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NASA NTRS1993

Establishment of computerized numerical databases on thermophysical and other properties of molten as well as solid materials and data evaluation and validation for generating recommended reliable reference data

The Center for Information and Numerical Data Analysis and Synthesis, (CINDAS), measures and maintains databases on thermophysical, thermoradiative, mechanical, optical, electronic, ablation, and physical properties of materials. Emphasis is on aerospace structural materials especially composites and on infrared detector/sensor materials. Within CINDAS, the Department of Defense sponsors at Purdue several centers: the High Temperature Material Information Analysis Center (HTMIAC), the Ceramics Information Analysis Center (CIAC) and the Metals Information Analysis Center (MIAC). The responsibilities of CINDAS are extremely broad encompassing basic and applied research, measurement of the properties of thin wires and thin foils as well as bulk materials, acquisition and search of world-wide literature, critical evaluation of data, generation of estimated values to fill data voids, investigation of constitutive, structural, processing, environmental, and rapid heating and loading effects, and dissemination of data. Liquids, gases, molten materials and solids are all considered. The responsibility of maintaining widely used databases includes data evaluation, analysis, correlation, and synthesis. Material property data recorded on the literature are often conflicting, diverging, and subject to large uncertainties. It is admittedly difficult to accurately measure materials properties. Systematic and random errors both enter. Some errors result from lack of characterization of the material itself (impurity effects). In some cases assumed boundary conditions corresponding to a theoretical model are not obtained in the experiments. Stray heat flows and losses must be accounted for. Some experimental methods are inappropriate and in other cases appropriate methods are carried out with poor technique. Conflicts in data may be resolved by curve fitting of the data to theoretical or empirical models or correlation in terms of various affecting parameters. Reasons (e.g. phase transitions) must be found for unusual dependence or any anomaly. Such critical evaluation involves knowledge of theory, experience in measurement, familiarity with metallurgy (microstructural behavior) and not inconsiderable judgment. An examination of typical data compiled and analyzed by CINDAS shows that the thermal conductivity of a material reported in the literature may vary by a factor of two of more; the range of reported values increases as temperature increases reflecting the difficulty of high temperature measurements. Often only estimates of melt behavior are available, despite the importance of melt properties in modeling, welding, or other solidification processes. There may be only a few measurements available for properties such as kinematic viscosity, even for widely used materials such as stainless steel. In the face of such a paucity of existing data and in a national environment where too few new data are being generated it is nonetheless the responsibility of CINDAS to select and disseminate recommended values of a wide variety of thermophysical properties.

Ho, C. Y.↗

NASA NTRS1986

Method of making macrocrystalline or single crystal semiconductor material

A macrocrystalline or single crystal semiconductive material is formed from a primary substrate including a single crystal or several very large crystals of a relatively low melting material. This primary substrate is deposited on a base such as steel or ceramic, and it may be formed from such metals as zinc, cadmium, germanium, aluminum, tin, lead, copper, brass, magnesium silicide, or magnesium stannide. These materials generally have a melting point below about 1000 C and form on the base crystals the size of fingernails or greater. The primary substrate has an epitaxial relationship with a subsequently applied layer of material, and because of this epitaxial relationship, the material deposited on the primary substrate will have essentially the same crystal size as the crystals in the primary substrate. If required, successive layers are formed, each of a material which has an epitaxial relationship with the previously deposited layer, until a layer is formed which has an epitaxial relationship with the semiconductive material. This layer is referred to as the epitaxial substrate, and its crystals serve as sites for the growth of large crystals of semiconductive material. The primary substrate is passivated to remove or otherwise convert it into a stable or nonreactive state prior to deposition of the seconductive material.

Shlichta, P. J.↗

NASA NTRS2017

Chemical, Mineralogical, and Physical Properties of Martian Dust and Soil

Global and regional dust storms on Mars have been observed from Earth-based telescopes, Mars orbiters, and surface rovers and landers. Dust storms can be global and regional. Dust is material that is suspended into the atmosphere by winds and has a particle size of 1-3 micrometer. Planetary scientist refer to loose unconsolidated materials at the surface as "soil." The term ''soil'' is used here to denote any loose, unconsolidated material that can be distinguished from rocks, bedrock, or strongly cohesive sediments. No implication for the presence or absence of organic materials or living matter is intended. Soil contains local and regional materials mixed with the globally distributed dust by aeolian processes. Loose, unconsolidated surface materials (dust and soil) may pose challenges for human exploration on Mars. Dust will no doubt adhere to spacesuits, vehicles, habitats, and other surface systems. What will be the impacts on human activity? The objective of this paper is to review the chemical, mineralogical, and physical properties of the martian dust and soil.

