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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Additive manufacturing of carbon fiber-reinforced thermoset composites via in-situ thermal curing

Fiber-reinforced polymer composites are lightweight structural materials widely used in the transportation and energy industries. Current approaches for the manufacture of composites require expensive tooling and long, energy-intensive processing, resulting in a high cost of manufacturing, limited design complexity, and low fabrication rates. Here, we report rapid, scalable, and energy-efficient additive manufacturing of fiber-reinforced thermoset composites, while eliminating the need for tooling or molds. Use of a thermoresponsive thermoset resin as the matrix of composites and localized, remote heating of carbon fiber reinforcements via photothermal conversion enables rapid, in-situ curing of composites without further post-processing. Rapid curing and phase transformation of the matrix thermoset, from a liquid or viscous resin to a rigid polymer, immediately upon deposition by a robotic platform, allows for the high-fidelity, freeform manufacturing of discontinuous and continuous fiber-reinforced composites without using sacrificial support materials. This method is applicable to a variety of industries and will enable rapid and scalable manufacture of composite parts and tooling as well as on-demand repair of composite structures.

36 MATERIALS SCIENCE↗
NASA NTRS2019

Exceptional Thermal Properties of Polymer-Derived Ceramic Composites Reinforced with High Volume Fractions of Boron Nitride Nanotube at Elevated Temperature

We report for the first time the synthesis of boron nitride nanotube (BNNT) reinforced ceramic composites using the polymer derived ceramic (PDC) processing route. The nanocomposites had a BNNT loading of up to 35.4 vol.%. TGA results showed that the nanocomposites have good thermal stability up to 900 oC in air. BNNTs in the nanocomposites survived in an oxidizing environment up to 900 oC, revealing that the nanocomposites can be used for high temperature applications. Thermal conductivity of PDC reinforced with 35.4 vol.% BNNT was measured as 4.123 W/(m·K) at room temperature, which is a 2100 % increase compared to that of pristine PDC. The thermal conductivity value increases with the increase of BNNT content. A thermal conductivity percolation phenomenon appeared when the BNNT content increased to 36±5 vol.%. The results of this study showed that BNNTs could effectively improve the thermal conductivity of PDC materials. BNNT reinforced PDC could be used as thermal structural materials in a harsh environment at the temperature up to 900 deg C.

Yujun Jia↗
NASA NTRS2002

High-Glass-Transition-Temperature Polyimides Developed for Reusable Launch Vehicle Applications

Polyimide composites have been traditionally used for high-temperature applications in aircraft engines at temperatures up to 550 F (288 C) for thousands of hours. However, as NASA shifts its focus toward the development of advanced reusable launch vehicles, there is an urgent need for lightweight polymer composites that can sustain 600 to 800 F (315 to 427 C) for short excursions (hundreds of hours). To meet critical vehicle weight targets, it is essential that one use lightweight, high-temperature polymer matrix composites in propulsion components such as turbopump housings, ducts, engine supports, and struts. Composite materials in reusable launch vehicle components will heat quickly during launch and reentry. Conventional composites, consisting of layers of fabric or fiber-reinforced lamina, would either blister or encounter catastrophic delamination under high heating rates above 300 C. This blistering and delamination are the result of a sudden volume expansion within the composite due to the release of absorbed moisture and gases generated by the degradation of the polymer matrix. Researchers at the NASA Glenn Research Center and the Boeing Company (Long Beach, CA) recently demonstrated a successful approach for preventing this delamination--the use of three-dimensional stitched composites fabricated by resin infusion.

