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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 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Joining Dissimilar Materials via Rotational Hammer Riveting Technique

A mechanically robust joining method for Mg/Al and Mg/CFRP could enable multi-material assemblies that decrease vehicle weight while offering more flexibility for designers. However, certain challenges exist for joining Mg/Al and Mg/CFRP. Mechanical joining, such as conventional riveting, clinching and bolting do not form a metallurgical bond between the fastener and metal sheet being fastened. Large differences in physical and mechanical properties of metals and polymers make joining Al or Mg to CFRP challenging via various welding techniques. With solid-state and fusion based welding, rapid formation of brittle intermetallic compounds at the Mg/Al interface lead to interfacial fracture under mechanical loading. In this study, a Rotational Hammer Rivet (RHR) technique was developed to fabricate Mg/CFRP and Mg/Al joints. With RHR technique, direct joining between Mg/Al and Mg/CFRP were replaced by joining Mg rivet head and top Mg sheet. Through heat generated by plastic deformation of an Mg rivet, RHR creates a metallurgical bond between rivet head and Mg sheet which seals corrosive electrolyte from penetrating around the rivet head.

riveting, magnesium alloys, CFRP, Dissimilar Joini↗
NASA NTRS1988

Space erectable radiator system development

The NASA Space Station's Space Erectable Radiator System features modular radiator panels with high-capacity tapered artery heat pipes bonded within their aluminum honeycomb structures. Simple, dry aluminum-to-aluminum thermal contact surfaces are used for the connections, thereby requiring no fluid joints; a uniformly distributed clamping force at the radiator panel-to-thermal transport loop interface heat exchange surface yields high thermal contact conductance as well as minimum area and weight for the requisite performance. The design has been optimized for weight and cost.

Oren, J. A.↗
NASA NTRS2011

Temperature Effects on Adhesive Bond Strengths and Modulus for Commonly Used Spacecraft Structural Adhesives

A study was performed to observe how changes in temperature and substrate material affected the strength and modulus of an adhesive bondline. Seven different adhesives commonly used in aerospace bonded structures were tested. Aluminum, titanium and Invar adherends were cleaned and primed, then bonded using the manufacturer's recommendations. Following surface preparation, the coupons were bonded with the adhesives. The single lap shear coupons were then pull tested per ASTM D 1002 Standard Test Method for Apparent Shear Strength of Single- Lap-Joint over a temperature range from -150 deg C up to +150 deg C. The ultimate strength was calculated and the resulting data were converted into B-basis design allowables. Average and Bbasis results were compared. Results obtained using aluminum adherends are reported. The effects of using different adherend materials and temperature were also studied and will be reported in a subsequent paper. Dynamic Mechanical Analysis (DMA) was used to study variations in adhesive modulus with temperature. This work resulted in a highly useful database for comparing adhesive performance over a wide range of temperatures, and has facilitated selection of the appropriate adhesive for spacecraft structure applications.

structural adhesives testing↗
NASA NTRS2005

Integrity of Polymethylmethacrylate (PMMA) Chemically Welded Joints Examined

NASA Glenn Research Center s Capillary Flow Experiments (CFE) program is developing experiment payloads to explore fluid interfaces in microgravity on the International Space Station. The information to be gained from the CFE is relevant to the design of fluid-bearing systems in which capillary forces predominate, for example in the passive positioning of liquids in spacecraft fuel tanks. To achieve the science goals of CFE, Glenn researchers constructed several types of experiment vessels. One type of vessel, known as the interior corner flow (ICF), will be used to determine important transients for low-gravity liquid management in a two-phase system. Each vessel has a cylindrical fluid reservoir connected to each end of the test chamber by internal transport tubes, each with a quarter-turn shutoff valve (see the following photograph). These multipiece vessels are made from polymethylmethacrylate (PMMA) because of its excellent optical properties (i.e., the fluids can be observed easily in the vessel). Because of the complexity of certain vessels, the test chamber had to be manufactured in pieces and welded chemically. Some past experience with adhesive bonded plastic showed that the experiment fluid degraded the adhesive to the point of failure. Therefore, it was necessary to see if the fluid also degraded the chemically welded PMMA joints.

Lerch, Bradley A.↗
NASA NTRS2006

Active Metal Brazing and Adhesive Bonding of Titanium to C/C Composites for Heat Rejection System

Robust assembly and integration technologies are critically needed for the manufacturing of heat rejection system (HRS) components for current and future space exploration missions. Active metal brazing and adhesive bonding technologies are being assessed for the bonding of titanium to high conductivity Carbon-Carbon composite sub components in various shapes and sizes. Currently a number of different silver and copper based active metal brazes and adhesive compositions are being evaluated. The joint microstructures were examined using optical microscopy, and scanning electron microscopy (SEM) coupled with energy dispersive spectrometry (EDS). Several mechanical tests have been employed to ascertain the effectiveness of different brazing and adhesive approaches in tension and in shear that are both simple and representative of the actual system and relatively straightforward in analysis. The results of these mechanical tests along with the fractographic analysis will be discussed. In addition, advantages, technical issues and concerns in using different bonding approaches will also be presented.

