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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 OSTI2025

Fiber orientation and porosity in large-format extrusion process: The role of processing parameters

Controlling fiber orientation and porosity in short-fiber thermoplastic composites is important for enhancing mechanical, electrical and thermal properties in large-format additive manufacturing. This study employs a factorial design of experiments (DoE) to assess the effects of nozzle diameter (5.08 mm–10.16 mm), temperature (230–250 °C), and extruder screw speed (150–280 rpm) on flow rate, shear rate, porosity, fiber orientation, fiber length and tensile strength in 20 % carbon fiber-filled acrylonitrile butadiene styrene. ANOVA results show that screw speed significantly impacts flow rate, while nozzle diameter and temperature have lesser effects. Shear rate increases with smaller nozzles and higher speeds. Porosity decreases from 5.58 % with a 10.16 mm nozzle to 3.11 % with a 5.08 mm nozzle at 150 rpm due to increased shear rates, which induce shear thinning, reducing viscosity and facilitating gas escape. Larger nozzles (10.16 mm) produce larger, more heterogeneous pores, while smaller nozzles (5.08 mm) yield smaller, uniform pores. Beads produced with the 5.08 mm nozzle exhibit longer fiber lengths due to reduced residence time, lower shear stress, and better alignment. Fiber orientation improves with smaller nozzles due to higher shear rates but decreases with higher screw speeds (280 rpm) due to shorter residence times. The highest fiber alignment (A xx ∼ 0.65) and low porosity (∼3%) were achieved with a 5.08 mm nozzle at 150 rpm, while equivalent additive manufacturing-compression molding samples exhibited better tensile strength (∼93 MPa) under these conditions. In conclusion, these findings emphasize the importance of optimizing processing parameters to enhance fiber alignment and reduce porosity for improved mechanical performance.

Design of experiments↗
NASA NTRS2007

Aligning Optical Fibers by Means of Actuated MEMS Wedges

Microelectromechanical systems (MEMS) of a proposed type would be designed and fabricated to effect lateral and vertical alignment of optical fibers with respect to optical, electro-optical, optoelectronic, and/or photonic devices on integrated circuit chips and similar monolithic device structures. A MEMS device of this type would consist of a pair of oppositely sloped alignment wedges attached to linear actuators that would translate the wedges in the plane of a substrate, causing an optical fiber in contact with the sloping wedge surfaces to undergo various displacements parallel and perpendicular to the plane. In making it possible to accurately align optical fibers individually during the packaging stages of fabrication of the affected devices, this MEMS device would also make it possible to relax tolerances in other stages of fabrication, thereby potentially reducing costs and increasing yields. In a typical system according to the proposal (see Figure 1), one or more pair(s) of alignment wedges would be positioned to create a V groove in which an optical fiber would rest. The fiber would be clamped at a suitable distance from the wedges to create a cantilever with a slight bend to push the free end of the fiber gently to the bottom of the V groove. The wedges would be translated in the substrate plane by amounts Dx1 and Dx2, respectively, which would be chosen to move the fiber parallel to the plane by a desired amount Dx and perpendicular to the plane by a desired amount Dy. The actuators used to translate the wedges could be variants of electrostatic or thermal actuators that are common in MEMS.

Morgan, Brian↗
NASA NTRS2018

Quantification of Error Associated with Using Misaligned Meshes in Continuum Damage Mechanics Material Models for Matrix Crack Growth Predictions in Composites

The ability of a material model to capture in-plane matrix mode I and mode II crack growth is an essential component for modeling ply level damage evolution in composite structures. Previous studies using a continuum damage mechanics (CDM) approach have shown success in satisfying benchmark solutions for mode I and II crack growth. However, success was shown using a fiber-aligned meshing strategy, which encourages matrix cracks to propagate in a single band of elements, along the fiber direction. Generating a fiber-aligned mesh becomes a highly involved process for laminates including off-axis (non 0° or 90°) plies. The objective of this study is to quantify the effect of non-fiber aligned mesh discretization on predictions of in-plane matrix crack propagation. The approach taken incrementally varies the mesh orientation angle relative to the fiber orientation; more specifically, misaligned meshes are used to quantify the effect of element angle orientation relative to the initial crack orientation on the energy released during matrix crack propagation simulations using a CDM method. CDM solutions obtained with the misaligned meshes are evaluated against known benchmarks for mode I and II matrix crack growth. The CDM solutions reveal a near-polynomial trend of increased predicted failure stress with increased mesh misalignment angle; hence implying a potential relationship between element orientation angle and apparent fracture toughness.