Ming, D. W.↗

NASA NTRSDate not supplied

Promoted Combustion Behavior of 316 Stainless Steel and 6061 Aluminum Alloys in Elevated Pressure Nitrox Environments

Promoted combustion testing (outlined in the ASTM G124 “Standard Test Method for Determining the Combustion Behavior of Metallic Materials in Oxygen Enriched Atmospheres”) refers to a useful testing method to evaluate how metallic materials will behave when combusted in environments with high oxygen concentrations, elevated pressure, or both. These tests yield data which is useful for engineers and scientists from a variety of industries who need and rely on oxygen systems. Oxygen Compatibility Assessments (OCA’s) are vital for ensuring that materials will be safe for use, and these assessments rely on data from OCA’s or interpolation if a desired pressure/concentration is outside of previously tested bounds. It was identified that these bounds leave out significant areas of data for materials which are tested at high pressures (above 1500 psi) and variable oxygen concentrations (with nitrogen as the diluent gas). For this reason, the authors posited that conducting promoted combustion testing on materials above 1500 psi and in various concentrations of oxygen would be incredibly useful in future analyses for oxygen compatibility with similar environments (such as breathing air) as well as for further understanding of how materials behave at very high pressures (such as 10000 psi). Two materials were selected which are commonly used in industry today - 316 stainless steel and 6061 aluminum – and they were tested and analyzed for the purposes of this study.

oxygen compatibility↗

NASA NTRS1972

Torsion pendulum measurements on viscoelastic materials during vacuum exposure

A torsional pendulum apparatus designed for testing in situ in vacuum, the dynamic mechanical properties of materials is described. The application of this apparatus to an experimental program to measure the effects of vacuum on the mechanical properties of two ablator materials (a foamed material and a filled elastomer) and a solid rocket propellant (a filled elastomer) is presented. Results from the program are discussed as to the effects of vacuum on the mechanical properties of these three materials. In addition, time-temperature-superposition, as a technique for accelerating vacuum induced changes in mechanical properties, is discussed with reference to the three materials tested in the subject program.

Ward, T. C.↗

NASA NTRS2000

Beyond Coordination: Joint Planning and Program Execution. The IHPRPT Materials Working Group

"Partnership is more than just coordination," stated then-Commander of the Air Force Research Laboratory (AFRL), Major General Dick Paul (USAF-Ret), at this year's National Space and Missile Materials Symposium. His comment referred to the example of the joint planning and program execution provided by the Integrated High Payoff Rocket Propulsion Technology (IHPRPT) Materials Working Group (IMWG). Most people agree that fiscal pressures imposed by shrinking budgets have made it extremely difficult to build upon our existing technical capabilities. In times of sufficient budgets, building advanced systems poses no major difficulties. However, with today's budgets, realizing enhanced capabilities and developing advanced systems often comes at an unaffordable cost. Overcoming this problem represents both a challenge and an opportunity to develop new business practices that allow us to develop advanced technologies within the restrictions imposed by current funding levels. Coordination of technology developments between different government agencies and organizations is a valuable tool for technology transfer. However, rarely do the newly developed technologies have direct applicability to other ongoing programs. Technology requirements are typically determined up-front during the program planning stage so that schedule risk can be minimized. The problem with this process is that the costs associated with the technology development are often borne by a single program. Additionally, the potential exists for duplication of technical effort. Changing this paradigm is a difficult process but one that can be extremely worthwhile should the right opportunity arise. The IMWG is one such example where NASA, the DoD, and industry have developed joint requirements that are intended to satisfy multiple program needs. More than mere coordination, the organizations comprising the group come together as partners, sharing information and resources, proceeding from a joint roadmap.