Singh, M.↗
DOE OSTI2022

Metallurgical Joining of immiscible system: Pure Mg and Pure Fe

Understanding the metallurgical joinability of pure Mg and pure Fe and their interfacial microstructure lays the foundation for deciphering the complicated mechanism of joining various magnesium alloys and steels in applications. We first produced a successful metallurgical joint between pure Mg and pure Fe using the friction stir assisted scribe technique. Through detailed characterization, we found that the two immiscible metals are bonded by a critical interfacial oxide layer that spans only ~40 ± 10 nm. We present the first direct experimental evidence of the presence of a Mg/Fe oxide rich interfacial layer using high-resolution electron microscopy and discuss the contribution of oxide formation toward a successful joining mechanism.

Das, Hrishikesh↗
NASA NTRS1999

Friction Stir Welding of SiC/Aluminum Metal Matrix Composites

Friction Stir Welding (FSW) is a new solid state process for joining metals by plasticizing and consolidating materials around the bond line using thermal energy producing from frictional forces. A feasibility study for FSW of Metal Matrix Composites (MMC) was investigated using aluminum 6092 alloy reinforced with 17% SiC particulates. FSW process consists of a special rotating pin tool that is positioned to plunge into the MMC surface at the bond line. As the tool rotates and move forward along the bond line, the material at the bond line is heated up and forced to flow around the rotating tip to consolidate on the tip's backside to form a solid state joint. FSW has the potential for producing sound welds with MMC because the processing temperature occurs well below the melting point of the metal matrix; thereby eliminating the reinforcement-to-matrix solidification defects, reducing the undesirable chemical reactions and porosity problems.

Lee, Jonathan A.↗
DOE OSTI2021

Silicon Dioxide Deposited Using Atmospheric Pressure Plasma Chemical Vapor Deposition for Improved Adhesion and Water Intrusion Resistance for Lightweight Manufacturing

This work aims to demonstrate the barrier coating, and adhesion promoting properties of silica-based coatings deposited using an atmospheric pressure plasma torch (APPT). This is achieved by applying an industrial grade adhesive to silica thin films deposited, on the surfaces to be joined, using atmospheric pressure plasma chemical vapor deposition (APP-CVD), to make single joint lap shear samples of different metal combinations commonly found in lightweight manufacturing such as aluminum and magnesium as well as steel. To deposit these thin films, two separate silicon based organic precursors, hexamethyldisiloxane (HMDSO), and tetraehylorthosilicate (TEOS), are used. Here, samples are bonded using DuPont Betamate 1486 adhesive, and the lap shear results for these films are compared to the lap shear results of a chemically cleaned control using the same adhesive. The APPT uses a microwave power supply and gas mixtures of N 2 and Ar. The adhesion of the films are tested using lap shear, and elevated temperature water soaks are conducted on the joints as well to simulate environmental exposure. Lap shear results from samples with silica thin films max shear stress are 25%-115% increase compared to control samples depending on material. After exposure to water soak the max shear strength of the joints decreased by less than 15%, which demonstrates the films capabilities as a water barrier. Film morphology is examined using Scanning Electron Microscopy (SEM), and the film’s composition and approximate thickness are obtained using Rutherford Backscattering Spectroscopy (RBS).

36 MATERIALS SCIENCE↗
DOE OSTI2022

Experimental studies of a high-gradient X-band welded hard-copper split accelerating structure

We report on recent research on high-gradient radio frequency (RF) accelerating structures indicates that the use of hard copper alloys provides improvement in high gradient performance over annealed copper. Such structures are made by bonding individually manufactured parts. However, there are no well-established bonding techniques that preserve the hardness, surface finish and cleanliness required for high gradient operation. To preserve the copper hardness, RadiaBeam has developed a novel high-gradient split accelerating structure, based on electron beam welding joining technique. This technique provides efficient bonding with strong, clean welds and minimal thermal loading, while maintaining a clean inner RF environment. Our RF design and fabrication methodology limits the small heat affected zone to the outer cavity envelop, with virtually no distortions or thermal loading of critical RF surfaces. It also incorporates provisions to precisely control the gap despite conventional issues with weld joint shrinkage. To date we have manufactured and validated an RF accelerating structure joined by electron-beam welding that incorporates a novel open split design to significantly reduce the assembly complexity and cost. In this paper, we will present the electromagnetic design of this structure, discuss bonding, and present the results of high-power tests, where the accelerating gradients of 140 MV m -1 with surface peak fields of 400 MV m -1 were achieved for flat-top pulse length of 600 ns with an RF breakdown rate of 10 -4 1/(pulsecm).

