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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
DOE OSTI2026

Impact of DMP-30 catalyst concentration on the degradation and kinetics of bisphenol A epoxy thermosets cured with linear amine hardener

Epoxy thermosets are a crucial component in carbon-fiber composites, serving as the organic binding matrix. Catalysts are commonly used in prepolymer formulations to accelerate curing of the thermosets. However, the impact of catalysts on the thermal stability, degradation pathways, and kinetics of the final thermoset is poorly understood. Here, in this work, Product-Specific Kinetics (PSK) analysis was utilized with isoconversional kinetics to provide a first look into the degradation kinetics of major pyrolysis pathways in bisphenol A (BPA) epoxy resins and determine the impact of altering catalysis concentrations on these kinetic pathways. Results revealed new insights into previously identified degradation pathways, provided evidence of multiple degradation pathways for some products, and showed that use of excess catalyst results in polymer network alterations and reduced thermal stability of the thermosets.

Bisphenol A↗
NASA NTRS1998

Automated Fabrication Technologies for High Performance Polymer Composites

New fabrication technologies are being exploited for building high graphite-fiber-reinforced composite structure. Stitched fiber preforms and resin film infusion have been successfully demonstrated for large, composite wing structures. Other automatic processes being developed include automated placement of tacky, drapable epoxy towpreg, automated heated head placement of consolidated ribbon/tape, and vacuum-assisted resin transfer molding. These methods have the potential to yield low cost high performance structures by fabricating composite structures to net shape out-of-autoclave.

Shuart , M. J.↗
DOE OSTI2020

Chemical–Switching Strategy for Synthesis and Controlled Release of Norcantharimides from a Biomass–Derived Chemical

Catalytic strategies were developed to synthesize and release chemicals for applications in fine chemicals, such as drugs and polymers, from a biomass-derived chemical, 5-hydroxymethyl furfural (HMF). The combination of the diene and aldehyde functionalities in HMF enabled catalytic production of acetalized HMF derivatives with diol or epoxy reactants to allow reversible synthesis of norcantharimide derivatives upon Diels-Alder reaction with maleimides. Reverse-conversion of the acetal group to an aldehyde yielded mismatches of the molecular orbitals in norcantharimides to trigger retro Diels-Alder reaction at ambient temperatures and released reactants from the coupled molecules under acidic conditions. In conclusion, these strategies provide for the facile synthesis and controlled release of high-value chemicals.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Controlled Pyrolysis: A Robust Scalable Composite Recycling Technology

The reinforced composites industry is facing significant challenges in handling the scrap composite material from automobile manufacturing, the wind turbine industry, and others. The fibers in the material, whether they be carbon, glass, or other materials have commercial value if they can be recovered successfully. Successfully means the fibers are clean with no sizing or other binders and have adequate strength and physical properties that would allow them to be economically reprocessed into valuable product. The composites recycling project was an industry-collaborative effort to develop a composite recycling technology using controlled pyrolysis. Through the recycling of scrap and end-of-life (EOL) cured composite materials, this pilot study was intended to create a business case by realizing a cost-effective means for recycling EOL and production scrap composite materials, ultimately reducing the volume of composite materials destined for landfill. The project was led by the Institute for Advanced Composites Manufacturing Innovation (IACMI), the American Composites Manufacturers Association (ACMA), Oak Ridge National Laboratory (ORNL), Continental Structural Plastics (CSP) a Teijin Group Company, CHZ Technologies, and A. Schulman with support from Owens Corning, John Deere, General Electric (GE), Ashland LLC, and Plastics Europe (CEFIC). The team studied and tested CHZ Technologies’ controlled pyrolysis system, known as the Thermolyzer TM , which operates on a scalable basis to convert organic polymer materials into a clean synthesis gas and char containing the recoverable carbon and glass fiber reinforcement. The recoverable energy contained in the input polymers creates the synthesis gas that can be used to provide heat to the Thermolyzer TM primary reactor in a sustainable manner. That is, once the Thermolyzer TM is started with a small amount of external natural gas, the synthesis gas that is created from the polymers will continue to operate the burners so long as feedstock is supplied. The reinforcing fiber materials remaining in the solid phase char were separated and cleaned for re-use in other polymer systems based on the retained properties of the fibers. The study created reports (attached in the appendix) on the Mass and Energy Balances, syngas analytics, VOC assessment, yield analysis and other analytics necessary for a Techno-Economic Analysis (TEA) to quantify the economic impact of the recovery and sustainable re-use of the carbon and glass fibers. The process consisted of 4 steps: Selection of 4 samples of cured composite waste materials from project partners interested in materials recycling and recovering the reinforcing fibers for best case re-use. The materials included glass fiber (GF) polyester/vinyl ester automotive SMC from CSP, GF epoxy balsa/PVC foam wind blades from GE, carbon fiber (CF) epoxy wind blade laminated spar caps from GE, and GF/CF epoxy hybrid assembly from John Deere. Processing the waste composite samples into 1-2” shreds. Packaging the shredded composites into bulk sacks on international shipping pallets for shipment to KUG in Forst (Lausitz), Germany. Pyrolysis of the shredded composites under controlled conditions designed for each polymer system. Collecting samples of the gas and char for analysis. Shipping the char containing the CF/GF back to the US for the next steps of testing the fibers and developing protocols for sustainable re-use of the fibers in composite applications.

