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At least 289 records · Page 16

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NASA NTRS1987

A viscoplastic constitutive theory for metal matrix composites at high temperature

A viscoplastic theory is presented for representing the high-temperature deformation behavior of metal matrix composites. The point of view taken is a continuum one where the composite is considered a material in its own right, with its own properties that can be determined for the composite as a whole. It is presumed that a single preferential (fiber) direction is identifiable at each material point (continuum element) admitting the idealization of local transverse isotropy. A key ingredient in this work is the specification of an experimental program for the complete determination of the material functions and parameters for characterizing a particular metal matrix composite. The parameters relating to the strength of anisotropy can be determined through tension/torsion tests on longitudinally and circumferentially reinforced thin-walled tubes. Fundamental aspects of the theory are explored through a geometric interpretation of some basic features analogous to those of the classical theory of plasticity.

Robinson, D. N.↗

NASA NTRS1973

Experimental stress analysis of large plastic deformations in a hollow sphere deformed by impact against a concrete block

An experimental plastic strain measurement system is presented for use on the surface of high velocity impact test models. The system was used on a hollow sphere tested in impact against a reinforced concrete block. True strains, deviatoric stresses, and true stresses were calculated from experimental measurements. The maximum strain measured in the model was small compared to the true failure strain obtained from static tensile tests of model material. This fact suggests that a much greater impact velocity would be required to cause failure of the model shell structure.

Morris, R. E.↗

NASA NTRS1974

Investigation of Kevlar fabric based materials for use with inflatable structures

Design, manufacture and testing of laminated and coated composite materials incorporating a structural matrix of Kevlar are reported in detail. The practicality of using Kevlar in aerostat materials is demonstrated and data are provided on practical weaves, lamination and coating particulars, rigidity, strength, weight, elastic coefficients, abrasion resistance, crease effects, peel strength, blocking tendencies, helium permeability, and fabrication techniques. Properties of the Kevlar based materials are compared with conventional, Dacron reinforced counterparts. A comprehensive test and qualification program is discussed and quantitative biaxial tensile and shear test data are provided. The investigation shows that single ply laminates of Kevlar and plastic films offer significant strength to weight improvements, are less permeable than two ply coated materials, but have a lower flex life.

Niccum, R. J.↗

NASA NTRS1979

Fire resistant aircraft seat program

Foams, textiles, and thermoformable plastics were tested to determine which materials were fire retardant, and safe for aircraft passenger seats. Seat components investigated were the decorative fabric cover, slip covers, fire blocking layer, cushion reinforcement, and the cushioning layer.

Fewell, L. A.↗

DOE OSTI2022

Deformation and Fracture Behaviors of Cylindrical Battery Shell During Thermal Runaway

Thermal runaway is one of the catastrophic failure modes of lithium-ion cells. During thermal runaway in cylindrical cells, sidewall shell rupture has been identified as a contributing factor for thermal runaway propagation in battery packs. Herein, the deformation and fracture behaviors of the battery shell during thermal runaway are investigated based on in-situ and ex-situ characterization as well as physics-based modeling. The deformation and fracture modes of the battery shell with/without Carbon Fiber Reinforced Polymer (CFRP) sleeves are identified. In the simulation, the strain introduced by thermal expansion of the system is considered, as well as the thermal and strain rate effects on the plastic stage. The final cell shell modeling is validated by cell thermal runaway tests. Results reveal the quantitative relation between shell deformation behaviors and the pressure and temperature distribution. Both the experiment and model demonstrate the effectiveness of adding a tight-fitting CFRP sleeve around the cell in limiting the side-wall rupture of the shell. The use of CFRP tubes introduces a novel phenomenon in the context of uneven temperature distribution. Results shed light on the mechanistic analysis of a cell side-wall rupture during thermal runaway and provide essential guidance for the next-generation safe battery design.

battery casing↗

NASA NTRS1939

Physical Properties of Synthetic Resin Materials

A study was made to determine the physical properties of synthetic resins having paper, canvas, and linen reinforcements, and of laminated wood impregnated with a resin varnish. The results show that commercial resins have moduli of elasticity that are too low for structural considerations. Nevertheless, there do exist plastics that have favorable mechanical properties and, with further development, it should be possible to produce resin products that compare favorably with the light-metal alloys. The results obtained from tests on Compound 1840, resin-impregnated wood, show that this material can stand on its own merit by virtue of a compressive strength four times that of the natural wood. This increase in compressive strength was accomplished with an increase of density to a value slightly below three times the normal value and corrected one of the most serious defects of the natural product.

