Results for “Advanced Structures and Materials” — Page 35

NASA NTRS2017

Predictive Modeling of Fast-Curing Thermosets in Nozzle-Based Extrusion

This work presents an approach to modeling the dynamic spreading and curing behavior of thermosets in nozzle-based extrusions. Thermosets cover a wide range of materials, some of which permit low-temperature processing with subsequent high-temperature and high-strength working properties. Extruding thermosets may overcome the limited working temperatures and strengths of conventional thermoplastic materials used in additive manufacturing. This project aims to produce technology for the fabrication of thermoset-based structures leveraging advances made in nozzle-based extrusion, such as fused deposition modeling (FDM), material jetting, and direct writing. Understanding the synergistic interactions between spreading and fast curing of extruded thermosetting materials will provide essential insights for applications that require accurate dimensional controls, such as additive manufacturing [1], [2] and centrifugal coating/forming [3]. Two types of thermally curing thermosets -- one being a soft silicone (Ecoflex 0050) and the other being a toughened epoxy (G/Flex) -- served as the test materials in this work to obtain models for cure kinetics and viscosity. The developed models align with extensive measurements made with differential scanning calorimetry (DSC) and rheology. DSC monitors the change in the heat of reaction, which reflects the rate and degree of cure at different crosslinking stages. Rheology measures the change in complex viscosity, shear moduli, yield stress, and other properties dictated by chemical composition. By combining DSC and rheological measurements, it is possible to establish a set of models profiling the cure kinetics and chemorheology without prior knowledge of chemical composition, which is usually necessary for sophisticated mechanistic modeling. In this work, we conducted both isothermal and dynamic measurements with both DSC and rheology. With the developed models, numerical simulations yielded predictions of diameter and height of droplets, along with width and height of extruded lines cured at varied temperatures. Experimental results carried out on a goniometric platform and a nozzle-based 3D printer showed agreement with the numerical simulations. Finally, this presentation will show how the models are adaptable to the planning of tool paths and designs in additive manufacturing.

Xie, Jingjin↗

DOE OSTI2024

Integrating crystallographic and computational approaches to carbon-capture materials for the mitigation of climate change

Here, this article presents an overview of the current state of the art in the structure determination of microporous carbon-capture materials, as discussed at the recent NIST workshop “Integrating Crystallographic and Computational Approaches to Carbon-Capture Materials for the Mitigation of Climate Change”. The continual rise in anthropogenic CO 2 concentration and its effect on climate change call for the implementation of carbon capture technologies to reduce the CO 2 concentration in the atmosphere. Porous solids, including metal–organic frameworks (MOFs), are feasible candidates for gas capture and storage applications. However, determining the structure of these materials represents a significant obstacle in their development into advanced sorbents. The existing difficulties can be overcome by integrating crystallographic methods and theoretical modeling. The workshop gathered experimentalists and theorists from academia, government, and industry to review this field and identify approaches, including collaborative opportunities, required to develop tools for rapid determination of the structures of porous solid sorbents and the effect of structure on the carbon capture performance. We highlight the findings of that workshop, especially in the need for reference materials, standardized procedures and reporting of sorbent activation and adsorption measurements, standardized reporting of theoretical calculations, and round-robin structure determination.

36 MATERIALS SCIENCE↗

NASA NTRS1985

Advanced research and technology programs for advanced high-pressure oxygen-hydrogen rocket propulsion

A research and technology program for advanced high pressure, oxygen-hydrogen rocket propulsion technology is presently being pursued by the National Aeronautics and Space Administration (NASA) to establish the basic discipline technologies, develop the analytical tools, and establish the data base necessary for an orderly evolution of the staged combustion reusable rocket engine. The need for the program is based on the premise that the USA will depend on the Shuttle and its derivative versions as its principal Earth-to-orbit transportation system for the next 20 to 30 yr. The program is focused in three principal areas of enhancement: (1) life extension, (2) performance, and (3) operations and diagnosis. Within the technological disciplines the efforts include: rotordynamics, structural dynamics, fluid and gas dynamics, materials fatigue/fracture/life, turbomachinery fluid mechanics, ignition/combustion processes, manufacturing/producibility/nondestructive evaluation methods and materials development/evaluation. An overview of the Advanced High Pressure Oxygen-Hydrogen Rocket Propulsion Technology Program Structure and Working Groups objectives are presented with highlights of several significant achievements.

