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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Design of Multifunctional Hierarchical Space Structures

We describe a system for the design of space structures with tunable structural properties based on the discrete assembly of modular lattice elements. These lattice elements can be constructed into larger beam-like elements, which can then be assembled into large scale truss structures. These discrete lattice elements are reversibly assembled with mechanical fasteners, which allows them to be arbitrarily reconfigured into various application-specific designs. In order to assess the validity of this approach, we design two space structures with similar geometry but widely different structural requirements: an aerobrake, driven by strength requirements, and a precision segmented reflector, driven by stiffness and accuracy requirements. We will show agreement between simplified numerical models based on hierarchical assembly and analytical solutions. We will also present an assessment of the error budget resulting from the assembly of discrete structures. Lastly, we will address launch vehicle packing efficiency issues for transporting these structures to lower earth orbit.

Aeronautics↗
DOE OSTI2023

Investigation of 3D printed lightweight hybrid composites via theoretical modeling and machine learning

Hybrid composites combine two or more different fillers to achieve multifunctional or advanced material properties, such as lightweight and enhanced mechanical properties. The properties of the composites significantly depend on their microstructures, which can be tailored via advanced 3D printing processes. Understanding the process-structure-property relationships is critical to enable the design and engineering of novel hybrid composites for applications in aerospace, automotive, and protective coatings. Here, for this work, we develop 3D printable and lightweight hybrid composites and leverage the conventional design of experiments, a theoretical hybrid model, and an image-driven machine learning (ML) method to investigate their mechanical behaviors. The hybrid composites are formulated with elastomer matrix, microfillers, and thin-shell particles, enabling a significant degree of design freedom of microstructures with densities and mechanical properties varying up to 70% and 91%, respectively. Our statistical analysis indicates that the 3D printing path direction and the microfibers fraction are dominating process parameters with contribution percentages of 45.3% and 57.7% on the specific stiffness and strength, respectively. A hybrid mechanics model is developed based on a simple Weibull distribution function and classical single-filler models to effectively capture the variations in mechanical properties, however, it overestimates the values due to its statistical constraints and idealization of experimental uncertainty. The image-driven ML model leverages the microscale images directly without losing the structural details, shows more accurate predictions with experimental data, and has 48.6% lower root mean square error than the theoretical model.

3D printing↗
NASA NTRS2002

A Multifunctional Interface Method for Coupling Finite Element and Finite Difference Methods: Two-Dimensional Scalar-Field Problems

A multifunctional interface method with capabilities for variable-fidelity modeling and multiple method analysis is presented. The methodology provides an effective capability by which domains with diverse idealizations can be modeled independently to exploit the advantages of one approach over another. The multifunctional method is used to couple independently discretized subdomains, and it is used to couple the finite element and the finite difference methods. The method is based on a weighted residual variational method and is presented for two-dimensional scalar-field problems. A verification test problem and a benchmark application are presented, and the computational implications are discussed.

Ransom, Jonathan B.↗
NASA NTRS2009

Electrical Resistance of SiC/SiC Ceramic Matrix Composites for Damage Detection and Life-Prediction

Ceramic matrix composites (CMC) are suitable for high temperature structural applications such as turbine airfoils and hypersonic thermal protection systems due to their low density high thermal conductivity. The employment of these materials in such applications is limited by the ability to accurately monitor and predict damage evolution. Current nondestructive methods such as ultrasound, x-ray, and thermal imaging are limited in their ability to quantify small scale, transverse, in-plane, matrix cracks developed over long-time creep and fatigue conditions. CMC is a multifunctional material in which the damage is coupled with the material s electrical resistance, providing the possibility of real-time information about the damage state through monitoring of resistance. Here, resistance measurement of SiC/SiC composites under mechanical load at both room temperature monotonic and high temperature creep conditions, coupled with a modal acoustic emission technique, can relate the effects of temperature, strain, matrix cracks, fiber breaks, and oxidation to the change in electrical resistance. A multiscale model can in turn be developed for life prediction of in-service composites, based on electrical resistance methods. Results of tensile mechanical testing of SiC/SiC composites at room and high temperatures will be discussed. Data relating electrical resistivity to composite constituent content, fiber architecture, temperature, matrix crack formation, and oxidation will be explained, along with progress in modeling such properties.

