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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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

A Sustainable and Environmentally Friendly Concrete for Structural Applications

The purpose of this study is to utilize waste products—precipitated calcium carbonate (PCC) and upcycled recycled concrete aggregate (upcycled RCA or UCA)—in civil works projects. To do so, tests must be performed to determine the engineering properties of the materials in which PCC and UCA are sequestered. PCC is a fine to coarse grain waste product generated during the production of sugar from sugar beets. UCA is produced from demolished and returned concrete by the extraction of primarily calcium and alkalinity. The study also includes the use of both PCC and UCA in the same concrete mix design. The test results on PCC alone show that the optimum content to achieve a minimum 28 MPa (4000 psi) compressive strength is 25% and 30%. The corresponding compressive strength of mixes in which conventional aggregate was replaced by UCA is about 48 MPa (7000 psi) to 55 MPa (8000 psi) at the same water: cement ratio (0.44) by weight. The compressive strength of concrete with 25% to 30% cement replaced by PCC and varying aggregates replaced with UCA ranges from 19.3 to 40 MPa (2800 to 5800 psi). Other tests on PCC and UCA include tensile strength of 2 to 3 MPa (293 to 423 psi) and flexural strength of 1.3 to 1.9 MPa (183 to 279 psi). Analytical techniques such as X-ray diffraction (XRD), energy-dispersive X-ray spectrometry (EDX), and scanning electron microscopy (SEM) were used to identify the constituent elements and chemical compounds present in PCC, including calcium carbonate and silica. Based on the test results, the composition of PCC by weight indicates 45.9% calcium, 39.4% oxygen, and 9.2% carbon. Based on the results of this study, we can expect to reduce carbon emissions in the production of cement and aggregates, as well as utilize waste products in the civil engineering field.

42 ENGINEERING↗
DOE OSTI2024

Processing, Microstructure, and Properties of Bimetallic Steel-Ni Alloy Powder HIP

This work explores technical feasibility in hot isostatic pressing (HIP) manufacturing of an integral bimetallic component using steel and Ni alloy powder for supercritical carbon dioxide (sCO2) turbomachinery. Lab-scale bimetallic HIP specimens using HAYNES® 282® and SS316L or SS415 powder are investigated in powder configuration, heat treatment, microstructure, and tensile properties up to 400 °C. Interdiffusion profiles at dissimilar alloy interfaces caused by HIP cycle is predicted by DICTRA simulations and validated by electron probe microanalysis (EPMA). The interdiffusion distance of most elements is around 100 μm, while C and N have a higher interdiffusion distance. Dense distribution of Ti-rich carbonitrides and alumina particles are found to decorate prior particle boundaries near joining interface on the 282 side, affecting tensile strength across interface as well as tensile failure location. A higher amount of excessive carbonitride formation near interface is observed in SS316L/282 than in SS415/282, which is consistent with the predicted greater degree of interdiffusion effect in SS316L/282. Typical HAYNES® 282® heat treatment condition is applicable to 282/SS316L and 282/SS415 combinations, resulting in a higher strength than cast CF8M and CA6NM. A pilot-scale bimetallic SS415/282 pipe is then demonstrated to show the promise of scaleup.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Low-Cost, High-Performance Carbon Fiber for Compressed Natural Gas Storage Tanks (Final Technical Report – Down Select Report)