Justusson, Brian↗
DOE OSTI2021

Fiber orientation effects on ultra-high performance concrete formed by 3D printing

Despite the growing interest in 3D concrete printing, its current progress is limited by reinforcing methods. Inclusion of steel fibers is a potential reinforcing solution; however, the effect of printing process on orientation of the fibers is still unknown. This study aims to quantitatively investigate the orientation distribution of steel fibers in 3D printed ultra-high performance concrete. The effects of extrusion nozzle size, Cartesian print speed, and fiber volume fraction on the orientation of fibers were evaluated using digital image analysis. The consequent effects of the fiber orientation on the mechanical properties of the 3D-printed specimens were also determined. The results were compared with those of the conventionally mold-cast specimens. The results revealed that the smaller nozzle size and higher fiber volume fraction significantly enhanced the fiber alignment parallel to the printing direction. This preferential fiber alignment led to superior mechanical performance of the printed specimens to the mold-cast specimens.

36 MATERIALS SCIENCE↗
NASA NTRS2018

Influence of Fiber Volume and Alignment on Impact Resistance of Braided Carbon Fiber Epoxy Composites

The effect of axial tow alignment within a laminate ply stack on the impact penetration threshold for a series of composite panels was evaluated; specifically, the effect of a lateral shift in alignment to induce fiber nesting. Panels were fabricated from braided T700S carbon fiber and TenCate Advanced Composites's TC275-1 epoxy resin prepreg. Axial tows in each ply were aligned, offset, or rotated to evaluate the influence of such parameters on impact penetration resistance. Panel-to-panel variation in thickness, resin content, and fiber volume ratio were measured. Ultimately, process-related deviations drove penetration limits on impact. Influence of axial tow alignment was difficult to discern outside of the processing-induced variations between panels.

process variation↗
NASA NTRS1989

Apparatus Impregnates Weak Fibers

Low-cost apparatus developed for use in conventional drum winding machine to impregnate fibrous materials having very low tensile strengths. Fiber fitted onto freely-spinning unwinding creel. Unwinds from creel between two tension bars onto guide spools, aligns fiber so properly enters sealed reservoir of resin. Stainless-steel metering die at entrance to reservoir aligns fiber and seals reservoir. Beneficial results obtained by use of reservoir made of polyethylene. Composite material made from resin matrices reinforced by fibers have great potential for solving challenging and often critical problems in design of spacecraft, space structures, and terrestrial structures.

Stanfield, Clarence E.↗
DOE OSTI2021

Melt extruded versus extrusion compression molded glass-polypropylene long fiber thermoplastic composites

Long fiber thermoplastic (LFT) composites are processed either with extrusion compression or fiber injection processes. The properties of LFT materials are highly influenced by processing techniques, which lead to different porosity contents, fiber length distributions, and fiber orientation distributions. It is important to understand the various LFT processing techniques and their effects on mechanical, thermal, and microscopic properties. This work considered LFT sheets processed via extrusion, which offers highly aligned fibers (referred to as “Tecnogor composites”), and LFT composites produced via extrusion compression molding (ECM), which offers a random distribution of fibers. Tecnogor composites exhibited higher flexural strength (35–65%), flexural modulus (132–172%), tensile strength (39–52%), tensile modulus (67–75%), and Izod impact resistance (195–220%) than the random LFT composites. This response was attributed to the aligned fibers in Tecnogor composites. Mathematical models including Halpin-Tsai and Lavengood-Goettler were used to predict and compare the Young’s modulus of Tecnogor and ECM composites, respectively.

mechanical testing↗
NASA NTRS2018

Implementation of a Matrix Crack Spacing Parameter in a Continuum Damage Mechanics Finite Element Model

Continuum Damage Mechanics (CDM) based progressive damage and failure analysis (PDFA) methods have demonstrated success in a variety of finite element analysis (FEA) implementations. However, the technical maturity of CDM codes has not yet been proven for the full design space of composite materials in aerospace applications. CDM-based approaches represent the presence of damage by changing the local material stiffness definitions and without updating the original mesh or element integration schemes. Without discretely representing cracks and their paths through the mesh, damage in models with CDM-based materials is often distributed in a region of partially damaged elements ahead of stress concentrations. Having a series of discrete matrix cracks represented by a softened region may affect predictions of damage propagation and, thus, structural failure. This issue can be mitigated by restricting matrix damage development to discrete, fiber-aligned rows of elements; hence CDM-based matrix cracks can be implemented to be more representative of discrete matrix cracks. This paper evaluates the effect of restricting CDM matrix crack development to discrete, fiber-aligned rows where the spacing of these rows is controlled by a user-defined crack spacing parameter. Initially, the effect of incrementally increasing matrix crack spacing in a unidirectional center notch coupon is evaluated. Then, the lessons learned from the center notch specimen are applied to open-hole compression finite element models. Results are compared to test data, and the limitations, successes, and potential of the matrix crack spacing approach are discussed.