Smith, Craig↗
NASA NTRS2010

A Multifunctional Coating for Autonomous Corrosion Control

Corrosion is a destructive process that often causes failure in metallic components and structures. Protective coatings are the most commonly used method of corrosion control. However, progressively stricter environmental regulations have resulted in the ban of many commercially available corrosion protective coatings due to the harmful effects of their solvents or corrosion inhibitors. This work concerns the development of a multifunctional, smart coating for the autonomous control of corrosion. This coating is being developed to have the inherent ability to detect the chemical changes associated with the onset of corrosion and respond autonomously to control it. The multi-functionality of the coating is based on microencapsulation technology specifically designed for corrosion control applications. This design has, in addition to all the advantages of other existing microcapsules designs, the corrosion controlled release function that allows the delivery of corrosion indicators and inhibitors on demand only when and where they are needed. Corrosion indicators as well as corrosion inhibitors have been incorporated into the microcapsules, blended into several paint systems, and tested for corrosion detection and protection efficacy.

Calle, Luz M.↗
NASA NTRSDate not supplied

Measuring Titanium Heat Pipe Thermal Conductivity for CO2 Adsorption Systems

Current models of the Air-Cooled Temperature Swing Adsorption Compressor (AC-TSAC) being developed for long duration space exploration utilize cooling chambers and heat plates to adsorb and desorb contaminants -13 . To reduce resources required and lower the equivalent system mass (ESM), the study focuses on determining the applications of titanium heat pipe systems to operate both phases, allowing for future research into the development of a heat pipe chamber to hold the zeolite formulations.

multifunctional sorbent↗
DOE OSTI2022

5.1.6 Demo #6: NanoStitch (NAWAStitch) Multifunctional Composites Trade Validation

The overall objective of the NanoStitch Multifunctional Composites Trade Validation Demonstration project was to determine the value proposition of adding NanoStitch to rapid-cure composite systems for structures used in the expanding sector of advanced air mobility (AAM) and specifically electric vertical take-off and landing (eVTOL) aircraft. The expected value proposition was stronger composite parts, with new multifunctional attributes, that are lower cost to fabricate and maintain. NanoStitch is a new composite innovation where a contiguous vertically aligned carbon nanotube (VACNT) forest is located between each ply of a laminate composite resulting in improved mechanical properties as well as other multifunctional properties such as enhanced thermal and electrical conductivity. NanoStitch was originally distributed by N12, later acquired by NAWA Technologies, now called NAWAStitch, and henceforth referred to in this document as NAWAStitch. Two significant evaluations were framed to help meet the overall objective. First, was Task 1 to evaluate the effects that adding NAWAStitch to a rapid cure material system would have on the mechanical and processing properties of the material. Second, was Task 2 to evaluate the workability of adding NAWAStitch to practical flight demonstration articles. From previous research, it was already known that the application of NAWAStitch to a composite structure can enhance the mechanical properties of that structure. However, this project will help the engineering community understand those benefits and the basic structural strength values to apply when incorporating NAWAStitch material into composite structure that utilizes a rapid-cure resin system, which is novel. Testing showed that by adding NAWAStitch to the prepreg, most material properties were improved because the VACNTs strengthened the resin to fiber interface, and the interface itself, between plies. For example compression strength improved by more than 20%, and erosion resistance by more than 50%. The UDRI team identified two flight demonstration articles through discussions with Aurora Flight Sciences (Aurora) and reviewing literature on air mobility and the eVTOL market. The demonstration articles were a thin skin honeycomb panel and a section from an eVTOL propeller blade. The manufacturing and testing trials of the demonstration articles were as follows: • NAWAStitch added no manufacturing complexity or detriment to the article physical qualities, while at the same time added multifunctional properties such as enhanced rain erosion and electrothermal de-icing besides enhanced mechanical properties • VACNTs did not increase or hurt the mechanical properties of the interface between honeycomb core materials and the thin skin face sheet • Demonstrated successful de-icing function in an eVTOL propeller meeting real-world specifications in uniformity and endurance • Multifunctional eVTOL propeller cost analysis showed a cost savings of at least 67 % for a single propeller blade with multifunctional de-icing capability and improved mechanical properties which equates to a potential savings of $10,116 per eVTOL aircraft with six three-bladed propellers Overall, the results of this project can provide additional tools for the composite industry to optimize energy efficiency through faster and stronger composite parts that are lower cost to fabricate and maintain. Additionally, the results of this effort can help US industry like NAWA America set the stage for rapid growth and establishment of a manufacturing facility in Ohio. The project has given NAWA America the basic understanding of how the addition of VACNTs to a composite structure can affect the mechanical properties and hence point them to potential commercial applications. The project has also provided Teijin Carbon US with another potential material application for their rapid cure materials that are manufactured at the Renegade facility in Miamisburg, OH.

