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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Additive manufacturing of nanotube-loaded thermosets via direct ink writing and radio-frequency heating and curing

Direct Ink Writing (DIW) is an extrusion-based additive manufacturing method where the print medium is a liquid-phase ‘ink’ dispensed out of nozzles and deposited along digitally defined paths. Conventional DIW of thermosetting resins relies on viscosity modifying agents, novel crosslinking chemistries, and/or long curing schedules in an oven. Here we demonstrate the use of a co-planar radio frequency applicator to generate an electric field, which can be used to rapidly heat and cure nano-filled composite resins as they are printed. This method avoids the need for an oven or post- curing step. This process consists of a sequential print-and-cure cycle which allows for printing of high-resolution, multi-layered structures. Every extruded layer is partially cured using RF before depositing the next layer; this allows the printed part to maintain structural integrity. The process enables both increased throughput and decreased touch time relative to traditional manufacturing. Commercial epoxy resin with varied nano-filler loadings were examined as DIW candidates. After printing, the thermo-mechanical properties, surface finish, and shape retention of RF-cured samples were comparable to conventionally cured samples. Furthermore, this method of manufacturing establishes RF heating as a suitable alternative to conventional methods, facilitating rapid, free-form processing of thermosetting resins without a mold.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Co-training of multiple neural networks for simultaneous optimization and training of physics-informed neural networks for composite curing

This paper introduces a Physics-Informed Neural Network (PINN) technique that co-trains neural networks (NNs) that represent each function in a system of equations to simultaneously solve equations representing an out-of-autoclave (OOA) cure process while conducting optimization in adherence to process requirements. Specifically, this co-training approach benefits from using NNs to represent OOA inputs (air temperature profile) and outputs (part and tool temperature profiles and degree of cure). Production requirements can then be levied on the inputs, such as maximum air temperature and minimum cure cycle, and simultaneously on the outputs, such as degree of cure, maximum part temperature, and part temperature rate limits. The technique is validated with finite element (FE) simulations and physical experiments for curing a Toray T830H-6 K/3900-2D composite panel. Furthermore, this novel approach efficiently models and optimizes the OOA cure process.

Composite curing↗
DOE OSTI2022

Microbial Curing of Cement for Energy Applications

Rutgers University, Lawrence Livermore National Laboratory, and the University of Arizona executed this program over 36 months with a 4-Task Program: (M1)-Microbial Engineering (M2)-Microstructure Modelling, (M3) Cement and Concrete Formulation, (M4)-Techno-economic analysis (TEA) and lifecycle assessment (LCA). This program developed a new carbonate cement concrete manufacturing process called microbial curing (MBC). MBC utilizes in-situ microbial production of CO 2 that dissolves into pore-bound water to carbonate a cementitious material creating a bonding matrix of CaCO 3 and SiO 2 that hardens and densifies the material. This is the first work of this type where calcium silicate was used in microbial studies. All other work reported in the literature always used a soluble form of calcium. This final report describes the work done in the final quarter, the best procedures and results, and the final techno-economic and lifecycle analyses. This quarter, we cast and cured twenty-five (4”x8”) cylinder samples. The compressive strength, split tensile, Young’s modulus, chloride permeability, and creep measurements were performed. These measurements demonstrated that MBC of calcium silicate concrete exhibits scaling problems due to the escape of ammonia gas, a product of the microbial reaction to generate CO 2 . As curing proceeds, the ability for the gas to escape from within the cylinder is restricted by the outer cylindrical portions densifying, making the outer portion highly impermeable to gas flow. In contrast, the small samples cured are uniformly cured, forming materials whose mechanical properties are 7x better than the large samples. This problem needs to be solved before this technology can be commercialized. The techno-economic and lifecycle analyses indicate that the technology developed in this program exhibits a significant opportunity to reduce the cost of cement and CO 2 emissions associated with concrete, provided the curing issue associated with larger samples can be addressed.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Prediction of curing kinetics of resorcinol‐added resole phenolic resins using differential scanning calorimetry for the fabrication of carbon/carbon composites