Hyder, Imran↗
DOE OSTI2021

Compact, All-PM Fiber Integrated and Alignment-Free Ultrafast Yb:Fiber NALM Laser With Sub-Femtosecond Timing Jitter

We report a simple and compact design of a dispersion compensated mode-locked Yb:fiber oscillator based on a nonlinear amplifying loop mirror (NALM). The fully polarization maintaining (PM) fiber integrated laser features a chirped fiber Bragg grating (CFBG) for dispersion compensation and a fiber integrated compact non-reciprocal phase bias device, which is alignment-free. The main design parameters were determined by numerically simulating the pulse evolution in the oscillator and by analyzing their impact on the laser performance. Experimentally, we achieved an 88 fs compressed pulse duration with sub-fs timing jitter at 54 MHz repetition rate and 51 mW of output power with 5.5×10 -5 [20 Hz, 1 MHz] integrated relative intensity noise (RIN). Furthermore, we demonstrate tight phase-locking of the laser's carrier-envelope offset frequency ( fceo ) to a stable radio frequency (RF) reference and of one frequency comb tooth to a stable optical reference at 291 THz.

47 OTHER INSTRUMENTATION↗
NASA NTRS2007

Flash Diffusivity Technique Applied to Individual Fibers

A variant of the flash diffusivity technique has been devised for determining the thermal diffusivities, and thus the thermal conductivities, of individual aligned fibers. The technique is intended especially for application to nanocomposite fibers, made from narrower fibers of polyphenylene benzobisthiazole (PBZT) and carbon nanotubes. These highly aligned nanocomposite fibers could exploit the high thermal conductivities of carbon nanotubes for thermal-management applications. In the flash diffusivity technique as practiced heretofore, one or more heat pulse(s) is (are) applied to the front face of a plate or disk material specimen and the resulting time-varying temperature on the rear face is measured. Usually, the heat pulse is generated by use of a xenon flash lamp, and the variation of temperature on the rear face is measured by use of an infrared detector. The flash energy is made large enough to produce a usefully high temperature rise on the rear face, but not so large as to significantly alter the specimen material. Once the measurement has been completed, the thermal diffusivity of the specimen is computed from the thickness of the specimen and the time dependence of the temperature variation on the rear face. Heretofore, the infrared detector used in the flash diffusivity technique has been a single-point detector, which responds to a spatial average of the thermal radiation from the rear specimen surface. Such a detector cannot distinguish among regions of differing diffusivity within the specimen. Moreover, two basic assumptions of the thermaldiffusivity technique as practiced heretofore are that the specimen is homogeneous and that heat flows one-dimensionally from the front to the rear face. These assumptions are not valid for an inhomogeneous (composite) material.

Mayeaux, Brian↗
DOE OSTI2025

The Anisotropic Adsorption of De Novo Allosteric Two‐Component Protein Fibers on Mica Surfaces

Protein adsorption at solid–liquid interfaces underlies many biomedical and materials applications, yet the mechanisms governing adsorption of proteins and their assemblies remain poorly understood. Here we investigate de novo–designed proteins that self-assemble into three fibrillar morphologies — small (S), large (L), and helical (H)—on muscovite mica. S-fibers are metastable, forming first but diminishing as L- and H-fibers develop and deposit. Adsorption of both fibers and monomers depends on fiber morphology and solvent environment, which is modulated by the substrate. The anisotropic surface features of the fiber types—long axis of S- and L-fibers and helical grooves of H-fibers—correlate with specific crystallographic directions on mica (001). S- and L-fibers align along the unique lattice axis, while the substrate-facing groove of H-fibers preferentially aligns along the remaining symmetry-related directions. Increasing potassium chloride (KCl) concentrations to molar levels alters adsorption, decreasing monomer coverage relative to fibers. These observations, interpreted through the effect of interfacial interface, indicate that ion-mediated modulation of hydration layers governs electrostatic interactions and alignment. This study reveals how coupling between protein topography, substrate crystallography, and hydration structure dictates selective adsorption and orientation of protein assemblies, offering insights for rational biomolecular material design.

