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Kumar, Vipin

Publications and source records attributed to Kumar, Vipin.

9 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Vertical z-axis discontinuous carbon fibers for improved lightning strike performance of continuous fiber-reinforced polymer composites

Effective lightning strike protection for critical aerospace and wind applications requires high electrical conductivity to dissipate current efficiently. However, polymer matrix composites face a challenge due to their inherently insulating nature. While conventional carbon fiber-reinforced composites (CFRP) exhibit electrical conductivity in the planar direction, achieving through-thickness conductivity remains an ongoing challenge. In this work, we have undertaken the fabrication of CFRP interleaved with vertically oriented carbon fibers (Z-fiber) to impart higher electrical conductivity along the thickness direction. Two Z-fiber composite variations are prepared: Z-1 with a single layer of Z-fiber and Z-5 with five interleaved layers and compared with no Z-fiber layer (Z-0) composite. The composite panels were subjected to lab-scale lightning strike tests with a current magnitude of 100 kA. To emulate real-world service conditions, an aerospace-grade paint coating was applied to the composite laminates. Comparative analysis shows Z-1 reduces damage diameter to ∼22 mm compared to Z-0 (∼26 mm), while Z-5 exhibits the least damage (∼16.7 mm), confirmed by optical microscopy. Z-5 demonstrates nine times higher through-thickness electrical conductivity than Z-0, reducing electrical anisotropy substantially. Thermal-electric finite element damage modeling predicts surface damage within 6% of experimental values for both Z-0 and Z-5 composites. Flexural tests post-lightning reveal Z-5 retains 66% flexural strength and 86% modulus, significantly better than Z-0, which retains less than 40% for both properties. This study highlights the efficacy of Z-fiber composites in lightning strike protection, offering improved through-thickness conductivity and mechanical property retention.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effect of plasma treatment on LMPAEK/CF tape and composites manufactured by automated tape placement (ATP)

Automated tape placement (ATP) process is widely used in aerospace for its advanced process control and multi-axis capabilities but faces issues like limited choice of materials and suboptimal tape consolidation. This study investigates air plasma treatment on ATP carbon fiber thermoplastic feedstock tape to address these challenges. The effects on low melt Polyaryletherketone/carbon fiber unidirectional tape (LMPAEK/CF UD tape) were analyzed. Treated and untreated tapes were used to fabricate composites and evaluated for physical, thermal, mechanical, and interfacial properties. Atomic force microscopy (AFM), X-ray photoelectron spectroscopy (XPS) and Fourier transform infrared (FTIR) analyses revealed surface roughness changes (on LMPAEK), extent of oxidation, and the presence of hydroxyl/carboxyl groups. Composites from plasma-treated tapes showed a 7.6% increase in tensile strength, 8% in tensile modulus, 18% in flexural strength, and 8.3% in flexural modulus. Further, the interlaminar shear strength improved by 18.7%. Failure analysis showed untreated composites failed via inter-ply and fiber-matrix delamination, while treated composites experienced matrix cracking and fiber breakage. This study highlights atmospheric plasma treatment as a solution to ATP’s limitations, significantly enhancing LMPAEK/CF UD tape composites’ properties.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Design optimization of lightweight automotive seatback through additive manufacturing compression overmolding of metal polymer composites

With the growing demand for enhanced automotive fuel efficiency and environmental sustainability, there is a need for lightweighting automotive components through innovative design and manufacturing processes. Here, this study leverages a combination of numerical iterative design optimization and hybrid additive manufacturing–compression molding (AM-CM) technique for metal polymer composites to lightweight an automotive seatback. The AM-CM process enables robust mechanical interlocking between metals and composites, boasting high stiffness and strength with low overall density. Replacing metallic components with such metal polymer composites allows for comparable mechanical performance while significantly reducing the overall weight. First, the automotive seatback design space is reduced to critical load carrying regions using topology optimization and high stress concentration areas are identified using finite element analysis. Next, a lightweight metal polymer subcomponent is designed for a high stress concentration region. The full seatback frame with spatially heterogeneous material-specific design is then iteratively optimized to enable enhanced stiffness with minimal weight. Overall, the automotive seatback frame designed with location-specific metal, polymer, and metal polymer composite materials weighs 20% less than the metal-only design while exhibiting similar stiffness.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Oak Ridge National Laboratory Thermoplastic Composite Joining of Pultruded Continuous Fiber Spars for Multi-Functional Battery Enclosure