Chuang, Kathy↗
NASA NTRS2016

Self-Healing Composite of Thermoset Polymer and Programmed Super Contraction Fibers

A composition comprising thermoset polymer, shape memory polymer to facilitate macro scale damage closure, and a thermoplastic polymer for molecular scale healing is disclosed; the composition has the ability to resolve structural defects by a bio-mimetic close-then heal process. In use, the shape memory polymer serves to bring surfaces of a structural defect into approximation, whereafter use of the thermoplastic polymer for molecular scale healing allowed for movement of the thermoplastic polymer into the defect and thus obtain molecular scale healing. The thermoplastic can be fibers, particles or spheres which are used by heating to a level at or above the thermoplastic's melting point, then cooling of the composition below the melting temperature of the thermoplastic. Compositions of the invention have the ability to not only close macroscopic defects, but also to do so repeatedly even if another wound/damage occurs in a previously healed/repaired area.

Li, Guoqiang↗
NASA NTRS1991

Levitation of superconducting composites

The inverse levitation of a high temperature superconductor polymer composite consisting of powdered quench melt growth Ba2YCu3O(7-delta) and cyanoacrylate is reported. Magnetic hysteresis loop measurements for the composite are compared to those measured for the bulk material prior to powdering. Differences in the flux pining capability between the two material forms are small but significant.

Chiang, C. K.↗
NASA NTRS1984

Development of an impact- and solvent-resistant thermoplastic composite matrix

Synthesis, moldability and chloroform, acetone and tricresyl phosphate resistance of 16 polymer compositions are described. These aliphatic heterocyclic polymers include polyimides, polybenzimidazoles, and N-arylenepolybenzimidazoles. A solution condensation (cresol) method to prepare imidized aliphaic polyimides is described. Two polyimides and one polybenzimidazole demonstrate no crazing or cracking during 500 hr exposure to the cited solvents under stress. Modification of one aliphatic polyimide with several aromatic amines suggests that m-phenylenediamine is singular in its behavior to improve the chloroform resistance of that class of polyimides.

Delano, C. B.↗
NASA NTRS1992

The role of biaxial stresses in discriminating between meaningful and illusory composite failure theories

The irrelevance of most composite failure criteria to conventional fiber-polymer composites is claimed to have remained undetected primarily because the experiments that can either validate or disprove them are difficult to perform. Uniaxial tests are considered inherently incapable of validating or refuting any composite failure theory because so much of the total load is carried by the fibers aligned in the direction of the load. The Ten-Percent Rule, a simple rule-of-mixtures analysis method, is said to work well only because of this phenomenon. It is stated that failure criteria can be verified for fibrous composites only by biaxial tests, with orthogonal in-plane stresses of the same as well as different signs, because these particular states of combined stress reveal substantial differences between the predictions of laminate strength made by various theories. Three scientifically plausible failure models for fibrous composites are compared, and it is shown that only the in-plane shear test (orthogonal tension and compression) is capable of distinguishing between them. This is because most theories are 'calibrated' against the measured uniaxial tension and compression tests and any cross-plied laminate tests dominated by those same states of stress must inevitably 'confirm' the theory.

Hart-Smith, L. J.↗
NASA NTRS2003

Composite Development and Applications for RLV Tankage

The development of polymer composite cryogenic tanks is a critical step in creating the next generation of launch vehicles. Future launch vehicles need to minimize the gross liftoff weight (GLOW), which is possible due to the 28%-41% reduction in weight that composite materials can provide over current aluminum technology. The development of composite cryogenic tanks, feedlines, and unpressurized structures are key enabling technologies for performance and cost enhancements for Reusable Launch Vehicles (RLVs). The technology development of composite tanks has provided direct and applicable data for feedlines, unpressurized structures, material compatibility, and cryogenic fluid containment for highly loaded complex structures and interfaces. All three types of structure have similar material systems, processing parameters, scaling issues, analysis methodologies, NDE development, damage tolerance, and repair scenarios. Composite cryogenic tankage is the most complex of the 3 areas and provides the largest breakthrough in technology. A building block approach has been employed to bring this family of difficult technologies to maturity. This approach has built up composite materials, processes, design, analysis and test methods technology through a series of composite test programs beginning with the NASP program to meet aggressive performance goals for reusable launch vehicles. In this paper, the development and application of advanced composites for RLV use is described.

