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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 577 records · Page 32
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Development of Additive Construction Technologies for Application to Development of Lunar/Martian Surface Structures Using In-Situ Materials

For long-duration missions on other planetary bodies, the use of in situ materials will become increasingly critical. As human presence on these bodies expands, so must the breadth of the structures required to accommodate them including habitats, laboratories, berms, radiation shielding for natural radiation and surface reactors, garages, solar storm shelters, greenhouses, etc. Planetary surface structure manufacturing and assembly technologies that incorporate in situ resources provide options for autonomous, affordable, pre-positioned environments with radiation shielding features and protection from micrometeorites, exhaust plume debris, and other hazards. The ability to use in-situ materials to construct these structures will provide a benefit in the reduction of up-mass that would otherwise make long-term Moon or Mars structures cost prohibitive. The ability to fabricate structures in situ brings with it the ability to repair these structures, which allows for the self-sufficiency and sustainability necessary for long-duration habitation. Previously, under the auspices of the MSFC In-Situ Fabrication and Repair (ISFR) project and more recently, under the jointly-managed MSFC/KSC Additive Construction with Mobile Emplacement (ACME) project, the MSFC Surface Structures Group has been developing materials and construction technologies to support future planetary habitats with in-situ resources. One such additive construction technology is known as Contour Crafting. This paper presents the results to date of these efforts, including development of novel nozzle concepts for advanced layer deposition using this process. Conceived initially for rapid development of cementitious structures on Earth, it also lends itself exceptionally well to the automated fabrication of planetary surface structures using minimally processed regolith as aggregate, and binders developed from in situ materials as well. This process has been used successfully in the fabrication of construction elements using lunar regolith simulant and Mars regolith simulant, both with various binder materials. Future planned activities will be discussed as well.

Werkheiser, Niki J.↗
NASA NTRS1989

Ceramic Honeycomb Structures and Method Thereof

The present invention relates to a method for producing ceramic articles and the articles, the process comprising the chemical vapor deposition (CVD) and/or chemical vapor infiltration (CVI) of a honeycomb structure. Specifically the present invention relates to a method for the production of a ceramic honeycomb structure, including: (a) obtaining a loosely woven fabric/binder wherein the fabric consists essentially of metallic, ceramic or organic fiber and the binder consists essentially of an organic or inorganic material wherein the fabric/binder has and retains a honeycomb shape, with the proviso that when the fabric is metallic or ceramic the binder is organic only; (b) substantially evenly depositing at least one layer of a ceramic on the fabric/binder of step (a); and (c) recovering the ceramic coated fiber honeycomb structure. In another aspect, the present invention relates to a method for the manufacture of a lightweight ceramic-ceramic composite honeycomb structure, which process comprises: (d) pyrolyzing a loosely woven fabric a honeycomb shaped and having a high char yield and geometric integrity after pyrolysis at between about 700 degrees and 1,100 degrees Centigrade; (e) substantially evenly depositing at least one layer of ceramic material on the pyrolyzed fabric of step (a); and (f) recovering the coated ceramic honeycomb structure. The ceramic articles produced have enhanced physical properties and are useful in aircraft and aerospace uses.

