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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

Properties and performance of lignin-based polyurethane foams from lignin and castor oil as synergistic bio-polyols

Lignin and castor oil with intrinsic hydroxyl groups are attractive green resources for polyurethane (PU) applications. However, lignin's heterogeneous and highly crosslinked structure, poor processability, as well as the feedstock variability, lead to inconsistent and poor performance of the final foam products. Castor oil-based polyurethane foam (PUF) has a relatively high price and density, which are big hurdles to its practical applications. Here, in this study, we hypothesized that synergistic bio-polyol mixtures composed of lignin and castor oil could balance the drawbacks from individual component. Castor oil could improve the dispersity of lignin, while lignin simultaneously addressed the issues caused by PUF prepared with castor oil, such as its high density and low thermal stability. For a comprehensive understanding of the effects of structural properties of lignin on its PUF processing and applications, various lignin fractions were isolated by co-solvent enhanced lignocellulosic fractionation (CELF) from different species, including hardwood, softwood, and herbaceous plants, and the processed lignins with different molecular weights were applied with castor oil. The lignin fractions with lower molecular weight showed good dispersity in castor oil with a high lignin content (up to 50 wt%) and completely replaced petroleum-based polyols. The produced foam with 50 wt% low-molecular-weight lignin fractions from woody biomass showed comparable/higher compressive strength (up to 20 psi) and thermal insulation performance (up to 5.69 R-value in −1 for 50 % L-Pine foam). In addition, this study revealed the relationship between lignin's structural properties and foam performance, providing insights for practical applications of lignin-based PUF.

Jeong, Soyeon [State Univ. of New York (SUNY), Syr↗
DOE OSTI2026

A physically based mechanical model for Mullins effect in thermoplastic polyurethanes

Despite decades of research, connecting the chemical and physical structure of thermoplastic polyurethanes to their mechanical properties remains highly challenging. Of particular note are their large-deformation and rate-dependent behaviors, which vary greatly with molecular chemistry, including the type and relative content of soft and hard segments. In this work, we develop a physically motivated mechanical theory for predicting the behavior of thermoplastic polyurethanes. The theory incorporates a representation of microstructural evolution during mechanical deformation, which captures the signatures of stress softening over cyclic loading (commonly referred to as the Mullins effect). There are only eight physically motivated fitting parameters, including a direct dependence on the hard segment fraction. The model predicts that increasing the hard segment fraction leads to higher stiffness and greater energy dissipation, in quantitative agreement with published experimental data. Furthermore, we provide a comprehensive analysis of the model and validate its predictions across several independent datasets focused on mechanical characterization. Direct comparisons to experimental data demonstrate its predictive capability on the effect of loading rate, cyclic deformations, and applied tension or compression. Altogether, this work establishes a predictive framework that connects polymer chemistry and microstructure to emergent mechanical behaviors.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Plasticizer-Free Gradient-Crosslinked Polyurethane Electrolyte for Room-Temperature Solid-State Lithium Batteries

Polymer-based solid-state electrolytes are promising for next-generation lithium metal batteries, yet their limited ionic conductivity and mechanical stability at ambient conditions remain key challenges. Herein, we report a novel gradient crosslinked polymer electrolyte (PU/PUA/PU) synthesized via a sequential in situ UV-curing process that integrates a mechanically robust polyurethane acrylate (PUA) core with soft linear polyurethane (PU) interfaces. This all-solid membrane operates without any liquid plasticizer and the interfacial PU layers ensure low interfacial resistance and intimate electrode contact, while the PUA core provides enhanced dimensional stability and dendrite suppression. As a result, the gradient electrolyte delivers an impressive ∼2.6 × 10 −4 S cm −1 ionic conductivity at 25 °C (two orders of magnitude higher than conventional PEO) and remains electrochemically stable >5 V (vs Li + /Li). Structural analysis confirms the formation of a well-defined crosslinked network with suppressed crystallinity and expanded interchain spacing. Electrochemical impedance spectroscopy (EIS) and linear sweep voltammetry (LSV) further validate these properties. When applied in a Li||NMC811 cell, the PU/PUA/PU electrolyte delivers stable cycling with high capacity at both 60 °C and 25 °C, demonstrating its potential for room-temperature solid-state battery applications without reliance on plasticizers or heating. In conclusion, this gradient design offers a practical path toward ambient-condition operation of solid-state lithium batteries, providing a paradigm for overcoming the traditional trade-off between ionic conductivity and mechanical robustness.