36 MATERIALS SCIENCE↗
NASA NTRS1982

Incombustible resin composition

Incombustible resin compositions composed of aromatic compounds were obtained through (1) combustion polymer material and (2) bisphenol A or halogenated bisphenol A and bisphenol A diglycidl ether or halogenated bisphenol A diglycidyl ether. The aromatic compound is an adduct of bifunctional phenols and bifunctional epoxy resins.

Akima, T.↗
NASA NTRS2002

Structural Health Monitoring of Composite Wound Pressure Vessels

The increasing use of advanced composite materials in the wide range of applications including Space Structures is a great impetus to the development of smart materials. Incorporating these FBG sensors for monitoring the integrity of structures during their life cycle will provide valuable information about viability of the usage of such material. The use of these sensors by surface bonding or embedding in this composite will measure internal strain and temperature, and hence the integrity of the assembled engineering structures. This paper focuses on such a structure, called a composite wound pressure vessel. This vessel was fabricated from the composite material: TRH50 (a Mitsubishi carbon fiber with a 710-ksi tensile strength and a 37 Msi modulus) impregnated with an epoxy resin from NEWPORT composites (WDE-3D-1). This epoxy resin in water dispersed system without any solvents and it cures in the 240-310 degrees F range. This is a toughened resin system specifically designed for pressure applications. These materials are a natural fit for fiber sensors since the polyimide outer buffer coating of fiber can be integrated into the polymer matrix of the composite material with negligible residual stress. The tank was wound with two helical patterns and 4 hoop wraps. The order of winding is: two hoops, two helical and two hoops. The wall thickness of the composite should be about 80 mil or less. The tank should burst near 3,000 psi or less. We can measure the actual wall thickness by ultrasonic or we can burst the tank and measure the pieces. Figure 1 shows a cylinder fabricated out of carbon-epoxy composite material. The strain in different directions is measured with a surface bonded fiber Bragg gratings and with embedded fiber Bragg gratings as the cylinder is pressurized to burst pressures. Figure 2 shows the strain as a function of pressure of carbon-epoxy cylinder as it is pressurized with water. Strain is measured in different directions by multiple gratings oriented in both axial and hoops directions.