Stropki, Michael A.↗

DOE OSTI2025

Multi-plane moment-of-fluid interface reconstruction in 3D

Moment-of-fluid (MOF) methods for interface reconstruction approximate the region occupied by material in each mesh element only through reference to its geometric moments. Here, we present a 3D MOF method that represents the material (POM) in each cell as the convex intersection of the cell and multiple half-spaces, each selected to minimize the least-squares error between computed moments of the approximated material and provided reference moments. This optimization problem is highly non-linear and non-convex, making the numerical result very sensitive to the initial guess. To create an effective initial guess in each cell, we construct an ellipsoid from 0th–2nd order reference moments such that its shape corresponds with that of the POM. Within this ellipsoid we inscribe a polyhedron, and initialize the minimization problem with the half-spaces defined by each of its faces. The inscribed polyhedron has minimally 4 faces, and using up to 3rd order moments permits optimization over up to 20 unknown values. We therefore define MOF methods that utilize 4, 5, or 6 half-spaces, correspondingly initialized with the faces of a single inscribed tetrahedron, triangular prism, or hexahedron. Stability of the non-linear optimization is further improved with a prepossessing step that normalizes the reference moments according to the axes of the reference ellipsoid. Using this approach, the non-linear least-squares solver reliably converges to a near-global minimum from a single initial guess. We demonstrate accuracy and robustness using single-cell and multi-cell examples over a wide spectrum of geometry. In particular, we demonstrate our ability to exactly reproduce several important and complex features defined by up to four half-spaces, such as corners, filaments, filament tips, and embedded material in the cell.

3D interface reconstruction↗

DOE OSTI2023

Performance investigation of alkaline direct methanol fuel cell with commercial PGM-free cathodic materials

Because little progress has been made in investigating the performance of alkaline direct methanol fuel cells (ADMFCs) with commercial materials (including platinum group metal (PGM)-free catalysts, anion exchange ionomers (AEIs), and anion exchange membranes (AEMs)), the objective of this work is to evaluate the performance of ADMFCs with all commercial materials, in order to establish a reference against which the performance of newly developed materials can be compared. Fe-N-C catalysts, Fumasep (FAA-3-50) based AEMs, and FAA3 based AEIs are here employed, and the parameters such as of operating temperature and methanol concentration are investigated and optimized. Electrochemical measurements show a performance increase with the temperature from 40 to 60 °C, and with the methanol concentration (from 1 to 5 M); followed by insignificant decrease with the further increase to 10 M. The best performance is achieved with 5 M methanol at 60 °C, and the remarkable powder density of 48.2 mW cm -2 was demonstrated under these conditions. This work provides insight into the large-scale application of ADMFC with commercial PGM-free materials.

25 ENERGY STORAGE↗

NASA NTRS2018

Qualifying Bulk Metallic Glass Gear Materials for Spacecraft Applications

NASA is evaluating bulk metallic glass (BMG) gears for extreme environment (cryogenic) applications; e.g., Europa Lander. The main purpose of this report is to recommend a quality assurance (QA) protocol for the production of consistent and reliable gear castings. Currently, there are two, separate manufacturers involved; Materion Corporation produces re-melt stock and Visser Precision Cast, Inc. produces BMG castings. Division of the existing alloy specifications document into material supplier-specific documents is proposed. Until a composition-based specification is established, processability- and performance-based methodologies may be an option during manufacturing development. It is recommended that each of the documents has a distinct focus; the processing behavior of crystalline feedstock, and the mechanical behavior of amorphous castings. The report addresses the “gray area” in QA testing between these materials suppliers by outlining an equitable division of responsibilities. The use of a number of dedicated reference dies to produce witness materials for physical and mechanical property evaluation is strongly recommended. Allocation of QA tests between screen testing of gear castings, and formal testing of witness materials, including cryogenic properties, is also proposed. The most effective suite of tests for both physical and mechanical property determination are down-selected from available national and international standards. The contents of this report create a solid basis for selection of QA tests, thereby setting the stage for negotiations between the materials suppliers and the customer.This technical paper:a) provides recommendations to advance materials specifications document JPL D-56223,Rev. A from “draft” to “preliminary” status;b) proposes division of the current document into two supplier-specific documents;c) separates testing methods by “ingots/castings” and “witness materials”;d) classifies test methodology based on “processability” and “performance”;e) assembles candidate ASTM specifications for “screen testing” and “formal testing”;f) identifies standard tests compatible with evaluation of BMG flexspline gears;g) suggests division of responsibilities for processability and performance testing; andh) addresses the QA “gray area” between production of ingots and castings.The report recommends that:a) processability- and performance-based QA methods might be used in lieu ofcompositional specifications during manufacturing development only;b) reference dies be designed for “acceptance” and “qualification” castings;c) witness materials provide physical and mechanical property data;d) formal testing be conducted at ambient and cryogenic temperatures; ande) processing/properties be correlated with compositional variations.