36 MATERIALS SCIENCE↗
NASA NTRS1985

A research program in active control/aeroelasticity

In this research period a synthesis methodology for multifunctional robust aeroservoelastic systems was developed. The development consisted of the following stages: (1) development of an universal diagram to determine phase and gain margins of a multi-input multi-output (MIMO) system using singular value based stability margin criteria; (2) determination of singular value gradients with respect to design parameters and their application to improve stability margins of multiloop system; and (3) application of constrained optimization techniques to synthesize a low order robust controller for a high order MIMO aeroservoelastic system while satisfying several design constraints on the dynamic loads and responses and stability margins at the plant input and output. Overall research activities are summarized.

Source record↗
NASA NTRS2012

A Multifunctional Smart Coating for Autonomous Corrosion Control

Corrosion is a destructive process that often causes failure in metallic components and structures. Protective coatings are the most commonly used method of corrosion control. However, progressively stricter environmental regulations have resulted in the ban of many commercially available corrosion protective coatings due to the harmful effects of their solvents or corrosion inhibitors. This work concerns the development of a multifunctional, smart coating for the autonomous control of corrosion. This coating is being developed to have the inherent ability to detect the chemical changes associated with the onset of corrosion and respond autonomously to control it. The multi-functionality of the coating is based on micro-encapsulation technology specifically designed for corrosion control applications. This design has, in addition to all the advantages of other existing microcapsules designs, the corrosion controlled release function that allows the delivery of corrosion indicators and inhibitors on demand only when and where needed. Corrosion indicators as well as corrosion inhibitors have been incorporated into microcapsules, blended into several paint systems, and tested for corrosion detection and protection efficacy. This

Calle, Luz Marina↗
DOE OSTI2021

Surface lattice engineering for fine-tuned spatial configuration of nanocrystals

Hybrid nanocrystals combining different properties together are important multifunctional materials that underpin further development in catalysis, energy storage, et al., and they are often constructed using heterogeneous seeded growth. Their spatial configuration (shape, composition, and dimension) is primarily determined by the heterogeneous deposition process which depends on the lattice mismatch between deposited material and seed. Precise control of nanocrystals spatial configuration is crucial to applications, but suffers from the limited tunability of lattice mismatch. Here, we demonstrate that surface lattice engineering can be used to break this bottleneck. Surface lattices of various Au nanocrystal seeds are fine-tuned using this strategy regardless of their shape, size, and crystalline structure, creating adjustable lattice mismatch for subsequent growth of other metals; hence, diverse hybrid nanocrystals with fine-tuned spatial configuration can be synthesized. This study may pave a general approach for rationally designing and constructing target nanocrystals including metal, semiconductor, and oxide.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2025

Machine learning-driven design and self-sensing capabilities of automotive bumper lattices for adaptive impact response

We present a novel approach to design an automotive bumper energy absorber using carbon fiber reinforced polymer composites, optimized to meet conflicting performance requirements for two distinct impact scenarios. The design must satisfy both a low-speed (2.5 mph) pendulum intrusion test, simulating vehicle-to-vehicle collisions, and a high-speed (25 mph) leg flexion test, replicating pedestrian impacts. These tests demand opposing deformation characteristics: high flexibility (deformation < 85 mm) for the former and high stiffness (deformation < 22 mm) for the latter. To address these contradictory requirements, we developed a machine learning (ML) framework for inverse optimization of lattice designs and material selection. Unlike traditional iterative design processes, our ML model directly outputs optimal design parameters and material choices based on target performance inputs. The energy absorber was fabricated using advanced additive manufacturing techniques, including extrusion deposition and digital light processing. The integration of carbon fibers provides multifunctionality to the bumper structure, enabling self-sensing capabilities through changes in electrical resistivity under compression. This electrical response demonstrates high repeatability under multiple cycles at 2% compression and exhibits distinct signatures during crack formation under high deformation. This research offers adaptive performance through innovative design methodologies and smart material integration. The approach has potential applications in various fields requiring adaptive energy absorption and real-time structural health monitoring.