Fishbein, Meyer↗

NASA NTRS1999

Friction Stir Welding of SiC/Aluminum Metal Matrix Composites

Friction Stir Welding (FSW) is a new solid state process for joining metals by plasticizing and consolidating materials around the bond line using thermal energy producing from frictional forces. A feasibility study for FSW of Metal Matrix Composites (MMC) was investigated using aluminum 6092 alloy reinforced with 17% SiC particulates. FSW process consists of a special rotating pin tool that is positioned to plunge into the MMC surface at the bond line. As the tool rotates and move forward along the bond line, the material at the bond line is heated up and forced to flow around the rotating tip to consolidate on the tip's backside to form a solid state joint. FSW has the potential for producing sound welds with MMC because the processing temperature occurs well below the melting point of the metal matrix; thereby eliminating the reinforcement-to-matrix solidification defects, reducing the undesirable chemical reactions and porosity problems.

Lee, Jonathan A.↗

DOE OSTI2022

Long fiber injection molding

An improved method for obtaining high fiber volume fraction, long fiber injection molded articles is provided. According to one embodiment, the method includes forming an injection molding feedstock by cutting pre-impregnated fiber-reinforced tape into platelets. The platelets can be coated with a thin layer of polymer to allow sliding of the platelets with respect to each other at the early stages of plastication, rather than forcing relative motion of fibers with respect to each other. The method can further include the dispersion of material only in the final stages of the injection molding screw to promote gentle motion of the feedstock at the earlier stages of the plastication process. The method allows improvement of mechanical properties of articles manufactured with equipment and techniques that are prevalent in high volume automotive and consumer industries.

Kunc, Vlastimil↗

DOE OSTI2023

A study of adhesive bonding in metal–metal, metal–CFRP, and CFRP–CFRP material combinations under shear deformation: Fracture morphologies and damage mechanisms

Safe design of adhesive joining in multi-materials in engineered structures requires the accumulation of numerous experimental data on the failure behavior of various adhesively-bonded material combinations under different loading conditions. The deep understanding of mechanical performance, fracturing morphologies, and main damage mechanisms is also quintessential for accelerating the development of proper physics-based and multi-scale models for assisting the design. Towards this goal, this work presents a comprehensive characterization of the failure behavior of adhesively-bonded metal–metal, metal–CFRP, and CFRP–CFRP material combinations under global shear deformation via single lap shear testing. Thanks to a synergistic combination of measurement methods by using Digital Imaging Correlation (DIC) and 3D optical profilometry, adhesive features on the adherend after failure were quantified and the main progressive damage mechanisms were identified. The characterization performed in this work provides quantitative data that contributes to a better understanding of shear failure in adhesive bonding across different bi-material combinations. Finally, the obtained results have practical implications, including the potential to enhance adhesive bonding design, identify failure causes in adhesive joints, and develop or validate computational models capable of capturing the observed behavior in various adhesively-bonded materials under global shear deformation.

36 MATERIALS SCIENCE↗

NASA NTRS2010

Depositing nanometer-sized particles of metals onto carbon allotropes

A process for depositing nanometer-sized metal particles onto a substrate in the absence of aqueous solvents, organic solvents, and reducing agents, and without any required pre-treatment of the substrate, includes preparing an admixture of a metal compound and a substrate by dry mixing a chosen amount of the metal compound with a chosen amount of the substrate; and supplying energy to the admixture in an amount sufficient to deposit zero valance metal particles onto the substrate. This process gives rise to a number of deposited metallic particle sizes which may be controlled. The compositions prepared by this process are used to produce polymer composites by combining them with readily available commodity and engineering plastics. The polymer composites are used as coatings, or they are used to fabricate articles, such as free-standing films, fibers, fabrics, foams, molded and laminated articles, tubes, adhesives, and fiber reinforced articles. These articles are well-suited for many applications requiring thermal conductivity, electrical conductivity, antibacterial activity, catalytic activity, and combinations thereof.

Watson, Kent A.↗

DOE OSTI2025

Neuromorphic ionic computing in droplet interface synapses

Ionic devices with memory capabilities can emulate neural functionality, enabling neuromorphic computing and biomedical applications. In this study, we report an ionic spiking synapse based on aqueous droplet interface bilayer assembly. Under stepwise triangular voltages, the device displays coupled memcapacitive-memristive behavior, showing noncrossing pinched hysteretic I-V loops. This hysteretic ion dynamics can be regulated by modifying bilayer components, reconstituting protein channels, or adjusting droplet assembly configuration. Droplet interface synapses (DIS) exhibit fundamental neuromorphic behaviors such as paired-pulse facilitation/depression, spike rate–dependent plasticity, Hebbian learning, and short-term associative learning under classical conditioning. We also used reservoir computing with DIS to implement two learning algorithms: a classification algorithm that recognizes handwritten digits and a reinforcement learning algorithm that learns to play a board game of tic-tac-toe.

