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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 OSTI2024

Aluminum/SmCo 5 composites for structural and magnetic applications

Metal-bonded magnetic composites (MBMCs) present a promising alternative to dense sintered magnets, particularly for intricate components. Compared to polymer-based bonded magnets, MBMCs have wider applicability in harsh environments. In this paper, we demonstrate a solid-state shear-based manufacturing technique to introduce localized magnetization into a paramagnetic aluminum matrix by embedding SmCo5 permanent magnet particles. Our magnetic composites display hard magnetic behavior with a coercivity of 13 kOe and a remanent magnetization of 4.32 emu/g. In addition to magnetization, we also report a 9% improvement in Young’s modulus. Despite the local temperature rise during processing, the magnetic phases didn’t decompose into unwanted phases, preserving the composite's hard magnetic properties. Creation of an interfacial metallurgical bond with the matrix ensured the suitability of the composites for structural applications. Our study investigates the mechanical, and functional properties of composites, paving the way for lightweight structural magnetic composites with a transformative potential in the aerospace, nuclear, and automotive applications. This work underscores the potential for further optimization and development to drive innovations in magnet and equipment design.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Active, tailorable adhesives for dissimilar material bonding, repair and reassembly

Joining of materials and components is inevitable as it allows versatility in assembly and repair along with reduction in time and cost of manufacturing. However, joints are mostly considered the ‘weak-links’ of the structure due to the complex phenomena and interactions of several elements of either similar or dissimilar materials. These complexities combined with the need for lightweight structures and increased safety require better understanding and development of robust dissimilar material joints. The proposed technique uses ‘active adhesives’ and inherits all the advantages of bonded joints, such as lightweight, elimination of holes and associated stress-concentrations, and overcomes its shortcomings of disassembly and repair. Thermoplastic adhesives modified by the incorporation of electrically conductive graphene nanoplatelets at a concentration above the percolation point provide a unique synergy of mechanical, thermal and electrical properties. While the choice of the thermoplastic is governed by the desired application, the addition of the graphene nanoplatelets allows energy to be deposited primarily in the adhesive. The percolated network of graphene particles in the adhesive can quickly couple to microwave (MW) radiation via non-contact methods and increase the adhesive temperature to above the required processing temperatures. The adhesive melts and flows over the adherends and upon cooling forms a structural adhesive bond. Furthermore, the process can be used to disassemble the adhesive joint if repair or reworking is required. The dissimilar material joints in this study include fiber reinforced polymer composites (FRP) made of glass and carbon fibers being joined with metals such as advanced high strength steel (AHSS) and aluminum (Al). The global objectives of the proposed work were achieved through: a) processing, material development and optimization of the active adhesive, b) lab-scale evaluation and detailed material characterization and, c) design, testing and applications. An integrated experimental and numerical approach that used novel non-destructive evaluation techniques to validate the simulations were used. Such experimentally validated simulations could be used to predict designs beyond the experimental matrix. Overall, this project showed the feasibility and robustness of ‘active’, ‘reversible’ thermoplastic adhesives and their use in large-scale multi-material joints.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Bandwidth Study on Energy Use and Potential Energy Savings Opportunities in U.S. Titanium Manufacturing

Energy bandwidth studies can serve as foundational references in framing the range (or bandwidth) of potential energy savings opportunities in U.S. manufacturing. This bandwidth study is one of a series of six energy bandwidth studies on lightweight structural materials manufacturing. The study examines energy consumption and potential energy savings opportunities in U.S. titanium manufacturing. The study relies on multiple sources to estimate the energy used in the manufacturing of the lightweight material for four application areas (automotive, wind energy, aerospace, and pressure vessels), accounting for approximately 75% of overall U.S. titanium production in 2010. Energy savings opportunities for the three manufacturing subareas studied are based on technologies currently in use or under development.

energy bandwidth study, titanium, advanced manufac↗
DOE OSTI2017

Bandwidth Study on Energy Use and Potential Energy Saving Opportunities in U.S. Magnesium Manufacturing