Hales, Stephen J.↗

NASA NTRS1996

Role of the micro/macro structure of welds in crack nucleation and propagation in aerospace aluminum-lithium alloy

Al-Li alloys offer the benefits of increased strength, elastic modulus and lower densities as compared to conventional aluminum alloys. Martin Marietta Laboratories has developed an Al-Li alloy designated 2195 which is designated for use in the cryogenic tanks of the space shuttle. The Variable Polarity Plasma Arc (VPPA) welding process is currently being used to produce these welds [1]. VPPA welding utilizes high temperature ionized gas (plasma) to transfer heat to the workpiece. An inert gas, such as Helium, is used to shield the active welding zone to prevent contamination of the molten base metal with surrounding reactive atmospheric gases. [1] In the Space Shuttle application, two passes of the arc are used to complete a butt-type weld. The pressure of the plasma stream is increased during the first pass to force the arc entirely through the material, a practice commonly referred to as keyholing. Molten metal forms on either side of the arc and surface tension draws this liquid together as the arc passes. 2319 Al alloy filler material may also be fed into the weld zone during this pass. During the second pass, the plasma stream pressure is reduced such that only partial penetration of the base material is obtained. Al 2319 filler material is added during this pass to yield a uniform, fully filled welded joint. This additional pass also acts to alter the grain structure of the weld zone to yield a higher strength joint.

Talia, George E.↗

NASA NTRS1972

Thermophysical characterization of composite materials under transient heating conditions

Thermophysical property measurements were made under transient heating conditions on several materials being considered for use in SCOUT rocket motors. The materials included were ATJ graphite, MX 2600 silica phenolic, FM 5272 cellulose phenolic, and two carbon-carbon composites: CARBITEX 700 and RPP-4. The ATJ was included as a reference or base line material to check performance of the transient tests as it was not expected to be sensitive to heating rate. Measurements included in the program were thermal conductivity, strength, compressive stress-strain (carbon-carbon only), thermal expansion and the effective thermal expansion under partially restrained conditions. Development of this latter measurement was a major part of the program. It consisted of partially restraining the expansion of a specimen as it was heated, measuring the load and strain which occurred (together with a simultaneous modulus determination by superimposing a small cyclic load) and using these quantities to calculate what the effective thermal expansion would have to be to produce the observed stress and deformation. For materials which are sensitive to heating rate, such as reinforced phenolics, it was believed that this would provide a more realistic determination of the thermal expansion as it more nearly simulates the conditions experienced in end use.

Roetling, J.↗

DOE OSTI2020

Polymers for Extreme Conditions Designed Using Syntax-Directed Variational Autoencoders

We report the design/discovery of new materials is highly nontrivial owing to the near-infinite possibilities of material candidates and multiple required property/performance objectives. Thus, machine learning tools are now commonly employed to virtually screen material candidates with desired properties by learning a theoretical mapping from material-to-property space, referred to as the forward problem. However, this approach is inefficient and severely constrained by the candidates that the human imagination can conceive. Thus, in this work on polymers, we tackle the materials discovery challenge by solving the inverse problem: directly generating candidates that satisfy desired property/performance objectives. We utilize syntax-directed variational autoencoders (VAE) in tandem with Gaussian process regression (GPR) models to discover polymers expected to be robust under three extreme conditions: (1) high temperatures, (2) high electric field, and (3) high temperature and high electric field, useful for critical structural, electrical, and energy storage applications. This approach to learn from and augment) human ingenuity is general and can be extended to discover polymers with other targeted properties and performance measures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRSDate not supplied