AFM↗
NASA NTRS2000

Near-Net-Shape Processing of Sintered Fibrous Ceramics Achieved

A variety of sintered fibrous ceramic (SFC) materials have been developed over the last 50 years as thermal barrier materials for reentry applications. SFC materials typically exhibit very low thermal conductivities combined with low densities and good thermal stability up to 2500 F. These materials have flown successfully on the space shuttle orbiters since the 1960's. More recently, the McDonnell Douglas Corporation successfully used SFC tiles as a heat shield on the underside of its DC X test vehicle. For both of these applications, tiles are machined from blocks of a specific type of SFC called an alumina-enhanced thermal barrier (AETB). The sizes of these blocks have been limited by the manufacturing process. In addition, as much as 80 to 90 percent of the material can be lost during the machining of tiles with significant amounts of curvature. To address these problems, the NASA Glenn Research Center at Lewis Field entered a cooperative contract with the Boeing Company to develop a vacuum-assisted forming process that can produce large (approximately 4 square feet), severely contoured panels of AETB while saving costs in comparison to the conventional cast-and-machine billet process. For shuttle use, AETB is slurry cast, drained, and fired to form square billets conforming to the shape of the filtration box. The billets are then cut into tiles of the appropriate size for thermally protecting the space shuttle. Processing techniques have limited the maximum size of AETB billets to 21.5 square inches by 6.5-in. thick, but the space shuttles use discrete heat shield tiles no more than 8 to 12 square inches. However, in other applications, large, complex shapes are needed, and the tiling approach is undesirable. For such applications, vacuum-assisted forming can produce large parts with complex shapes while reducing machining waste and eliminating cemented joints between bonded billets. Because it allows contoured shapes to be formed, material utilization is inherently high. Initial estimates show that the amount of material lost during machining can be reduced by 50 percent or more. In addition, a fiber alignment favorable for minimum heat transfer is maintained for all panel shapes since the fibers are aligned parallel to the contoured surface of the forming tool or mold. The vacuum-assisted forming process can complete the entire forming operation in a matter of minutes and can produce multiple parts whose size is limited only by the size of the forming tool. To date, panels as large as 2 square feet have been demonstrated The vacuum-assisted forming process starts with the fabrication of a permeable forming tool, or mold, with the proper part contour. This reusable tool is mounted over an internal rib support structure, as depicted in the diagram, such that a vacuum can be pulled on the bottom portion of the tool. AETB slurry is then poured over and around the tool, liquid is drawn from the slurry, and the part forms over the tool surface. The part is then dried, fired, and finished machined. Future plans include an evaluation of the need for additional coatings and surface-toughness treatments to extend the durability and performance of this material.

Angel, Paul W.↗
NASA NTRS1993

Influence of fiber packing structure on permeability

The study on the permeability of an aligned fiber bundle is the key building block in modeling the permeability of advanced woven and braided preforms. Available results on the permeability of fiber bundles in the literature show that a substantial difference exists between numerical and analytical calculations on idealized fiber packing structures, such as square and hexagonal packing, and experimental measurements on practical fiber bundles. The present study focuses on the variation of the permeability of a fiber bundle under practical process conditions. Fiber bundles are considered as containing openings and fiber clusters within the bundle. Numerical simulations on the influence of various openings on the permeability were conducted. Idealized packing structures are used, but with introduced openings distributed in different patterns. Both longitudinal and transverse flow are considered. The results show that openings within the fiber bundle have substantial effect on the permeability. In the longitudinal flow case, the openings become the dominant flow path. In the transverse flow case, the fiber clusters reduce the gap sizes among fibers. Therefore the permeability is greatly influenced by these openings and clusters, respectively. In addition to the porosity or fiber volume fraction, which is commonly used in the permeability expression, another fiber bundle status parameter, the ultimate fiber volume fraction, is introduced to capture the disturbance within a fiber bundle.

Cai, Zhong↗
NASA NTRS1993

Development of braided fiber seals for engine applications

A new type of braided fiber seal was developed for high temperature engine applications. Development work performed includes seal design, fabrication, leakage flow testing, and flow resistance modeling. This new type of seal utilizes the high flow resistance of tightly packed fibers and the conformability of textile structures. The seal contains a core part with aligned fibers, and a sheath with braided fiber layers. Seal samples are made by using the conventional braiding process. Leakage flow measurements are then performed. Mass flow rate versus the simulated engine pressure and preload pressure is recorded. The flow resistance of the seal is analyzed using the Ergun equation for flow through porous media, including both laminar and turbulent effects. The two constants in the Ergun equation are evaluated for the seal structures. Leakage flow of the seal under the test condition is found to be in the transition flow region. The analysis is used to predict the leakage flow performance of the seal with the determined design parameters.