Phenolic resins are commonly used as carbon precursors for the fabrication of carbon/carbon composites due to their high carbon yield and aromatic nature. To decrease curing times, acid catalysts are generally used, but the addition of resorcinol was found to have a similar effect while being incorporated into the resin matrix with no contamination or corrosion issues. In this work, the curing kinetics of pure, 10, 20, and 30 wt% resorcinol-added phenolic resins were investigated through differential scanning calorimetry. Heating rates of 0.5, 1, 2.5, and 5°C min -1 were used with several curing models to predict isothermal curing. Averaged mean absolute error (MAE) for the isoconversional mathematical approaches namely Kissinger–Akahira–Sunose (MAE = 12.9 min), Flynn–Wall–Ozawa (15.8 min), and Vyazovkin (14 min) show that these methods provide the best predictions, attributed to their adoption of an activation energy that depends on the extent of cure (E a (α)). The Kissinger method (MAE = 36 min), which depends only on peak temperature with a constant activation energy assumption, and the data noise sensitive Friedman model (MAE = 1144.7 min) provide the least accurate results. Thermogravimetric analysis revealed that resorcinol decreases the curing times by up to 71% without lowering carbon yield.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Revealing nanoscale dynamics during an epoxy curing reaction with x-ray photon correlation spectroscopy

In this work the evolution of nanoscale properties is measured during the thermally triggered curing of an industrial epoxy adhesive. We use x-ray photon correlation spectroscopy (XPCS) to track the progression of the curing reaction through the local dynamics of filler particles that reflect the formation of a thermoset network. Out-of-equilibrium dynamics are resolved through identification and analysis of the intensity– intensity autocorrelation functions obtained from XPCS. The characteristic time scale and local velocity of the filler is calculated as functions of time and temperature. We find that the dynamics speed up when approaching the curing temperature (T cure ), and decay rapidly once T cure is reached. We compare the results from XPCS to conventional macroscale characterization by differential scanning calorimetry (DSC). The demonstration and implementation of nanoscale characterization of curing reactions by XPCS proves useful for future development and optimization of epoxy thermoset materials and other industrial adhesive systems.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Development of a Cure Model for Unsaturated Polyester Resin Systems Based on Processing Conditions

Unsaturated polyester resin (UPR) systems are extensively used in composite materials for applications in the transportation, marine, and infrastructure sectors. There are continually evolving formulations of UPRs that need to be evaluated and optimized for processing. Differential Scanning Calorimetry (DSC) provides valuable insight into the non-isothermal and isothermal behavior of UPRs within a prescribed temperature range. In the present work, non-isothermal DSC tests were carried out between temperatures of 0.0 °C and 250 °C, through different heating and cooling ramp rates. The isothermal DSC tests were carried out between 0.0 and 170 °C. The instantaneous rate of cure of the tested temperatures were measured. The application of an autocatalytic model in a calculator was used to simulate curing behaviors under different processing conditions. As the temperature increased from 10 °C up to 170 °C, the rate of cure reduced, and the heat of reaction increased. The simulated cure behavior from the DSC data showed that the degree of cure (α) maximum value of 71.25% was achieved at the highest heating temperature of 85 °C. For the low heating temperature, i.e., 5 °C, the maximum degree of cure (α) did not exceed 12% because there was not enough heat to activate the catalyst to crosslink further.

Polymer Science↗
DOE OSTI2022

How Optical and Electrical Properties of ITO Coated Willow Glass Affect Photonic Curing Outcome for Upscaling Perovskite Solar Cell Manufacturing

Indium tin oxide (ITO) coated Willow® glass is an excellent substrate for roll-to-roll manufacturing of perovskite solar cells (PSCs) but can have large variability in its optical and electrical properties. Photonic curing uses intense light pulses instead of heat to process materials and can facilitate faster processing speeds in roll-to-roll manufacturing to upscale the production of PSCs. Since the entire film stack can absorb light and contributes to the photonic curing outcome, the substrate materials’ properties play an integral role. Furthermore, we present the effect of ITO transmittance on the photonic curing of nickel nitrate sol-gel precursors into nickel oxide and consequently the performance of PSCs fabricated with only photonic curing and no thermal annealing. Unexpectedly, ITO samples processed by photonic curing show improved optical and electrical properties.

