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DOE OSTI2024

Additive Manufacturing with Cellulose-Based Composites: Materials, Modeling, and Applications

Recent advances in large-scale additive manufacturing (AM) with polymer-based composites have enabled efficient production of high-performance materials. Cellulose nanomaterials (CNMs) have emerged as bio-based feedstocks due to their exceptional strength and sustainability. However, challenges such as hornification and poor dispersion in polymer matrices still limit large-scale CNM–polymer composite manufacturing, requiring novel strategies. Here, this review outlines an approach starting with atomic-level simulations to link molecular composition to key parameters like bulk density, viscosity, and modulus. These simulations provide data for finite element analysis (FEA), which informs large-scale experiments and reduces the need for extensive trials. The strategy explores how atomic interactions impact the morphology, adhesion, and mechanical properties of CNM-based composites in AM processes. The review also discusses current developments in AM, along with predictions of mechanical and thermal properties for structural applications, packaging, flexible electronics, and hydrogel scaffolds. By integrating experimental findings with molecular dynamics (MD) simulations and finite element modeling (FEM), valuable insights for material design, process optimization, and performance enhancement in CNM-based AM are provided to address ongoing challenges.

36 MATERIALS SCIENCE↗

NASA NTRS2007

The Use of Tribocharging in the Electrostatic Beneficiation of Lunar Simulant

Any future lunar base and habitat must be constructed from strong dense materials in order to provide for thermal and radiation protection. Lunar soil may meet this need. Lunar regolith has high concentrations of aluminum, silicon, calcium, iron, sodium, and titanium oxides. Refinement or enrichment of specific minerals in the soil before it is chemically processed may be more desirable as it would reduce the size and energy requirements required to produce the virgin material and it may significantly reduce the process' complexity. Also, investigations into the potential production of breathable oxygen from oxidized mineral components are a major research initiative by NASA. In this study. the objective was to investigate the use of tribocharging to charge lunar simulants and pass them through a parallel plate separator to enrich different mineral fractions. This technique takes advantage of the high Lunar vacuum in which much higher voltages can be used on the separation plates than in air. Additionally, the Lunar g1avity, only being 1/6 that of Earth, allows the particles more separation time between the plates and therefore enhances separation. For the separation studies, two lunar stimulants were used. The first simulant was created in-house, labeled KSC-1. using commercially supplied (sieved to 325 mesh) materials, and was composed of 40 wt. % feldspar ((Na,K,Ca)AlSi3O8;SiO2), 40 wt. % olivine ((Mg,Fe)2SiO4), 10 wt. % ilmenite (FeTiO3). and 10 wt. % spodumene (LiAlSi2O6) (pyroxene). The advantage of the in-house mixture is that the composition can he varied to simulate different soil compositions from different areas on the moon. This simulant was used to show proof-of-concept using the designed separator in air. The second stimulant was JSC-1. used for the vacuum experiments. JSC-1 is principally basalts, containing phases of plagioclase. pyroxene. olivine, and ilmenite. The JSC-1 was sieved to provide a 50-75 micron size range to correlate with the mean grain size found on the moon's surface [1]. Four different materials were investigated for the triboelectrification process; aluminum, copper. stainless steel, and PTFE. These materials were selected because they offer a wide variation in work functions (aluminum 4.28 eV, copper 4.65 eV. stainless steel 5.04 eV, and PTFE 5.75 eV). The difference between the work function of each material and the simulant influences the charge obtained by the grains. Each simulant was analyzed before and after separation using X-ray Photoelectron Spectroscopy (XPS) to determine mineral surface composition. In addition. Raman spectroscopy was performed on the JSC-1 before and after separation in vacuum to determine the mineral composition. Charge-to-mass (Q/M) measurements were performed using a fluidizing bed in air and passing the simulant through a static mixer of a particular material and collecting it in a Faraday pail grounded through an electrometer. To measure the Q/M in vacuum, a special device was constructed consisting of a heater/shaker cup that fed into a solid block of material (either PTFE, copper, or aluminum) in which a channel composed of a "zig-zag" series of inclines greater than 50 degrees has been cut. The voltage to the vibrating motor can be varied to control the amount of simulant passing through the channel. Figure I shows the Q/M measurements for JSC-1 tribocharged using the static mixers and the incline plane chargers in air, and the incline plane chargers in vacuum.