The aim of this project is to reduce the cost of Type IV, carbon fiber (CF) composite overwrap compressed gas storage tanks by reducing the cost of CF and CF composites. The project team worked to reduce the cost of CF by exploring and testing opportunities for a low-cost alternative precursor material for CF production to supplant market-dominant and costly polyacrylonitrile (PAN). Concurrently, the team aimed to reduce the cost of the tanks at the composite level by improving the interfacial adhesion between the fibers and the matrix resin through the incorporation of low-cost nanoparticles recycled from waste materials, which would reduce the volume of costly CF required to achieve the same tank performance. At the end of the first year, the project team selected mesophase pitch as the primary precursor candidate from a field of materials based on the superior mechanical performance and cost-saving potential. During the second year, the team produced CFs derived from mesophase pitch achieving an average tensile strength of 365.6 ksi and average tensile modulus of 40.74 Msi. Facility availability for spinning and converting these fibers at greater scale has hindered scale-up demonstration, but the team has identified opportunities to conduct this work in the near term. Cost modeling shows that these mesophase pitch-derived CFs can be up to 40% less expensive than PAN-derived CFs due to the lower cost of the feedstock material, higher throughput, greater conversion yield, and lower cost spinning method and compared to PAN. Additionally, the team has demonstrated at lab-scale that nanoparticle coating CFs can significantly increase the interfacial shear strength and load transfer efficiency of CFs in a matrix. Single filament pull-out testing showed a 27% average increase in max interfacial shear strength due to this coating. A continuous method of applying these coatings to a tow of CF has been developed for scale-up. 26 m tows of coated CFs were produced using this system and formed into composite ring samples for ASTM ring burst testing. Issues with the testing protocol have limited assessment of these results. A prototype Type IV tank was designed to meet ANSI HGV2 standards, and the design criteria set out by DOE, using the CF properties developed by the team paired with a proprietary resin matrix, a polyamide liner, and aluminum end bosses. The tank weighs 153.1 kg and with a total capacity of 5.8 kg H2 (5.6 kg usable), which yields a gravimetric capacity of 1.17 kWh/kg. Cost modeling predicts that the tank will have a projected cost of $15.73/kWh. Tank performance modeling does not include considerations for fiber-matrix load transfer efficiency improvements offered by nanoparticle coating method.

08 HYDROGEN↗
NASA NTRS1992

Chemistry and properties of poly(arylene ether 1,3,4-oxadiazole)s and poly(arylene ether 1,2,4-triazole)s

Poly(arylene ether)s containing l,3,4-oxadiazole and 1,2,4-triazole units were prepared by the aromatic nucleophilic displacement reaction of bisphenol oxadiazole and bisphenol triazole compounds with activated aromatic dihalides. The polymers exhibited glass transition temperatures (Tg) ranging from 182 to 242 C, and several polymers exhibited melting transitions (Tm) ranging from 265 to 390 C. Inherent viscosities ranged from 1.02 to 3.40 dl/g, indicating relatively high molecular weights. Thin films exhibited tensile strengths, moduli, and elongations at 23 C of 90-110 MPa, 2.7-3.6 GPa, and 4-7 percent, respectively. Titanium-to-titanium tensile shear specimens of a poly(arylene ether 1,3,4-oxadiazole) exhibited tensile shear strengths at 23 and 150 C of 22.1 and 17.9 MPa, respectively.

Connell, J. W.↗
DOE OSTI2022

Brazing characteristics, microstructure, and wettability of laser powder bed fusion additive manufactured GRCop-84 compared to CuCrZr and OFC, and brazing to titanium-zirconium-molybdenum alloy limiters

Laser Powder Bed Fusion (L-PBF) of Glenn Research Copper 84 (GRCop-84), a Cr 2 Nb (8 at. % Cr, 4 at. % Nb) precipitation hardened alloy, produces a fully dense, high conductivity alloy with a yield strength of 500 MPa and ultimate tensile strength (UTS) of 740 MPa with 20% elongation; superior to other competing copper alloys. Braze wetting characteristics of GRCop-84 with Ag-Cu-X, and Au-Cu brazes were similar to CuCrZr, but less than oxygen free copper. No difference in wetting was observed between infill and surface contour areas in L-PBF GRCop-84. Wet sanding to 240 grit (R a =0.24 µm) was considered the optimal surface condition. Silver diffusing through GRCop-84 depleted Cr 2 Nb precipitates from the copper grain and deposited agglomerations of coarsened precipitates within silver-rich regions of intergranular diffusion once a density threshold was reached. Microstructure modification was minimized with 50Au-50Cu braze implying that silver caused precipitate coarsening and agglomeration, and not high temperature exposure. Coarsened precipitates were observed on the surface within braze pools implying a contribution to braze wetting. Palcusil-25, Ticusil, CuSil-ABA, and 50Au-50Cu brazes were suitable for brazing to unplated Titanium-Zirconium-Molybdenum (TZM), while sulfamate nickel plating to allows wetting with CuSil or other non-active brazes. Additionally, vacuum brazing techniques were developed to join a 1 mm thick layer of TZM to the front of additive manufactured GRCop-84 waveguides considering the brazing characteristics of both GRCop-84, TZM, and internal stress from the difference in coefficient in thermal expansion.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Development and Characterization of a Sustainable Bio-Polymer Concrete with a Low Carbon Footprint