Energy bandwidth studies can serve as foundational references in framing the range (or bandwidth) of potential energy savings opportunities in U.S. manufacturing. This bandwidth study is one of a series of six energy bandwidth studies on lightweight structural materials manufacturing. The study examines energy consumption and potential energy savings opportunities in U.S. magnesium manufacturing. The study relies on multiple sources to estimate the energy used in the manufacturing of the lightweight material for four application areas (automotive, wind energy, aerospace, and pressure vessels), accounting for approximately 32% of overall U.S. magnesium production in 2010. Energy savings opportunities for the four manufacturing subareas studied are based on technologies currently in use or under development.

energy energy bandwidth study, magnesium, advanced↗
DOE OSTI2017

Bandwidth Study on Energy Use and Potential Energy Saving Opportunities in U.S. Aluminum Manufacturing

Energy bandwidth studies can serve as foundational references in framing the range (or bandwidth) of potential energy savings opportunities in U.S. manufacturing. This bandwidth study is one of a series of six energy bandwidth studies on lightweight structural materials manufacturing. The study examines energy consumption and potential energy savings opportunities in U.S. aluminum manufacturing. The study relies on multiple sources to estimate the energy used in the manufacturing of the material for lightweighting applications (automotive and aerospace), accounting for approximately 28% of overall U.S. aluminum production in 2010. Energy savings opportunities for the five manufacturing subareas studied are based on technologies currently in use or under development.

energy energy bandwidth study, aluminum, advanced ↗
DOE OSTI2017

Bandwidth Study on Energy Use and Potential Energy Saving Opportunities in U.S. Carbon Fiber Reinforced Polymer Manufacturing

Energy bandwidth studies can serve as foundational references in framing the range (or bandwidth) of potential energy savings opportunities in U.S. manufacturing. This bandwidth study is one of a series of six energy bandwidth studies on lightweight structural materials manufacturing. The study examines energy consumption and potential energy savings opportunities in U.S. carbon fiber reinforced polymer composites manufacturing. The study relies on multiple sources to estimate the energy used in the manufacturing of the lightweight material for four application areas (automotive, wind energy, aerospace, and pressure vessels), accounting for approximately 51% of overall U.S. carbon fiber production in 2010. Energy savings opportunities for the six manufacturing sub-processes studied are based on technologies currently in use or under development.

energy energy bandwidth study, carbon fiber, reinf↗
DOE OSTI2017

Bandwidth Study on Energy Use and Potential Energy Saving Opportunities in U.S. Advanced High Strength Steels Manufacturing

Energy bandwidth studies can serve as foundational references in framing the range (or bandwidth) of potential energy savings opportunities in U.S. manufacturing. This bandwidth study is one of a series of six energy bandwidth studies on lightweight structural materials manufacturing. The study examines energy consumption and potential energy savings opportunities in U.S. advanced high strength steel (AHSS) manufacturing. The study relies on multiple sources to estimate the energy used in the manufacturing of the lightweight material for automotive applications, accounting for nearly 100% of U.S. AHSS production in 2010. Energy savings opportunities for the six manufacturing subareas studied are based on technologies currently in use or under development.

energy bandwidth study, advanced high strength ste↗
DOE OSTI2017

Bandwidth Study on Energy Use and Potential Energy Saving Opportunities in U.S. Glass Fiber Reinforced Polymer Manufacturing

Energy bandwidth studies can serve as foundational references in framing the range (or bandwidth) of potential energy savings opportunities in U.S. manufacturing. This bandwidth study is one of a series of six energy bandwidth studies on lightweight structural materials manufacturing. The study examines energy consumption and potential energy savings opportunities in U.S. glass fiber reinforced polymer composites manufacturing. The study relies on multiple sources to estimate the energy used in the manufacturing of the lightweight material for four application areas (automotive, wind energy, aerospace, and pressure vessels), accounting for approximately 47% of overall U.S. glass fiber production in 2010. Energy savings opportunities for the six manufacturing sub-processes studied are based on technologies currently in use or under development.

energy energy bandwidth study, glass fiber, reinfo↗
DOE OSTI2026

Low-Cost Highly Recyclable Structural Composites Utilizing Vitrimers and Natural Fibers (Basalt) Manufactured via a Novel Pultrusion Method for High-Volume Applications