25 ENERGY STORAGE↗
NASA NTRS1966

Storage-stable foamable polyurethane is activated by heat

Polyurethane foamable mixture remains inert in storage unit activated to produce a rapid foaming reaction. The storage-stable foamable composition is spread as a paste on the surface of an expandable structure and, when heated, yields a rigid open-cell polyurethane foam that is self-bondable to the substrate.

Source record↗
NASA NTRS1973

Investigation into reversion of polyurethane encapsulants

The effect of high humidity (95% RH) at 60 C, 70 C, 85 C and 100 C on the solid-to-liquid reversion of polyurethane elastomers (used for potting electrical connectors and conformal coating printed circuit boards) was investigated. Hardness measurements were conducted on eleven elastomers to track reversion for a 101-day period. The primary purpose of the tests was to provide data to predict service life for the polyurethane elastomers. This was not accomplished as the hardness did not deteriorate rapidly enough at the lower test temperatures. The tests did determine that the potting and coating materials most widely used on the S-1C Program are susceptible to reversion but appear adequate for service in the S-1C environment.

Lynch, C. R.↗
NASA NTRS1974

Coating processes for increasing the moisture resistance of polyurethane baffle material

An investigation was conducted with the objective to improve the hydrolytic stability of reticulated polyurethane baffle material. This material is used in fuel tanks of aircraft and ground vehicles. The most commonly used foam of this type is hydrolytically unstable. Potential moisture barrier coatings which were evaluated include Parylene, epoxy-polysulfide, polyether based polyurethanes, polysulfides, polyolefin rubbers, and several other materials. Parylene coatings of at least 0.2 mil were found to provide the greatest improvement in hydrolytic stability.

Bilow, N.↗
NASA NTRS1975

Cryogenic line insulation made from prefabricated polyurethane shells

Prefabricated polyurethane foam insulation is inexpensive and easily installed on cryogenic lines. Insulation sections are semicircular half shells. Pair of half shells is placed to surround cryogenic line. Cylindrically-shaped knit sock is pulled over insulation then covered with polyurethane resin to seal system.

Lerma, G.↗
NASA NTRS1977

Relative toxicity of pyrolysis products of some polyurethane and polychloroprene foams

Results of toxicity screening tests on some polyurethane and polychloroprene flexible foams are presented. The test method involves the exposure of four Swiss albino male mice in a 4.2-liter hemispherical chamber to the pyrolysis effluents from 1 g of sample exposed to temperatures rising from 200 to 800 C at a rate of 40 C/min. Mortality and times to incapacitation and to death are recorded. Comparisons indicate that flexible polyurethane foams without fire retardant are more toxic than the corresponding foams containing fire retardant, and polychloroprene foams are least toxic.

Hilado, C. J.↗
NASA NTRS1978

Flame retardant spandex type polyurethanes

Flame retardant elastomeric compositions were developed, comprised of: (1) spandex type polyurethane having incorporated into the polymer chain, halogen containing polyols; (2) conventional spandex type polyurethanes in physical admixture flame retardant additives; and (3) fluoroelastomeric resins in physical admixture with flame retardant additives. Methods of preparing fibers of the flame retardant elastomeric materials are presented and articles of manufacture comprised of the elastomeric materials are mentioned.

Howarth, J. T.↗
NASA NTRS1984

Polyurethane Filler for Electroplating

Polyurethane foam proves suitable as filler for slots in parts electroplated with copper or nickel. Polyurethane causes less contamination of plating bath and of cleaning and filtering tanks than wax fillers used previously. Direct cost of maintenance and indirect cost of reduced operating time during tank cleaning also reduced.

Beasley, J. L.↗
NASA NTRS1984

Unidirectional fibers and polyurethane elastomer matrix based composites synthesis and properties

A study of the properties and manufacturing techniques for long-fiber reinforced elastomeric composites for flexible and damping structural materials is presented. Attention is given to the usage of polyurethane in the matrix to obtain plastic elastomeric matrices and vitreous transition temperatures which vary from -80 C to 10 C, as well as assure good fiber adhesion. Various polyurethane formulations synthesized from diisocyanate prepolymers are examined in terms of mechanical and thermal properties. The principal reinforcing fiber selected is a unidirectional glass cloth.