Polymer concrete (PC) has been used to replace cement concrete when harsh service conditions exist. Polymers have a high carbon footprint when considering their life cycle analysis, and with increased climate change concerns and the need to reduce greenhouse gas emission, bio-based polymers could be used as a sustainable alternative binder to produce PC. This paper examines the development and characterization of a novel bio-polymer concrete (BPC) using bio-based polyurethane used as the binder in lieu of cement, modified with benzoic acid and carboxyl-functionalized multi-walled carbon nanotubes (MWCNTs). The mechanical performance, durability, microstructure, and chemical properties of BPC are investigated. Moreover, the effect of the addition of benzoic acid and MWCNTs on the properties of BPC is studied. The new BPC shows relatively low density, appreciable compressive strength between 20–30 MPa, good tensile strength of 4 MPa, and excellent durability resistance against aggressive environments. The new BPC has a low carbon footprint, 50% lower than ordinary Portland cement concrete, and can provide a sustainable concrete alternative in infrastructural applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Enabling Industrial Re-Use of Large-Format Additive Manufacturing Molding and Tooling

Large-format additive manufacturing (LFAM) is an enabling manufacturing technology capable of producing large parts with highly complex geometries for a wide variety of applications, including automotive, infrastructure/construction, and aerospace mold and tooling. In the past decade, the LFAM industry has seen widespread use of bio-based, glass, and/or carbon fiber reinforced thermoplastic composites which, when printed, serve as a lower-cost alternative to metallic parts. One of the highest-volume materials utilized by the industry is carbon fiber (CF)-filled polycarbonate (PC), which in out-of-autoclave applications can achieve comparable mechanical performance to metal at a significantly lower cost. Previous work has shown that if this material is recovered at various points throughout the manufacturing process for both the lab and pilot scale, it can be mechanically recycled with minimal impacts on the functional performance and printability of the material while significantly reducing the feedstock costs. End-of-life (EOL) CF-PC components were processed through industrial shredding, melt compounding, and LFAM equipment, followed by evaluation of the second-life material properties. Experimental assessments included quantitative analysis of fiber length attrition, polymer molecular weight degradation using gel permeation chromatography (GPC), density changes via pycnometry, thermal performance using dynamic mechanical analysis (DMA), and mechanical performance (tensile properties) in both the X- and Z-directions. Results demonstrated a 24.6% reduction in average fiber length compared to virgin prints, accompanied by a 21% decrease in X-direction tensile strength and a 39% reduction in tensile modulus. Despite these reductions, Z-direction tensile modulus improved by 4%, density increased by 6.8%, and heat deflection temperature (HDT) under high stress retained over 97% of its original value. These findings underscore the potential for integrating mechanically recycled CF-PC into industrial LFAM applications while highlighting the need for technological innovations to mitigate fiber degradation and enhance material performance for broader adoption. This critical step toward circular material practices in LFAM offers a pathway to reducing feedstock costs and environmental impact while maintaining functional performance in industrial applications.

additive manufacturing↗
NASA NTRS1979

Transverse and longitudinal tensile properties at 760 C of several oxide dispersion strenghened nickel-base alloys

The transverse and longitudinal tensile properties of the oxide dispersion strengthened nickel base alloys MA-793, MA-754, MA-755E, and MA-6000E were determined at 760 C. Transverse tensile strengths were comparable to longitudinal strengths. Transverse ductility levels generally were less than two percent elongation. Both tensile and yield strengths increased with increasing strain rate over the range 0.001 to 0.05 per second. Ductility was not strain rate sensitive, but related to grain size and grain aspect ratio. The fracture mode of most alloys changed from transgranular for longitudinally oriented specimens to intergranular for transverse specimens. Transverse properties of DM MAR M-200 + Hf were also determined for comparison.

Anglin, A. E., Jr.↗
NASA NTRS1984

Optical contacting for gravity probe star tracker

A star-tracker telescope, constructed entirely of fused silica elements optically contacted together, has been proposed to provide submilliarc-second pointing accuracy for Gravity Probe. A bibliography and discussion on optical contacting (the bonding of very flat, highly polished surfaces without the use of adhesives) are presented. Then results from preliminary experiments on the strength of optical contacts including a tensile strength test in liquid helium are discussed. Suggestions are made for further study to verify an optical contacting method for the Gravity Probe star-tracker telescope.