Cagliostro, Domenick E.↗
NASA NTRS2014

Origins of the Lunar and Planetary Laboratory, University of Arizona

The roots of the Lunar and Planetary Laboratory (LPL) extend deep into the rich fabric of G. P. Kuiper's view of the Earth as a planet and planetary systems as expected companions to most stars, as well as the post-war emergent technology of infrared detectors suitable for astronomy. These concepts and events began with Kuiper's theoretical work at Yerkes Observatory on the origin of the Solar System, his discovery of two planetary satellites and observational work with his near-infrared spectrometer on the then-new McDonald 82-inch telescope in the mid- to late-1940s. A grant for the production of a photographic atlas of the Moon in the mid-1950s enabled him to assemble the best existing images of the Moon and acquire new photographs. This brought E. A. Whitaker and D. W. G. Arthur to Yerkes. Others who joined in the lunar work were geologist Carl S. Huzzen and grad student E. P. Moore, as well as undergrad summer students A. B. Binder and D. P. Cruikshank (both in 1958). The Atlas was published in 1959, and work began on an orthographic lunar atlas. Kuiper's view of planetary science as an interdisciplinary enterprise encompassing astronomy, geology, and atmospheric physics inspired his vision of a research institution and an academic curriculum tuned to the combination of all the scientific disciplines embraced in a comprehensive study of the planets. Arrangements were made with the University of Arizona (UA) to establish LPL in affiliation with the widely recognized Inst. of Atmospheric Physics. Kuiper moved to the UA in late 1960, taking the lunar experts, graduate student T. C. Owen (planetary atmospheres), and associate B. M. Middlehurst along. G. van Biesbroeck also joined the migration to Tucson; Binder and Cruikshank followed along as new grad students. Astronomy grad student W. K. Hartmann came into the academic program at UA and the research group at LPL in 1961. Senior faculty affiliating with LPL in the earliest years were T. Gehrels, A. B. Meinel, H. L. Johnson, and F. J. Low, each with their own grad students and associates. Work began on IR spectroscopy and a rectified lunar atlas. Kuiper and Johnson started the search for future observatory sites in N. America and Hawaii.

Planets↗
NASA NTRS2016

Additive Manufacturing of Silicon Carbide-Based Ceramic Matrix Composites: Technical Challenges and Opportunities

Advanced SiC-based ceramic matrix composites offer significant contributions toward reducing fuel burn and emissions by enabling high overall pressure ratio (OPR) of gas turbine engines and reducing or eliminating cooling air in the hot-section components, such as shrouds, combustor liners, vanes, and blades. Additive manufacturing (AM), which allows high value, custom designed parts layer by layer, has been demonstrated for metals and polymer matrix composites. However, there has been limited activity on additive manufacturing of ceramic matrix composites (CMCs). In this presentation, laminated object manufacturing (LOM), binder jet process, and 3-D printing approaches for developing ceramic composite materials are presented. For the laminated object manufacturing (LOM), fiber prepreg laminates were cut into shape with a laser and stacked to form the desired part followed by high temperature heat treatments. For the binder jet, processing optimization was pursued through silicon carbide powder blending, infiltration with and without SiC nano powder loading, and integration of fibers into the powder bed. Scanning electron microscopy was conducted along with XRD, TGA, and mechanical testing. Various technical challenges and opportunities for additive manufacturing of ceramics and CMCs will be presented.

ceramic matrix composites↗
NASA NTRS2017

High Performance Composite Dielectric Ink for Ultracapacitors

The present invention is a dielectric ink and means for printing using said ink. Approximately 10-20% of the ink is a custom organic vehicle made of a polar solvent and a binder. Approximately 30-70% of the ink is a dielectric powder having an average particle diameter of approximately 10-750 nm. Approximately 5-15% of the ink is a dielectric constant glass. Approximately 10-35% of the ink is an additional amount of solvent. The ink is deposited on a printing substrate to form at least one printed product, which is then dried and cured to remove the solvent and binder, respectively. The printed product then undergoes sintering in an inert gas atmosphere.

Rolin, Terry D.↗
NASA NTRS2016

Electrostatic Discharge Testing of Carbon Composite Solar Array Panels for the Europa Mission to Jupiter

Carbon composite solar array panel coupons similar to those considered for use on the planned NASA Europa Mission were exposed to energetic electrons to observe the size and rate of electrostatic discharge production. The discharge size and rate were found to be primarily dependent on the quantity of dielectric binder pooled on the surface of the sample. Cooling the samples to cryogenic temperatures increased the size of discharges but an end of mission radiation dose had only minimal effects. Samples were composed of M55J carbon composite impregnated with an RS3 binder. Additional samples tested included a co-cured Kapton surface.