Wright, Richard J.↗
NASA NTRS2005

Finite Element Analysis of Adaptive-Stiffening and Shape-Control SMA Hybrid Composites

Shape memory alloy hybrid composites with adaptive-stiffening or morphing functions are simulated using finite element analysis. The composite structure is a laminated fiber-polymer composite beam with embedded SMA ribbons at various positions with respect to the neutral axis of the beam. Adaptive stiffening or morphing is activated via selective resistance heating of the SMA ribbons or uniform thermal loads on the beam. The thermomechanical behavior of these composites was simulated in ABAQUS using user-defined SMA elements. The examples demonstrate the usefulness of the methods for the design and simulation of SMA hybrid composites. Keywords: shape memory alloys, Nitinol, ABAQUS, finite element analysis, post-buckling control, shape control, deflection control, adaptive stiffening, morphing, constitutive modeling, user element

Gao, Xiujie↗
NASA NTRS2018

Aerogel-Based Insulation Materials for Cryogenic Applications

Many different aerogel-based materials are now being used in thermal insulation systems for cryogenic applications. These materials include flexible composite blankets, bulk-fill particles, and polymer composites in both evacuated and non-evacuated environments. In ambient environments, aerogels provide superior thermal performance compared to conventional polymeric foam and cellular glass insulations while offering unique advantages in avoiding problems with weathering, moisture, and mechanical damage. Aerogels are also used as spacer materials in multilayer insulation systems. These layered systems provide combined structural-thermal capability for cryogenic systems in either vacuum-jacketed or externally-applied insulation designs. Test data (effective thermal conductivity) include a wide range of both commercial and experimental aerogel materials. Testing was performed using laboratory cryostats and standard methods including full range vacuum (from ambient pressure to high vacuum) and boundary temperatures 293 K and 78 K. Examples of aerogel-based insulation systems are given for both evacuated and non-evacuated applications.

heat transfer↗
NASA NTRS2018

Aerogel-Based Insulation Materials for Cryogenic Applications

Many different aerogel-based materials are now being used in thermal insulation systems for cryogenic applications. These materials include flexible composite blankets, bulk-fill particles, and polymer composites in both evacuated and non-evacuated environments. In ambient environments, aerogels provide superior thermal performance compared to conventional polymeric foam and cellular glass insulations while offering unique advantages in solving problems with weathering, moisture, and mechanical damage. Aerogels are also used as spacer materials in multilayer insulation systems. These layered systems provide combined structural-thermal capability for cryogenic systems in either vacuum-jacketed or externally-applied insulation designs. Test data (effective thermal conductivity) include a wide range of both commercial and experimental aerogel materials. Testing was performed using laboratory cryostats and standard methods including full range vacuum (from ambient pressure to high vacuum) and boundary temperatures 293 K and 78 K. Examples of aerogel-based insulation systems are given for both evacuated and non-evacuated applications.

aerogel layered composites↗
NASA NTRSDate not supplied

Development of the Advanced Regolith Ground Operations (ARGO) Test Bed– A Robotic Construction Test Facility with Simulated Lunar Environments

NASA’s Artemis Program is working towards developing a sustained presence on the Moon and eventually Mars. To achieve this goal, robotic excavation, site preparation and construction technologies are under development to establish the capability to construct infrastructure such as launch/landing pads and radiation protection shelters. Technologies must be proven in simulated Lunar conditions prior surface demonstration missions. To that end, the Relevant Additive Construction Technology (REACT) Announcement of Collaboration Opportunities (ACO) project with AI Space Factory and the NASA Kennedy Space Center’s (KSC) Granular Mechanics and Regolith Operations Laboratory (a.k.a. Swamp Works) has developed the Advanced Regolith Ground Operations (ARGO) Test Bed. ARGO includes a ~1.5m x 1.5m x 1.2m (~5x5x4ft) vacuum chamber, cryogenically cooled thermal shroud, a 3-axis robotic positioning system, and a regolith bin. For the REACT project, a pellet extruder and feed hopper have been installed on ARGO to advance the Technology Readiness Level (TRL) of regolith-polymer composite Fused Deposition Modeling (FDM) additive construction systems, processes, and materials. This paper will focus on the design and operational characteristics of the ARGO Test Bed with pellet extruder.