Hydrophobicity of Cryogenic Fluids for Fuel Transfer in Space Applicaitons

Introduction Hydrophobicity is the tendency of a fluid to repel another material or fluid. Hydrophobiciy can be measured through the wetting angle of the fluid on the surface of the other material. The greater the wetting angle, the more hydrophobic the surface is against the fluid. Hydrophobicity properties can be caused by one of two means, either through physical properties or chemical properties [\citenum{NARBUTT2020121}]. Physical hydrophobicity due to the surface of a solid creating surface roughness/patterning, minimizing the contact area between the fluid and the surface. This can be observed throughout nature, such as the surface of lotus leaves or butterfly wings. This physical property can be induced on a variety of surfaces, namely through laser etching, allowing a surface to be finely lineated to imitate these natural surfaces while controlling quantity, depth, and patterns of the etching on the surface [\citenum{10.1063/1.4905616}]. Physical hydrophobicity is therefore dependent on several variables, including the surface that the fluid is on and properties of the fluid itself, such as density and surface tension, both of which are dependent on temperature and/or pressure. Chemical hydrophobicity [\citenum{MadeiraHydrophobocicicici}] is due to the inherent chemical properties of the materials being used. This is most commonly due to the molecular structures changing the polarity of the materials. Depending on a nonpolar material will repel a polar material, proving to be hydrophobic, conversely if the polarity of the materials is the same (polar – polar, nonpolar – nonpolar), they will attract each other. Cryogenics refers to the behavior of materials at very low temperatures (<\ang{-100} C) [\citenum{ZOHURI20181}]. In space applications many things are inherently cryogenic, therefore this is an important field. There has been little research in how hydrophobicity changes at cryogenic temperatures. Cryogenic fluids are commonly used as fuels for spacecraft, therefore, integrating a hydrophobic surface can increase the transfer rate of the fuel. To test this, several experiments were set up to determine the hydrophobic properties of cryogenic fluids, including nitrogen (LN2), argon (LAr), oxygen (LOx), hydrogen (LH2), and methane (CH4), at cryogenic temperatures. Etched Wafer Testing A silicon wafer cut from a crystal of silicon [100] was used to model the potential hydrophobicity of various cryogenic fluids. Silicon [100] references to the crystallographic orientation of the silicon crystals in the wafer. These wafers were then laser etched to create a surface that is more likely to be hydrophobic. To test the hydrophobicity of the wafers at cryogenic temperatures, the temperatures of the wafers must be reduced to the same temperature as the cryogenic fluid being used to prevent rapid boil-off. To achieve this a double-walled vacuum insulated glass chamber was utilized. The chamber is open, with a double-walled glass that can be placed in a vacuum to remove condensation from the outside to allow easier viewing of the experiment. Furthermore, the silicon wafer's temperature must be lowered to the temperature of LN2, as well as maintain the temperature throughout the experiment. To achieve this a piece of 6061 aluminum was used, creating a stand-off for the wafer and it would allow for the insulation of the temperature of the wafers. The container was then filled with LN2 and once the LN2 stabilized the vaporization and the levels of LN2 dropped under the height of the wafer, the wafer was then allowed to air dry. Once the wafer was dry from the LN2, drops of LN2 were placed on the surface of the wafer for observation. During the first trial, the LN2 that was dropped on the surface displayed nonhydrophobic behaviors, spreading out along the surface, with a minimal wetting angle (too small to be measured). This process was repeated for liquid argon. Further testing with other cryogenic liquids will require different testing apparatuses due to being more volatile. Furthermore, several papers [\citenum{voltvolt7}] have suggested that running a voltage can induce a hydrophobic effect throughout a surface, further testing will include a voltage (constant and oscillating) to determine if voltage influences inducing hydrophobicity at cryogenic temperatures. Chemical Testing Coating the interior walls of the fuel tanks and fuel lines can successfully create a hydrophobic surface. The inherent problem is finding a material that can be used to coat the surface, furthermore, at these temperatures, the coating will remain solid, which could pose issues in maintaining the hydrophobic properties. To test this water (polar) is hydrophobic against oils and fats (nonpolar), therefore the same experiment as the etched wafer testing was conducted to determine if the hydrophobic properties will persist as the nonpolar material remains solid and the polar material remains a fluid. The water remained hydrophobic, allowing testing can expand to the cryogenic fluids. However, another hurdle is faced in finding a chemically opposite material to the cryogenic fluids being tested. As many of the cryogenic fluids being tested are diatomic, they are inherently nonpolar, therefore, the material used for the hydrophobic coating must be polar. Polar greases and lubricants are difficult to come by, however, lithium stearate, appears to be a potential candidate for creating a coated hydrophobic surface for cryogenic fluids at cryogenic temperatures.

