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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Porthole die extrusion of aluminum 6063 industrial scrap by shear assisted processing and extrusion

Shear Assisted Processing and Extrusion (ShAPE) is presented as a new manufacturing technology for converting aluminum scrap directly into extruded products. In this work, a porthole die configuration is integrated within the rotating ShAPE process to extrude circular, square, trapezoidal, and two-cell trapezoidal profiles from aluminum alloy 6063 industrial scrap. This is the first time that a rotating billet has been used to impart severe plastic deformation (SPD) during extrusion of noncircular profiles. Microstructural characterization is presented for a trapezoidal profile having an average grain size of 6.7 µm in the as-extruded condition. Dimensional stability was evaluated by measuring wall thickness along the extrusion length; the thickness varied by <5%. Round tubes achieved yield strength (246.9 ± 10.4 MPa), ultimate tensile strength (270.8 ± 9.6 MPa), and uniform elongation (16.5 ± 2.4%) exceeding industry standards.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Conversion of real-world aluminum scrap streams into high-performance Al–Mg–Si–Cu automotive alloys using shear assisted processing and extrusion

The conversion of post-consumer aluminum (Al) scrap into usable Al alloys without adding primary Al is challenging because of excess impurities. In this work, >99% post-consumer Twitch, used beverage cans (UBCs), and remelt scrap ingots (RSIs) were used as feedstock materials. As-cast and solution heat-treated feedstock billets were extruded using Shear Assisted Processing and Extrusion (ShAPE) at ~510°C, followed by press quenching. To explore the development of the microstructure, texture, and underlying mechanisms and how they contribute to the overall strengthening in as-extruded and artificially aged samples, scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD) were used to collect microstructure and texture data. The enhanced strength and ductility were corroborated with the microstructural features and crystallographic texture. Simple shear $\textrm{A}/\bar{\textrm{A}}$, $\textrm{A}_1^*/\textrm{A} _2^*$ texture components along with weak $\textrm{C}$ and $\textrm{B}/\bar{\textrm{B}}$ texture components were formed during extrusion; the texture was strengthened after heat treatment. The refined second-phase particles helped to retain the deformed microstructure and texture. The contributions of dislocation and precipitate strengthening were maximized when billets were solution-heat-treated prior to extrusion. This is attributed to the formation of effective supersaturated solid solutions during the ShAPE process, which precipitate out during the peak age treatment. Overall, the highest yield strength of 305 MPa, ultimate tensile strength of 350 MPa, and elongation of 12% were achieved in artificially aged samples, which are comparable to those of Al 6082-T6.

Al alloy↗
DOE OSTI2026

Achieving strength-ductility synergy in hierarchical aluminum metal matrix composites via friction extrusion

We report the fabrication of aluminum metal matrix composites (Al-MMCs) with hierarchical architectures via friction extrusion (FE), a scalable, single-step, solid-phase processing technique. Precursor pucks containing 0–15 vol% Al₂O₃ particles were extruded into fully dense AA6061-based composite rods. The FE induced a tree-ring-like architecture of concentric particle-rich and particle-lean bands, yielding refined grains in particle-rich regions and coarser grains elsewhere. At the nanoscale, magnesium in AA6061 selectively reacted with Al₂O₃ particles to form virus-like nodes, improving particle–matrix bonding. This multi-scale design strategy, combining mesoscale architecture, microscale grain refinement, and nanoscale interface engineering overcome the conventional strength–ductility trade-off. Tensile testing showed substantial increases in yield and ultimate tensile strengths while retaining high ductility ( > 20%). Enhanced strain hardening, driven by the accumulation of geometrically necessary dislocations at interfaces, contributed to the performance. The hierarchical microstructure produced by FE demonstrates a promising pathway for scalable fabrication of lightweight MMCs for structural applications requiring a combined high strength and ductility.