Moon↗
NASA NTRS2006

N-15 NMR Spectroscopy as a Method for Comparing the Rates of Imidization of Several Diamines

The relative rates of the conversion of amide-acid to imide was measured for a series or aromatic diamines that have been identified as potential replacements for 4,4'-methylene dianiline (MDA) in high-temperature polyimides and polymer composites. These rates were compared with the N-15 NMR resonances of the unreacted amines. The initial rates of imidization track with the difference in chemical shift between the amine nitrogens in MDA and those in the subject diamines. This comparison demonstrated that N-15 NMR spectroscopy is appropriate for the rapid screening of candidate diamines to determine their reactivity relative to MDA, and can serve to provide guidance to the process of creating the time-temperature profiles used in processing these materials into polymer matrix composites.

Johnson, J. Christopher↗
NASA NTRS1999

Effect of High Temperature on the Tensile Behavior of CFRP and Cementitious Composites

Concrete and other composite manufacturing processes are continuing to evolve and become more and more suited for use in non-Earth settings such as the Moon and Mars. The fact that structures built in lunar environments would experience a range of effects from temperature extremes to bombardment by micrometeorites and that all the materials for concrete production exist on the Moon means that concrete appears to be the most feasible building material. it can provide adequate shelter from the harshness of the lunar environment and at the same time be a cost effective building material. With a return to the Moon planned by NASA to occur after the turn of the century, it will be necessary to include concrete manufacturing as one of the experiments to be conducted in one of the coming missions. Concrete's many possible uses and possibilities for manufacturing make it ideal for lunar construction. The objectives of this research are summarized as follows: i) study the possibility of concrete production on the Moon or other planets, ii) study the effect of high temperature on the tensile behavior of concrete, and iii) study the effect of high temperature on the tensile behavior of carbon fiber reinforced with inorganic polymer composites. Literature review indicates that production of concrete on the Moon or other planets is feasible using the indigenous materials. Results of this study has shown that both the tensile strength and static elastic modulus of concrete decreased with a rise in temperature from 200 to 500 C. The addition of silica fume to concrete showed higher resistance to high temperatures. Carbon fiber reinforced inorganic polymer (CFRIP) composites seemed to perform well up to 300 C. However, a significant reduction in strength was observed of about 40% at 400 C and up to 80% when the specimens were exposed to 700 C.

Toutanji, Houssam A.↗
NASA NTRS1998

A Novel Ultrasonic Method for Characterizing Microstructural Gradients in Tubular Structures

Ultrasonic velocity and time-of-flight (TOF) imaging that uses back surface reflections to gage volumetric material quality is highly suited for quantitative characterization of microstructural gradients including those due to pore fraction, density, fiber fraction, and chemical composition variations. However, a weakness of conventional pulse echo ultrasonic velocity and TOF imaging is that the image shows the effects of thickness as well as microstructural variations, unless the part is uniformly thick. This limits this imaging method's usefulness in practical applications. Prior studies have described a pulse echo TOF based ultrasonic imaging method that requires using a single transducer in combination with a reflector plate placed behind samples which, eliminates the effect of thickness variation in the image. In those studies, this method was successful at isolating ultrasonic variations due to material in plate like samples of silicon nitride, metal matrix composite, and polymer matrix composite. In this study, the method is engineered for inspection of more complex shaped structures- those having (hollow) tubular or curved geometry. The experimental inspection technique and results are described as applied to a polymer matrix composite "proof of concept" tube that contains machined patches of various depths and an as manufactured monolithic silicon nitride ceramic tube that might be used in "real world" applications.

Roth, Don J.↗