Cryogenics↗

NASA NTRS2000

Probabilistic Multi-Scale, Multi-Level, Multi-Disciplinary Analysis and Optimization of Engine Structures

Aircraft engines are assemblies of dynamically interacting components. Engine updates to keep present aircraft flying safely and engines for new aircraft are progressively required to operate in more demanding technological and environmental requirements. Designs to effectively meet those requirements are necessarily collections of multi-scale, multi-level, multi-disciplinary analysis and optimization methods and probabilistic methods are necessary to quantify respective uncertainties. These types of methods are the only ones that can formally evaluate advanced composite designs which satisfy those progressively demanding requirements while assuring minimum cost, maximum reliability and maximum durability. Recent research activities at NASA Glenn Research Center have focused on developing multi-scale, multi-level, multidisciplinary analysis and optimization methods. Multi-scale refers to formal methods which describe complex material behavior metal or composite; multi-level refers to integration of participating disciplines to describe a structural response at the scale of interest; multidisciplinary refers to open-ended for various existing and yet to be developed discipline constructs required to formally predict/describe a structural response in engine operating environments. For example, these include but are not limited to: multi-factor models for material behavior, multi-scale composite mechanics, general purpose structural analysis, progressive structural fracture for evaluating durability and integrity, noise and acoustic fatigue, emission requirements, hot fluid mechanics, heat-transfer and probabilistic simulations. Many of these, as well as others, are encompassed in an integrated computer code identified as Engine Structures Technology Benefits Estimator (EST/BEST) or Multi-faceted/Engine Structures Optimization (MP/ESTOP). The discipline modules integrated in MP/ESTOP include: engine cycle (thermodynamics), engine weights, internal fluid mechanics, cost, mission and coupled structural/thermal, various composite property simulators and probabilistic methods to evaluate uncertainty effects (scatter ranges) in all the design parameters. The objective of the proposed paper is to briefly describe a multi-faceted design analysis and optimization capability for coupled multi-discipline engine structures optimization. Results are presented for engine and aircraft type metrics to illustrate the versatility of that capability. Results are also presented for reliability, noise and fatigue to illustrate its inclusiveness. For example, replacing metal rotors with composites reduces the engine weight by 20 percent, 15 percent noise reduction, and an order of magnitude improvement in reliability. Composite designs exist to increase fatigue life by at least two orders of magnitude compared to state-of-the-art metals.

Chamis, Christos C.↗

NASA NTRS1978

Chemical aspects of the formation of the solar system

Application of Alfven's theory for the formation of the solar system and the constraints imposed by the chemical composition of space materials are discussed with reference to chemical processes involved in the formation of the solar system. Evidence for the chemical properties of the space medium and the chemical consequences of the postulated physical differentiation processes are outlined, and interpretations based on structure and composition of meteorite material are indicated. A large range of topics, including processes involving chemical differentiation, temperature effects, and isotope fractionation, are examined.

