster than filament optimization. Integrating it in the equilibrium optimization stage can potentially exclude equilibria with difficult-to-design coils, without significantly increasing the computation time per iteration. QUADCOIL finds the exact, global minimum in a large parameter space when possible, and otherwise finds a well-performing approximate global minimum. It supports most regularization techniques developed for NESCOIL and REGCOIL. We demonstrate QUADCOIL’s effectiveness in coil topology control, minimizing non-convex penalties, and predicting filament coil complexity with three numerical examples.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Fused Deposition Modeling Additive Manufacturing of Carbonized Structures via Waste-Enhanced Filaments

This report details the development, characterization, and use of coal-enhanced composite materials in additive manufacturing applications. High coal loading formulations—containing up to 70 wt.% coal—were successfully extruded and processed using commercially available 3D printers. Extensive experimental testing was conducted to assess the mechanical, thermal, and microstructural properties of the composites. In parallel, multi-scale computational modeling was employed to elucidate atomistic interactions and evaluate the effects of printing-induced defects on structural performance. Large-scale printability trials demonstrated the feasibility of fabricating complex components for tooling and construction applications, including wind turbine blade molds and modular wall sections. Techno-economic analyses demonstrated the cost-effectiveness and scalability of coal-enhanced composites for large-scale additive manufacturing applications such as wind turbine blade tooling.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Enhanced Cross-Shelf Exchange by the Eddies Associated With Plume Front

Broadened width of high chlorophyll concentration band with wavy structures, patches, and filaments are often observed along the western coastal next to the Pearl River Estuary over the northern South China Sea shelf during the transition period from winter to summer monsoon. Whereas, there is no such wide band in other seasons. By using a high-resolution numerical model, we reveal that the complex structure and wider band of high coastal chlorophyll concentration results from the smaller scale eddies (about 20–50 km in diameter) associated with buoyant plume-induced salinity front and density fronts, which are roughly along the 30 and 50 m isobaths, respectively. Two trains of eddies are formed along the fronts by the baroclinic instability triggered by frequently alternating winds over the fronts during the period of monsoon transition. The influences of these two trains of eddies are extended in the cross-shelf direction by their interactions, and they can temporally enhance the cross-shelf flow and material exchange. In conclusion, they serve as an efficient pathway to link the inner shelf toward the continental slope.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Additive manufacturing of sandwich panels with continuous fiber reinforced high modulus composite facings

Abstract An improved approach consisting of a combination of fiber placement and fused filament fabrication is introduced for the additive manufacture (AM) of structural grade sandwich beams. Here, sandwich beams are additively manufactured using in‐situ deposition and consolidation of continuous fiber unidirectional facings made from a commingled yarn system of e‐glass fiber (~50% vol.) and amorphous PET, and a hexagonal honeycomb core structure made from PETG. Both facings and the sandwich core are manufactured on a single machine, in one sequence (skin‐core‐skin), employing the benefit of matrix compatibility to create autohesion at the interfaces. Flexural and transverse shear rigidity are determined experimentally and compared with analytical predictions and show correlation to within 3%. Flexural strength and core shear strength are also measured. Post‐mortem examinations show that core fracture and core facing debond were the dominant failure mode in flexure. Single cantilever beam tests were performed to evaluate core facing debond toughness. Subsequently, surface preheat using infrared heaters was utilized to increase autohesion between core and facing. The results show debond toughness was increased 4 times using infrared heating. This research effort presents a manufacturing approach that has the potential for the AM of stiff, well bonded, structural grade sandwich beams, in an integrated sequence, employing in‐situ consolidation to the facings, without the need for the use of intermediate adhesives for skin‐to‐core bonding. Highlights An improved additive manufacturing technique for making sandwich panels is developed. Sandwich panel facings have fiber volume fractions of approximately 50%. Surface preheat improves core‐to‐facing debond toughness by a factor of 4. Top and bottom facings are consolidated during manufacture leading to better properties. Experimental results are compared to analytical predictions and show good correlation.

17 WIND ENERGY↗