Joseph Grant↗
DOE OSTI2024

Hierarchical Composites Patterned via 3D Printed Cellular Fluidics

Additive manufacturing of freeform structures containing multiple materials with deterministic spatial arrangement and interactions remains a challenge for most 3D printing processes, due to complex fabrication tool requirements and limitations in printability of some material classes. Here, in this paper, a versatile method is reported to produce architected composites using the concept of cellular fluidics, in which lattices of unit cells are used as templating scaffolds to guide flowable infill materials in a programmed spatial pattern, upon which they are cured in place to produce a deterministically ordered multimaterial solid. The lattice design relies on the unit cell size, type, strut diameter, surface wetting, and distribution of cellular structures to control liquid flow and retention. Individual unit cells are tuned to achieve reliable infilling and combined into higher-order architectures to achieve multiscale composite materials with disparate mechanical properties, including those considered non-printable. Lattice design considerations for leveraging capillary phenomena and demonstrate several methods of patterning polymers in 3D-printed cellular fluidic structures are presented. The concept of tuning the compressive response of an architected composite using a flexible-elastomer as the lattice and a stiff-epoxy as the infill material is illustrated.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Effect of Molecular Flexibility upon Ice Adhesion Shear Strength

Ice formation on aircraft surfaces effects aircraft performance by increasing weight and drag leading to loss of lift. Current active alleviation strategies involve pneumatic boots, heated surfaces, and usage of glycol based de-icing fluids. Mitigation or reduction of in-flight icing by means of a passive approach may enable retention of aircraft capabilities, i.e., no reduction in lift, while reducing the aircraft weight and mechanical complexity. Under a NASA Aeronautics Research Institute Seedling activity, the effect of end group functionality and chain length upon ice adhesion shear strength (IASS) was evaluated with the results indicating that chemical functionality and chain length (i.e. molecular flexibility) affected IASS. Based on experimental and modeling results, diamine monomers incorporating molecular flexibility as either a side chain or in between diamine functionalities were prepared, incorporated into epoxy resins that were subsequently used to fabricate coatings on aluminum substrates, and tested in a simulated icing environment. The IASS was found to be lower when molecular flexibility was incorporated in the polymer chain as opposed to a side chain.

Smith, Joseph G.↗
DOE OSTI2023

Core-shell structured tow-pregs enabled additive manufacturing of continuously reinforced thermoset composites

One of the major challenges in thermally curable polymer composite additive manufacturing is the slow curing time of thermally curable resins, coupled with a significant drop in thermoset viscosity upon heating, making the formation of complex shapes difficult. To tackle these issues, we have introduced a novel rapid composite preformation strategy called Tow-Preg Cladding (TPC). This technique involves the use of a thin and rapidly curable dual-cure resin, which combines a thermally curable resin (such as epoxy) with a fast photo-curable resin. The dual-cure resin is applied as a coating over a thermally curable resin tow-preg, enabling the formation of a rigid cladding that supports and shapes the tow-pregs into the desired geometries and patterns. The key advantage of this approach lies in the sequential formation of an interpenetrating polymer network (IPN) at the interlayer between laminates, resulting from the curing of the photocurable resin and the thermally curable resin sequentially. This IPN formation enhances interlaminar bonding in the composite, contributing to its overall strength and performance. The composites produced using this technique exhibited impressive mechanical properties, including longitudinal tensile strength of 1058.2 MPa, longitudinal tensile modulus of 74.2 GPa, flexural strength of 1080.4 MPa, and flexural modulus of 41.7 GPa. Overall, our Tow-Preg Cladding approach shows great promise in overcoming the challenges associated with thermally curable polymer composite additive manufacturing. It offers a viable solution to creating strong, shape-specific thermoset composites efficiently with enhanced mechanical properties.

42 ENGINEERING↗
DOE OSTI2024

Product-specific kinetics reveal effect of epoxy crystallization on thermoset thermal degradation