Marsik, S. J.↗

NASA NTRS1985

Advanced research and technology program for advanced high pressure oxygen-hydrogen rocket propulsion

A research and technology program for advanced high pressure, oxygen-hydrogen rocket propulsion technology is presently being pursued by the National Aeronautics and Space Administration (NASA) to establish the basic discipline technologies, develop the analytical tools, and establish the data base necessary for an orderly evolution of the staged combustion reusable rocket engine. The need for the program is based on the premise that the USA will depend on the Shuttle and its derivative versions as its principal Earth-to-orbit transportation system for the next 20 to 30 yr. The program is focused in three principal areas of enhancement: (1) life extension, (2) performance, and (3) operations and diagnosis. Within the technological disciplines the efforts include: rotordynamics, structural dynamics, fluid and gas dynamics, materials fatigue/fracture/life, turbomachinery fluid mechanics, ignition/combustion processes, manufacturing/producibility/nondestructive evaluation methods and materials development/evaluation. An overview of the Advanced High Pressure Oxygen-Hydrogen Rocket Propulsion Technology Program Structure and Working Groups objectives are presented with highlights of several significant achievements.

Marsik, S. J.↗

NASA NTRSDate not supplied

Testbed for Lunar Extreme Environment Wear Tolerant Applications

The abrasive dust from lunar regolith poses significant long-term durability and performance challenges to materials, vehicles, mechanisms and structures that will be used for the next generation of lunar exploration. The development of advanced materials, coatings and device technologies that can withstand these abrasive particles and extreme environmental conditions is critical. However, the lack of standardized and accessible methods for evaluating such materials and devices in a facsimile of the harsh lunar environment hinders progress in dust-tolerant technologies. To address this challenge, NASA Langley Research Center is creating an extreme environment testbed. This reconfigurable testbed will allow rapid, repeatable wear testing of material and candidate mechanisms under vacuum conditions, facilitating the development of critical materials technologies for lunar exploration. Preliminary results from exposing an actuating mechanism similar to a pin joint to lunar regolith simulant under high vacuum are reported.

lunar dust↗

NASA NTRSDate not supplied

Testbed for Lunar Extreme Environment Wear Tolerant Applications

The abrasive dust from lunar regolith poses significant long-term durability and performance challenges to materials, vehicles, mechanisms and structures that will be used for the next generation of lunar exploration. The development of advanced materials, coatings and device technologies that can withstand these abrasive particles and extreme environmental conditions is critical. However, the lack of standardized and accessible methods for evaluating such materials and devices in a facsimile of the harsh lunar environment hinders progress in dust-tolerant technologies. To address this challenge, NASA Langley Research Center is creating an extreme environment testbed. This reconfigurable testbed will allow rapid, repeatable wear testing of material and candidate mechanisms under vacuum conditions, facilitating the development of critical materials technologies for lunar exploration. Preliminary results from exposing an actuating mechanism similar to a pin joint to lunar regolith simulant under high vacuum are reported.

lunar dust↗

NASA NTRSDate not supplied

Testbed for Lunar Extreme Environment Wear Tolerant Applications

The abrasive dust from lunar regolith poses significant long-term durability and performance challenges to materials, vehicles, mechanisms and structures that will be used for the next generation of lunar exploration. The development of advanced materials, coatings and device technologies that can withstand these abrasive particles and extreme environmental conditions is critical. However, the lack of standardized and accessible methods for evaluating such materials and devices in a facsimile of the harsh lunar environment hinders progress in dust-tolerant technologies. To address this challenge, NASA Langley Research Center is creating an extreme environment testbed. This reconfigurable testbed will allow rapid, repeatable wear testing of material and candidate mechanisms under vacuum conditions, facilitating the development of critical materials technologies for lunar exploration. Preliminary results from exposing an actuating mechanism similar to a pin joint to lunar regolith simulant under high vacuum are reported.

lunar dust↗

NASA NTRS1994

A CMC database for use in the next generation launch vehicles (rockets)

Ceramic matrix composites (CMC's) are being envisioned as the state-of-the-art material capable of handling the tough structural and thermal demands of advanced high temperature structures for programs such as the SSTO (Single Stage to Orbit), HSCT (High Speed Civil Transport), etc. as well as for evolution of the industrial heating systems. Particulate, whisker and continuous fiber ceramic matrix (CFCC) composites have been designed to provide fracture toughness to the advanced ceramic materials which have a high degree of wear resistance, hardness, stiffness, and heat and corrosion resistance but are notorious for their brittleness and sensitivity to microscopic flaws such as cracks, voids and impurity.