Oak Ridge National Laboratory (ORNL) worked with DowAksa Industry to investigate the potential of using PA66 material to produce larger composite parts, transcending the limitations of traditional presses. The project aimed to develop a suitable material for printing battery boxes using Nylon 66 infused with 40 wt.% carbon fiber, compatible with the ORNL Additive Manufacturing and Compression Molding (AM-CM) system. However, even with extensive work, it was concluded that the material is not compatible with the AMCM process and suitable for joining using compression technique. Main reason for the incompatibility were found to be very high crystallinity of the PA66 grade chosen for this work. To improve printability, a modifier (proprietary) was added to decrease crystallinity, but this led to reduced thermal stability and adhesion issues.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Unsupervised Spatio-Temporal Data Mining Framework for Burned Area Mapping

A method reduces processing time required to identify locations burned by fire by receiving a feature value for each pixel in an image, each pixel representing a sub-area of a location. Pixels are then grouped based on similarities of the feature values to form candidate burn events. For each candidate burn event, a probability that the candidate burn event is a true burn event is determined based on at least one further feature value for each pixel in the candidate burn event. Candidate burn events that have a probability below a threshold are removed from further consideration as burn events to produce a set of remaining candidate burn events.

Boriah, Shyam↗
NASA NTRS2016

Unsupervised Framework to Monitor Lake Dynamics

A method of reducing processing time when assigning geographic areas to land cover labels using satellite sensor values includes a processor receiving a feature value for each pixel in a time series of frames of satellite sensor values, each frame containing multiple pixels and each frame covering a same geographic location. For each sub-area of the geographic location, the sub-area is assigned to one of at least three land cover labels. The processor determines a fraction function for a first sub-area assigned to a first land cover label. The sub-areas that were assigned to the first land cover label are reassigned to one of the second land cover label and the third land cover label based on the fraction functions of the sub-areas.

Boriah, Shyam↗
NASA NTRS2004

Recent History of Large-Scale Ecosystem Disturbances in North America Derived from the AVHRR Satellite Record

Ecosystem structure and function are strongly impacted by disturbance events, many of which in North America are associated with seasonal temperature extremes, wildfires, and tropical storms. This study was conducted to evaluate patterns in a 19-year record of global satellite observations of vegetation phenology from the Advanced Very High Resolution Radiometer (AVHRR) as a means to characterize major ecosystem disturbance events and regimes. The fraction absorbed of photosynthetically active radiation (FPAR) by vegetation canopies worldwide has been computed at a monthly time interval from 1982 to 2000 and gridded at a spatial resolution of 8-km globally. Potential disturbance events were identified in the FPAR time series by locating anomalously low values (FPAR-LO) that lasted longer than 12 consecutive months at any 8-km pixel. We can find verifiable evidence of numerous disturbance types across North America, including major regional patterns of cold and heat waves, forest fires, tropical storms, and large-scale forest logging. Summed over 19 years, areas potentially influenced by major ecosystem disturbances (one FPAR-LO event over the period 1982-2000) total to more than 766,000 km2. The periods of highest detection frequency were 1987-1989, 1995-1997, and 1999. Sub- continental regions of Alaska and Central Canada had the highest proportion (greater than 90%) of FPAR-LO pixels detected in forests, tundra shrublands, and wetland areas. The Great Lakes region showed the highest proportion (39%) of FPAR-LO pixels detected in cropland areas, whereas the western United States showed the highest proportion (16%) of FPAR-LO pixels detected in grassland areas. Based on this analysis, an historical picture is emerging of periodic droughts and heat waves, possibly coupled with herbivorous insect outbreaks, as among the most important causes of ecosystem disturbance in North America.

Potter, Christopher↗
NASA NTRS1994

Very fast motion planning for highly dexterous-articulated robots

Due to the inherent danger of space exploration, the need for greater use of teleoperated and autonomous robotic systems in space-based applications has long been apparent. Autonomous and semi-autonomous robotic devices have been proposed for carrying out routine functions associated with scientific experiments aboard the shuttle and space station. Finally, research into the use of such devices for planetary exploration continues. To accomplish their assigned tasks, all such autonomous and semi-autonomous devices will require the ability to move themselves through space without hitting themselves or the objects which surround them. In space it is important to execute the necessary motions correctly when they are first attempted because repositioning is expensive in terms of both time and resources (e.g., fuel). Finally, such devices will have to function in a variety of different environments. Given these constraints, a means for fast motion planning to insure the correct movement of robotic devices would be ideal. Unfortunately, motion planning algorithms are rarely used in practice because of their computational complexity. Fast methods have been developed for detecting imminent collisions, but the more general problem of motion planning remains computationally intractable. However, in this paper we show how the use of multicomputers and appropriate parallel algorithms can substantially reduce the time required to synthesize paths for dexterous articulated robots with a large number of joints. We have developed a parallel formulation of the Randomized Path Planner proposed by Barraquand and Latombe. We have shown that our parallel formulation is capable of formulating plans in a few seconds or less on various parallel architectures including: the nCUBE2 multicomputer with up to 1024 processors (nCUBE2 is a registered trademark of the nCUBE corporation), and a network of workstations.

Challou, Daniel J.↗