Crystallization is a common problem for epoxy resins, which are ubiquitous in industrial and commercial use. Integration of crystallized epoxy monomers into cured thermosets has been shown to alter the thermosets’ final mechanical properties. However, no studies have investigated the impact of these crystals on the thermal stability of the thermoset. Here we investigate the degradation kinetics of a bisphenol F–based epoxy thermoset with and without crystallized monomers using Product-Specific Kinetic (PSK) analysis coupled with Evolved Gas Analysis-Mass Spectrometry (EGA-MS). PSK analysis revealed significant differences in evolved product ion kinetics, suggesting changes in the degradation kinetics between thermoset configurations. Further, it was concluded that early stages of degradation are influenced most by crystal presence due to the high concentration of unreacted epoxy monomers and lower cross-linking density of the cured network. After post-cure annealing, significant changes are observed in the degradation kinetics of thermosets without crystal inclusions. Conversely, post-cure annealing procedures of crystal integrated thermosets showed little change in the thermoset degradation kinetics across all conversion extents. These findings suggest that post-cure annealing of thermosets with crystals present at the onset does not alter the cross-linking density of the polymer network enough to significantly change the degradation kinetics. We hypothesize this is because the excess monomers from the melted crystals are unable to find suitable reaction sites for complete binding into the polymer network, which has direct implications for the material properties and final thermal stability of the thermoset.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1993

Flame-Retardant Diaminobenzenes Containing Phosphorus

Diamines polymerized with dianhydrides or diacyl halides to produce fire-resistant polymers. Properties of polymers useful as matrices in laminated composite-material aircraft structural components that resist fire and exhibit desirable mechanical properties as high tensile strength. Diamines used as encapsulating or potting compounds when reacted with epoxy resins. Free phosphonic acids, byproducts of synthesis of diamines used as complexing agents to extract metals from aqueous solutions or as corrosion inhibitors for metals.

Kourtides, Demetrius A.↗
NASA NTRSDate not supplied

Computationally Guided Design of Polymer-Coated Microparticles as Reusable Materials

Long-duration space exploration missions and sustained lunar or Martian surface operations present greater demands for multifunctional and reusable materials. By scaling down the amount of material to be launched from Earth, both mission cost and risk can be reduced. In this regard, leveraging in-space manufacturing capabilities with reusable feedstock materials is an attractive option, as it will allow for articles to be generated on demand, utilized, and then recycled for additional use. NASA’s Enabling Sustained Presence Using Recyclables (ESPUR) project aims to develop reusable materials using polymer-coated microparticles that are bonded via reversible Diels-Alder reactions, where only modest heat is needed to trigger the reverse reaction and enable reuse. For proof-of-concept demonstration, research is currently focused on the fabrication of epoxy microparticles that contain a copoly(carbonate urethane) coating with maleimide and furan functionalities. Here, we discuss the integration of computational materials modeling approaches to help navigate the large design space in this development effort. We perform molecular dynamics (MD) simulations with atomistic and coarse-grained models of the copolymer, which allow us to evaluate the effects of design parameters like the molecular weight and composition on the molecular interactions and chain dynamics. We show how the properties change with the reversible bonds. We also leverage discrete element method (DEM) simulations to assess how microparticle design parameters like the size ratio and volume fraction can be tuned to increase the packing density and number of microparticle contacts to improve the mechanical properties. Our results demonstrate how computational tools can be used in close collaboration with experimental efforts to accelerate material design.

reusable materials↗
DOE OSTI2024

Understanding interfacial crystallization dynamics on carbon fiber reinforced polypropylene composite manufacturing

Reinforcing polymers with discontinuous fibers improves mechanical properties, such as strength and stiffness, and in some cases achieve isotropic properties, rendering them suitable for various engineering applications. Matrix materials are generally highly engineered thermosets (e.g. crosslinked epoxies), bonded to the fiber periphery by proprietary surface and sizing chemistries. Semicrystalline thermoplastic matrices are less utilized due to poor fiber-matrix bonding resulting in inefficient interfacial load-transfer in reinforced composites. However, flexibility with melt-processing or molding conditions can be leveraged to promote non-covalent interfacial bonding between matrix and fiber via crystallization of the matrix onto fiber surface. In the present study, we utilize a co-mingle chopped carbon and isotactic polypropylene fibers to form isotropic composites, tailoring interfacial immobilized matrix or interphase morphology to optimize performance through precise control of thermal processing/molding windows. Calorimetry and optical microscopy were employed to investigate the impact of carbon fiber at various volume fractions (10, 20, and 30 %) on isotactic polypropylene crystallization and mechanical performance. Variations in mechanical properties correspond to the structural evolution of the interfacial region and are correlated to underlying microstructural attributes using wide-angle X-ray scattering, thermal analysis, and low-field nuclear magnetic resonance spectroscopy. These results provide a practical framework for the manufacturing of thermoplastic matrix composites. In conclusion, the results presented provide a guide for the strategic optimization of interphase design, showcasing tailorable tensile strengths which outperform any isotactic polypropylene carbon fiber composites previously reported in literature.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Multifunctional fiber-reinforced composites for passive sensing and energy harvesting with enhanced mechanical performance