Kalsar, Rajib [Pacific Northwest National Laborato↗
DOE OSTI2020

Two Strengths of Ordinary Chondritic Meteoroids as Derived from Their Atmospheric Fragmentation Modeling

The internal structure and strength of small asteroids and large meteoroids is poorly known. Observation of bright fireballs in the Earth’s atmosphere can explore meteoroid structure by studying meteoroid fragmentation during the flight. Earlier evaluations showed that the meteoroid’s strength is significantly lower than that of the recovered meteorites. We present a detailed study of atmospheric fragmentation of seven meteorite falls, all ordinary chondrites, and 14 other fireballs, where meteorite fall was predicted but the meteorites, probably also ordinary chondrites, were not recovered. All observations were made by the autonomous observatories of the European Fireball Network and include detailed radiometric light curves. A model, called the semiempirical fragmentation model, was developed to fit the light curves and decelerations. Videos showing individual fragments were available in some cases. The results demonstrated that meteoroids do not fragment randomly but in two distinct phases. The first phase typically corresponds to low strengths of 0.04–0.12 MPa. In two-thirds of cases, the first phase was catastrophic or nearly catastrophic with at least 40% of mass lost. The second phase corresponds to 0.9–5 MPa for confirmed meteorite falls and somewhat lower strengths, from about 0.5 MPa, for smaller meteoroids. All of these strengths are lower than the tensile strengths of ordinary chondritic meteorites cited in the literature, 20–40 MPa. We interpret the second phase as being due to cracks in meteoroids and the first phase as a separation of weakly cemented fragments, which reaccumulated at the surfaces of asteroids after asteroid collisions.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS1977

Hybrid composites - State-of-the-art review: Analysis, design, application and fabrication

The review covers hybrid composites that consist of two or more different types of fibers (or fiber composites) in a frequently repeated pattern in a laminate. The fibers considered are boron, graphite, glass, and Kevlar; the resins considered include mostly structural epoxies, with some utilization of polyimides and thermoplastics. The review shows that considerable data have been generated for the tensile strength properties, as well as tensile and thermal fatigue, of interply hybrids, and for the impact resistance of interply and intraply hybrids. The rule of mixtures appears to be adequate for predicting longitudinal and transverse mechanical properties of unidirectional interply hybrids, and linear laminate theory appears to be adequate for predicting the elastic response of hybrids.

Chamis, C. C.↗
NASA NTRS1985

Evaluation of a high temperature adhesive for fabricating graphite/PMR-15 polyimide structures

Tests are conducted to measure shear strength, shear modulus and flatwise tensile strength of the A7F (amide-imide modified LARC-13) adhesive system. An investigation is also conducted to determine the effect of geometric material parameters, and elevated temperature on the static strength of standard joints. Single-lap and double-lap composite joints, and single, double and step lap composite to metal joints are characterized. A series of advanced joints consisting of preformed adherends, adherends with scalloped edges and joints with hybrid interface plies are tested and compared to baseline single and double-lap designs.

Hill, S. G.↗
NASA NTRS1985

Investigation of instability, dynamic forces, and effect of dynamic loading on strength of cages for the bearings in the high pressure oxygen turbopumps for the space shuttle main engine

Experiments were performed to determine the effect of cyclic loading on bearing cage strength. A long term working tensile load of approximately 1300 N (300 lbs) was found to be the likely maximum. Higher loads caused a decrease in cage tensile strength after the 125,000 cycle testing period. Poisson's ratio in compression was found to be highly dependent upon the direction of the fiberglass plies. At room temperature the value was 0.15 with the plies and 0.68 across the plies. At -196 C (-321 F), the value with the plies was 0.20. The results of the analyses conducted have again demonstrated the critical need for improved lubrication in the high pressure oxygen turbopump bearings. Lubricant films with low shear strength and low friction coefficients promote cage stability and decrease ball/cage forces during marginal operating conditions. The analysis of the effect of combined bearing loads on ball/cage loads has identified a radial load of 3600 N (800 lbs) as the maximum for the current clearance of the balls and cage pockets. Liquid oxygen impinging on the cage in the direction of rotation was found to enhance cage stability.

Dufrane, K. F.↗
NASA NTRS1998

IM7/LARC(tm) MPEI-1 Polymide Composites

LARC(Trademark) MPEI-1 (Langley Research Center(Trademark) modified phenylethynyl imide-1) phenylethynyl containing aromatic polymide, is based on the reaction of biphenyl dianhydride (BPDA), 3,4'-oxydianiline (3,4'-ODA), 1,3-bis(3-aminophenoxy)benzene (APB), 2,4,6-triaminopyrimidine (TAP) and 4-phenylethynyl phthalic anhydride (PEPA), presumably resulting in a mixture of linear, branched and star shaped phenylethynyl containing imides which was evaluated as a matrix for high-performance composites. The poly(amid acid) solution of MPEI-1 in N-methypyrrolidinone was synthesized at 35% and 42% solids. Unidirectional prepreg was fabricated from these solutions and Hercules IM7 carbon fiber utilizing NASA- Langley's multipurpose prepreg machine. The temperature-dependent volatile depletion rates, thermal crystallization behavior and resin theology were characterized. Based on this information, a composite molding cycle was developed which yielded well consolidated, void-free laminates. Composite mechanical properties such as short beam shear strength, longitudinal and transverse flexural strength and flexural modulus, longitudinal tensile strength and notched and unnotched compression strengths were measured at room temperature (RT) and elevated temperatures. These mechanical properties are compared with those of IM7/LARC(Trademark) PETI-5 composites.