The project’s overall goal is to explore and demonstrate as proof-of-concept that a highly recyclable and repairable composite material system, that is reinforced with natural fibers, can be used to produce lightweight structural components using a low-cost manufacturing process for high-volume automotive applications. More specifically, the project’s objectives will focus on vitrimer resins (which are a hybrid polymeric system of thermoplastics and thermosets) reinforced with basalt fibers and manufactured using pultrusion technologies. Pultrusion, as a method, is well-known to be one of the lowest-cost manufacturing processes for high-volume applications. However, to date, the validity and viability of such attractive objectives have not been demonstrated in support of the automotive industry.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Unveiling Atomistic Mechanisms Governing Additive Manufacturing Processability and Mechanical Behavior of a Refractory Complex Concentrated Alloy

Extending the concept of complex concentrated alloys (CCAs) to the refractory alloys (solidus temperature over 2000 °C) space potentially facilitates the design of lightweight structural alloys with service temperatures that exceed those of Ni and Co‐based alloys. However, the room and elevated temperature tensile properties of the current refractory‐CCAs (R‐CCAs) are inferior to those of the Ni/Co‐based alloys. Furthermore, the manufacturing scalability of R‐CCAs remains challenging, in that cracks are prevalent in all R‐CCAs when processed using near‐net shape manufacturing processes, such as fusion‐based additive manufacturing (F‐BAM). Still, mechanisms governing the poor F‐BAM processability of R‐CCAs remain unexplored. Here, to this end, this work unveils the atomistic mechanisms underlying F‐BAM process‐induced cracking in a NbTiTaMoHfZrC R‐CCA. The implications of light elements’ presence for intrinsic ductility and grain boundary cohesion, and subsequently for F‐BAM processability and mechanical behavior, are revealed. Leveraging the insights, we accomplish what is, to the best of the knowledge, the first instance of crack‐free F‐BAM processing of any R‐CCA. Additionally, the R‐CCA exhibits over 20% tensile ductility and ≈160 MPa tensile yield strength at 1200 °C. In addition to facilitating the design of lightweight R‐CCAs, findings enable scalable manufacturing of these ultra‐high temperature alloys for structural applications.

Refractory alloys↗
DOE OSTI2022

Manufacturing of Complex Silicon–Carbon Structures: Exploring Si x C y Materials

This paper reports on the manufacturing of complex three-dimensional Si/C structures via a chemical vapor deposition method. The structure and properties of the grown materials were characterized using various techniques including scanning electron microscopy, aberration-corrected transmission electron microscopy, confocal Raman spectroscopy, and X-ray photoelectron spectroscopy. The spectroscopy results revealed that the grown materials were composed of micro/nanostructures with various compositions and dimensions. These included two-dimensional silicon carbide (SiC), cubic silicon, and various SiC polytypes. The coexistence of these phases at the nano-level and their interfaces can benefit several Si/C-based applications ranging from ceramics and structural applications to power electronics, aerospace, and high-temperature applications. With an average density of 7 mg/cm 3 , the grown materials can be considered ultralightweight, as they are three orders of magnitude lighter than bulk Si/C materials. This study aims to impact how ceramic materials are manufactured, which may lead to the design of new carbide materials or Si/C-based lightweight structures with additional functionalities and desired properties.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Monitoring system for the quality assessment in additive manufacturing