Trigwell, S.↗

DOE OSTI2020

Size effect in stainless steel thin wires under tension

Miniaturization of modern devices drives the exploration into how materials behave in small dimensions. However, the mechanical behaviors of micro-scale specimens under varied loading conditions are still challenging to characterize and predict. In this work, specimen size-dependent weakening effect was experimentally revealed in 316L stainless steel thin wires under tension with wire diameter decreasing from 200 μm down to 61 μm. The underlying mechanisms were primarily associated with surface grain softening and strain localization, which were largely dependent on the number of grains across wire diameter. Through an analog composite model with surface and interior grains that follows the Hall-Petch relation, the extent of surface grain softening was found to coincide with the flow stress reduction due to lack of boundary strengthening. Further using elasto-plastic self-consistent polycrystal modeling, the stress-strain behaviors of interior and surface grains were well described in analogy to those of bulk materials with similar-size grains and extremely large grains, respectively. Subsequently, the analog composite model well simulated the specimen size-dependent weakening effect under tension. This article provided more insights into the size effect exploration and proposed a practical model for describing size-dependent mechanical behaviors of small-scale materials to be applied to miniaturized devices.

316L stainless steel↗

NASA NTRS1994

Climatic, eustatic, and tectnoic controls on Quarternary deposits and landforms, Red Sea coast, Egypt

The degree to which local climatic variations, eustatic sea level fluctuations, and tectonic uplift have influenced the development of Quaternary marine and fluvial landforms and deposits along the Red Sea coast, Eastern Desert, was investigated using a combination of remote sensing and field data, age determinations of corals, and numerical simulations. False color composites generated from Landsat Thematic Mapper and SPOT image data, digital elevation models derived from sterophotogrammetric analysis of SPOT data, and field observations document that a approximately 10-km wide swath inland from the coast is covered in many places with coalescing alluvial fans of Quaternary age. Wadis cutting through the fans exhibit several pairs of fluvial terraces, and wadi walls expose alluvium interbedded with corraline limestone deposits Further, three distinct coral terraces are evident along the coatline. Climatic, eustatic, and tectonic uplift controls on the overall system were simulated using a cellular automata algorithm with the following characteristics: (1) uplift as a function of position and time, as defined by the elevations and ages of corals; (2) climatic variations driven by insolation changes associated with Milankovitch cycles; (3) sea level fluctuations based on U/Th ages of coral terraces and eustatic data; and (4) parametrized fluvial erosion and deposition. Results imply that the fans and coralline limestones were generated in a setting in which the tectonic uplift rate decreased over the Quarternary to negligible values at present. Coralline limestones formed furing eustatic highstands when alluvium was trapped uspstream and wadis filled with debris. During lowstands, wadis cut into sedimentary deposits; coupled with continuing uplift, fans were dissected, leaving remnant surfaces, and wadi-related terraces were generated by down cutting. Only landforms from the past three to four eustatic sea level cycles (i.e., approximately 300 to 400 kyr) are likely to have survived erosion and deposition associated with fluvial processes.

Arvidson, Raymond↗

NASA NTRS1991

Probabilistic micromechanics for metal matrix composites

A probabilistic micromechanics-based nonlinear analysis procedure is developed to predict and quantify the variability in the properties of high temperature metal matrix composites. Monte Carlo simulation is used to model the probabilistic distributions of the constituent level properties including fiber, matrix, and interphase properties, volume and void ratios, strengths, fiber misalignment, and nonlinear empirical parameters. The procedure predicts the resultant ply properties and quantifies their statistical scatter. Graphite copper and Silicon Carbide Titanlum Aluminide (SCS-6 TI15) unidirectional plies are considered to demonstrate the predictive capabilities. The procedure is believed to have a high potential for use in material characterization and selection to precede and assist in experimental studies of new high temperature metal matrix composites.

Engelstad, S. P.↗

DOE OSTI2016

Simulating the Cranfield geological carbon sequestration project with high-resolution static models and an accurate equation of state

In this study, a field-scale carbon dioxide (CO 2 ) injection pilot project was conducted as part of the Southeast Regional Sequestration Partnership (SECARB) at Cranfield, Mississippi. We present higher-order finite element simulations of the compositional two-phase CO 2 -brine flow and transport during the experiment. High- resolution static models of the formation geology in the Detailed Area Study (DAS) located below the oil- water contact (brine saturated) are used to capture the impact of connected flow paths on breakthrough times in two observation wells. Phase behavior is described by the cubic-plus-association (CPA) equation of state, which takes into account the polar nature of water molecules. Parameter studies are performed to investigate the importance of Fickian diffusion, permeability heterogeneity, relative permeabilities, and capillarity. Simulation results for the pressure response in the injection well and the CO 2 breakthrough times at the observation wells show good agreement with the field data. For the high injection rates and short duration of the experiment, diffusion is relatively unimportant (high P clet numbers), while relative permeabilities have a profound impact on the pressure response. High-permeability pathways, created by fluvial deposits, strongly affect the CO 2 transport and highlight the importance of properly characterizing the formation heterogeneity in future carbon sequestration projects.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2019