Fiber-reinforced polymer composites (FRPCs) are valid alternatives to metals, especially in the aerospace industry, for their superior strength-to-weight ratio. FRPCs are generally manufactured by stacking layers of fibers and infusing them with epoxy-based adhesives to result in laminates. Such layer-by-layer structure often ensues a poor interlaminar property of the composites. Additionally, FRPCs can sustain complex damage modes because of their inherent anisotropic characteristics. For example, delamination can occur due to low-velocity impact at a subsurface level, which can result in premature catastrophic failures if undetected. Thus, structural monitoring is crucial to identify such damage. Point-based sensors (e.g., strain gauges, accelerometers, among many) can be embedded in the FRPCs for structural monitoring. However, their electrical power demand often embroils their usage. Therefore, the main objective of this research is to design and implement multifunctional composites that can simultaneously perform passive sensing and energy harvesting while exhibiting better mechanical performance. Previous research efforts have demonstrated that a continuous feed-through deposition of functional materials on fiber surfaces simultaneously enhanced the mechanical and sensing properties of the FRPCs. This study explores a similar approach to encode passive sensing and energy harvesting properties in the FRPCs by integrating ferroelectric microparticles on the fiber surfaces. Upon ensuring their superior interlaminar shear strength, sensing and energy harvesting properties were characterized through experimental studies. The outcome is a multifunctional composite fabricated by coating the fibers with functional microparticles through a high throughput, scalable, and low-cost approach that enables passive sensing, energy harvesting, and improved mechanical performance.

Gupta, Sumit↗
NASA NTRS2009

Structural/Radiation-Shielding Epoxies

A development effort was directed toward formulating epoxy resins that are useful both as structural materials and as shielding against heavy-ion radiation. Hydrogen is recognized as the best element for absorbing heavy-ion radiation, and high-hydrogen-content polymers are now in use as shielding materials. However, high-hydrogen-content polymers (e.g. polyethylene) are typically not good structural materials. In contrast, aromatic polymers, which contain smaller amounts of hydrogen, often have the strength necessary for structural materials. Accordingly, the present development effort is based on the concept that an ideal structural/ heavy-ion-radiation-shielding material would be a polymer that contains sufficient hydrogen (e.g., in the form of aliphatic molecular groups) for radiation shielding and has sufficient aromatic content for structural integrity.

Connell, John W.↗
NASA NTRS2019

Viscoelastic Characterization of Polymers for Deployable Composite Booms

Deployable space structures have been built from thin-walled fiber-reinforced polymer composite materials due to their high specific strength, high specific stiffness, and bistability. However, the inherent viscoelastic behavior of the resin matrix can cause dimensional instability when parts are stored under strain. The extended time of stowage between assembly and deployment in space can result in performance degradation and in the worst case, mission failure. In this study, the viscoelastic properties of candidate commercial polymers for deployable boom structures of solar sails were evaluated. Stress relaxation master curves of the candidate polymers were used to predict the relaxation that would occur in 1 year at room temperature under relatively low strains of ~0.1%. A bismaleimide (BMI) showed less stress relaxation (about 20%) than the baseline Novolac epoxy (about 50%). Carbon fiber composites fabricated with the BMI resin showed a 44% improvement in relaxation compared to the baseline epoxy composite. Other difunctional and tetrafunctional epoxies, thermoplastic, and thermosetting polyimides were also evaluated.

Kang, Jin Ho↗