14 SOLAR ENERGY↗
DOE OSTI2021

Photonic Curing of Nickel Oxide Transport Layer and Perovskite Active Layer for Flexible Perovskite Solar Cells: A Path Towards High-Throughput Manufacturing

High-throughput roll-to-roll (R2R) manufacturing of perovskite solar cells (PSCs) is currently limited by thermal processes that take tens of minutes each, translating to impractically long annealing tools at high web speeds. In addition, PSCs are usually made with metal oxide transport layer materials that require high temperatures for thermal annealing. Here, we demonstrate the fabrication of PSCs using photonic curing, instead of thermal annealing, to convert NiO x directly from sol-gel precursors for hole transport layers and to crystallize methylammonium lead iodide (MAPbI 3 ) active layers on flexible Willow ® Glass substrates. Photonic curing uses short, intense pulses of light to process materials at a high speed, hence it is compatible with R2R manufacturing. We achieved power conversion efficiencies (PCEs) of 11.7% in forward-scan and 10.9% in reverse-scan for PSCs made with photonic cured NiO x and MAPbI 3 films. Furthermore, both NiO x and MAPbI 3 films could be processed with a single photonic curing pulse, with a web speed of 5.7 m/min, and still produce PCEs comparable to thermally annealed control samples. Based on the single-pulse photonic curing condition for each film, we project a web speed of 26 m/min, laying a pathway to high-throughput production of perovskite solar modules.

14 SOLAR ENERGY↗
DOE OSTI2023

Impact of carbamate formation on the surface tension of epoxy‐amine curing systems

Abstract Epoxy‐amine reactive systems, including their surface tension, have been studied due to their use and importance in composites and adhesives in laboratory and industrial applications. Understanding how the system's surface tension changes during curing could help target applications for tailored composites. Using the Wilhelmy plate method, surface tensions for epoxy‐curing agent systems were investigated under different environments. While the epoxy exhibited an expected negative temperature coefficient of −0.096 mN/m/°C, the curing agent exhibited a positive temperature coefficient of 0.073 mN/m/°C, which is due to the curing agent reacting with atmospheric CO 2 to form carbamate through a zwitterion pathway and functional groups accumulating at the surface of the reacting systems. Carbamate formation results in a surface tension below that of the individual constituents in the epoxy‐amine curing agent system. Fourier transform infrared (FTIR) spectroscopy was used to verify in situ formation of carbamate, and by reducing the system's temperature, it was demonstrated that the system surface tension profiles displayed micellar surfactant‐like characteristics. FTIR was used to explore the difference in composition between the surface and the bulk, in particular carbamate formation at the surface, resulting in a lowering of the surface tension of reacting systems.

Shenk, Timothy M.↗
DOE OSTI2020

Chemical structure and curing dynamics of bisphenol S, PEEK™-like, and resveratrol phthalonitrile thermoset resins

This effort provides a multifaceted analysis of the structural changes and material dynamics of thermally driven softening and curing of three distinct phthalonitrile (PN) resins that cross-link into thermally stable and oxidation-resistant thermosets. Although this material system has yielded a large subset of fire-retardant composites that require facile processing and low-temperature curing, to date, insufficient information had been available on the fundamental processes that drive their softening and curing stages. Our approach conducted a complementary analysis the chemistry, monomer mobility, and rheology of three PN polymers in order to correlate the curing processes with corresponding structural and behavioral transformations of thermosets. Here, we focused on PNs with a bisphenol S backbone, a bisphenol A (PEEK™-like) backbone, and a resveratrol backbone. We relied on quasi-elastic neutron scattering (QENS) in order to analyze the in situ dynamics and self-diffusion properties of PN monomers, and to track changes in their mobilities during cross-linking and staging. Our analysis facilitates proper control over the staging and final curing of these resins and enables more efficient processing of these thermosets.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Understanding curing dynamics of arylacetylene and phthalonitrile thermoset blends