Cai, Zhong↗
NASA NTRS1990

Structural monitoring of filamentary composites using embedded fiber optics

The feasibility of monitoring overall integrity of structural components made of filamentary composites, by embedding optical fibers between lamina of a composite beam, is investigated using a beam constructed of Kevlar/epoxy cloth with embedded optical fibers aligned with the longitudinal axis of the beam. Phase changes were monitored in three different optical fibers as the composite beam was subjected to pure bending, and the strain response of the fibers was compared to the strain gage readings taken at the surface, showing a strong correlation between the phase change and the applied deformation.

Cashon, John L.↗
NASA NTRS1992

Development of composite structures in hypermonotectic alloys through the use of in-situ fibers

This study demonstrates how the otherwise detrimental surface wetting and coarsening in a metallic system can be put to advantage through the inclusion of aligned fibers which accrue the excess liquid II phase while passing through the range of the miscibility gap and, some lower temperature, uniformly incorporate it into the solid I plus liquid II matrix. This is initially shown through the utilization of a hypermonotectic succinonitrile-glycerol mixture, a transparent organic system which exhibits solidification behavior in a manner analogous to metals. Results are compared with the analogue study and both are reviewed in terms of relevant wetting theory and surface area considerations.

Grugel, R. N.↗
NASA NTRS2000

Orientation and length of mammalian skeletal myocytes in response to a unidirectional stretch

Effects of mechanical forces exerted on mammalian skeletal muscle cells during development were studied using an in vitro model to unidirectionally stretch cultured C2C12 cells grown on silastic membrane. Previous models to date have not studied these responses of the mammalian system specifically. The silastic membrane upon which these cells were grown exhibited linear strain behavior over the range of 3.6-14.6% strain, with a Poisson's ratio of approximately 0.5. To mimic murine in utero long bone growth, cell substrates were stretched at an average strain rate of 2.36%/day for 4 days or 1.77%/day for 6 days with an overall membrane strain of 9.5% and 10.6%, respectively. Both control and stretched fibers stained positively for the contractile protein, alpha-actinin, demonstrating muscle fiber development. An effect of stretch on orientation and length of myofibers was observed. At both strain rates, stretched fibers aligned at a smaller angle relative to the direction of stretch and were significantly longer compared to randomly oriented control fibers. There was no effect of duration of stretch on orientation or length, suggesting the cellular responses are independent of strain rate for the range tested. These results demonstrate that, under conditions simulating mammalian long bone growth, cultured myocytes respond to mechanical forces by lengthening and orienting along the direction of stretch.

Non-NASA Center↗
NASA NTRS2004

Ballistic Impact of Braided Composites With a Soft Projectile

Impact tests using a soft gelatin projectile were performed to identify failure modes that occur at high strain energy density during impact loading. Use of a soft projectile allows a large amount of kinetic energy to be transferred into strain energy in the target before penetration occurs. Failure modes were identified for flat aluminum plates and for flat composite plates made from a triaxial braid having a quasi-isotropic fiber architecture with fibers in the 0 and +/- 60 deg. directions. For the aluminum plates, a large hole formed as a result of crack propagation from the initiation site at the center of the plate to the fixed boundaries. For the composite plates, fiber tensile failure occurred in the back ply at the center of the plate. Cracks then propagated from this site along the +/- 60 deg. fiber directions until triangular flaps opened to allow the projectile to pass through the plate. The damage size was only slightly larger than the initial impact area. It was difficult to avoid slipping of the fixed edges of the plates during impact, and slipping was shown to have a large effect on the penetration threshold. Failure modes were also identified for composite half-rings fabricated with the 0 deg. fibers aligned circumferentially. Slipping of the edges was not a problem in the half-ring tests. For the composite half-rings, fiber tensile failure also occurred in the back ply. However, cracks initially propagated from this site in a direction transverse to the 0 deg. fibers. The cracks then turned to follow the +/- 60 deg. fibers for a short distance before turning again to follow 0 deg. fibers until two approximately rectangular flaps opened to allow the projectile to pass through the plate. The damage size in the composite half-rings was also only slightly larger than the initial impact area. Cracks did not propagate to the boundaries, and no delamination was observed. The damage tolerance demonstrated by the quasi-isotropic triaxial braid composites indicate that composites of this type can reasonably be considered as a lightweight alternative to metals for fan cases in commercial jet engines.

Roberts, Gary D.↗