Mahanta, Kamala↗

DOE OSTI2024

Design Methods, Tools, and Data for Ceramic Solar Receivers

This report presents the development of tools and methods for evaluating the reliability and performance of ceramic materials in high temperature solar receivers. As Concentrating Solar Power (CSP) technologies aim for higher operating temperatures to enhance efficiency and meet industrial process heat requirements, current high temperature metallic materials face challenges in maintaining structural integrity. This report explores advanced ceramics as a promising alternative, given their superior high temperature strength and lower thermal expansion, compared to metals. To address the need for effective ceramic receiver design tools, this report integrates statistical failure models of ceramics into the existing srlife tool: an open-source software package designed to estimate the life of high temperature CSP components. These failure models account for the inherent variability and flaw distribution in ceramics, as well as the impact of subcritical crack growth under high temperature cyclic loads. The report also presents experimental data collected for a commercially available ceramic material, SiC, and details the process of estimating reliability model parameters from these data. A comparative design analysis is then performed between ceramic (SiC) and metallic (current nickel-based superalloys A740H and A282) receiver. This comparison demonstrates that SiC receivers can achieve service life exceeding 30 years under high incident heat flux conditions, compared to just a few years for metallic receivers.

14 SOLAR ENERGY↗

DOE OSTI2022

Development of Lightweight Structural Materials with Improved Properties for Fission Batteries

Fission batteries require lightweight structural materials that demonstrate structural resilience when subjected to repeated shutdown, transportation, startup cycles, and certain external conditions, including rare events such as seismic vibrations and tsunamis. The objectives of this project are (1) to produce lightweight structural materials whose strength-to-weight ratios and fatigue resistance exceed those of current widely used structural materials such as 316 stainless steels (SS316), and (2) to enhance radiation tolerance of structural materials over a suitable service temperature range. To achieve these, (1) a lattice structure will be produced, (2) advanced modeling and simulation tools will be employed to design lattice structures (e.g., a gyroid structure) that reduce stress concentrations and thus increase fatigue resistance, and (3) one-dimensional (1-D) carbon nanotubes will be added to enhance radiation resistance. To validate our solution, high-temperature tensile and fatigue testing, in combination with microstructure characterization, will be conducted on wrought materials, additively manufactured solid materials, and the designed lightweight lattice structure material. Ion irradiation, microstructure characterization, and nanoindentation will be carried out to investigate the effect of 1-D carbon nanotubes on radiation tolerance. Successful completion of this project will deliver a material to serve as a substitute for current SS316 using the same chemistry but with lighter weight and improved mechanical properties. In addition, a material with carbon nanotubes can be designed for improved radiation tolerance over a suitable service temperature range. This project will establish new techniques in innovative materials/lattice design, advanced macroscale properties prediction, and the application of state-of-the-art processes.

36 MATERIALS SCIENCE↗

NASA NTRS1988

Hydrogen and advanced aerospace materials

The hydrogen embrittlement is briefly reviewed and discussed in terms of specific structural materials considered for use on a generic, hydrogen-fueled, hypersonic aerospace vehicle. A few unusual hydrogen-material incompatibility concerns are identified and some solution methodologies are discussed that could potentially lessen these concerns.

Nelson, Howard G.↗

NASA NTRS2004

Advanced Ceramic Matrix Composites with Multifunctional and Hybrid Structures

Ceramic matrix composites are leading candidate materials for a number of applications in aeronautics, space, energy, and nuclear industries. Potential composite applications differ in their requirements for thickness. For example, many space applications such as "nozzle ramps" or "heat exchangers" require very thin (< 1 mm) structures whereas turbine blades would require very thick parts (> or = 1 cm). Little is known about the effect of thickness on stress-strain behavior or the elevated temperature tensile properties controlled by oxidation diffusion. In this study, composites consisting of woven Hi-Nicalon (trademark) fibers a carbon interphase and CVI SiC matrix were fabricated with different numbers of plies and thicknesses. The effect of thickness on matrix crack formation, matrix crack growth and diffusion kinetics will be discussed. In another approach, hybrid fiber-lay up concepts have been utilized to "alloy" desirable properties of different fiber types for mechanical properties, thermal stress management, and oxidation resistance. Such an approach has potential for the C(sub I)-SiC and SiC(sub f)-SiC composite systems. CVI SiC matrix composites with different stacking sequences of woven C fiber (T300) layers and woven SiC fiber (Hi-Nicalon (trademark)) layers were fabricated. The results will be compared to standard C fiber reinforced CVI SiC matrix and Hi-Nicalon reinforced CVI SiC matrix composites. In addition, shear properties of these composites at different temperatures will also be presented. Other design and implementation issues will be discussed along with advantages and benefits of using these materials for various components in high temperature applications.

Singh, Mrityunjay↗

DOE OSTI2020

Gel Electrocatalysts: An Emerging Material Platform for Electrochemical Energy Conversion

Not provided.

Chemistry↗

NASA NTRS1982

Validation of structural analysis methods using the in-house liner cyclic rigs

Test conditions and variables to be considered in each of the test rigs and test configurations, and also used in the validation of the structural predictive theories and tools, include: thermal and mechanical load histories (simulating an engine mission cycle; different boundary conditions; specimens and components of different dimensions and geometries; different materials; various cooling schemes and cooling hole configurations; several advanced burner liner structural design concepts; and the simulation of hot streaks. Based on these test conditions and test variables, the test matrices for each rig and configurations can be established to verify the predictive tools over as wide a range of test conditions as possible using the simplest possible tests. A flow chart for the thermal/structural analysis of a burner liner and how the analysis relates to the tests is shown schematically. The chart shows that several nonlinear constitutive theories are to be evaluated.