Additive Manufacturing (AM) refers to a process by which a set of digital data -representing a certain complex 3dim design - is used to grow the respective 3dim real structure equal to the corresponding design. For the powder-based EOS manufacturing process a variety of plastic and metal materials can be used. Thereby, AM is in many aspects a very powerful tool as it can help to overcome particular limitations in conventional manufacturing. AM enables more freedom of design, complex, hollow and/or lightweight structures as well as product individualisation and functional integration. As such it is a promising approach with respect to the future design and manufacturing of complex 3dim structures. On the other hand, it certainly calls for new methods and standards in view of quality assessment. In particular, when utilizing AM for the design of complex parts used in aviation and aerospace technologies, appropriate monitoring systems are mandatory. In this respect, recently, sustainable progress has been accomplished by joining the common efforts and concerns of a manufacturer Additive Manufacturing systems and respective materials (EOS), along with those of an operator of such systems (MTU Aero Engines) and experienced application engineers (Carl Metrology), using decent know how in the field of optical and infrared methods regarding non-destructive-examination (NDE). The newly developed technology is best described by a high-resolution layer by layer inspection technique, which allows for a 3D tomography-analysis of the complex part at any time during the manufacturing process. Thereby, inspection costs are kept rather low by using smart image-processing methods as well as CMOS sensors instead of infrared detectors. Moreover, results from conventional physical metallurgy may easily be correlated with the predictive results of the monitoring system which not only allows for improvements of the AM monitoring system, but finally leads to an optimisation of the quality and insurance of material security of the complex structure being manufactured. Both, our poster and our oral presentation will explain the data flow between the above mentioned parties involved. A suitable monitoring system for Additive Manufacturing will be introduced, along with a presentation of the respective high resolution data acquisition, as well as the image processing and the data analysis allowing for a precise control of the 3dim growth-process.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Multi-material additive manufacturing of aluminum 6061-T6 alloy with stainless steel 304: Suppression of intermetallic compounds and interface growth mechanism

Fabricating integrated aluminum-steel structures is difficult because of metallurgical incompatibilities that promote intermetallic compound (IMC) formation at their interfaces. This work introduces a practical route for additively manufacturing 6061-T6 aluminum alloy (AA6061-T6) directly onto 304 stainless steel (SS304) using a high shear strain rate-assisted interfacial bonding mechanism. Through the friction extrusion deposition-based additive manufacturing method, both single- and multi-layer deposits of AA6061-T6 were successfully fabricated on SS304, yielding a robust hybrid multi-material structure. Comprehensive analyses of deposition quality, interface porosity, and bonding performance showed that the interface achieved a tensile strength exceeding 154 MPa under quasi-static loading. Microstructural observations revealed that the deposited aluminum layers experienced severe plastic deformation, resulting in pronounced grain refinement. Importantly, the interfacial zone was found to be free of brittle IMCs, instead containing a thin amorphous layer that evolved through a non-linear reaction-zone growth law. This solid-state additive strategy establishes a promising pathway for lightweight structural systems, nuclear energy component cladding, and multifunctional engineering components, redefining how dissimilar metals can be integrated for advanced applications.

Aluminum alloy↗
DOE OSTI2024

TEAMER: Results of Investigating Structural Design Concepts and Alternative Materials for a Wave Power System

Included here are materials from a study on the design of a three-body Wave Energy Converter (WEC) utilizing a heave plate, dual Power Take Offs (PTOs), and single point mooring. A material trade study has been conducted to evaluate the effects of introducing various metallic and fiber-reinforced polymer (FRP) elements to the design. The baseline design is C-Power's patented k2 Wave Power System (WPS). This Testing Expertise and Access for Marine Energy Research (TEAMER) Request for Technical Support (RFTS) 9 effort resulted in alternative designs of the WPS center member, the nacelle. The analysis resulting from this study will inform the design of a lightweight structure with lower manufacturing and operating costs that increases energy conversion and power-to-weight ratio of the device. The dataset contains several components: finite element analysis (FEA) data, hand calculations, and CAD models. FEA files includes those used for and generated by finite element simulations. Calculations include hand calculations performed using Microsoft Excel, which assess core laminate properties, buckling, and other structural aspects in accordance with risk management DNV-RP-C201 standards. CAD materials include Solidworks files for parts, assemblies, and drawings of the evaluated models.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

Acrylonitrile-butadiene-lignin thermoplastic rubber adhesive for enhanced metal-to-metal joining