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Resist! : Sustaining forest carbon sequestration and wood production after insect disturbance

Disturbances from insect pests threaten ecologically and economically important goods and services supplied by forests, including wood production and carbon sequestration. We highlight the factors that influence these services’ resistance, a term quantifying the initial response to disturbance. Insects inflict damage through a range of mechanisms, prompting distinct plant physiological responses that scale to influence ecosystem processes and, with time, goods and services. The degree and timing of tree mortality and defoliation affect the amount of residual vegetation available to support compensatory wood production and influence carbon sequestration by changing rates of detritus-fueled decomposition. Compounding, or sequential, insect attacks may prime a forest for additional disturbance, further eroding wood production and carbon sequestration. Forest management practices that promote biological and structural diversity, and augment or retain limiting biological and nutrient resources, may buffer against the effects of insect pests on wood production and carbon sequestration.

Gough, Christopher M. [Virginia Commonwealth Univ.↗
DOE OSTI2025

Reviving the carbon sink: The influence of moderate wind disturbance in a secondary temperate mixed forest

Global forests are increasingly exposed to climate-driven perturbations, which may in turn alter their climate mitigation potential. As tropical cyclones expand poleward due to climate warming, wind disturbances in temperate forests have become increasingly frequent. The consequences of moderate wind disturbances remain poorly understood, hindering efforts to quantify their role in the global carbon cycle. Here, we used 16 years of continuous eddy covariance and biometric measurements to investigate the impacts of moderate wind disturbances on the structure and carbon sink dynamics of a temperate forest in Northeast China. Following Typhoon Maysak in 2020, the mortality of large trees (particularly the aging pioneer species) increased ninefold, whereas that of small trees decreased by nearly half. Both stand basal area and leaf area index were reduced between 2019 and 2023, with aging pioneer tree species being more vulnerable than mid-to-late species to wind disturbances. Shifts in species composition altered the environmental sensitivity of forest carbon sink function. Unexpectedly, wind disturbances reversed the declining trends in net ecosystem production and ecosystem carbon use efficiency of this secondary forest. A novel composite structural indicator—the standardized leaf area index (the maximum leaf area supported by per basal area of the stand)—provided robust predictions (R 2 > 0.4) of carbon sink dynamics throughout the study period. The selective removal of less efficient pioneer trees accelerated succession and reversed the aging-related decline in forest carbon sink strength and carbon use efficiency. In conclusion, these findings highlight the potential role of moderate wind disturbances in enhancing forest carbon sink function and offer a framework for understanding, assessing, and predicting forest carbon dynamics under increasing disturbance frequencies driven by climate change.

Carbon sink↗
DOE OSTI2026

Deep Learning Reconstruction of Daily Soil CO 2 Efflux Reveals Biogeochemical Insights and Reduces Annual Estimate Uncertainty Despite Limited Daily Predictability

Soil CO 2 efflux is commonly measured monthly or seasonally, leaving daily dynamics poorly resolved and contributing to global estimation uncertainty. We trained a single Long Short-Term Memory (LSTM) model to predict daily soil CO 2 efflux across 82 globally distributed sites in COSORE, with 0.2%–46.9% daily data coverage from 2003 to 2020. Despite using far fewer sites than are typically used to train a single deep learning model, with observations biased toward temperate mesic sites, the LSTM model performed well at approximately one-third of sites, reconstructed nearly 2 decades of daily efflux, and outperformed commonly used approaches for estimating daily efflux when applied to the same data set. Performance was weakest at pronounced peaks and troughs and at non-temperate sites with <1.5 years of observations and irregular data patterns. Nevertheless, annual efflux from reconstructed daily data had <40% error even at underperforming sites, substantially improving estimates derived from monthly and seasonal sampling (maximum errors of 95% and 136%, respectively). Temperature sensitivity (Q 10 ) estimated from reconstructed daily predictions closely matched estimates from daily observations, whereas Q 10 values derived from monthly or seasonal observations deviated substantially, suggesting that coarse temporal sampling may contribute to uncertainty in reported Q 10 values. Consistent daily reconstructions further enabled trend analyses for well-performing, predominantly temperate sites and showed increasing soil CO 2 efflux at most sites from 2003 to 2020, with more variable summer trends. Despite limitations, these results demonstrate the potential of LSTM models to reconstruct daily soil CO 2 efflux and reduce estimation uncertainties from sparse observations.