Li, Zhongwu [Lawrence Livermore National Laborator↗

DOE OSTI2023

Ultrafine-grained Fe-TiB 2 high-modulus nanocomposite steel with high strength and isotropic mechanical properties by laser powder bed fusion

Fe-TiB 2 metal matrix composite, also called high-modulus steels (HMSs), are of great interest for applications in fuel-efficient transportation infrastructure, aerospace, and wear industries due to their high specific stiffness and yield strength. However, conventional cast Fe-TiB 2 HMSs often contain coarse and sharp-edged TiB 2 particles which easily trigger premature cracking during loading. Here, we synthesized a Fe-TiB 2 nanocomposite HMS via laser powder bed fusion (LPBF) additive manufacturing of mixed micro-sized powders of Fe, Ti, and Fe 2 B. We investigated the microstructure formation and mechanical behavior of the Fe-TiB 2 HMS. We found that in situ chemical reaction of Ti and Fe 2 B enables the formation of TiB 2 particles at nanoscale during rapid solidification of LPBF. These nanoscale TiB 2 particles can serve as heterogeneous nucleation sites and promote the formation of ultrafine and equiaxed α-Fe grains with random crystallographic textures, which differ from many other additively manufactured (AM) metal alloys characteristic of strong crystallographic textures. As such, isotropic mechanical properties were achieved in the AM Fe-TiB 2 nanocomposite HMS with a high elastic modulus of ~ 240 GPa, an exceptional yield strength of ~ 1450 MPa, and a large plasticity of ~ 20% under compression. Quantitative analysis reveals that the high yield strength primarily originates from strengthening contributions of the ultrafine grains with an average grain size of ~450 nm, the nanoscale TiB 2 reinforcing particles of 20–180 nm, and a high density of printing-induced dislocations of the order of 10 15 m –2 . In situ synchrotron high-energy X-ray diffraction unveils the load partitioning from the softer α-Fe matrix to the stiffer and stronger TiB 2 nanoparticles, contributing to the sustained strain hardening during compression. Our work not only provides a general pathway for achieving high-performance metal matrix nanocomposites by in situ chemical reaction and precipitation of ceramic nanoparticles during additive manufacturing, but also offers mechanistic insights into the deformation mechanism of nanoparticle-reinforced HMS composites.

36 MATERIALS SCIENCE↗

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↗

DOE OSTI2025

Effects of chemical composition and physicochemical properties of poplar biomass on the performance of 3D printed poplar-reinforced PLA materials

Lignocellulosic biomass has been well-acknowledged as a filler for making 3D printed composites. The technical performances of composites were influenced by the characteristics of the components. The correlations between poplar biomass properties and the mechanical and thermal performances of the 3D printed poplar-plastic composites were investigated. The characteristics of poplar were modified by different pretreatment methods, including using hot water, dilute acid, and organic solvent (organosolv), and each treated poplar biomass was applied as a filler in a polylactic acid (PLA) polymer matrix to produce eco-friendly materials. These solvent pretreatments increased the hydrophobicity and surface area of poplar. Organosolv treated poplar showed the highest cellulose content and significantly increased Young's modulus of its biocomposites. Principal component analysis revealed that the specific surface area and water contact angle of biomass contributed to the thermal stability of biocomposites. Additionally, the degree of polymerization of cellulose and xylan content within the biomass correlated with the biocomposites' break stress. Notably, the crystallinity of biocomposites impacted the modulus of these materials. The reported relationships between biomass characteristics and 3D printed composite behaviors provide guidance for optimizing biomass processing in biocomposite applications.

Ji, Anqi [State Univ. of New York (SUNY), Syracuse↗

DOE OSTI2021

Development of coherent-precipitate-hardened high-entropy alloys with hierarchical NiAl/Ni 2 TiAl precipitates in CrMnFeCoNiAl x Ti y alloys

Coherent precipitates hardening is currently emerging strengthening mechanism of the various high entropy alloys (HEAs). Recently, CrMnFeCoNiAl x HEAs have been studied to show a phase transition from face-centered-cubic (FCC) to body-centered-cubic (BCC) and formation of coherent precipitates (B2-NiAl) within the BCC matrix. The coherent precipitates in the CrMnFeCoNiAl x alloys could contribute to increase the strength but lead to considerable reduction of the ductility. The present work systematically investigated a series of CrMnFeCoNiAl 0.5 Ti x alloys to further improve the strength and plasticity, as compared to the previously reported CrMnFeCoNiAl x HEAs. As a result, an increase of Ti addition leads to the phase transition from FCC to BCC and formation of lamellar structure and hierarchical precipitates reinforced by B2-NiAl and L2 1 -Ni 2 TiAl phases. Excellent mechanical properties were achieved from CrMnFeCoNiAl 0.5 Ti 0.1 and CrMnFeCoNiAl 0.5 Ti 0.2 alloys. Herein, the mechanical properties of the CrMnFeCoNiAl 0.5 Ti x alloys were discussed via theoretical strengthening mechanisms.