Green, Nelson W.↗
NASA NTRS2019

Additive Manufacturing of Multi-Material Systems for Aerospace Applications

Additive manufacturing methods for producing single materials are rapidly improving. The resulting material properties and microstructures are becoming more comparable to those of conventionally fabricated materials. However, the need for multi-functional and complex structures and components requires additional innovations in manufacturing such as multi-material and hybrid additive manufacturing approaches. Additive manufacturing machines with multiple print capabilities and combinations of AM, machining, and conventional processing methods will further open up design spaces and possibilities. In this presentation, several examples of the needs and methods for multi-material fabrication will be discussed with a focus on aerospace applications. Direct printing of silver coils in conjunction with fused deposition modeling, machined parts, and, binder jetting is being developed for innovative stator designs. Binder jetting of silicon-based materials with powder bed additions is being developed for heat exchanger applications. Additive manufacturing of bi-material systems is being pursued to fabricate lightweight, integrated, multifunctional structures.

multi-materials↗
NASA NTRSDate not supplied

Ultrahigh Mass Loading Batteries with Holey Graphene-Enabled Dry-Pressed Cathode Architectures

Holey graphene is a structural derivative of graphene with arrays of nanometer-sized, through-thickness holes across the lateral surface of the atomically thin nanosheet. It has been widely acknowledged that the presence of holes improves ion transport through the graphene planes, making holey graphene an ideal electrode material for electrochemical energy storage. We recently discovered another unique attribute of holey graphene in that it can be directly compressed from powder into electrode in a single step without the use of solvent or binder. In addition to neat holey graphene electrodes, composite electrodes with holey graphene as an ultralightweight scaffold host filled with various active materials can also be readily prepared in a similar solvent-free and binder-free fashion. The active materials can be metal-containing catalysts for lithium-oxygen batteries, lithium-ion battery electrode materials, or high energy density components such as sulfur. Compared to the conventional slurry-based process, the dry-press method is comparably much more suitable toward the facile and scalable preparation of ultrahigh mass loading electrodes with ultrahigh areal capacities.

holey graphene, cathode scaffold, lithium metal, h↗
NASA NTRSDate not supplied

Development of Aluminum Feedstock for Additive Manufacturing

The rapid evolution of materials science and manufacturing technologies in recent years has offered new pathways to manipulate materials for bespoke manufacturing. Here we aim to develop feedstocks for applications such as radiator panels, fuel tanks, and structural components for outfitting. As a strong, light weight and thermally conductive material aluminum is ideal for these applications. An often-overlooked source of aluminum waste is food packaging used on the International Space Station. Reusing this waste stream will reduce the cost and logistics of regular sparing. In Space Manufacturing (ISM) will utilize this technology is such areas as sparing and outfitting. However, processing aluminum can present challenges, especially in the context of additive manufacturing and sintering, due to its high reactivity and tendency to form a tenacious oxide layer. Identifying appropriate binders and sintering profiles can overcome these challenges. Herein we present our work on obtaining aluminum powder derived from food packaging, binder selection for aluminum feedstock, and a demonstration of bound metal deposition printing.

aluminum↗
DOE OSTI2020

Pelletized immobilized amine sorbent for CO2 capture

The disclosure describes a pelletized sorbent comprising a first component comprising Basic Immobilized Amine Sorbent, a second component comprising inorganic strength additive, and a third component comprising polymer binder, where the Basic Immobilized Amine Sorbent and solid inorganic strength additive are interconnected by the polymer binder. The pelletized sorbent is useful for removing CO2 from a gaseous mixture such as a post combustion gas stream.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Superhydrophobic coating and process of making same

An improved superhydrophobic coating and a process of making it is provided herein. More particularly, a robust superhydrophobic coating is produced by using carbon dioxide to enhance the integration of a binder material into the superhydrophobic coating. The carbon dioxide may be used to infiltrate and fill the interstitial voids of a superhydrophobic material, such as diatomaceous earth. Consequently, occupying these voids in the superhydrophobic material effectively blocks other components (e.g., binders) from entering the voids. As a result, the coating formulations of the present invention are more robust and may strongly adhere to the substrates to which they are applied.

36 MATERIALS SCIENCE↗
DOE OSTI2021

High energy density secondary lithium batteries

A lithium ion battery includes a positive electrode comprising carbon fibers, a binder composition with conductive carbon, and a lithium rich composition. The lithium rich composition comprises at least one selected from the group consisting of Li 1+x (My Mz II Mw III )O 2 where x+y+z+w = 1, and where M, M II and M III are interchangeably manganese, nickel and cobalt, and LiM* 2-x M x * II O 4 , where M* and M* II are manganese and nickel, respectively, with x = 0.5. A negative electrode comprises carbon fibers having bound thereto silicon nanoparticles, and a mesophase pitch derived carbon binder between the silicon nanoparticles and the carbon fibers. An electrolyte is interposed between the positive electrode and the negative electrode. Methods of making positive and negative electrodes are also disclosed.