Hou, T. H.↗
NASA NTRS1977

Longitudinal shear behavior of several oxide dispersion strengthened alloys

Two commercial oxide dispersion strengthened (ODS) alloys, MA-753 and MA-754, and three experimental ODS alloys, MA-757E, MA-755E, and MA-6000E, were tested in shear at 760 C. Comparisons were made with other turbine-blade and vane alloys. All of the ODS alloys exhibited less shear strength than directionally solidified Mar-M 200 + Hf or than conventionally cast B-1900. The strongest ODS alloy tested, MA-755E, was comparable in both shear and tensile strength to the lamellar directionally solidified eutectic alloy gamma/gamma-prime - delta. Substantial improvements in shear resistance were found for all alloys tested when the geometry of the specimen was changed from one generating a transverse tensile stress in the shear area to one generating a transverse compressive stress. Finally, 760-C shear strength as a fraction of tensile strength was found to increase linearly with the log of the transverse tensile ductility.

Glasgow, T. K.↗
NASA NTRS1978

Longitudinal shear behavior of several oxide dispersion strengthened alloys

Two commercial oxide dispersion strengthened (ODS) alloys, MA-753 and MA-754, and three experimental ODS alloys, MA-757E, MA-755E, and MA-6000E, were tested in shear at 760 C. Comparisons were made with other turbine blade and vane alloys. All of the ODS alloys exhibited less shear strength than directionally solidified Mar-M 200 = Hf or then conventionally cast B-1900. The strongest ODS alloy tested, MA-755E, was comparable in both shear and tensile strength to the lamellar directionally solidified eutectic alloy gamma/gamma prime - delta. Substantial improvements in shear resistance were found for all alloys tested when the geometry of the specimen was changed from one generating a transverse tensile stress in the shear area to one generating a transverse compressive stress. Finally, 760 C shear strength as a fraction of tensile strength was found to increase linearly with the log of the transverse tensile ductility.

Glasgow, T. K.↗
DOE OSTI2020

A generalized power-law criterion for rocks based on Mohr failure theory

Nonlinearity of Mohr envelopes confirmed by past laboratory test data can be of considerable importance in theoretical interpretation of rock strength behaviors and many practical applications. Current nonlinear failure criteria are introduced with parameters to empirically fit test data, and the physical and mechanical meanings of these fitting parameters are often not known. Predicted strengths by theoretical criteria (e.g., Griffith criterion) generally do not agree well with test data. Considering the nonlinear properties of a Mohr envelope, a nonlinear failure criterion in a generalized power-law form is derived in this paper based on strength magnitude coefficient (a) and failure envelope curvature coefficient (n) which are expressed in terms of uniaxial tensile strength, uniaxial compressive strength, and angle of internal friction. Test data on granite, marble, dolomite, and andesite from published literature were chosen to test the performance of the proposed criterion along with Griffith and Hoek-Brown criteria. Statistical analysis was performed to evaluate the application of different criteria in predicting the strength of rocks. In addition, some Griffith-typed criteria are mathematically shown to be the special cases of the proposed criterion. The proposed and Hoek-Brown criteria have similar power-law forms with a significant difference in the coefficient functions that govern the shear strength magnitude of rock. The different tensile and compressive failure mechanisms are also investigated from the perspective of the relationship between the uniaxial tension Mohr circle and the proposed failure envelope.