Observation and Implications of Composition Inhomogeneity Along Grain Boundaries in Thin Film Polycrystalline CdTe Photovoltaic Devices

Abstract Leading photovoltaic technologies such as multicrystalline Si, CdTe, Cu(In,Ga)Se 2 , and lead halide perovskites are polycrystalline, yet achieve relatively high performance. At the moment polycrystalline photovoltaic technologies stand at a juncture where further advances in device performance and reliability necessitate additional characterization and modeling to include nanoscale property variations. Properties and implications of grain boundaries are previously studied, yet chemistry variations along individual grain boundaries and its implications are not yet fully explored. Here, the effects of bromine etching of CdTe absorber layers on the nanoscale chemistry are reported. Bromine etching is commonly used for improving CdTe back contacts, yet it removes both cadmium and chlorine along grain boundaries to depths closer to 1 µm. 2D device simulations reveal these composition modifications limit photovoltaic performance. Since grain boundaries and their intersections with surfaces and interfaces are universal to thin film photovoltaics, these findings call for similar studies in each of the photovoltaic technologies to further enable advances.

Misra, Sudhajit↗

NASA NTRS2017

A Model-Based, Bayesian Solution for Characterization of Complex Damage Scenarios in Aerospace Composite Structures

Ultrasonic damage detection and characterization is commonly used in nondestructive evaluation (NDE) of aerospace composite components. In recent years there has been an increased development of guided wave based methods. In real materials and structures, these dispersive waves result in complicated behavior in the presence of complex damage scenarios. Model-based characterization methods utilize accurate three dimensional finite element models (FEMs) of guided wave interaction with realistic damage scenarios to aid in defect identification and classification. This work describes an inverse solution for realistic composite damage characterization by comparing the wavenumber-frequency spectra of experimental and simulated ultrasonic inspections. The composite laminate material properties are first verified through a Bayesian solution (Markov chain Monte Carlo), enabling uncertainty quantification surrounding the characterization. A study is undertaken to assess the efficacy of the proposed damage model and comparative metrics between the experimental and simulated output. The FEM is then parameterized with a damage model capable of describing the typical complex damage created by impact events in composites. The damage is characterized through a transdimensional Markov chain Monte Carlo solution, enabling a flexible damage model capable of adapting to the complex damage geometry investigated here. The posterior probability distributions of the individual delamination petals as well as the overall envelope of the damage site are determined.

H. Reed↗

DOE OSTI2019

Materials design of perovskite solid solutions for thermochemical applications

Perovskites are excellent candidate materials as oxygen carriers in thermochemical processes. Due to their versatile composition, it is possible to fine-tune the perovskite's properties. Here, we present a method for the rational design of AMO 3– δ perovskite solid solutions with two different species on the Msite in order to tune their redox behavior. To account for the different ionic radii of different transition metal species M, two distinct ions are used in a solid solution on the A site, allowing tolerance-factor adjusted materials design. Using this methodology, we can create stable perovskites over a large range of different compositions. Leveraging the infrastructure of Materials Project, we calculate redox enthalpies for the reduction of over 240 of these $(\text {A}^{\prime}_x\text {A}^{\prime\prime}_{1-x})(\text {M}^{\prime}_y\text {M}^{\prime\prime}_{1-y})$O 3 perovskites to their brownmillerite phases based on density functional theory (DFT). We compare this data to experimentally measured data on thermodynamics of 24 of these materials to verify our theoretical framework. An empirical model is formulated for predicting the enthalpy and entropy changes as a function of the perovskites non-stoichiometry δ , which can be used to simulate the equilibrium composition as a function of temperature and oxygen partial pressure and to create a perovskite search engine based on an energetic analysis of the redox cycles. The data has been added as a contribution to MPContribs, which now includes publicly available user-controlled interactive graphs based on our theoretical and experimental data.