Chawla, Komal [ORNL] (ORCID:0000000190327565)↗
DOE OSTI2020

A new approach of reduction of carbon dioxide emission and optimal use of carbon and hydrogen content for the desired syngas production from coal

We report this research is designed to make progress in overcoming the challenges through the development of a two-stage coal processing. Specifically, a two-stage process was used to maximize the use of the carbon in coal or increase the carbon monoxide yield or lower carbon dioxide and methane yields. Carbon dioxide-char gasification in the absence of water can generate carbon monoxide with near-zero methane, which is desired to produce high-carbon and low-hydrogen chemicals such as oxalic acid through catalytic carbon monoxide coupling and hydrolysis. The technology is applicable to any coal, although Power River Basin (PRB) coal is used as an example feedstock in this research Also, the sodium-iron catalyst can accelerate not only the reaction kinetics in both stages but also increase the hydrogen/carbon monoxide ratio in the syngas produced in the second stage. In other words, the catalyst is a multifunctional agent, which can not only intensify the overall coal process efficiency but also improve the qualities of the desired syngas products and reduce carbon dioxide emission. Thus, In the 1st stage, the catalysts can significantly reduce the CO 2 -char gasification by as high as 75.00%. In the 2nd stage, the H 2 /CO ratio of ideal syngas is ~2:1 with near-0 CH 4 generation and the CH4 production can be reduced as high as 61.29% for the CO 2 –H 2 O-Char coal gasification. The activation energy for the 2nd stage is reduced by as high as 35.43% than that of raw coal without use Na–Fe catalyst. The overall carbon footprint reduction for the study is reduced by 87.33% in the 1st stage and 96.77% compared to the direct coal combustion.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1997

Automated Liquid-Level Control of a Nutrient Reservoir for a Hydroponic System

A microprocessor-based system for control of the liquid level of a nutrient reservoir for a plant hydroponic growing system has been developed. The system uses an ultrasonic transducer to sense the liquid level or height. A National Instruments' Multifunction Analog and Digital Input/Output PC Kit includes NI-DAQ DOS/Windows driver software for an IBM 486 personal computer. A Labview Full Development system for Windows is the graphical programming system being used. The system allows liquid level control to within 0.1 cm for all levels tried between 8 and 36 cm in the hydroponic system application. The detailed algorithms have been developed and a fully automated microprocessor based nutrient replenishment system has been described for this hydroponic system.

Smith, Boris↗
NASA NTRS2009

Improved Joining of Metal Components to Composite Structures

Systems requirements for complex spacecraft drive design requirements that lead to structures, components, and/or enclosures of a multi-material and multifunctional design. The varying physical properties of aluminum, tungsten, Invar, or other high-grade aerospace metals when utilized in conjunction with lightweight composites multiply system level solutions. These multi-material designs are largely dependent upon effective joining techAn improved method of joining metal components to matrix/fiber composite material structures has been invented. The method is particularly applicable to equipping such thin-wall polymer-matrix composite (PMC) structures as tanks with flanges, ceramic matrix composite (CMC) liners for high heat engine nozzles, and other metallic-to-composite attachments. The method is oriented toward new architectures and distributing mechanical loads as widely as possible in the vicinities of attachment locations to prevent excessive concentrations of stresses that could give rise to delaminations, debonds, leaks, and other failures. The method in its most basic form can be summarized as follows: A metal component is to be joined to a designated attachment area on a composite-material structure. In preparation for joining, the metal component is fabricated to include multiple studs projecting from the aforementioned face. Also in preparation for joining, holes just wide enough to accept the studs are molded into, drilled, or otherwise formed in the corresponding locations in the designated attachment area of the uncured ("wet') composite structure. The metal component is brought together with the uncured composite structure so that the studs become firmly seated in the holes, thereby causing the composite material to become intertwined with the metal component in the joining area. Alternately, it is proposed to utilize other mechanical attachment schemes whereby the uncured composite and metallic parts are joined with "z-direction" fasteners. The resulting "wet" assembly is then subjected to the composite-curing heat treatment, becoming a unitary structure. It should be noted that this new art will require different techniques for CMC s versus PMC's, but the final architecture and companion curing philosophy is the same. For instance, a chemical vapor infiltration (CVI) fabrication technique may require special integration of the pre-form and

Semmes, Edmund↗
DOE OSTI2020

Catalytic Removal of Oxygen and Pollutants in Exhaust Gases from Pressurized Oxy-Combustors