Wright, J. J.↗
NASA NTRS1987

Polyenamines from aromatic diacetylenic diketones and diamines

The synthesis and characterization of several polyenamine ketones are discussed wherein conjugated diacetylenic diketones and aromatic diamines are used as a route to the formation of high molecular weight polyenamine ketones which exhibit good mechanical properties and can be cast into creasible films. Typical polymerization conditions involved the reaction of stoichiometric amounts of 1,4- or 1,3-PPPO and a diamine at 60 to 130 C in m-cresol at (w/w) solids content of 8 to 26% for a specified period of time under a nitrogen atmosphere. Novel polyenamine ketones were prepared with inherent viscosities as high as 1.99 dl/g and tough, clear amber films with tensile strengths of 12,400 psi and tensile moduli of 397,000 psi were cast from solutions of the polymers in chloroform. In most cases, the elemental analyses for the polyenamine ketones agree within + or - 0.3% of the theoretical values.

Hergenrother, Paul M.↗
NASA NTRS1988

Polyenamines from aromatic diacetylenic diketones and diamines

The synthesis and characterization of several ployenamine ketones are discussed wherein conjugated diacetylenic diketones and aromatic diamines are used as a route to the formation of high molecular weight polyenamine ketones which exhibit good mechanical properties and can be cast into creasible films. Typical polymerization conditions involved the reaction of stoichiometric amounts of 1,4- or 1,3-PPPO and a diamine at 60°-130° C. in m-cresol at (w/w) solids content of 8-26% for a specified period of time under a nitrogen atmosphere. Novel polyenamine ketones were prepared with inherent viscosities as high as 1.99 dl/g and tough, clear amber films with tensile strengths of 12,400 psi and tensile moduli of 397,000 psi were cast from solutions of the polymers in chloroform. The polymers exhibited T g s as high as 235° C. and weight losses of 14% after aging at 232° C. in circulating air for sixty hours. The specific conditions for the preparation of the various polyenamine ketones are presented in Table I. In most cases, the elemental analyses for the polyenamine ketones, shown in Table II, agree within ±0.3% of the theoretical values.

Paul M Hergenrother↗
NASA NTRS1993

Alloys For Corrosive, Hydrogen-Rich Environments

"NASA-23" denotes class of alloys resisting both embrittlement by hydrogen and corrosion. Weldable and castable and formed by such standard processes as rolling, forging, and wire drawing. Heat-treated to obtain desired combinations of strength and ductility in ranges of 100 to 180 kpsi yield strength, 120 to 200 kpsi ultimate tensile strength, and 10 to 30 percent elongation at break. Used in place of most common aerospace structural alloy, Inconel(R) 718.

Mcpherson, William B.↗
NASA NTRS2021

Development of a Computational Framework for the Design of Resilient Space Structures

Cyber-physical testing provides a unique platform to enable the design of resilient space structures. This hybrid approach requires the development of a structural model that accounts for various hazards (e.g., micrometeorite and debris impact) and interacts with physical tests and other sub-system models (e.g., thermal) of the space habitat. A two-dimensional finite element analysis code was developed in MATLAB to facilitate the evaluation of potential designs under operating and unexpected loads and prepare the computational framework for eventually performing cyber-physical testing. The code’s efficiency was enhanced by using an object-oriented programming approach that reduced data transfer between functions. In this study, the code is implemented to predict the response of a dome-style structure made of regolith concrete to impact loading and identify the force magnitude that will cause the tensile strength to be exceeded in domes with different thicknesses.

Tensile strength↗
NASA NTRS1982

Correlation of tensile and shear strengths of metals with their friction properties

The relation between the theoretical tensile and the shear strengths and the friction properties of metals in contact with diamond, boron nitride, silicon carbide, manganese-zinc ferrite, and the metals themselves in vacuum was investigated. The relationship between the actual shear strength and the friction properties of the metal was also investigated. An estimate of the theoretical uniaxial tensile strength was obtained in terms of the equilibrium surface energy, interplanar spacing of the planes perpendicular to the tensile axis, and the Young's modulus of elasticity. An estimate of the theoretical shear strength for metals was obtained from the shear modulus, the repeat distance of atoms in the direction of shear of the metal and the interplanar spacing of the shear planes. The coefficient of friction for metals was found to be related to the theoretical tensile, theoretical shear, and actual shear strengths of metals. The higher the strength of the metal, the lower the coefficient of friction.

Miyoshi, K.↗
NASA NTRS1978

Ultra-high-strength boron fibers

Boron-on-tungsten fibers with tensile strength and strain-to-failure values increased by fifty percent over commercial grades are produced by controlled chemical-etching process. Improved fibers have potential applications as lightweight composites in ground vehicles, spacecraft, and rotors for energy storage.

Behrendt, D. R.↗