Smykalov, Valerie [Pennsylvania State University, ↗
DOE OSTI2025

A general framework for nitrogen deposition effects on soil respiration in global forests

Since the Industrial Revolution, human activities have altered atmospheric nitrogen (N) deposition to global forests, affecting carbon dioxide emissions from soils (soil respiration or SR) – one of the largest land-atmosphere carbon fluxes. However, experimental studies have demonstrated both positive and negative effects of N deposition on SR in global forests, leading to debates on how N deposition increases or decreases SR. We developed a framework for generalizing SR responses to N deposition using synthesized data from 168 N addition experiments worldwide and observed SR across the global natural N deposition gradient. The findings indicate that N deposition decreased SR in 2.9% of global forested areas, particularly in eastern China, western Europe, and the eastern USA. However, the net effect of N deposition increased the global forest SR by ~5% (1.7 ± 0.1 PgC yr –1 ). If N pollution could be effectively controlled, global forest SR would decrease, potentially contributing to a reduction in the terrestrial carbon emissions.

Cen, Xiaoyu [National Forestry and Grassland Admin↗
NASA NTRS1982

Materials for advanced turbine engines. Volume 1: Advanced blade tip seal system

Project 3, the subject of this technical report, was structured toward the successful engine demonstration of an improved-efficiency, long-life, tip-seal system for turbine blades. The advanced tip-seal system was designed to maintain close operating clearances between turbine blade tips and turbine shrouds and, at the same time, be resistant to environmental effects including high-temperature oxidation, hot corrosion, and thermal cycling. The turbine blade tip comprised an environmentally resistant, activated-diffussion-bonded, monocrystal superalloy combined with a thin layer of aluminium oxide abrasive particles entrapped in an electroplated NiCr matrix. The project established the tip design and joint location, characterized the single-crystal tip alloy and abrasive tip treatment, and established the manufacturing and quality-control plans required to fully process the blades. A total of 171 blades were fully manufactured, and 100 were endurance and performance engine-tested.

Zelahy, J. W.↗
NASA NTRS1985

Computer-aided design of polymers and composites

This book on computer-aided design of polymers and composites introduces and discusses the subject from the viewpoint of atomic and molecular models. Thus, the origins of stiffness, strength, extensibility, and fracture toughness in composite materials can be analyzed directly in terms of chemical composition and molecular structure. Aspects of polymer composite reliability are considered along with characterization techniques for composite reliability, relations between atomic and molecular properties, computer aided design and manufacture, polymer CAD/CAM models, and composite CAD/CAM models. Attention is given to multiphase structural adhesives, fibrous composite reliability, metal joint reliability, polymer physical states and transitions, chemical quality assurance, processability testing, cure monitoring and management, nondestructive evaluation (NDE), surface NDE, elementary properties, ionic-covalent bonding, molecular analysis, acid-base interactions, the manufacturing science, and peel mechanics.

Kaelble, D. H.↗
DOE OSTI2022

Power Electronics Materials and Bonded Interfaces - Reliability and Lifetime

Wide-bandgap devices have pushed the operational limit of semiconductor devices in automotive power electronics packages to higher temperatures (>200 C). While a higher efficiency can be achieved through the use of wide-bandgap devices, the entire package must be re-designed with components that can withstand the higher temperature limits. Sintered silver and transient liquid phase bonds are potential candidates as bonded materials for use in higher temperatures however, the underlying mechanics of deformation under thermal loads and the resulting failure mechanisms in these materials are not well understood. Accelerated experiments conducted at NREL reveal that high-lead solder joints have better reliability than sintered silver under extreme thermal cycling conditions. Furthermore, efforts to develop a crack propagation model for the high-temperature materials are described.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

An N$\cdots$H$\cdots$N low-barrier hydrogen bond preorganizes the catalytic site of aspartate aminotransferase to facilitate the second half-reaction

Pyridoxal 5'-phosphate (PLP)-dependent enzymes have been extensively studied for their ability to fine-tune PLP cofactor electronics to promote a wide array of chemistries. Neutron crystallography offers a straightforward approach to studying the electronic states of PLP and the electrostatics of enzyme active sites, responsible for the reaction specificities, by enabling direct visualization of hydrogen atom positions. Here we report a room-temperature joint X-ray/neutron structure of aspartate aminotransferase (AAT) with pyridoxamine 5'-phosphate (PMP), the cofactor product of the first half reaction catalyzed by the enzyme. Between PMP N SB and catalytic Lys258 Nζ amino groups an equally shared deuterium is observed in an apparent low-barrier hydrogen bond (LBHB). Density functional theory calculations were performed to provide further evidence of this LBHB interaction. The structural arrangement and the juxtaposition of PMP and Lys258, facilitated by the LBHB, suggests active site preorganization for the incoming ketoacid substrate that initiates the second half-reaction.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