36 MATERIALS SCIENCE↗

NASA NTRS1979

Glass fiber reinforced concrete for terrestrial photovoltaic arrays

The use of glass-fiber-reinforced concrete (GRC) as a low-cost structural substrate for terrestrial solar cell arrays is discussed. The properties and fabrication of glass-reinforced concrete structures are considered, and a preliminary design for a laminated solar cell assembly built on a GRC substrate is presented. A total cost for such a photovoltaic module, composed of a Korad acrylic plastic film front cover, an aluminum foil back cover, an ethylene/vinyl acetate pottant/adhesive and a cotton fabric electrical isolator in addition to the GRC substrate, of $9.42/sq m is projected, which is less than the $11.00/sq m cost goal set by the Department of Energy. Preliminary evaluations are concluded to have shown the design capabilities and cost effectiveness of GRC; however, its potential for automated mass production has yet to be evaluated.

Maxwell, H.↗

NASA NTRS2019

Development and Characterization of Hot-Pressed Matrices for Engineered Ceramic Matrix Composites (E-CMCs)

The present research effort was undertaken to develop a new generation of SiC fiber-reinforced engineered ceramic matrix composites (E-CMCs). In contrast to traditional CMCs with a brittle SiC matrix, an E-CMC is designed to consist of a matrix engineered to possess sufficient high temperature plasticity to minimize crack propagation, relatively high fracture toughness, and self-healing capabilities to prevent oxygen ingress to the BN-coated fibers through surface-connected cracks. The present paper discusses the bend strength, isothermal oxidation, microstructures and self-healing properties of several silicide-behaved engineered matrices. Based on the oxidation tests, where it was observed that some of the matrices exhibited either catastrophic oxidation ("pesting") or spalling of the oxide scale, two engineered matrices, CrSi2/SiC/Si3N4 and CrMoSi/SiC/Si3N4, were down-selected for further investigation. Four-point bend tests were conducted on these two engineered matrices between room temperature and 1698 degrees Kelvin. Although these matrices were brittle at low temperatures, it was observed that the bend strengths and bend ductility increased at high temperatures as the silicide particles became more ductile, which was qualitatively consistent with the theoretically expected behavior that crack blunting at these particles should increase the matrix strength. Additional studies were conducted to study the effects of different additives on the self-healing properties of the engineered matrices, which helped to identify the most effective additives.

Composite Materials↗

DOE OSTI2025

Hygrothermal Aging and Thermomechanical Characterization of As-Manufactured Tidal Turbine Blade Composites

This study investigates the hygrothermal aging behavior and thermomechanical properties of as-manufactured glass fiber-reinforced epoxy and thermoplastic composite tidal turbine blades. The blades were previously deployed in a marine environment and subsequently analyzed through a comprehensive suite of material characterization techniques, including hygrothermal aging, dynamic mechanical analysis (DMA), tensile testing and X-ray computed tomography (XCT). Hygrothermal aging experiments revealed that while thermoplastic composites exhibited lower overall water absorption (0.78% vs. 0.47%), they had significantly higher diffusion coefficients than epoxy (2.1 vs. 12.1 × 10 −13 m 2 s −1 ), suggesting faster saturation in operational environments. DMA results demonstrated that water ingress caused plasticization in epoxy matrices, reducing the glass transition temperature and increasing damping (112 °C to 104 °C), while thermoplastic composites showed more stable thermal behavior (87 °C glass transition temperature). Tensile testing revealed substantial reductions in ultimate strength (>40%) for both materials after prolonged water exposure, with minimal change in elastic modulus, highlighting the role of matrix degradation over fiber reinforcement. XCT image analysis showed that both composites were manufactured with high quality: no large voids or cracks were present, and the degree of misalignment was low. These findings inform future marine renewable energy composite designs by emphasizing the critical influence of moisture on long-term structural integrity and the need for optimized material systems in harsh marine environments. This work provides a rare real-world comparison of epoxy and recyclable thermoplastic tidal turbine blades, showing how laboratory aging tests and advanced imaging reveal the influence of material and manufacturing choices on long-term marine durability.

16 TIDAL AND WAVE POWER↗