36 MATERIALS SCIENCE↗

NASA NTRS1984

ICAN: Integrated composites analyzer

The ICAN computer program performs all the essential aspects of mechanics/analysis/design of multilayered fiber composites. Modular, open-ended and user friendly, the program can handle a variety of composite systems having one type of fiber and one matrix as constituents as well as intraply and interply hybrid composite systems. It can also simulate isotropic layers by considering a primary composite system with negligible fiber volume content. This feature is specifically useful in modeling thin interply matrix layers. Hygrothermal conditions and various combinations of in-plane and bending loads can also be considered. Usage of this code is illustrated with a sample input and the generated output. Some key features of output are stress concentration factors around a circular hole, locations of probable delamination, a summary of the laminate failure stress analysis, free edge stresses, microstresses and ply stress/strain influence coefficients. These features make ICAN a powerful, cost-effective tool to analyze/design fiber composite structures and components.

Murthy, P. L. N.↗

NASA NTRS1984

ICAN - Integrated composites analyzer

Murthy, P. L. N.↗

NASA NTRS2022

Improved Global Wetland Carbon Isotopic Signatures Support Post-2006 Microbial Methane Emission Increase

Atmospheric concentrations of methane, a powerful greenhouse gas, have strongly increased since 2007. Measurements of stable carbon isotopes of methane can constrain emissions if the isotopic compositions are known; however, isotopic compositions of methane emissions from wetlands are poorly constrained despite their importance. Here, we use a process-based biogeochemistry model to calculate the stable carbon isotopic composition of global wetland methane emissions. We estimate a mean global signature of −61.3 ± 0.7‰ and find that tropical wetland emissions are enriched by ~11‰ relative to boreal wetlands. Our model shows improved resolution of regional, latitudinal and global variations in isotopic composition of wetland emissions. Atmospheric simulation scenarios with the improved wetland isotopic composition suggest that increases in atmospheric methane since 2007 are attributable to rising microbial emissions. Our findings substantially reduce uncertainty in the stable carbon isotopic composition of methane emissions from wetlands and improve understanding of the global methane budget.

Methane↗

NASA NTRS1992

An infiltration/cure model for manufacture of fabric composites by the resin infusion process

A 1-D infiltration/cure model was developed to simulate fabrication of advanced textile composites by the resin film infusion process. The simulation model relates the applied temperature and pressure processing cycles, along with the experimentally measured compaction and permeability characteristics of the fabric preforms, to the temperature distribution, the resin degree of cure and viscosity, and the infiltration flow front position as a function of time. The model also predicts the final panel thickness, fiber volume fraction, and resin mass for full saturation as a function of compaction pressure. Composite panels were fabricated using the RTM (Resin Transfer Molding) film infusion technique from knitted, knitted/stitched, and 2-D woven carbon preforms and Hercules 3501-6 resin. Fabric composites were fabricated at different compaction pressures and temperature cycles to determine the effects of the processing on the properties. The composites were C-scanned and micrographed to determine the quality of each panel. Advanced cure cycles, developed from the RTM simulation model, were used to reduce the total cure cycle times by a factor of 3 and the total infiltration times by a factor of 2.

Weideman, Mark H.↗

NASA NTRS2002

Thermomechanical Response Variability of Stiffened Composite Panels

A significant numerical simulation capability now exists for studying the various phenomena associated with the response, failure, and performance of multilayered composite panels and shells subjected to combined pressure, mechanical, and thermal loads. The phenomena involved cover a wide range of length scales from local to global structural response. The modeling approaches used for multilayered panels include micromechanical models, three-dimensional continuum models, quasi-three-dimensional models, and two-dimensional plate and shell models. Within each category a number of models with several levels of sophistication has evolved. The four categories are described in review papers. Despite the extensive literature cited in the afore-mentioned references, only a few studies have been reported on the effects of stiffness discontinuities, such as those associated with an abrupt stiffener termination or dropped plies, on the response of composite panel. Stiffener termination is often necessary in composite aerospace structures to satisfy detailed design requirements, and therefore an understanding and a prediction of its effect on the response and failure of composite panels are desirable. Such a prediction must take into account the fact that current measurement technology does not allow the accurate determination of the material parameters that are used in the analytical models.