Thompson, R. L.↗

DOE OSTI2023

Advances in imaging, scattering, spectroscopy, and machine learning-aided approaches for multiscale characterization of cementitious systems

Recent progress in methods used in the multiscale characterization of cementitious systems is reviewed, focusing on advances in imaging, scattering, and spectroscopy. The review includes relevant applications and developments in machine learning and other data analytics approaches to enhance characterization. Developments in imaging using light and electron microscopy as well as x-ray (i.e., from synchrotron) methods are summarized. Updates include scanning electron microscopy (SEM), transmission electron microscopy (TEM), tomography, and holography. A critical overview of spectroscopy (e.g., MAS NMR, Raman) and scattering (e.g., neutron, x-ray, synchrotron x-ray) methods is provided, and the intersection of these with imaging is developed (e.g., Raman imaging). Additionally, the paper summarizes recent developments in and implementations of state-of-the-art machine-learning algorithms and data analytics methods for automated, systematic, and/or quantitative analyses of image data sets. The review considers but is not limited to the application of these methods for investigating the hydration and microstructure development of cement phases, low-carbon-footprint cements (e.g., limestone calcined clay cements, LC3), environmental interactions (e.g., ASR) and model systems. Finally, the present work provides a critical presentation of advances in characterization methods that link together the composition and multiscale structure of cementitious materials.

42 ENGINEERING↗

DOE OSTI2022

Exploring superconductivity at the edge of magnetic or structural instabilities

Modern research of condensed matters devotes in understanding how properties of complex solids are determined by their structural and electronic degrees of freedom. In the last decade, the discovery of Fe-based high-temperature superconductors as well as the discovery of protected surface state in bulk materials arising from the non-trivial topological electronic structures have brought revolutionary breakthroughs, advancing our understanding of the interplay of structure, band topology, spin and charge degrees of freedom to a new level. Despite the exciting progresses, significant materials challenges remain. To address such challenges, our research funded by this award focuses on the design, synthesis and property characterization of two types of quantum materials. One is quasi-two-dimensional materials with structural/magnetic instability, the other is topological materials, especially the “ideal” ones where only minimum non-trivial bands exist at the Fermi level. The objective of our research is to design quantum materials that lie at the edge of structural/magnetic instabilities as well as the ones with non-trivial band topology, aiming at the discovery of quantum materials with emergent phenomena and the in-depth understanding of the entanglement of band topology and various degrees of freedoms through thermodynamic, transport, X-ray, and neutron measurements.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Review of Layered Transition Metal Oxide Materials for Cathodes in Sodium-Ion Batteries

The growing interest in sodium-ion batteries (SIBs) is driven by scarcity and the rising costs of lithium, coupled with the urgent need for scalable and sustainable energy storage solutions. Among various cathode materials, layered transition metal oxides have emerged as promising candidates due to their structural similarity to lithium-ion battery (LIB) counterparts and their potential to deliver high energy density at reduced costs. However, significant challenges remain, including limited capacity at high charge/discharge rates and structural instability during extended cycling. Addressing these issues is critical for advancing SIB technology toward industrial applications, particularly for large-scale energy storage systems. This review provides a comprehensive analysis of layered sodium transition metal oxides, focusing on their structural properties, electrochemical performance, and degradation mechanisms. Special attention is given to the intrinsic and extrinsic factors contributing to their instability, such as structural phase transitions, and cationic/anionic redox behavior. Additionally, recent advancements in material design strategies, including doping, surface modifications, and composite formation, are discussed to highlight the progress toward enhancing the stability and performance of these materials. This work aims to bridge the knowledge gaps and inspire further innovations in the development of high-performance cathodes for sodium-ion batteries.

Ahangari, Mehdi (ORCID:0000000345803969)↗

DOE OSTI2020

Initial development of a method for correlating indentation test results to damage accumulation in high temperature structural materials

This report describes an experimental approach based on microindentation creep or relaxation tests for assessing the remaining creep life of a sample material. The objective for this experimental program is to complement the development of passively loaded in situ surveillance specimens. These surveillance specimens could be placed in future advanced reactors to assess the degradation of structural properties, primary creep and creep-fatigue life, when the material is exposed to actual reactor operating conditions. The specimens and the corresponding indentation test protocol could form the basis of a structural health monitoring program designed to ensure the safe continued operation of the component given the relatively unknown effect of the reactor coolant chemistry, radiation exposure, and other environmental effects on the material properties of the constituent structural materials.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