Tetrakis(phenylethynyl)benzene (TPEB), a high char yield arylacetylene resin, was blended with a resorcinol-based PEEK™-like oligomeric phthalonitrile resin (Res). Here, we observed the influence of each polymer precursor on the structural changes and material dynamics of different mixtures of these resins during thermal curing to produce thermosets with high char retention. We provide insight to help understand fundamental processes that control and tune this complex thermally driven curing mechanism, which, to date, has not been well understood. We show that an equivalent blend of Res and TPEB mitigates the exothermic curing process and exhibits a low viscosity, which may facilitate processing of these thermosetting blends for composite manufacturing. To obtain a more comprehensive overview of the different dynamics of these polymers during curing, we correlated thermodynamic changes with rheology, materials characterization, and molecular dynamics derived from neutron scattering. Our efforts shed more light on the thermally driven chemical changes, physical transformation, and gelation dynamics that drive or accompany softening and curing of these two distinct crosslinking resin groups.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Real-time cure monitoring of fiber-reinforced polymer composites using infrared thermography and recursive Bayesian filtering

Despite the desirable characteristics of fiber-reinforced polymer (FRP) composites, their utilization in high volume production industries is limited by a lack of efficient manufacturing techniques. Monitoring the curing process of these composites can help with improving the quality and efficiency of the manufacturing process. This article discusses a method that uses Kalman-filter-based fusion of the information obtained from infrared thermography (surface temperature measurements) and a heat conduction model to estimate degrees of cure and internal temperatures of curing FRP composite parts in real time. The effectiveness of the methodology is demonstrated by successfully monitoring the curing of an FRP composite part in a laboratory experiment. Finally, the proposed methodology is a crucial step towards identifying anomalies in the curing process that negatively impact the quality of FRP composite parts.

36 MATERIALS SCIENCE↗
DOE OSTI2024

System and method for in situ volumetric sensing of 3D cure state of resin being used in an additive manufacturing system

An in situ cure monitoring control system for use with a volumetric three dimensional (3D) printing system, wherein the volumetric 3D system includes a container defining a build volume, the container includes a photocurable resist used for making a 3D part, and the resist is responsive to an optical curing beam from a light source, which is controlled by a controller, and which is passed through the resist. The cure monitoring control system includes an optical signal source which generates optical signals having a wavelength selected in relation to a characteristic of the resist, and directed to pass through the build volume. A detector detects the optical signals and generates output signals in accordance therewith. Software monitors the output signals and uses the output signals to modify the curing beam to help optimize curing of the resist.

Panas, Robert Matthew↗
DOE OSTI2021

Microstructural refinement of cement paste internally cured by polyacrylamide composite hydrogel particles containing silica fume and nanosilica

Supplementary cementitious materials were incorporated into hydrogel-based internal curing agents to improve the hydration, microstructure, and ultimately strength of internally cured high-performance cement paste. Polyacrylamide composite hydrogel particles containing amorphous silica – either silica fume or nanosilica – and two different polymer network crosslink densities were synthesized and incorporated into cement paste. The presence of silica and low crosslink density increased the absorption capacity of the particles in pore solution. Micrographs of internally cured paste indicated a significant improvement in hydrogel-related void-filling ability and an increase in void size for low crosslink density particles containing silica. Compressive strength and electrical resistivity increased at later ages for paste samples containing particles with higher silica dosage. The relationship between extent of hydration, void size, and void-filling activity was found to strongly influence the paste's long-term strength and is thus an important structure-property relationship to consider when selecting hydrogels for internal curing purposes.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Properties and reaction mechanism of phosphoric acid activated metakaolin geopolymer at varied curing temperatures

Reaction mechanism of phosphoric activated metakaolin is studied by techniques of calorimetry, ICP-OES, FTIR and NMR taking curing temperature and [H{sub 3}PO{sub 4}] as variables. A two-stage curing method including pre-curing at 40 °C for 24 h and second curing at 60/80 °C for another 24 h effectively mitigates thermal-cracking of the obtained silico-aluminate phosphate (SAP) samples, whose maximum compressive strength reaches 120 MPa. Dealumination of metakaolin in H{sub 3}PO{sub 4} solution produces low aluminate-containing silicate units and subsequently condensation of silicate tetrahedrons occurs. Higher temperature and H{sub 3}PO{sub 4} concentration accelerate the two processes. After complete reaction, A{sub VI} structure from metakaolin disappears and the dissolved Al preferably forms Al{sub VI}-O-P units. During reaction, metastable P-O-P intermediate appears in SAPs with higher P/Al ratio and finally transforms into Al-O-P structure upon PO{sub 4}{sup 3−} consumption. Phosphate units as P(OAl){sub x}(H{sub 2}O){sub 4-x} are connected with Si or Al structure units. Major structural units of the SAPs include Al-O-P, Si-O-P, Si-O-Si, and Si-O-Al.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Internal curing of cement pastes by means of superabsorbent polymers visualized by neutron tomography