With the growing requirement for lightweight structural materials in automotive, aerospace, and infrastructure applications, multi-material joints made with adhesive have attracted intense research interest. Commercial thermoset adhesives are one-time cures, and difficult to disassemble the bonded components for repair and recycling. Our prior work with a thermoplastic acrylonitrile-butadiene-lignin rubber (ABL) addresses this sustainability/recycling challenge, but the adhesive exhibits deficient joining strength compared to standard thermosets. Here, we modify the ABL matrix by loading particulate fillers to enhance its modulus and toughness. Further, the goal is to manufacture a cure-free thermoplastic adhesive system with a simple dispensing protocol and characteristic ductility combined with a high yield stress for improved shear strength of a bonded joint. Fumed silica (FS) and epoxidized glass spheres (EGS) were used as fillers in the ABL to promote the dispersion of lignin particles that tailored the functionalities and free energy components of the adhesive surface. With optimal loading of FS (5 wt%) and EGS (30 wt%) in the ABL adhesive matrix, the lap-shear strength of the bonded aluminum joint was elevated by 128%, compared to the neat ABL, reaching 21 MPa, which is 90% of the performance of a commercial epoxy-based adhesive.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Bioinspired Nacre‐Like Alumina with a Metallic Nickel Compliant Phase Fabricated by Spark‐Plasma Sintering

Abstract Many natural materials present an ideal “recipe” for the development of future damage‐tolerant lightweight structural materials. One notable example is the brick‐and‐mortar structure of nacre, found in mollusk shells, which produces high‐toughness, bioinspired ceramics using polymeric mortars as a compliant phase. Theoretical modeling has predicted that use of metallic mortars could lead to even higher damage‐tolerance in these materials, although it is difficult to melt‐infiltrate metals into ceramic scaffolds as they cannot readily wet ceramics. To avoid this problem, an alternative (“bottom‐up”) approach to synthesize “nacre‐like” ceramics containing a small fraction of nickel mortar is developed. These materials are fabricated using nickel‐coated alumina platelets that are aligned using slip‐casting and rapidly sintered using spark‐plasma sintering. Dewetting of the nickel mortar during sintering is prevented by using NiO‐coated as well as Ni‐coated platelets. As a result, a “nacre‐like” alumina ceramic displaying a resistance‐curve toughness up to ≈16 MPa m ½ with a flexural strength of ≈300 MPa is produced.

Wat, Amy↗
DOE OSTI2025

Stimulating β -Series Precipitation in Mg–Nd Alloys Via Microalloying: A Comparison of Electron Microscopy and Small-Angle Scattering Techniques

The Mg–Nd alloy system is of particular interest in the development of high-strength, lightweight structural alloys due to the formation of strengthening metastable Mg–Nd β-series precipitates during heat treatment. The strengthening is primarily provided by a combination of the β''' and β 1 precipitation. It is therefore important to understand how the precipitation behavior can be enhanced by other common alloying elements. In this work, the effects of 0.2 wt pct Zn and Ca on β-series precipitation were studied. Small-angle/ultra-small-angle X-ray scattering (SAXS/USAXS) techniques in combination with scanning transmission electron microscopy (STEM) were used to study the evolution of precipitation microstructure. Here, it is found that the Zn additions refine the precipitates, leading to an increase in hardness with aging at 200 °C. On the other hand, the Ca additions result in an acceleration in the formation of larger β 1 precipitates and chains which provides less strengthening. The β 1 chains are surrounded by precipitate-free zones (PFZs) that further contribute to the decreases in hardness observed in the over-aged condition. This paper demonstrated that SAXS/USAXS provides a powerful tool for an in situ study of the early stages of precipitation in the Mg–Nd-based alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Molecular Statics Analyses of Thermodynamics and Kinetics of Hydrogen Cottrell Atmosphere Formation Around Edge Dislocations in Aluminum

Aluminum alloys are being explored as lightweight structural materials for use in hydrogen-containing environments. In this paper, to understand hydrogen effects on deformation, we perform molecular statics studies of the hydrogen Cottrell atmosphere around edge dislocations in aluminum. First, we calculate the hydrogen binding energies at all interstitial sites in a periodic aluminum crystal containing an edge dislocation dipole. This allows us to use the Boltzmann equation to quantify the hydrogen Cottrell atmosphere. Based on these binding energies, we then construct a continuum model to study the kinetics of the hydrogen Cottrell atmosphere formation. Finally, we compare our results with existing theories and discuss the effects of hydrogen on deformation of aluminum-based alloys.

36 MATERIALS SCIENCE↗