Nanda, Jagjit↗
DOE OSTI2021

Inkjet-Based 3D Printing: From Quantum Dots to Steel Tools

Inkjet-based additive manufacturing (AM) technologies are highly versatile among manufacturing processes due to their ability to shape any material in powder or ink form. The two inkjet-based AM technologies are binder jetting and material jetting, and as each of their names suggest, the former uses inkjet to deposit binder into the actual build material and the latter uses inkjet to deposit the actual build material. With each of these technologies comes unique opportunities in the form of embedding functional components within the build, creating material gradients within parts by selectively layering feedstocks, shaping non-weldable materials, and creating low-cost tooling with conformal cooling channels. Dr. Amy Elliott at Oak Ridge National Laboratory has explored a variety of materials and approaches with inkjet-based manufacturing technologies, focusing on industry-relevant applications such as injection molding tooling and mining drills.

Elliott, Amy↗
DOE OSTI2021

Electrodes with silicon oxide active materials for lithium ion cells achieving high capacity, high energy density and long cycle life performance

Improved negative electrodes can comprise a silicon based active material blended with graphite to provide more stable cycling at high energy densities. In some embodiments, the negative electrodes comprise a blend of polyimide binder mixed with a more elastic polymer binder with a nanoscale carbon conductive additive. The silicon-based blended graphite negative electrodes can be matched with positive electrodes comprising nickel rich lithium nickel manganese cobalt oxides to form high energy density cells with good cycling properties.

Venkatachalam, Subramanian↗
DOE OSTI2021

Regenerable battery electrode

A binder-free, self-supporting electrode including an electrochemically active material in the absence of a binder and a current collector is claimed. The electrochemically active material is a self-supporting transition metal oxide. A method of regenerating the electrode to restore capacity of the electrode is also claimed.

Takeuchi, Esther Sans↗
DOE OSTI2022

ADDITIVELY MANUFACTURED SURFACE HEAT TRANSFER ENHANCEMENTS FOR THE TRANSFORMATIONAL CHALLENGE REACTOR

The Transformational Challenge Reactor (TCR) is a high-temperature gas-cooled reactor design that uses additively manufactured fuel elements. TCR fuel elements have walls made of silicon carbide and are filled with tristructural-isotropic fuel particles. These fuel elements can have radically different shapes and integrated features than existing designs due to the reduced cost for complex structures in binder jet additive manufacturing. As such, binder jet additive manufacturing enables wall surface features to be embedded that can deliver superior heat transfer performance than smooth wall designs. In this work, the authors conducted a computational fluid dynamics study to evaluate selected wall features integrated into TCR fuel elements. Results show that surface features can outperform smooth wall designs; however, there are unique challenges for gas-cooled reactor core designs that have not been fully explored by previous research. For example, the rough surface finish and process variability of ceramics additive manufacturing make it challenging to predict surface roughness effects before fabrication. Additionally, the small hydraulic diameters of coolant channels in reactor cores make it difficult to engineer surface features that do not significantly increase the pressure drop. Engineers must carefully size surface features for heat transfer enhancement in additive fuel elements to operate above the base material's surface roughness effects and below the coolant channel size.

Weinmeister, Justin↗
DOE OSTI2022

Additive manufacturing of complex objects using refractory matrix materials

A method for the manufacture of a three-dimensional object using a refractory matrix material is provided. The method includes the additive manufacture of a green body from a powder-based refractory matrix material followed by densification via chemical vapor infiltration (CVI). The refractory matrix material can be a refractory ceramic (e.g., silicon carbide, zirconium carbide, or graphite) or a refractory metal (e.g., molybdenum or tungsten). In one embodiment, the matrix material is deposited according to a binder-jet printing process to produce a green body having a complex geometry. The CVI process increases its density, provides a hermetic seal, and yields an object with mechanical integrity. The residual binder content dissociates and is removed from the green body prior to the start of the CVI process as temperatures increase in the CVI reactor. The CVI process selective deposits a fully dense coating on all internal and external surfaces of the finished object.

Terrani, Kurt A.↗