Highlights: • The kinetics of water release from SAPs were studied by neutron tomography. • The time window for internal curing was linked to the water release from SAPs. • The water release links to the SAP effectiveness to mitigate autogenous shrinkage. • One SAP type was effective while another prematurely released its stored water. Superabsorbent polymers (SAPs) are used to counteract self-desiccation in order to mitigate autogenous shrinkage, a problem in cementitious systems with a low water-to-cement ratio. The release kinetics during internal curing are of importance as not all SAP types are able to efficiently mitigate autogenous shrinkage. In this study, neutron tomography is used to study and visualize the water release kinetics over time. Per-voxel analysis of the time-attenuation curve was performed using piecewise-constant functions. Two different SAP types were studied, one being able to mitigate autogenous shrinkage and one quickly releasing its stored water after final setting. The tomography results correspond to autogenous shrinkage measurements and nuclear magnetic resonance tests. The visualization provides information on the time of water release by the SAPs after setting and the time window of internal curing. This opens additional insights towards the application of SAPs in the construction sector and provides information on the mechanism of internal curing.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Screening candidate supplementary cementitious materials under standard and accelerated curing through time-series surface resistivity measurements and change-point detection

Time-series surface resistivity (SR) measurements are evaluated as an indicator of pozzolanicity in concretes containing 13 materials of both known and unknown pozzolanicity, under standard and accelerated curing conditions, and the results were validated against portlandite consumption obtained through thermogravimetric analysis. Change-point detection (CPD) analysis is applied to the data to provide a rigorous indicator of hydration age of the onset and rate of the pozzolanic reaction, if occurring. The SR measurements were able to capture the onset of the pozzolanic reactions in concretes curing at elevated temperature regimes, which allows determination of pozzolanicity weeks earlier than at standard curing temperatures. Using CPD along with slope analysis allows a comprehensive analysis of a material's reactivity and determination of pozzolanicity in as quickly as two days. Time-series SR measurements at elevated curing conditions, along with limits on material composition, are recommended for determination of pozzolanic reactivity in novel or variable materials.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Longitudinal Plasma Proteomic Profiling Reveals Divergent Immune Responses in Durably Cured and Relapsed Pulmonary Tuberculosis

Background: Predicting the risk of tuberculosis (TB) relapse is vital to improving treatment outcomes. Although clinical risk factors of relapse are well characterized, the biological mechanisms driving relapse, particularly host immune responses, remain poorly understood. Elucidating these mechanisms is necessary to better predict relapse risk. Methods: We conducted a longitudinal, global proteomic study on 60 participants with active pulmonary TB, half who were durably cured and half who relapsed. Plasma was collected at seven time-points: at treatment initiation (baseline), during therapy, and 52 weeks post-baseline. Samples were analyzed by high-resolution LC-MS/MS. Results: 2,418 proteins were identified across all samples, with 1,756 being differentially expressed relative to baseline (unadjusted p < 0.05). 956 proteins were differentially abundant between cured and relapsed participants. Relapsed participants showed heightened humoral immunity throughout treatment, as well as upregulated complement activation and HDL particles. Cured participants exhibited elevated recovery-related pathways by week 4, including downregulated epithelial invasion and upregulated oxygen transport. Conclusions: Heightened humoral and innate immune responses were associated with relapse, whereas recovery signatures were associated with durable cure. These findings advance our understanding of host responses to treatment and provide a basis for developing blood-based biomarkers to identify patients at increased risk of relapse.

LC-MS/MS↗