Chakar, A.↗
NASA NTRS1990

The corrosion protection of 6061-T6 aluminum by a polyurethane-sealed anodized coat

The corrosion protection of 6061-T6 anodized aluminum afforded by a newly patented polyurethane seal was studied using the ac impedance technique. Values of the average corrosion rates over a 27-day exposure period in 3.5 percent NaCl solutions at pH 5.2 and pH 9.5 compared very favorably for Lockheed-prepared polyurethane-sealed and dichromate-sealed coats of the same thickness. Average corrosion rates for both specimens over the first 7 days of exposure compared well with those for a hard anodized, dichromate-sealed coat, but rose well above those for the hard anodized coat over the entire 27-day period. This is attributed both to the greater thickness of the hard anodized coat, and possibly to its inherently better corrosion protective capability.

Danford, M. D.↗
NASA NTRS1992

Tests Of Polyurethane And Dichromate Coats On Aluminum

Report describes experiments to determine relative effectiveness of new polyurethane and more-conventional dichromate coat in helping to retard corrosion of anodized 6061-T6 aluminum. Concludes by suggesting greater protection against corrosion achieved by combining polyurethane-sealing method with hard-anodizing method and by increasing thickness of coat.

Danford, M. D.↗
NASA NTRS1982

Thermal Performance of Aircraft Polyurethane Seat Cushions

Aircraft seat materials were evaluated in terms of their thermal performance. The materials were evaluated using (a) thermogravimetric analysis, (b) differential scanning calorimetry, (c) a modified NBS smoke chamber to determine the rate of mass loss and (d) the NASA T-3 apparatus to determine the thermal efficiency. In this paper, the modified NBS smoke chamber will be described in detail since it provided the most conclusive results. The NBS smoke chamber was modified to measure the weight loss of material when exposed to a radiant heat source over the range of 2.5 to 7.5 W/sq cm. This chamber has been utilized to evaluate the thermal performance of various heat blocking layers utilized to protect the polyurethane cushioning foam used in aircraft seats. Various kinds of heat blocking layers were evaluated by monitoring the weight loss of miniature seat cushions when exposed to the radiant heat. The effectiveness of aluminized heat blocking systems was demonstrated when compared to conventional heat blocking layers such as neoprene. All heat blocking systems showed good fire protection capabilities when compared to the state-of-the-art, i.e., wool-nylon over polyurethane foam.

Kourtides, D. A.↗
NASA NTRS2005

An Improved Thermal Conductivity Polyurethane Composite for a Space Borne 20KV Power Supply

This effort was designed to find a way to reduce the temperature rise of critical components of a 20KV High Voltage Power Supply (HVPS) by improving the overall thermal conductivity of the encapsulated modules. Three strategies were evaluated by developing complete procedures, preparing samples, and performing tests. The three strategies were: 1. Improve the thermal conductivity of the polyurethane encapsulant through the addition of thermally conductive powder while minimizing impact on other characteristics of the encapsulant. 2. Improve the thermal conductivity of the polyurethane encapsulated assembly by the addition of a slab of thermally conductive, electrically insulating material, which is to act as a heat spreader. 3. Employ a more thermally conductive substrate (Al203) with the existing encapsulation scheme. The materials were chosen based on the following criteria: high dielectric breakdown strength; high thermal conductivity, ease of manufacturing, high compliance, and other standard space qualified materials properties (low out-gassing, etc.). An optimized cure was determined by a statistical design of experiments for both filled and unfilled materials. The materials were characterized for the desired properties and a complete process was developed and tested. The thermal performance was substantially improved and the strategies may be used for space flight.

Pb free↗
NASA NTRS2007

Joint Test Report For Validation of Alternatives to Aliphatic Isocyanate Polyurethanes