Arrhenius, G.↗

NASA NTRS2025

Airports as Energy Nodes Activity Summary

Advanced aircraft concepts that use non-traditional aviation energy storage methods such as batteries or cryogenic hydrogen are in development and expected to enter regular service at airports worldwide within the next decade. The energy needs for these aircraft may quickly overwhelm the existing energy infrastructure at airports, particularly at smaller and more remote facilities. Without energy upgrades, these airports will not be able to host these advanced vehicles, but without the advanced vehicle traffic, these airports will not have the rationale or funding to build up their energy infrastructure. The Airports as Energy Nodes (ÆNodes) activity, a collaboration between the National Aeronautics and Space Administration (NASA) and the National Renewable Energy Laboratory (NREL), was executed to understand and model the energy needs that advanced aircraft concepts may levy on these smaller airports, determine cost-effective approaches to enhance the airport energy infrastructure, and demonstrate the enhanced resilience of these energy infrastructure upgrades to the airport and surrounding community via “digital twin” simulation at relevant energy and dynamic time scales. The ÆNodes team also investigated future reference aircraft designs and materials to enable cryogenic hydrogen storage for aircraft. The ÆNodes team conducted analysis at two U.S. airport partner sites — Winchester Regional Airport in Winchester, Virginia, and Tweed/New Haven Airport in New Haven, Connecticut. The goal of this partnership was to develop data and reference infrastructure designs that could accommodate advanced aircraft in the future at these airports while also enhancing the resiliency of the energy supply to the surrounding airport community, which could be used to capture funding to enable the infrastructure upgrades. Over the course of the study, a method was developed to estimate air traffic requiring advanced energy services over the course of a year using a mix of historical data and companion studies on advanced aircraft transportation networks. The study has concluded at NASA but continues at NREL, who will develop a final report discussing the energy infrastructure upgrades and digital twin results. Preliminary results indicate that unrestricted adoption of advanced battery-electric aircraft may double traffic at these airports and increase peak daily power usage by an order of magnitude, while increase electricity energy needs by a factor of two to four. The infrastructure upgrades necessary to accommodate these increased energy needs could be used to provide enhanced energy services to the airport community to offset the cost and increase the utility of the upgrades, which will be described in the NREL final report.

Airports↗

DOE OSTI2022

Effects of Mechanical Recycling on Carbon Fiber-Based Hybrid Composites

Carbon fiber (CF) reinforced composites are high-performing, highly utilized material systems historically used in aerospace. As the cost of CF decreases, other industries, such as automotive and energy generation, seek to adopt CF composites into their applications. A sudden increase in CF demand may create supply chain issues if the adoption happens without scaling up of the CF production. A solution for reducing the reliance on CF is to substitute some portion of the CF content with another fiber type without significantly reducing the material properties. When multiple reinforcing fillers are introduced into a composite system, the materials system is often referred to as a hybrid composite and in this case a CF-based hybrid composite. To further relieve reliance on CF and with sustainable manufacturing becoming more prominent in industry, mechanical recycling can be employed to replace all or a percentage of the virgin material content. Utilizing recycled content in place of virgin content will further aid in reducing the reliance on virgin CF and decrease overall material costs. Here, the effects of utilizing mechanically recycled feedstocks on the mechanical properties of injection molded samples are explored to understand the feasibility of re-manufacturing recycled CF-based hybrid composites. By determining the mechanical properties and mechanisms in which the properties change through varying recycled content, the assessment of how the material will perform in other manufacturing processes can be inferred. As a result, industry will gain better insight into utilizing mechanically recycled feedstocks to reduce their reliance on the CF supply chain.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Impact of neutron irradiation on the thermophysical properties of additively manufactured stainless steel and inconel

The deployment of additive manufacturing (AM) technologies to support the nuclear energy industry is limited by the current lack of data related to the irradiation performance of AM parts. The Colorado School of Mines is conducting a multi-year irradiation and post irradiation examination project to study the impacts of neutron irradiation on stainless steel 316L and Inconel 718 and 625 specimens produced by several commercially available AM techniques and irradiated in the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL). This paper presents initial results on the impact of neutron irradiation on the heat capacity, the thermal diffusivity, and the thermal conductivity of the specimens at temperatures between 100 oC and 400 oC. The unirradiated AM specimens have heat capacity values similar to, or lower than, the reference values, regardless of manufacturing method or material. The irradiated AM specimens have average heat capacities greater than the unirradiated specimens and reference values in every case. Additionally, the thermal diffusivities of the unirradiated AM specimens are either larger or statistically similar to the reference values. The irradiated AM specimens exhibit lower thermal diffusivities compared to the reference thermal diffusivity values. One of the stainless steel 316L laser powder bed fusion samples exhibited thermal diffusivity values with statistically significant anisotropy prior to and after irradiation. The thermal conductivities of the unirradiated AM stainless steel 316L specimens and the unirradiated Inconel 718 specimens are lower or statistically similar to the reference values. The unirradiated Inconel 625 specimens exhibit slightly higher thermal conductivity values than the reference values. The irradiated specimens show a significant increase in thermal conductivity compared to the unirradiated specimens and the reference values for all materials.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