The primary goal of this project was to develop and validate advanced catalytic materials and systems for purifying the flue gas generated from pressurized oxy-combustors in an effort to achieve the purity specifications of carbon dioxide (CO 2 ) streams required by the U.S. Department of Energy (USDOE) for application in enhanced oil recovery. The technology has shown great potential for improving energy efficiency, simplifying process complexity, and lowering costs compared with current state-of-the-art oxy-combustion flue gas purification technologies. Laboratory studies were conducted for the development, characterization, and screening of metal catalysts for residual oxygen (O 2 ) reduction with methane (CH 4 ) and multifunctional carbon catalysts for combined nitrogen oxides (NO x ), sulfur oxides (SO x ), and mercury (Hg) removal. A bench-scale reverse-flow fixed-bed (RFFB) reactor and a trickle-bed direct-contact cooler (DCC) reactor capable of treating 15 standard liters per min of pressurized oxy-combustion flue gas were fabricated and tested with both a simulated flue gas in the laboratory and a slipstream of actual flue gas at a 100 kW th Staged, Pressurized Oxy-Combustion (SPOC) pilot facility. Process simulation and techno-economic studies were performed to evaluate the energy efficiency and cost of the developed catalytic flue gas purification process integrated into a conceptual 550-MWe SPOC power plant. The goal and objectives of the project have been successfully accomplished. A cobalt-manganese (CoMn) oxide catalyst was developed and demonstrated in the bench-scale RFFB reactor in either a reverse-flow or one-direction flow mode of operation that met the success criterion of performance for residual O 2 reduction. A carbon catalyst was developed and demonstrated in the bench-scale DCC reactor that met the success criterion of performance for combined NO x /SO x /Hg removal. Slipstream testing of the integrated DCC-RFFB system at the SPOC pilot facility demonstrated stable operation and verified the superior performance obtained in the laboratory. The techno-economic analysis showed that a 550-MWe SPOC plant integrated with the catalytic flue gas purification process would result in costs of electricity of $\$$96.94/MWh and $\$$80.27/MWh in two assessed cases compared with $\$$91.07/MWh reported for the USDOE’s Current Technology Case, which generated only a partially pure CO 2 stream. On the basis of the results and findings from this project, scale-up studies of materials production and system demonstration and optimization studies of reactors and processes are recommended at the next stage of technology development.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS2001

Frontal Polymerization in Microgravity: Bubble Behavior and Convection on the KC-135 Aircraft

Frontal polymerization is a mode of converting monomer into polymer via a localized exothermic reaction zone that propagates through the coupling of thermal diffusion and Arrhenius reaction kinetics. Frontal polymerization was discovered in Russia by Chechilo and Enikolopyan in 1972. The macrokinetics and dynamics of frontal polymerization have been examined in detail and applications for materials synthesis considered. Large temperature and concentration gradients that occur in the front lead to large density gradients. A schematic is presented for a liquid monomer, usually a monoacrylate, being converted to a liquid (thermoplastic) polymer. The velocity can be controlled by the initiator concentration but is on the order of a cm/min. If the liquid monomer is multifunctional, then a solid (thermoset) polymer is formed. Convection can occur with all types of monomers if the front propagates up a tube. Bowden et al. studied liquid/solid systems. McCaughey et al. studied liquid polymer systems. Descending fronts in thermoplastic systems are also susceptible to the Rayleigh-Taylor instability.

Pojman, John A.↗
NASA NTRS2007

Multifunctional Composites for Improved Polyimide Thermal Stability

The layered morphology of silicate clay provides an effective barrier to oxidative degradation of the matrix resin. However, as resin thermal stability continues to reach higher limits, development of an organic modification with comparable temperature capabilities becomes a challenge. Typically, phyllosilicates used in polymer nanocomposites are modified with an alkyl ammonium ion. Such organic modifiers are not suited for incorporation into high temperature polymers as they commonly degrade below 200oC. Therefore, the development of nanoparticle specifically suited for high temperature applications is necessary. Several nanoparticles were investigated in this study, including pre-exfoliated synthetic clay, an organically modified clay, and carbon nanofiber. Dispersion of the layered silicate increases the onset temperature of matrix degradation as well as slows oxidative degradation. The thermally stable carbon nanofibers are also observed to significantly increase the resin thermal stability.

Miller, Sandi G.↗
NASA NTRSDate not supplied

TPSAS-NF1676L-15304-DND

The Subsonic Fixed Wing Project conducts research to improve prediction methods and technologies that will produce lower noise, lower emissions, and higher performing subsonic aircraft for the Next Generation Air Transportation System. Subproject: FW Structural Efficiency: Lightweight, multi-objective and multifunctional structures (e.g., structures that can carry load and attenuate noise at the same time) are being developed to reduce the weight of both airframes and engines. Adaptive and flexible wing structures with aeroelastic tailoring offer significant weight reduction due to the elimination of a heavy actuation system. Extensive use of polymer matrix composites (PMCs) in airframe and engine structures (where applicable) will offer significant weight reduction opportunities. Research on composite technology is focused on developing alternate processes that will enable fabrication of large structures, increasing the temperature capability toward greater usage in engine and supersonic airframe structures, developing advanced structural concepts, and modeling damage initiation and progression in composite structures.

Jason P Moore↗