58 GEOSCIENCES↗
NASA NTRS1974

Examination of the influence of coatings on thin superalloy sections. Volume 2: Detailed procedures and data

The effects of an aluminide coating, Codep B-1, and of section thickness were investigated on two cast nickel base superalloys, Rene 80 and Rene 120. Cast section thicknesses ranged from 0.038 cm to 0.15 cm. Simulated engine exposures for 1000 hours at 899C or 982C in a jet fuel burner rig with cyclic air cooling were studied, as were the effects of surface machining before coating and re-machining and re-coating after exposures. The properties evaluated included tensile at room temperature., 871C and 982C, stress rupture at 760C, 871C, 982C and 1093C, high cycle mechanical fatigue at room temperature., and thermal fatigue with a 1093C peak temperature. Thin sections had tensile strengths similar to standard size bars up to 871C and lower strengths at 982C and above, with equivalent elongation, and stress rupture life was lower for thin sections at all test conditions. The aluminide coating lowered tensile and rupture strengths up to 871C, with greater effects on thinner specimens. Elevated temperature exposure lowered tensile and rupture strengths of thinner specimens at the lower test temperatures. Surface machining had little effect on properties, but re-machining after exposure reduced thickness and increased metallurgical changes enough to lower properties at most test conditions.

Kaufman, M.↗
NASA NTRS1995

Mechanical Properties of Aerogels

Aerogels are extremely low density solids that are characterized by a high porosity and pore sizes on the order of nanometers. Their low thermal conductivity and sometimes transparent appearance make them desirable for applications such as insulation in cryogenic vessels and between double paned glass in solar architecture. An understanding of the mechanical properties of aerogels is necessary before aerogels can be used in load bearing applications. In the present study, the mechanical behavior of various types of fiber-reinforced silica aerogels was investigated with hardness, compression, tension and shear tests. Particular attention was paid to the effects of processing parameters, testing conditions, storage environment, and age on the aerogels' mechanical response. The results indicate that the addition of fibers to the aerogel matrix generally resulted in softer, weaker materials with smaller elastic moduli. Furthermore, the testing environment significantly affected compression results. Tests in ethanol show an appreciable amount of scatter, and are not consistent with results for tests in air. In fact, the compression specimens appeared to crack and begin to dissolve upon exposure to the ethanol solution. This is consistent with the inherent hydrophobic nature of these aerogels. In addition, the aging process affected the aerogels' mechanical behavior by increasing their compressive strength and elastic moduli while decreasing their strain at fracture. However, desiccation of the specimens did not appreciably affect the mechanical properties, even though it reduced the aerogel density by removing trapped moisture. Finally, tension and shear test results indicate that the shear strength of the aerogels exceeds the tensile strength. This is consistent with the response of brittle materials. Future work should concentrate on mechanical testing at cryogenic temperatures, and should involve more extensive tensile tests. Moreover, before the mechanical response of reinforced aerogels can be fully understood, more tests of unreinforced aerogels are necessary. Unreinforced aerogels are of particular use because their birefringent nature allows for visual determination of stress fields during mechanical testing. The success of any future tests depends on the availability of a large supply of quality specimens with well-documented preparation and storage histories.

Parmenter, Kelly E.↗
DOE OSTI2020

Water-Dependent Blending of Pectin Films: The Mechanics of Conjoined Biopolymers

Biodegradable pectin polymers have been recommended for a variety of biomedical applications, ranging from the delivery of oral drugs to the repair of injured visceral organs. A promising approach to regulate pectin biostability is the blending of pectin films. To investigate the development of conjoined films, we examined the physical properties of high-methoxyl pectin polymer-polymer (homopolymer) interactions at the adhesive interface. Pectin polymers were tested in glass phase (10–13% w/w water content) and gel phase (38–41% w/w water content). The tensile strength of polymer-polymer adhesion was measured after variable development time and compressive force. Regardless of pretest parameters, the adhesive strength of two glass phase films was negligible. In contrast, adhesion testing of two gel phase films resulted in significant tensile adhesion strength (p < 0.01). Adhesion was also observed between glass phase and gel phase films—likely reflecting the diffusion of water from the gel phase to the glass phase films. In studies of the interaction between two gel phase films, the polymer-polymer adhesive strength increased linearly with increasing compressive force (range 10–80 N) (R 2 = 0.956). In contrast, adhesive strength increased logarithmically with time (range 10–10,000 s) (R 2 = 0.913); most of the adhesive strength was observed within minutes of contact. Fracture mechanics demonstrated that the adhesion of two gel phase films resulted in a conjoined film with distinctive physical properties including increased extensibility, decreased stiffness and a 30% increase in the work of cohesion relative to native polymers (p < 0.01). Scanning electron microscopy of the conjoined films demonstrated cross-grain adhesion at the interface between the adhesive homopolymers. These structural and functional data suggest that blended pectin films have emergent physical properties resulting from the cross-grain intermingling of interfacial pectin chains.

62 RADIOLOGY AND NUCLEAR MEDICINE↗