Noor, Ahmed K.↗

NASA NTRS2013

Simulation Based Investigation of Hidden Delamination Damage Detection in CFRP Composites

Guided wave (GW) based damage detection methods have shown promise in structural health monitoring (SHM) and hybrid SHM-nondestructive evaluation (NDE) techniques. Much previous GW work in the aerospace field has been primarily focused on metallic materials, with a growing focus on composite materials. The work presented in this paper demonstrates how realistic three-dimensional (3D) GW simulations can aid in the development of GW based damage characterization techniques for aerospace composites. 3D elastodynamic finite integration technique is implemented to model GW interaction with realistic delamination damage. A local wavenumber technique is applied to simulation data in order to investigate the detectability of hidden delamination damage to enable accurate characterization of damage extent.

Leckey, Cara A. C.↗

NASA NTRS1989

An investigation of some mechanical and thermal properties of lunar simulant materials heated at 2.45 GHz

Lunar simulant material was fabricated to simulate Apollo 11, Apollo 15, and Apollo 16 soils. The approximate compositions which these soils simulate are given. Samples of each soil simulate were fabricated into right circular cylinders, placed into a microwave reaction cavity, and heated using 2.45 GHz radiation to a particular processing temperature at which it was held for a prescribed length of time. Examples are given of two microwave heating programs for these simulant samples. Upon completion of thermal processing, each sample had its top and bottom surfaces polished. A technique was employed which looks at hardness data to determine the fracture toughness of a material and then relates this to thermal shock resistance. Some advantages of this technique are its low cost for analysis and thermal shock resistance as a function of initial sample orientation in the microwave field can be determined. Samples were prepared for testing and results are expected. At the same time, other samples are currently being investigated using scanning electron microscopy to determine their microstructures.

Meek, T. T.↗

DOE OSTI2015

Density relaxation and particle motion characteristics in a non-ionic deep eutectic solvent (acetamide + urea): Time-resolved fluorescence measurements and all-atom molecular dynamics simulations

Temperature dependent relaxation dynamics, particle motion characteristics, and heterogeneity aspects of deep eutectic solvents (DESs) made of acetamide (CH{sub 3}CONH{sub 2}) and urea (NH{sub 2}CONH{sub 2}) have been investigated by employing time-resolved fluorescence measurements and all-atom molecular dynamics simulations. Three different compositions (f) for the mixture [fCH{sub 3}CONH{sub 2} + (1 − f)NH{sub 2}CONH{sub 2}] have been studied in a temperature range of 328-353 K which is ∼120-145 K above the measured glass transition temperatures (∼207 K) of these DESs but much lower than the individual melting temperature of either of the constituents. Steady state fluorescence emission measurements using probe solutes with sharply different lifetimes do not indicate any dependence on excitation wavelength in these metastable molten systems. Time-resolved fluorescence anisotropy measurements reveal near-hydrodynamic coupling between medium viscosity and rotation of a dissolved dipolar solute. Stokes shift dynamics have been found to be too fast to be detected by the time-resolution (∼70 ps) employed, suggesting extremely rapid medium polarization relaxation. All-atom simulations reveal Gaussian distribution for particle displacements and van Hove correlations, and significant overlap between non-Gaussian (α{sub 2}) and new non-Gaussian (γ) heterogeneity parameters. In addition, no stretched exponential relaxations have been detected in the simulated wavenumber dependent acetamide dynamic structure factors. All these results are in sharp contrast to earlier observations for ionic deep eutectics with acetamide [Guchhait et al., J. Chem. Phys. 140, 104514 (2014)] and suggest a fundamental difference in interaction and dynamics between ionic and non-ionic deep eutectic solvent systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1995

Probabilistic simulation of long term behavior in polymer matrix composites

A methodology to compute cumulative probability distribution functions (CDF) of fatigue life for different ratios, r of applied stress to the laminate strength based on first ply failure criteria has been developed and demonstrated. Degradation effects due to long term environmental exposure and mechanical cyclic loads are considered in the simulation process. A unified time-stress dependent multi-factor interaction equation model developed at NASA Lewis Research Center has been used to account for the degradation/aging of material properties due to cyclic loads. Fast probability integration method is used to perform probabilistic simulation of uncertainties. Sensitivity of fatigue life reliability to uncertainties in the primitive random variables are computed and their significance in the reliability based design for maximum life is discussed. The results show that the graphite/epoxy (0/+45/90) deg laminate with ply thickness 0.125 in. has 500,000 cycles life for applied stress to laminate strength ratio of 0.6 and a reliability of 0.999. Also, the fatigue life reliability has been found to be most sensitive to the ply thickness and matrix tensile strength. Tighter quality controls must therefore be enforced on ply thickness and matrix strength in order to achieve high reliability of the structure.

Shah, A. R.↗