National Aeronautics and Space Administration (NASA) and Air Force Space Command (AFSPC) have similar missions and therefore similar facilities and structures in similar environments. The standard practice for protecting metallic substrates in atmospheric environments is the application of an applied coating system. The most common topcoats used in coating systems are polyurethanes that contain isocyanates. Isocyanates are classified as potential human carcinogens and are known to cause cancer in animals. The primary objective of this effort was to demonstrate and validate alternatives to aliphatic isocyanate polyurethanes resulting in one or more isocyanate-free coatings qualified for use at AFSPC and NASA installations participating in this project. This joint Test Report (JTR) documents the results of the laboratory and field testing as well as any test modifications made during the execution of the testing. The technical stakeholders agreed upon test procedure modifications documented in this document. This JTR is made available as a reference for future pollution prevention endeavors by other NASA centers, the Department of Defense and commercial users to minimize duplication of effort. All coating system candidates were tested using approved NASA and AFSPC standard coating systems as experimental controls. This study looked at eight alternative coating systems and two control coating systems and was divided into Phase I Screening Tests, Phase II Tests, and Field Testing. The Phase I Screening Tests were preliminary tests performed on all the selected candidate coating systems. Candidate coating systems that did not meet the acceptance criteria of the screening tests were eliminated from further testing. Phase I Screening Tests included: Ease of Application, Surface Appearance, Dry-To-Touch (Sanding), Accelerated Storage Stability, Pot Life (Viscosity), Cure Time (Solvent Rubs), Cleanability, Knife Test, Tensile (pull-off) Adhesion, and X-Cut Adhesion by Wet Tape After a review of the Phase I test results, four of the alternative coating systems showed substandard performance in relation to the Control Systems and were eliminated from the Phase II testing. Due to the interest of stakeholders and time constraints, however, all eight alternatives were subjected to the following Phase II tests, along with field testing at Stennis Space Center (SSC), Mississippi: Hypergol Compatibility, Liquid Oxygen Compatibility, 18-Month Marine Exposure (Gloss Retention, Color Retention, Blistering, Visual Corrosion, Creepage from Scribe, Heat Adhesion), and Field Exposure (6- and 12-month Evaluation for Coating Condition, Color Retention, Gloss Retention). The remaining four alternative coating systems determined to be the best viable alternatives were carried on to Phase II testing that included: Removability, Repairability, Abrasion Resistance, Gravelometer, Fungus Resistance, Accelerated Weathering, Mandrel Bend Flexibility, and Cyclic Corrosion Resistance. Of the systems that continued to Phase II, three (3) alternative coating systems meet the performance requirements as identified by stakeholders. Two (2) other systems, that were not included in Phase II testing, performed well enough on the 18-Month Marine Exposure, the primary requirement for NASA technical standard NASA-STD-5008, Protective Coating of Carbon Steel, Stainless Steel, and Aluminum on Launch Structures, Facilities, and Ground Support Equipment, that they were also considered to be successful candidates. In total, five (5) alternative coating systems were approved for inclusion in the NASA-STD- 5008 Qualified Products List (QPL). The standard is intended to provide a common framework for consistent practices across NASA and is often used by other entities. The standard's QPL does not connote endorsement of the products by NASA, but lists those products that have been tested and meet the requirements as specified.

Lewis, Pattie↗
DOE OSTI2025

Scalable fabrication of a tough and recyclable spore-bearing biocomposite thermoplastic polyurethane

Thermoplastic polyurethanes (TPUs) are a class of versatile thermoplastic elastomers, but most of their products lack a proper recycling strategy or have no end-of-life solutions. To pursue a sustainable end-of-life solution for TPU-based products, self-disintegrating biocomposite TPUs have recently been developed by embedding spores of TPU-degrading bacteria into TPUs via melt extrusion. Herein, we improve upon spore-bearing biocomposites and demonstrate industrially relevant manufacturing conditions for fabricating biocomposite TPUs. To minimize the coloration of biocomposite TPUs, spore production was modified. The innate brown color of the resulting materials was diminished by reducing FeSO 4 in sporulation media, generating white spores without compromising spore productivity, viability, morphology or heat-shock tolerance. Biocomposite TPUs containing white spores displayed a 45 % increase in toughness compared to TPUs without spores, while retaining ∼ 90 % spore viability post processing. Furthermore, biocomposite TPU fabrication was demonstrated using a scalable continuous extruder followed by injection molding. Biocomposite TPUs generated by these industry-relevant processes exhibited comparable toughness improvement and spore viability to biocomposite TPU prepared using a lab scale microcompounder, while enhancing productivity by 30-fold. Finally, spore addition significantly improved the recyclability of biocomposite TPUs, enabling 80 % toughness retention after 5 rounds of iterative melt processing. Additionally, no negative effect on the lifespan of the generated TPUs was observed over 1 year of storage. Overall, this study confirms that spore-bearing biocomposite TPUs are promising for practical applications, offering an accessible method to enhance toughness and sustainability of commercial TPUs through the incorporation of spore-based living fillers.

36 MATERIALS SCIENCE↗